JLG 400CRT Service Manual

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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 BL OCKING OR OV ERHEAD SL ING, 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, NONFLA MMABLE CLEANING SOLVENTS.

3121111 – JLG Lift – a

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

b – JLG Lift – 3121111

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

3121111 – JLG Lift – i

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

ii – JLG Lift – 3121111

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

3121111 – JLG Lift – iii

TABLE OF CONTENTS

iv – JLG Lift – 3121111

SECTION 1 - SPECIFICATIONS

SECTION 1. SPECIFICATIONS

1.1 CAPACITIES

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)

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

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

Drive/Steer System

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

Drive Motor Displacement- 400 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

3.5 U.S. gallons (13.2 liters)

1.2 COMPONENT 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

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

1.3 PERFORMANCE 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

3121111 – JLG Lift – 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)

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)

1.5 LUBRICATION

Ta b l e 1-2. Hydraulic Oil

HYDRAULIC SYSTEM OPERATING

TEMPERATURE RANGE

0 to +23 degrees F

(-18 to -5 degrees C )

0 to +210 degrees F

(-18 to +100 degrees C)

+50 to +210 degrees F

(+10 to +100 degrees C)

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.

SAE VISCOSITY GRADE

10W

10W-20,10W-30

20W-20

1.4 TORQUE REQUIREMENTS

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

Lubrication Specifications

Table 1-3. Lubrication Specifications

KEY SPECIFICATIONS

MPG Multipurpose Grease having a minimum dripping

point of 350 degrees F. Excellent water resistance

and adhesive qualiti es, and being of extreme pres-

sure type. (Timken OK 40 pounds minimum.)

EPGL Extreme Pressure Gear Lube (oi l) meeting API ser-

vice classifica tion 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. A PI service classification GL-3, e .g.

Mobil 424.

1-2 – JLG Lift – 3121111

SECTION 1 - SPECIFICATIONS

4 Extends from

front of machine

Note: 500 Hrs. = 3 months 1000 Hrs. = 6 months 2000 Hrs. = 1 year 4000 Hrs. = 2 years

Figure 1-1. Lubrication Diagram

Table 1-4. Lubrication Chart

INDEX

1 Hydraulic Oil Res ervoir Fill Cap/Drain Pl ug HO - Check HO Le vel

2 Hydraulic Filter Element N/A Initial Change - 50 H ours 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

COMPONENT NUMBER/TYPE LUBE POINTS LUBE METHOD

HO - Change HO

NOTE: Recommended lubricating intervals are based on

machine operations under normal conditions. For machines used in multi-shift operations and/or exposed to hostile en viron ments or condi tions, lubr ication 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 si ght w indow s on tan k. Do no t overfill tank.

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

INTERVAL

HOURS

10/500

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SECTION 1 - SPECIFICATIONS

Figure 1-1. Torque Chart

1-4 – JLG Lift – 3121111

SECTION 1 - SPECIFICATIONS

Serial Number

(Stamped)

Figure 1-2. Serial Number Location

1.6 PRESSURE 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)

1.7 SERIAL 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.

Serial Number Plate

1.8 LIMIT 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).

3121111 – JLG Lift – 1-5

SECTION 1 - SPECIFICATIONS

1.9 CYLINDER SPECIFICATIONS

NOTE: All dimensions are given in inches (in), with the met-

ric equivalent, centimeters (cm), in parentheses.

Table 1-5. Cylinder Specifications

Description Bore Stroke Rod Di a

Lift Cylinder

(330CRT)

Upper Lift Cylinder

(400CRT)

Lower Lift Cylinder

(400CRT)

Lockout Cylinde r (Oscillating Axle)

Leveling Jack

Cylinder

Steer Cylinder 2.5

4.0

(10.2)

3.0

(7.62)

4.0

(10.2)

3.0

(7.6)

2.0

(5.1)

(6.4)

63.7

(161.8)

58.1

(147.6)

58.1

(147.6)

3.75 (9.5)

14.0

(35.6)

7.1

(18.1)

2.75

(7.0)

2.75

(7.0)

2.75

(7.0)

1.25

(3.2)

1.25

(3.2)

1.25

(3.2)

1.10 MAJOR COMPONENT WEIGHTS

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 wit h flywheel and hous-

ing)

Diesel Engine (Dry wi th flywheel and hous-

ing)

136 62

256 116

Table 1-6. Major Component Weights

Component Lb Kg

Fixed Platform 569 258

Platform Extension 230 104

Arm Assembly- 3 30CRT (Includes Lift Cy linder)

Arm Assembly- 4 00CRT (Includes Lift Cy linder)

Chassis with Foam Fil led Tires 4980 2259

3200 1452

3900 1769

1-6 – JLG Lift – 3121111

SECTION 2. PROCEDURES

SECTION 2 - PROCEDURES

2.1 GENERAL

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.

2.2 SERVICING 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.

3121111 – JLG Lift – 2-1

SECTION 2 - PROCEDURES

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.

2-2 – JLG Lift – 3121111

SECTION 2 - PROCEDURES

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.

2.4 CYLINDERS - 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.

2.5 VALVES - 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-

3121111 – JLG Lift – 2-3

SECTION 2 - PROCEDURES

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.

2.6 COMPONENT 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.

2.7 WEAR 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).

2.8 CYLINDER CHECKING PROCEDURES

NOTE: Cylinder checks must be performed any time a cylin-

der component is repl ac ed or wh en im pro per system operation is suspected.

Cylinder w/o Counterbalance Valves - Steer Cylinder

IM P O RTAN T

OPERATE FUNCTIONS FROM GROUND CONTROL STATION ONLY.

DO NOT FULLY EXTEND CYLINDER TO END OF STROKE. RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE.

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

2-4 – JLG Lift – 3121111

SECTION 2 - PROCEDURES

minute, carefully reconnect hose to extend port, then activate cylinder through one complete cycle and check for leaks.

Cylinders w/Single Counterbalance Valves Lift Cylinder

IM P O RTANT

OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY.

1. Using all applicable safety precautions, activate hydraulic system.

WHEN WORKING ON THE LIFT CYLINDER, RAISE THE PLATFORM COMPLETELY AND SUPPORT THE PLATFORM USING A SUITABLE OVERHEAD LIFTING DEVICE.

DO NOT FULLY EXTEND LIFT CYLINDER TO END OF STROKE. RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE.

2. Raise platform completely then retract cylinder slightly to avoid trapping pressure. Place a suitable overhead lifting device approximately 1 inch (2.5 cm) below the platform.

3. Shut down hydraulic system and allow machine to sit for 10-15 minutes. Carefully remove hydraulic hoses from cylinder port block.

4. There will be initial weeping of hydraulic fluid, which can be caught in a suitable container. After the initial discharge, there should not be any further leakage from the ports. If leakage continues at a rate of 6-8 drops per minute or more, the counterbalance valve is defective and must be replaced.

2. Remove the bolt and locknut securing the cylinder rod attach pin to the upper inner arm assembly. Using a suitable brass drift, drive out the rod end attach pin from the arm assembly.

3. Retract the lift cylinder rod completely.

4. Tag and disconnect the hydraulic lines, then cap the lift cylinder hydraulic lines and ports.

5. Remove the bolt and locknut securing the barrel end attach pin to the lower arm assembly. Using a suitable brass drift, drive out the barrel end attach pin from the arm assembly.

6. Carefully remove the cylinder from the scissor lift and place in a suitable work area.

Installation

1. Install lift cylinder in place using suitable slings, aligning barrel end attach pin mounting holes on lower arm assembly.

2. Using a suitable drift, drive the barrel end attach pin through the mounting holes in the lift cylinder and the lower arm assembly. Secure in place with the bolt and locknut.

3. Remove cylinder port plugs and hydraulic line caps and correctly attach lines to cylinder ports.

4. Extend the cylinder rod until the attach pin hole aligns with those in the upper arm assembly. Using a suitable drift, drive the cylinder rod attach pin through the aligned holes, taking care to align the pin retaining hole with the hole in arm assembly. Secure the pin in place with the bolt and locknut.

5. Lower platform to stowed position and shut down motor. Check hydraulic fluid level and adjust accordingly

5. If no repairs are necessary or when repairs have been made, carefully reconnect hydraulic hoses to the appropriate ports.

6. Remove lifting device from platform, activate hydraulic system and run cylinder through one complete cycle to check for leaks.

2.9 LIFT CYLINDER REMOVAL AND INSTALLATION

Removal

1. Place the machine on a flat and level surface. Start the motor and raise the platform. Shut down the engine and attach a suitable lifting device to the platform.

3121111 – JLG Lift – 2-5

SECTION 2 - PROCEDURES

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

2-6 – JLG Lift – 3121111

SECTION 2 - PROCEDURES

Figure 2-2. 330CRT Lift Cylinder

6. Remove the cylinder rod from the holding fixture.

7. Position the cylinder barrel in a suitable holding fixture.

IM P O RTANT

EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.

8. With barrel clamped securely, and while adequately supporting the rod, insert the piston end into the barrel cylinder. Ensure that the piston loading o-ring and seal ring are not damaged or dislodged.

9. Continue pushing the rod into the barrel until the cylinder head gland can be inserted into the barrel cylinder.

10. If applicable, secure the cylinder head retainer using a suitable chain wrench.

11. After the cylinder has been reassembled, the rod should be pushed all the way in (fully retracted) prior to the reinstallation of any holding valve or valves.

12. If applicable, install the cartridge-type holding valve and fittings in the port block using new o-rings as applicable.

3121111 – JLG Lift – 2-7

SECTION 2 - PROCEDURES

Figure 2-3. 400CRT LIft Cylinder

2-8 – JLG Lift – 3121111

SECTION 2 - PROCEDURES

IM P O RTAN T

IM P O RTANT

2.10 LIFT CYLINDER REPAIR

Disassembly

DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.

1. Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting.

DO NOT FULLY EXTEND CYLINDER TO END OF STROKE. RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE.

2. Operate the hydraulic power source and extend the cylinder. Shut down and disconnect the power source. Adequately support the cylinder rod, if necessary.

3. If applicable, remove the cartridge-type holding valve and fittings from the cylinder port block. Discard o-rings.

4. Place the cylinder barrel into a suitable holding fixture.

the cylinder head retainer cap screws, and remove cap screws from cylinder barrel.

Figure 2-5. Capscrew Removal

6. Using a spanner wrench, loosen the end cap or head retainer, and remove from cylinder barrel.

7. Attach a suitable pulling device to the cylinder rod port block end or cylinder rod end, as applicable.

EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFFCENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.

Figure 2-4. Cylinder Barrel Support

5. Mark cylinder head and barrel with a center punch for easy realignment. Using an allen wrench, loosen

8. With the barrel clamped securely, apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel.

Figure 2-6. Cylinder Rod Support

9. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible.

10. Loosen and remove the cap screw(s), if applicable, which attach the tapered bushing to the piston.

3121111 – JLG Lift – 2-9

SECTION 2 - PROCEDURES

Figure 2-7. Tapered Bushing Removal

11. Insert the cap screw(s) in the threaded holes in the outer piece of the tapered bushing. Progressively tighten the cap screw(s) until the bushing is loose on the piston.

12. Remove the bushing from the piston.

13. Screw the piston CCW, by hand, and remove the piston from cylinder rod.

7. Inspect threaded portion of piston for damage. Dress threads as necessary.

8. Inspect seal and o-ring grooves in piston for burrs and sharp edges. Dress applicable surfaces as necessary.

9. Inspect cylinder head inside diameter for scoring or other damage and for ovality and tapering. Replace as necessary.

10. Inspect threaded portion of head for damage. Dress threads as necessary.

11. Inspect seal and o-ring grooves in head for burrs and sharp edges. Dress applicable surfaces as necessary.

12. Inspect cylinder head outside diameter for scoring or other damage and ovality and tapering. Replace as necessary.

13. If applicable, inspect rod and barrel bearings for signs of correct excessive wear or damage. Replace as necessary.

a. Thoroughly clean hole, (steel bushing) of burrs,

dirt etc. to facilitate bearing installation.

14. Remove and discard the piston o-rings, seal rings, and backup rings.

15. Remove piston spacer, if applicable, from the rod.

16. Remove the rod from the holding fixture. Remove the cylinder head gland and retainer plate, if applicable. Discard the o-rings, back-up rings, rod seals, and wiper seals.

Cleaning and Inspection

1. Clean all parts thoroughly in an approved cleaning solvent.

2. Inspect the cylinder rod for scoring, tapering, ovality, or other damage. If necessary, dress rod with Scotch Brite or equivalent. Replace rod if necessary.

3. Inspect threaded portion of rod for excessive damage. Dress threads as necessary.

4. Inspect inner surface of cylinder barrel tube for scoring or other damage. Check inside diameter for tapering or ovality. Replace if necessary.

5. Inspect threaded portion of barrel for damage. Dress threads as necessary.

b. Inspect steel bushing for wear or other damage.

If steel bushing is worn or damaged, rod/barrel must be replaced.

c. Lubricate inside of the steel bushing with WD40

prior to bearing installation.

d. Using an arbor of the correct size, carefully

press the bearing into steel bushing.

14. Inspect travel limiting collar or spacer for burrs and sharp edges. If necessary, dress inside diameter surface with Scotch Brite or equivalent.

15. If applicable, inspect port block fittings and holding valve. Replace as necessary.

16. Inspect the oil ports for blockage or the presence of dirt or other foreign material. Repair as necessary.

17. If applicable, inspect piston rings for cracks or other damage. Replace as necessary.

6. Inspect piston surface for damage and scoring and for distortion. Dress piston surface or replace piston as necessary.

2-10 – JLG Lift – 3121111

SECTION 2 - PROCEDURES

Assembly

NOTE: Prior to cylinder assembly, ensure that the proper

cylinder seal kit is used . See your JL G Parts Ma nual. Apply a light film of hydraulic oil to all components

prior to assembly .

1. A special tool is used to install a new rod seal into the applicable cylinder head gland groove.

3. Place a new o-ring and back-up seal in the applicable outside diameter groove of the cylinder head.

Figure 2-10. Installation of Head Seal Kit

4. Install washer ring onto rod, carefully install the head gland on the rod, ensuring that the wiper and rod seals are not damaged or dislodged. Push the head along the rod to the rod end, as applicable.

5. Carefully slide the piston spacer on the rod.

6. If applicable, correctly place new o-ring in the inner piston diameter groove. (The backup ring side facing the O-ring is grooved.)

Figure 2-8. Rod Seal Installation

IM P O RTANT

WHEN INSTALLING "POLY-PAK" PISTON SEALS, ENSURE SEALS ARE INSTALLED PROPERLY. REFER TO WIPER SEAL INSTALLATION FOR CORRECT SEAL ORIENTATION. IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION.

2. Use a soft mallet to tap a new wiper seal into the applicable cylinder head gland groove. Install a new wear ring into the applicable cylinder head gland groove.

Figure 2-9. Wiper Seal Installation

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SECTION 2 - PROCEDURES

Figure 2-11. Piston Seal Kit Installation

7. If applicable, correctly place new seals and guide lock rings in the outer piston diameter groove. (A tube, with I.D. slightly larger than the O.D. of the piston is recommended to install the solid seal.)

NOTE: The backup rings for the solid seal have a radius on

one side. This side faces the solid seal.(See magnified insert in Figure 2-11.)The split of seals and backup rings are to be positioned so as not to be in alignment with each other.

screws) through the drilled holes in the bushing and into the tapped holes in the piston.

Figure 2-12. Tapered Bushing Installation

12. Tighten the capscrews evenly and progressively in rotation to the specified torque value. (See Table 2-1, Cylinder Component Torque.)

13. After the screws have been torqued, tap the tapered bushing with a hammer (16 to 24 oz.) and brass shaft (approximately 3/4" in diameter) as follows;

8. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to piston as possible.

9. Carefully thread the piston on the cylinder rod hand tight, ensuring that the o-ring and back-up rings are not damaged or dislodged.

10. Thread piston onto rod until it abuts the spacer end and install the tapered bushing.

NOTE: When installing the tapered bus hi ng, piston and mat-

ing end of ro d must be free of oil.

11. Assemble the tapered bushing loosely into the piston and insert JLG capscrews (not vendor cap-

a. Place the shaft against the cylinder rod and in

contact with the bushing in the spaces between the capscrews.

b. Tap each space once; this means the tapered

bushing is tapped 3 times as there are 3 spaces between the capscrews.

Figure 2-13. Seating the Tapered Bearing

14. Re torque the capscrews evenly and progressively in rotation to the specified torque value. (See Table 2-1, Cylinder Component Torque.)

2-12 – JLG Lift – 3121111

SECTION 2 - PROCEDURES

15. Remove the cylinder rod from the holding fixture.

16. Place new guide locks and seals in the applicable outside diameter grooves of the cylinder piston. (See Figure 2-11., Piston Seal Kit Installation)

Figure 2-14. Poly-Pak Piston Seal Installation

17. Position the cylinder barrel in a suitable holding fixture.

IM P O RTANT

EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.

as applicable. (See Table 2-1, Cylinder Component To rq u e ).

IF THE CYLINDER IS TO BE TESTED PRIOR TO INSTALLATION ON THE MACHINE, EXTREME CARE SHOULD BE USED TO INSURE THAT THE OUTER END OF THE ROD IS SUPPORTED. USE EITHER A TRAVELING OVERHEAD HOIST, FORK-LIFT, OR OTHER MEANS TO SUPPORT THE OVERHANGING WEIGHT OF THE EXTENDING ROD.

23. If applicable, install the cartridge-type holding valve and fittings in the port block using new o-rings as applicable. (SeeTable 2-2, Holding Valve Torque Specifications).

Table 2-1. Cylinder Component Torque

Component

Taper ed Bushing Retaining Screws - Lift C ylinder 80 ft lb

Head Retaining Scr ews - Lift Cylinder 9 ft lb

Torque Value

(w/Loctite)

(108 Nm)

(12 Nm)

18. With barrel clamped securely, and while adequately supporting the rod, insert the piston end into the barrel cylinder. Ensure that the piston loading o-ring and seal ring are not damaged or dislodged.

19. Continue pushing the rod into the barrel until the cylinder head gland can be inserted into the barrel cylinder.

20. Secure the cylinder head gland using the washer ring and socket head bolts.

Figure 2-15. Rod Assembly Installation

21. After the cylinder has been reassembled, the rod should be pushed all the way in (fully retracted) prior to the reinstallation of any holding valve or valves.

Table 2-2. Holding Valve Torque Specifications

Description Torque Value

Sun - 7/8 hex M20 x 1.5 thds 30 - 35 ft lb 4 1 - 48 Nm

Sun - 1-1/8 hex 1 - 1 4 UNS thds 45 - 50 ft lb 61 - 68 Nm

Sun - 1-1/4 hex M36 x 2 thds 150 - 153 ft lb 204 - 207 Nm

Racine - 1-1/8 h ex 1-1/16 - 12 thds 50 - 55 ft lb 68 - 75 Nm

Racine - 1-3/8 he x 1-3/16 - 12 thds 75 - 80 ft lb 102 - 109 Nm

Racine - 1-7/8 hex 1- 5/8 - 12 thds 100 - 11 0 ft lb 136 - 149 Nm

22. If applicable, install the cartridge-type holding valve and fittings in the rod port block, using new o-rings

3121111 – JLG Lift – 2-13

SECTION 2 - PROCEDURES

2.11 STEER CYLINDER REPAIR

Removal

Before beginning this procedure, ensure that the parking brake is engaged and the rear wheels are chocked.

1. Tag and disconnect the hydraulic lines to the steer cylinder, then cap the steer cylinder hydraulic lines and ports.

2. At each steer spindle, remove the bolt and lock nut securing the steer cylinder to the spindle.

3. When the steer cylinder is disconnected from the steer spindles, turn each wheel by hand to give clearance to remove the steer cylinder from the front axle.

4. Carefully lift the steer cylinder until the cylinder mounting block clears the mounting slot in the bot-

tom of the axle, then slowly remove the cylinder from the axle and place it in a suitable work area.

Disassembly

IM P O RTAN T

DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.

1. Place the cylinder barrel into a suitable holding fixture.

2. Using a suitable chain wrench, carefully remove the cylinder head retainer from one end of the cylinder barrel.

3. Attach a suitable pulling device to one end of the cylinder rod.

Figure 2-16. Steer Cylinder Assembly

2-14 – JLG Lift – 3121111

IM P O RTAN T

EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL-

IM P O RTANT

INDER ROD, SPACER, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.

4. With the barrel clamped securely, apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel.

5. Using a suitable chain wrench, carefully remove the remaining cylinder head retainer from the opposite end of the cylinder barrel. Remove the head and remove and discard the wiper, rod seal, 0-ring and wear ring.

6. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture.

7. Carefully remove the head from the cylinder rod and remove and discard the wiper, rod seal, o-ring and wear ring.

8. Carefully remove the spacers from the cylinder rod, then remove the retaining rings securing the piston in place on the cylinder rod. Discard the retaining rings.

9. Carefully remove the piston from the cylinder rod. Remove and discard the T-seal and o-ring.

10. Remove the cylinder rod from the holding fixture.

Cleaning and Inspection

1. Clean all parts thoroughly in an approved cleaning solvent.

2. Inspect the cylinder rod for scoring, tapering, ovality, or other damage. If necessary, dress the rod with Scotch Brite or equivalent. Replace the rod if necessary.

3. Inspect the threaded portion of the rod for excessive damage. Dress the threads as necessary.

SECTION 2 - PROCEDURES

8. Inspect the seal and o-ring grooves in the heads for burrs and sharp edges. Dress applicable surfaces as necessary.

9. Inspect the outside diameter of the spacers and heads for scoring or other damage and ovality and tapering. Replace as necessary.

10. Inspect the oil ports for blockage or the presence of dirt or other foreign material. Repair as necessary.

11. Inspect the cam follower for wear or damage. Replace as necessary.

Assembly

NOTE: Prior to cylinder assembly, ensure that the proper

cylinder seal kit is used. Apply a light film of hydraulic oil to all components

prior to assembly.

1. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture.

2. Place a new o-ring into the cylinder rod piston groove.

3. Place a new T-seal on the piston, then carefully install the piston the cylinder rod, ensuring that the o-ring in the rod groove is not damaged or dislodged. Secure the piston in place with two new retaining rings.

4. Carefully slide the spacers onto the cylinder rod.

5. Place a new wiper, rod seal, o-ring and wear ring on each of the two cylinder heads. Set the heads aside for later installation on the cylinder rod.

6. Remove the cylinder rod assembly from the holding fixture.

7. Position the cylinder barrel in a suitable holding fixture.

4. Inspect the inner surface of the cylinder barrel tube for scoring or other damage. Check the inside diameter for tapering or ovality. Replace the barrel if necessary.

5. Inspect the piston surface for damage, scoring and distortion. Dress the piston surface or replace the piston as necessary.

6. Inspect the seal and o-ring grooves in the piston for burrs and sharp edges. Dress applicable surfaces as necessary.

7. Inspect the inside diameter of the spacers and heads for scoring or other damage and for ovality and tapering. Replace as necessary.

EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, PISTON AND HEADS. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.

8. With the barrel clamped securely, and while adequately supporting the cylinder rod assembly, insert the cylinder rod assembly into the cylinder barrel. Ensure that the piston T-seal and o-ring are not damaged or dislodged.

9. Continue pushing the rod assembly into the cylinder barrel until the cylinder rod is approximately centered in the barrel.

3121111 – JLG Lift – 2-15

SECTION 2 - PROCEDURES

10. Carefully install one of the cylinder heads on one end of the cylinder rod and push the head onto the rod until it is snug against the end of the cylinder barrel.

11. Install one of the cylinder head retainers on the end of the cylinder barrel and tighten with a suitable chain wrench.

12. Carefully install the remaining cylinder head on the opposite end of the cylinder rod and push the head onto the rod until it is snug against the end of the cylinder barrel.

13. Install the remaining cylinder head retainer on the end of the cylinder barrel and tighten with a suitable chain wrench.

Installation

1. Carefully install the steer cylinder assembly into the front axle. Align the cylinder mounting block on the barrel with the mounting slot in the bottom of the axle and lower the steer cylinder until the mounting block rests in the slot.

2. Turn the steer wheels to line up the mounting holes in the steer spindles and the steer cylinder ends. Secure each end of the steer cylinder with a bolt and lock nut.

2.13 MAGNETIC SPEED PICKUP CLEANING PROCEDURE

1. Locate the magnetic speed pickup on the bell housing on the right side of the motor.

Figure 2-17. Magnetic Speed Pickup

2. Using an 11/16 wrench, loosen the jam nut and, using your fingers, thread the pickup out of the bell housing.

3. Reconnect the hydraulic hoses to the applicable cylinder ports.

2.12 OSCILLATION CYLINDER BLEEDING

NOTE: Park the machine on a firm an d lev el surf ace w ith th e

rear wheels block ed be fore s tarti ng the bl ee ding procedure.

1. Jack up the front of the machine so that both wheels are raised enough to allow the axle to fully oscillate.

2. Have a second person start the engine, press and hold the start button until Hi engine is activated.

3. On the side of the axle that is fully raised, loosen the bleeder screw to release any air that may be in the hydraulic line. Continue to bleed until no air bubbles are visible.

4. Tighten the bleeder screw then push the raised wheel down and repeat the process for the opposite level cylinder.

Figure 2-18. Magnetic Speed Pickup Removal

3. After cleaning and inspecting the magnetic speed pickup reinstall back into the bell housing.

4. The magnetic speed pickup should be tightened finger tight and then backed out 1/4 turn to properly set.

NOTE: Flats on the magnetic pickup must be oriented verti-

cally.

5. Replace the jam nut and tighten.

2-16 – JLG Lift – 3121111

SECTION 2 - PROCEDURES

Valve Knob

ctuator for Tow

Brake Release

Lift

Steer Right

Brake Release

Dump Valve

Main

Steer Right

Figure 2-19. Valve Components

Lift

Steer Left

2.14 PRESSURE SETTING PROCEDURES

NOTE: Make all pressure adjustments with the engine oper-

ating and the hydraulic oil at normal operating temperature. In addition, all functions must be operated from the platform control station in order to achieve full pump speed. It may be necessary to use an assistant to adjust the pressure settings while operating the functions from the platform control station.

Lift Relief Adjustments

1. Install a pressure gauge at gauge port MP, located on the front upper right side of the valve body. The port is identified by a stamping on the valve body.

2. From the platform control station, activate the Lift Up function by selecting the lift control switch and positioning the joystick to the up position.

Steer Left

3. Bottom out the Lift Up function and adjust the Lift Up relief to 2300 psi (159 bar) on the 330CRT and 2500 psi (172 bar) on the 400CRT.

4. Remove the pressure gauge from gauge port MP.

Steer Relief Adjustment

1. Install a pressure gauge at gauge port P2, located on the lower right side of the valve body. The port is identified by a stamping on the valve body.

2. Activate the Steer Right function and check Steer pressure. If necessary, adjust Steer pressure to 1600 psi (110 bar).

3. Activate the Steer Left function and check Steer pressure. If necessary, adjust Steer pressure to 2600 psi (179 bar).

4. Remove the pressure gauge from gauge port P2

3121111 – JLG Lift – 2-17

SECTION 2 - PROCEDURES

POSITIVE CONNECTION

AUTO-CHOKE ASSEMBLY

2.15 LIMIT SWITCH ADJUSTMENT

Speed Cutout Switch

The speed cutout switch is located on the right side of the frame of the machine. When activated, the switch cuts out the high drive function. Adjust the switch to activate when the platform is raised above the stowed position.

Drive Cutout Switch (400 CRT)

The drive cutout switch is located on the left side of the frame of the machine. When activated, the switch cuts out the drive function. Adjust the switch to activate when the platform is raised to 30 ft. (9.1m).

2.16 AUTOMATIC CHOKE - FIELD ADJUSTMENT (DF-750)

Inspection

NOTE: All automatic choke assemblies hav e been pre- set to

operate between 20°F and 100°F with little or no adjustment. If the machine will be operated for prolong use outside these temperature ranges, adjustments could be made to improve performance of the engine.

space between the plate and the wall of the carburetor.

NOTE: If the machine is run primarily on LP, rotate the top

cover until the choke butterfly is closed with 1/4 in. space between the plate and wall of the carbure t or.

Remember LP fuel nee ds no c hoke, all the way ope n is ok, if the unit is going to run on LP.

4. If the ambient temperature is less then 70°F the top cover counter should be rotated CCW 1 mark for every 5°F less then 70°F.

5. If the ambient temperature is more then 70°F the top cover counter should be rotated CW 1 mark for every 5°F less then 70°F.

TOP VIEW

VACUUM CONNECTION

VACUUM PULL-OFF

TOP COVER SCREW

RICH

The machine will take time to warm up and you may experience low power or rough running for the first few minutes of operation or until the engine warms up. LET THE ENGINE WARM UP.

Make sure that the choke shaft operates freely and does not bind. this can be done without removing the air horn by rotating the bronze coupling with an eraser on a pencil or by removing the vacuum pull off line at the manifold and supply a small amount of vacuum to the hose. the choke rod should move freely using either method.

Adjustments

NOTE: If the choke rod is binding make sure the support

bracket is straight

1. There are two adjustments Vertical (loosening the air horn nuts) and Horizontal (loosening the bracket to adaptor screws). These two adjustments should resolve any binding problem.

2. To adjust the choke at 70°F ambient, remove the air horn and reinstall the nut that holds the choke and support bracket securely making sure the choke moves freely.

SIDE VIEW

HORIZONTAL ADJUSTING

SCREWS

BRONZE COUPLING

AIR HORN

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

3. Loosen the 3 top cover screws and rotate the top

2-18 – JLG Lift – 3121111

cover till the choke butterfly is closed with 1/32 in

SECTION 2 - PROCEDURES

Reassembly

Reassemble the air horn making sure the choke is not binding, test to insure that none of the settings have moved and the choke is not binding.

The vacuum pull off should be set such that when vacuum is applied to the choke system the choke butterfly is full open.

NOTE: If the machine starts and stalls immediately or if it is

extremely cold, limiting the choke pull off to 75% to 90% may improve the performance of the machine. No adjustment is normally require d.

Diesel Engine

NOTE: Never run the fuel tank dry. Diesel engines cannot

be restarted after running out of fuel until the fuel system has been ai r-vented or ‘bled’ of air. See the Kubota Instruction Manual for the proper procedure.

2.17 ELECTRONIC CONTROL SYSTEM

To Connect the Hand Held Analyzer:

1. Connect the four pin end of the cable supplied with the analyzer, to the top connection of the motor controller and connect the remaining end of the cable to the analyzer.

NOTE: The cable has a four pin connector at each end of

the cable; the cable cannot be connected backwards.

2. Power up the Control System by turning the lower key to the platform position and pulling both emergency stop buttons on.

Using the Analyzer:

With the machine power on and the analyzer connected properly, the analyzer will display the following:

HELP:

PRESS ENTER

At this point, using the RIGHT and LEFT arrow keys, you can move between the top level menu items. To select a displayed menu item, press ENTER. To cancel a selected menu item, press ESC; then you will be able to scroll using the right and left arrow keys to select a different menu item.

The top level menus are as follows:

HELP

DIAGNOSTICS

ACTIVATE TESTS

ACCESS LEVEL

PERSONALITIES

MACHINE SETUP

LEVEL VEHICLE: (Access level 1 only)

If you press ENTER, at the HELP:PRESS ENTER display, and a fault is present during power up, the analyzer display will scroll the fault across the screen. If there was no fault detected during power up, the display will read: In platform mode, HELP: EVERYTHING OK, In ground mode, GROUND MODE OK

If ENTER is pressed again, the display moves to the following display:

LOGGED HELP

1: STARTUP (2/1): (Or last recorded fault)

At this point, the analyzer will display the current fault, if any are present. You may scroll through the fault logs to

3121111 – JLG Lift – 2-19

SECTION 2 - PROCEDURES

view what the last fifteen faults were. Use the right and left arrow keys to scroll through the fault logs. To return to the beginning, press ESC two times.

When a top level menu is selected, a new set of menu items may be offered; If for example you choose Personalities:

DRIVE

LIFT

IDLE

Pressing ENTER with any of the above displayed menus, will display additional sub-menus within the selected menu. In some cases the next level is the parameter or information to be changed. Refer to the flow chart for what menus are available within the top level menus. You may only view the personality settings for selected menus while in access level 2. Remember, you may always cancel a selected menu item by pressing the ESC key.

Changing the Access Level of the Hand Held Analyzer:

When the analyzer is first connected, you will be in access level 2 which enables you to only view most configuration settings which cannot be changed until you enter a password to advance to a lower level. This ensures that a setting cannot be accidentally altered. To change the access level, the correct password must be entered. To enter the password, scroll to the ACCESS LEVEL menu. For example:

MENU:

ACCESS LEVEL 2

Press ENTER to select the ACCESS LEVEL menu.

Using the UP or DOWN arrow keys, enter the first digit of the password, 3.

Then using the RIGHT arrow key, position the cursor to the right one space to enter the second digit of the password.

When a machine digit item is selected, press the UP or

DOWN arrow keys to adjust its value, for example:

GROUND ALARM:

2=DRIVE

The effect of the machine digit value is displayed along with its value. The above display would be selected if the machine was equipped with a ground alarm and you wanted it to sound when driving. There are certain settings allowed to install optional features or select the machine model.

When selecting the machine model to match the size of the machine, the personality settings will all default to the factory recommended settings.

NOTE: Refer to the appropriate Machine Personality Set-

tings Table, and the Machine Setup Table in the JLG Service Manual for the recommended factory settings.

Password 33271 will give you access to level 1, which will permit you to change all machine personality settings.

CHANGING THESE SETTINGS MAY ADVERSELY AFFECT THE PERFORMANCE OF YOUR MACHINE.

IM P O RTAN T

IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS. SHOULD PRESSUREWASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC. RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A MINIMUM DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM THESE COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPONENTS ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION.

Use the UP or DOWN arrow key to enter the second digit of the password which is 3.

Repeat this process until you have entered all five digits of the password which is 33271.

Once the correct password is displayed, press ENTER.

The access level should display the following, if the password was entered correctly:

MENU:

ACCESS LEVEL 1

Repeat the above steps if the correct access level is not displayed or you can not adjust the personality settings.

2-20 – JLG Lift – 3121111

2.18 FLASH CODES AND DESCRIPTIONS

Table 2-3. Help Messages and Flash Codes

FLASH CODE HELP MESSAGE AND DESCRIPTION

No Flash Code ALAR M SOUNDING - TILTED & ABOVE EL EVATION

Platform is elevat ed and the chassis is not level.

DIFFERENT FUNCTION SELECTED & IGNORED A function (i.e. Driv e, Lift, etc.) is active and the operat or has selected another function. T he system has ignored the new selection.

DRIVING AT CUTBACK - ABOVE ELEVATION Platform is elevat ed and the machine is in the dri ve mode of operation.

FUNCTION SELECTED BUT TRIGGER SWITCH OPEN A function (i.e. Driv e, Lift, etc.) has been selected by the o perator, but the trigger switch is not ac tive (closed).

JOYSTICK MOVED BUT NO FUNCT ION SELECTED The joystick was moved out of the center position before a funct ion was selected.

DRIVE PREVENTED Above drive cutout h eight.

2-1 STARTUP

A new system power u p has occurred since the last h elp message.

2-2 FUNCTIONS LOCKED OUT - SHORT TO PLATFORM ROW INPUT DETECTED

Battery power has bee n detected on a row input (pins J 1-8, J1-9, or J1-13).

FUNCTION PROBLEM - Horn permanently selected

FUNCTION PROBLEM - DRIVE PERMANENTLY SELECTED Drive select switch in the platform control box clos ed at start up or for more than ten s econds. Release switch to clear fau lt.

FUNCTION PROBLEM - LIFT PE RMANENTLY SELECTED Lift select swit ch in the platform control box cl osed at start up or for more than te n seconds. Release switch to c lear fault

FUNCTION PROB LEM - O/R PERMANENTLY SELECTED An outrigger selec t switch in the platform control box closed at start up or for more th an ten seconds. Release switch to c lear fault

FUNCTION PR OBLEM - START PERMANENTLY SELECTED Start switch in the platform control box clos ed at start up. Release switch to clear fault

FUNCTION PROBLEM - GLOW PLUG PERMANENTLY SELECTED Glow plug switch in the platform control box closed a t start up. Release switch to c lear fault

FUNCTION PROBLEM - STEER LEFT PERMANENTLY SELECTED Steer left switch in th e platform control box closed at start up. Release switch to clear fault

FUNCTION PROBLEM - STEER RIGHT PERMANENTLY SELECTED Steer right switch in the platform control box closed at start up. Release switch to clear fault

JOYSTICK FAULTY - WIPER OUT OF RANGE The joystick wiper signal input is outside the acceptab le voltage range. The wiper wire be ing off, the wiper wire shorted to ba ttery power, or the wiper wire short ed to battery negative could cause this .

JOYSTICK FAULTY - STEER SWITCHES ACTIVE TOGETHER Both the steer left and steer right inputs are closed at the same time. A short in the steer switch wiring or a failed steer switch can cause this.

FUNCTION LOCKED O UT - JOYSTICK NOT CENTER ED Selected function is not allowed because the joystick is not centered. Return joysti ck to center and reselect func tion.

FUNCTION PROBLEM - TRIGGER PERMANENTLY CLOSED Trigger switch in the pl atform control box closed at start u p. Release switch to clear fau lt.

TRIGGER CLOSED TOO LONG WH ILE IN NEUTRAL Trigger switch in the pl atform control box closed for more than ten seconds while the joys tick is in the neutral position. Rel ease switch to clear fault.

SECTION 2 - PROCEDURES

3121111 – JLG Lift – 2-21

SECTION 2 - PROCEDURES

Table 2-3. Help Messages and Flash Codes

2-3 FUNCTION PROBLEM - LIFT PE RMANENTLY SELECTED

Lift switch (up or d own) in the ground control box cl osed at start up. Release switch t o clear fault

FUNCTION PROBLEM - START PERMANENTLY SELECTED Start switch in the ground control box closed at start up. Release switch to c lear fault

FUNCTION PROBLEM - GLOW PLUG PERMANENTLY SELECTED Glow plug switch in the ground contro l box closed at start up. Release switch to clear fault

NO DATA FR OM TILT SENSOR - NOT CONNECTED OR FAULT Y No signal from the tilt switch. Check wiring and plug connections at the level se nsor and at the ground control boa rd.

2-5 DRIVE & LIFT UP PREVENTED

Oscillating axle not set

4-4 BATTERY VOLTAGE TOO LOW

Battery voltage belo w 8.0V. Check ba ttery and alternator.

BATTERY VOLTAGE TO O HIGH Battery voltage above 16V. Check bat tery and alternator.

5-5 ENGINE SHUTDOWN – OVERSPEED

The engine speed exce eded 4500 RPM for more than 2 seconds. C heck throttle actuator for debris or i nterference, which prevents free movemen t of actuator. Recycle power to clear the f ault and restart.

ENGINE SHUTDOWN - OIL PRES / COOLANT TEMP The engine oil pressure was too l ow or the engine coolant temperature was too high for more than 10 seconds. Check engine fluid levels. Recycle p ower to clear fault and restart.

2-22 – JLG Lift – 3121111

SECTION 2 - PROCEDURES

*(Test in Platform Mode)

**(Outrigger Option Only)

*(Te st in Platform Mode)

**(Duel Fuel E ngine Only)

***(Diesel Eng ine Only)

****(Outrig ger Option Only)

*(Test in Ground Mode)

**(Diesel Engine Only)

(Press Escape Twice to Return to Help)

*(Outrigger Option Only)

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

*(Outrigger Option Only)

*(Outrigge r Option Only)

3121111 – JLG Lift – 2-23

SECTION 2 - PROCEDURES

iewed

- Top Level Me nu

- Sub Level M enu

- Item to be

of Level During Calibration)

or C h an ge d

(Prompt before Calibration) (Shown After Calibration) (Shown If Sensor Not Detected) (Shown If more than 5° Out

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

BY PRESSING THESE ARROW KEYS ( ) YOU CAN SCROLL THROUGH THE TOP LEVEL MENUS.

2-24 – JLG Lift – 3121111

DRIVE

LIFT

IDLE

SECTION 2 - PROCEDURES

Table 2-4. Machine Model Adjustment

Adjustment Adjustment range Default Values - Gas Default Values - Diesel

Accel 1.0 to 5.0 sec 44 Decel 1.0 to 5.0 sec 22

FWD MIN 0 to 100% 21 21

FWD MAX 0 to 100% 48 48

FWD ELEV 0 to 35% 30 30

REV MIN 0 to 1 00% 21 21

REV MAX 0 to 100% 52 52

REV ELEV 0 to 35% 30 30

LO MAX 35 to 65% 50 50

ENGINE SPD 2800 to 3800 RPM 3600 3000

GAIN 0 to 999 180 50

DROOP 0 to 999 200 250

STABILITY 0 to 999 170 125

Accel 0 .2 TO 5.0 4 4

Decel 0.2 TO 5.0 0.5 0.5

UP MIN ENG 1400 TO 2200 RPM 2000 2000

UP MAX ENG 2600 to 3600 RPM 3000 3000

LO MAX 35 to 55% 50 50

GAIN 0 to 999 150 10

DROOP 0 to 999 220 240

STABILITY 0 to 999 125 70

ENGINE SPEED 1200 TO 1500 rpm 1500 1500

GAIN 0 to 999 150 10

DROOP 0 to 999 250 85

STABILITY 0 to 999 100 90

MIN ACT 0 T 0 100% 19 25

MAX ACT L/D 0 T0 100% 60 100

MAX ACT IDLE 0 T0 100% 55 40

CUT ACT 200 TO 2800 RPM 500 500

3121111 – JLG Lift – 2-25

SECTION 2 - PROCEDURES

NOTE: When configuring a CRT scissors machine, the

machine configuration must be completed before any personality settings can be changed. Changing the personality settings first and then changing the model number of the machine configuration will cause the personality settings to return to default values.

Table 2-5. Machine Configuration Programming Information

Configuration Digit Number Description Default Num-

ber

(Model #)

(Engine Selectio n)

(Tilt)

(Drive Cutout)

(Control Direction)

(Leveling Jacks)

(Axle Type)

1 2 3

0 1 2

0 1

0 1 2

Cutout lift up and dri ve if tilted and elevated. Required for AUS and BRZ markets

No drive cutout swi tch installed.

Cuts out drive when deck is elevated above a predetermi ned elevation

FWD & LIFT dn (for future use)

260 CRT 330 CRT 400 CRT

750 Dual Fuel

905 Diesel

1105 Diesel

No Cutout

(Default for 400 CRT)

FWD & LIFT u p

Yes

Domestic & CE Fixed DOmestic Os cillating

CE Oscillating

2-26 – JLG Lift – 3121111

SECTION 2 - PROCEDURES

IM P O RTAN T

2.19 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE

The preventive maintenance and inspection checks are listed and defined in the following table. This table is divided into two basic parts, the “AREA” to be inspected and the “INTERVAL” at which the inspection is to take place. Under the “AREA” portion of the table, the various systems along with the components that make up that system are listed. The “INTERVAL” portion of the table is divided into five columns representing the various inspection time periods. The numbers listed within the interval column represent the applicable inspection code for which that component is to be checked.

The checks and services listed in this schedule are not intended to replace any local or regional regulations that may pertain to this type of equipment nor should the lists be considered as all inclusive. Variances in interval times may occur due to climate and/or conditions and depending on the location and use of the machine.

JLG Industries requires that a complete annual inspection be performed in accordance with the “Annual Machine Inspection Report” form. Forms are supplied with each new machine and are also available from JLG Customer Service. Form must be completed and returned to JLG Industries.

The inspection and maintenance code numbers are as follows:

1. Check for proper and secure installation.

2. Check for visible damage and legibility.

3. Check for proper fluid level.

4. Check for any structural damage; cracked or broken welds; bent or warped surfaces.

5. Check for leakage.

6. Check for presence of excessive dirt or foreign material.

7. Check for proper operation and freedom of movement.

8. Check for excessive wear or damage.

9. Check for proper tightness and adjustment.

10. Drain, clean and refill.

11. Check for proper operation while pump/motor is running.

12. Check for proper lubrication.

13. Check for evidence of scratches, nicks or rust and for straightness of rod.

JLG INDUSTRIES REQUIRES THAT A COMPLETE ANNUAL INSPECTION BE PERFORMED IN ACCORDANCE WITH THE “ANNUAL MACHINE INSPECTION REPORT” FORM.

NOTE: This machine requires periodic safety and mainte-

nance inspections be a JLG Dealer. A decal located on the frame affords a place to record (stamp) inspection dates. Notify dealer if inspection is overdue.

14. Check for condition of element; replace as necessary.

15. Check for proper inflation.

16. Check Inspection Decal for current inspection stamp.

3121111 – JLG Lift – 2-27

SECTION 2 - PROCEDURES

Table 2-6. Preventive Maintenance and Safety Inspection

AREA INTERVAL

10Hours

(Daily)

P LA TF O RM

1. Controller 1,11

2. Switches 1,11

3. Placards and Decals 1,2

4. Control Tags 1,2

5. Hoses and Cables 4,8

6. Wear Pads 8

7. Handrails and Chains 1,4

C HA S S IS

1. Engine Oil 3 5

2. Battery 3 5

3. Air Cleaner 1 14

4. Exhaust System 1 1,5

5. Engine Mounts 1

6. Hydraulic Pump 1 5

7. Valves 1 5

8. Hydraulic Filter (See Lubrication Chart) 5,14 14

9. Hydraulic Hoses and Tubing 1 5

10. Hydraulic Oil Tank* 3 5 4

11. Hydraulic Tank Breath er 6,14

12. Fuel Tank 3,5 4

13. Lift Cylinder 1,12 5,6,13 4

14. Limit Switch 1,7

15. Tilt Alarm Switch 1,7

16. Placards and Decal s 1,2

17. Wheel and Tire Asse mblies 1 8,9

18. Drive Motors 1,5,6

19. Drive Brakes 1,6 8

20. Drive Torque Hubs 1,3,5,6

21. Steer Cylinder 1 5,6,13 4

22. Steer Components 1 4,6 8

23. Wheel Bearings (2 W heel Drive) 8 12

24. Sizzor Arms 1,4

25. Safety Props 1,4

26. Sliding Wear Pads 8

27. Pivot Pins/Bolts 1,4 7,8

28. Switches, Ground C ontrol 1,11

29. Control Tags 1,2

50 Hours (Weekly)

200 Hours

(Monthly)

500 Hours

(3 Month)

1000 Hours

(6 Month)

* Inspection and Maintenance code 10 to be performed annually

2-28 – JLG Lift – 3121111

SECTION 3 - TROUBLESHOOTING

SECTION 3. TROUBLESHOOTING

3.1 GENERAL

This section contains troubleshooting information to be used for locating and correcting most of the operating problems which may develop in the aerial platform. If a problem should develop which is not presented in this section or which is not corrected by listed corrective actions, technically qualified guidance should be obtained before proceeding with any maintenance.

Troubleshooting and maintenance information pertaining to the prime mover (engine/motor) that are not contained in this manual are contained in the applicable engine maintenance manual.

3.2 TROUBLESHOOTING INFORMATION

The troubleshooting procedures applicable to the aerial platform are listed and defined in Tables 3-1 through 3-4. As an aid to table use, the platform sizzor is divided into 4 major groups, each covered separately within this section. These groups are as follows: Platform, chassis, hydraulic system and electrical system.

Each malfunction within an individual group or system is followed by a listing of probable causes which will enable determination of the applicable remedial action. The probable causes and remedial action should, where possible, be checked in the order listed in the tables.

It should be noted that there is no substitute for a thorough knowledge of the equipment and related systems.

It should be recognized that the majority of the problems arising in the machine will be centered in the hydraulic and electrical systems. For this reason, every effort has been made to ensure that all likely problems in these areas are given the fullest possible treatment. In the remaining machine groups, only those problems which have more than one probable cause and remedy are included. This means that problems for which the probable cause and remedy may be immediately obvious are not listed in this section.

The first rule for troubleshooting any circuit that is hydraulically operated and electrically controlled is to determine if the circuit is lacking hydraulic oil and electrical power. This can be ascertained by overriding the bypass valve (mechanically or electrically) so that oil is available to the function valve, then overriding the function valve mechanically. If the function performs satisfactorily, the problem exists with the control circuit.

3.3 HYDRAULIC CIRCUIT CHECKS

The first reference for improper function of a hydraulic system, where the cause is not immediately apparent, should be the troubleshooting chart. The best place to begin the problem analysis is at the power source (pump) Once it is determined that the pump is serviceable, then a systematic check of the circuit components, beginning with the control, would follow. For aid in troubleshooting, refer to the Illustrated Parts Manual for hydraulic diagram of the various circuits.

3121111 – JLG Lift – 3-1

SECTION 3 - TROUBLESHOOTING

Table 3-1. Elevation System Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

No Response to LIft Control

Platform will not raise.

Platform will not lower

Platform Elevation System

Lift not performed w ithin three seconds after lift function switc h is selected.

Reselect lift function switch, then activate joystick within three seconds.

Lift control switch inoperative. Repair or replace control switch.

Hydraulic system oil low. Replenish oil as necessary.

Restricted or broken supply line on valve

Clean, repair or replace line.

bank or pump.

Control valve not functioning properly. Repair or replace valve.

Lift cylinder not functioning properly. Repair or replace cylinder.

Hydraulic pump not functioning properly. Repair or replace pump.

Joystick not activated within three seconds after lift switch is activated.

Load capacity exceeded. (Personnel

Activate lift switch, then activate joystick within three seconds.

Reduce load. (Refer to capacity placard).

and/or equipment on platform).

Hydraulic system oil low. Replenish oil as necessary.

Restricted or broken hydraulic line or fit-

Clean, repair, or replace line or fitting.

ting.

Control valve not functioning properly. Repair or replace valve.

Lift cylinder not functioning properly. Repair or replace lift cylinder.

Engine does not respond when lift control switch is moved to up position.

No electrical s ignal being sent to l ift up control valv e cartridge.

Joystick not activated within three sec. after lift switch is activated.

No electrical signal sent to lift down control valve cartridge.

Lift down control valve cartridge not functioning properly.

Refer to Electrical System Troubleshooting - No response to control switch.

Refer to Electrica l System Troubleshooting - No response to control switch.

Depress lift switch, then activate controller within three seconds.

Refer to Electrical System Troubleshooting - No response to control switch.

Repair or replace lift down control valve cartridge.

Lift cylinder not functioning properly. Repair or replace lift cylinder.

Engine does not respond when lift switch is moved to down position.

No electrical signal being sent to lift down control valve.

Refer to Electrical System Troubleshoot ing - No response to control switch.

Platform raises and lowers erratically

Hydraulic system oil low. Replenish oil as necessary.

Restricted or broken hydraulic line or fit-

C le a n , r e pa i r or r ep l a ce l in e .

ting.

3-2 – JLG Lift – 3121111

TROUBLE PROBABLE CAUSE REMEDY

Platform drifts down

SECTION 3 - TROUBLESHOOTING

Table 3-1. Elevation System Troubleshooting

Counterbalance valve on lift cyl. improprely adjusted or not functionin g properly.

Control valve not functioning properly. Repair or replace valve.

Worn seals in lift cylinder. Replace seals.

Lift cylinder not functioning properly. Repair or replace lift cylinder.

Manual lowering valve no t functioning properly.

Worn seals in lift cylinder. Replace seals.

Replace valve.

Repair or replace valve.

Holding valve on lift cylinder not functioning properly.

High Drive does not operate below horizontal

Damaged wiring on limit switch. Repair or replace wiring.

Damaged limit switch. Replace limit switch

Repair or replace valve.

3121111 – JLG Lift – 3-3

SECTION 3 - TROUBLESHOOTING

TROUBLE PROBABLE CAUSE REMEDY

No response to drive controller

Machine drives erratically

Machine will not travel forward

Machine will not travel in reverse

Table 3-2. Chassis Troubleshooting

Drive System

Joystick not activated within three seconds after drive select switch is activated.

Activate drive select switch, then activate joystick within three seconds.

Hydraulic system oil low. Replenish oil as necessary.

Hydraulic pump not functioning properly. Repair or replace pump.

Restricted or broken pump supply line. Clean, repair or replace line.

Drive motor not functioning properly. Repair or replace motor.

Damaged wiring on drive controller. Repair or replace wiring.

Drive controller not functioning properly. Repair or replace controller.

Drive brake not releasing. Determine cause and repair or replace

brake.

Microcircuit on controller improperly adjusted.

Joystick not activated within three seconds after drive switch is activated.

Adjust microswitch on controller for proper operation.

Activate drive switch, then activate joystick within three seconds.

Hydraulic system oil low. Replenish oil as necessary.

Restricted or broken hydraulic line or fit-

Clean, repair or replace line or fitting.

ting.

Control valve not functioning properly. Repair or replace valve.

Drive motor not functioning properly. Repair or replace motor.

Brake not functioning properly. Repair or replace brake.

Engine will not respond when enable switch is activated and drive controller is

Refer to Electrical System Troubleshooting - No response to control switch.

activated.

No electrical signal being sent to the drive valve cartridge.

Refer to Electrical System Troubleshooting - No response to control switch.

See: Machine will not travel forward.

High-Speed Drive function does not operate

3-4 – JLG Lift – 3121111

Table 3-2. Chassis Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

Loose or damaged wiring between drive controller and High Speed switch.

Defective high speed control switch. Replace high speed control switch.

Loose or damaged wiring in control box wire harness.

Loose or damaged wiring between platform and high speed solenoid.

High speed solenoid not functioning properly.

Loose or damaged wiring between high speed relay and high speed limit switch.

High speed limit switch not functioning properly.

Loose or damaged wiring in valve wiring harness.

No response to steer control switch on controller

Steer switch on controller not functioning properly.

Hydraulic system oil low. Replenish oil as necessary.

Hydraulic system pressure too low. Adjust pressure.

Loose or damaged wiring on control switch or solenoid valve.

Restricted or broken hydraulic line on valve bank or hydraulic pump.

Control valve not functioning properly. Repair or replace valve.

Steer cylinder not functioning properly. Repair or replace cylinder.

Machine hard to steer or steering is erratic

Hydraulic system oil low. Replenish oil as necessary.

Restricted or broken hydraulic line or fitting.

SECTION 3 - TROUBLESHOOTING

Ensure proper connection of wires. Using suitable test meter, perform continuity test on wiring between switches. Repair or replace wires as necessary.

Ensure proper connection of wires at the control switch. Using suitable test meter, perform conti nuity test on wires. Repair or replace harness as necessary.

Ensure proper connection of wires at the platform and at the high speed solenoid. Using suitable test meter, perform continuity test on wires. Repair or replace wires as necessary.

Replace solenoid.

Ensure proper connection of wires between high speed relay and high speed limit switch. Using suitable test meter, perform continuity test on wires. Repair or replace wires as necessary.

Repair or replace limit switch.

Ensure proper connection of wires at terminal strip. Using suitable test meter, perform continuity test on wires. Repair or replace wires as necessary.

Steering System

Repair or replace switch.

Ensure proper connection of wires at control switch or solenoid valve. Using suitable test meter, perform continuity test on wires. Repair or replace wires as necessary.

Clean, repair or replace line.

Clean, repair or replace line or fitting.

3121111 – JLG Lift – 3-5

SECTION 3 - TROUBLESHOOTING

Table 3-2. Chassis Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

Machine hard to steer or steering is erratic (cont.)

Lack of lubrication on steer components. Lubricate steer components in accor-

Restricted crossover relief valve. Clean or replace valve.

Steer system pressure low. Adjust pressure.

Bent steering linkage. Repair or replace linkage as required.

Hydraulic pump not functioning properly. Repair or replace valve.

Steer cylinder not functioning properly. Repair or replace cylinder.

Steering inoperative

Steer switch on controller not functioning properly.

Hydraulic system pressure too low. Adjust pressure.

Loose or damaged wiring on control switch or solenoid valve.

Solenoid valve not functioning properly. Repair or replace valve.

Restricted or broken hydraulic line on valve bank or hydraulic pump.

Relief valve improperly set or not functioning properly.

Steer cylinder not functioning properly. Repair or replace cylinder.

Machine will not steer left or right

Steer switch on controller not functioning properly.

Wiring on steer control switch is damaged.

Wiring on solenoid valve damaged. Repair or replace wiring.

Coil in solenoid damaged. Replace coil.

Bent cylinder rod. Repair or replace cylinder.

Damaged steer linkage. Repair or replace steer linkage.

Machine wanders; steering not firm

Crossover relief valve set too low or not functioning properly.

Steer linkage loose. Tighten linkage.

Spindle bushings badly worn. Replace bushings.

dance with Lubrication Chart.

Repair or replace switch.

Ensure proper connection of wires at control switch or solenoid valve. Using suitable test meter, perform continuity test on wires. Repair or replace wires as necessary.

Clean, repair or replace line.

Reset, repair or replace valve as necessary.

Replace controller.

Repair or replace wiring.

Reset, repair or replace valve as necessary.

3-6 – JLG Lift – 3121111

TROUBLE PROBABLE CAUSE REMEDY

Hydraulic pump noi sy

Pump cavitating (Vacuum in pump due to oil starvation

System overheating

Pump not delivering o il

System pressure too l ow

System(s) operate erra tically

SECTION 3 - TROUBLESHOOTING

Table 3-3. Hydraulic System Troubleshooting

Air entering system through broken line or fitting Repair or replace lin e or fitting

Air bubbles in oil Replenish oil as require d

Faulty pump couple r Replace coupler

Defective pump beari ng Repair or replace pu mp

Oil filter(s) dir ty Clean and/or replace filter(s) as necessary

Restricted suc tion line Clean, repair, or replace l ine

OIl in reserve low Replenish oil to proper level

Restricted reserv oir air vent Clean vent

Oil viscosity t o high Drain system and rep lace with recommended oil

(Refer to hydraulic oi ls)

Leak in suction line or manifold Repair or replace lin e or manifold as necessary

Oil viscosity t oo high Drain system and r eplace with recommended oil

(Refer to hydraulic oi ls)

Restricted or b locked hydraulic line Repair or replace line

Machine overloaded Check weight in platform

Main relief valv e set too high Reset valve as required

Hydraulic system o il low Replenish oi l as necessary

Restricted suc tion line Clean repair or replace line

Air entering system through broken line or fittin g (suction side)

Oil level too low Replenish oil to proper level

Plugged strainer in tank Clean strainer

Pump coupling defect ive Replace pump coupling

Broken pump drive s haft Repair or replace pu mp

Main relief valv e set too low Reset valve as required

Main rel ief valve st uck in open position Clean, repair or re place valve (Check system oil for

Hydraulic pump not func tioning properly Repair or replace pump

Leak in component, l ine or fitting Repair or replace component, line or fitting

Scored valve spo ol; Scored cylinder Replace valve; Rep lace cylinder

Sticking or bind ing valve spools, piston ro d, etc Clean, repair or replace c omponents as required

Hydraulic oil not a t optimum operating temperature

Pump drive slippi ng Repair or repl ace drive

Replace or repair l ine or fitting

contamination)

Allow oil sufficient time to warm up

3121111 – JLG Lift – 3-7

SECTION 3 - TROUBLESHOOTING

Table 3-4. Electrical System Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

Regardless of whi ch way handle is moved, only one function occurs

Improper or loose wi ring to the solenoid(s) Check all wiring for p roper connections

Directional valve stuck in one direction Repair or replace valve

Valve will not function when handl e is moved in either direction

Joystick not activated within the 3 seconds after function switch wa s depressed

No electrical power to handle Check electrical input to hand co ntroller (12V)

No electrical power to valve Check electrical output of printed circuit board and

Improper ground Check f or proper grounding of handle

Defective controller Repair or re place controller

Microswitches on controlle r bad or need adjustment

No response to a function co ntrol switch

Emergency stop switch not positi oned properly Place emergency stop sw itch to on

Platform/Ground select s witch not positioned properly

Circuit breaker open Determine and correct cause. Reset circuit

No voltage present at em ergency stop switch Check battery ca ble from battery to emergency

Emergency stop swit ch not functioning properly Replace switch

No voltage suppli ed to start relay from emer gency stop switch

No voltage input at terminal stri p Check wir e from battery to terminal strip for proper

No voltage pres ent at circuit breaker Check wire from termi nal strip to battery for proper

Defective circuit breaker Replace circuit breaker

No voltage present at P latform/Ground select switch

Defective Platform/Ground select switch Replace Platform/Ground select switch

HAND CONTROLLER

Reactivate function switch

electrical signal at the valve

Adjust or replac e switches

CONTROL SWITCHES

Place switch to pl atform or ground, as necessary

breaker

stop switch for proper conne ction or damage. Repair or replace cable as necessary

Check battery cable from sw itch to relay for proper connection or damage. R epair or replace cable as necessary

connection or damage. R epair or replace cable as necessary

Unplug ground control box harness from platform receptacle. check wi re from applicable pin in plug to control box po wer switch for proper connection. Using suitable test me ter, per form continuity test on wire. Repair or replace harness as necessary

3-8 – JLG Lift – 3121111

TROUBLE PROBABLE CAUSE REMEDY

Engine will not crank

Ammeter inoperativ e

Travel warning horn inopera tive

Hourmeter inoperativ e

SECTION 3 - TROUBLESHOOTING

Table 3-4. Electrical System Troubleshooting

No voltage present at fu nction control switch Check wiring from power switch to function control

switch for proper connection or damage. Repai r or replace wiring as ne cessary

Defective function control switch Replace function control switch

No voltage present at ap plicable control valve coil C heck applicable wire for proper conne ction at

terminal strip, valve har ness plug pin, valve harness receptacle pin and valve coil. Using suit able test meter, perform continuity test on wire. Repair or replace harness as necessary

No voltage supplied to motor from start relay Check ba ttery cable from relay to motor for proper

connection or dama ge. Repair or replace cable as necessary

Defective motor/pump assembly Replace motor/pump assembly

ENGINE STARTER SYSTEM

Discharged battery or l oose battery terminals Check and char ge battery or replace battery as

necessary. Clean and secure battery terminals

Starter relay faulty or faulty relay connections U sing a test meter, check relay coil termina ls for

presence of electrical power and for ene rgization of relay coil. Also check relay terminals for correct switching of con tacts. Replace relay as necessary

Malfunctioning starter s olenoid or motor Replace solenoid or motor in accordance with

applicable manufactu rer’s manual

Defective start l ockout solenoid Replace start l ockout solenoid

Malfunctioning ignition switch Using a test meter, check i gnition switch for cor-

rect switching of contacts. replace switch as necessary

Faulty ignition and/o r starter circuit wiring Check wiring continu ity. ref er to wiring diagram

Defective ring gear o r flywheel Replace ring gear

INSTRUMENTS AND IN DICATORS

Damaged wiring in circuits Repair or repl ace wiring

Ammeter not functio ning properly Replace ammeter

Alternator not charging Repai r or replace alternator

Circuit breaker open Determine and correct cause

Damaged wiring in horn circuit Replace horn

Damaged wiring in hourmeter circuit Repair or repl ace wiring

Inoperative hourmeter Replace hou rmeter

3121111 – JLG Lift – 3-9

SECTION 3 - TROUBLESHOOTING

GROUND

ELECTRONICS

3-10 – JLG Lift – 3121111

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

SECTION 3 - TROUBLESHOOTING

GROUND

ELECTRONICS

1870118_I

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

3121111 – JLG Lift – 3-11

SECTION 3 - TROUBLESHOOTING

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

3-12 – JLG Lift – 3121111

SECTION 3 - TROUBLESHOOTING

2792397 E

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

3121111 – JLG Lift – 3-13

SECTION 3 - TROUBLESHOOTING

This page intentionally left blank.

3-14 – JLG Lift – 3121111

McConnellsburg PA. 17233-9533

JLG Worldwide Locations

Corporate Office

JLG Industries, Inc.

1 JLG Drive

USA

Phone: (717) 485-5161

Fax: (717) 485-6417

JLG Industries (Austr a l ia) P.O. Box 5119 11 Bo lwarra Road Port Macquarie N.S.W. 2444 Australia Phone: (61) 2 65 811111 Fax: (61) 2 65 810122

JLG Latino Americana Ltda. Rua Eng. Carlos Stevenson, 80-Suite 71 13092-310 Campinas-SP Brazil Phone: (55) 19 3295 0407 Fax: (55) 19 3295 1025

JLG Industries (Europe) Kilmartin Place, Tannochside Park Uddingston G71 5PH Scotland Phone: (44) 1 698 811005 Fax: (44) 1 698 811055

JLG Industries (UK) Unit 12, Southside Bredbury Park Industrial Estate Bredbury Stockport SK6 2sP England Phone: (44) 870 200 7700 Fax: (44) 870 200 7711

JLG Europe B.V. Jupiterstraat 234 2132 HJ Foofddorp The Netherlands Phone: (31) 23 565 5665 Fax: (31) 23 557 2493

JLG Industries (Pty) Ltd. Unit 1, 24 Industrial Complex Herman Street Meadowdale Germiston South Africa Phone: (27) 11 453 1334 Fax: (27) 11 453 1342

JLG Deutschland GmbH Max Planck Strasse 21 D-27721 Ritterhude/lhlpohl Bei Bremen Germany Phone: (49) 421 693 500 Fax: (49) 421 693 5035

JLG Industries (Norge AS) Sofeimyrveien 12 N-1412 Sofienyr Norway Phone: (47) 6682 2000 Fax: (47) 6682 2001

Plataformas Elevadoras JLG Iberica, S.L. Trapadella, 2 P.I. Castellbisbal Sur 08755Castellbisbal Spain Phone: (34) 93 77 24700 Fax: (34) 93 77 11762

JLG Industries (Ital ia) Via Po. 22 20010 Pregnana Milanese - MI Italy Phone: (39) 02 9359 5210 Fax: (39) 02 9359 5845

JLG Polska UI. Krolewska 00-060 Warsawa Poland Phone: (48) 91 4320 245 Fax: (48) 91 4358 200

JLG Industries (Sweden) Enkopingsvagen 150 Box 704 SE - 175 27 Jarfalla Sweden Phone: (46) 8 506 59500 Fax: (46) 8 506 59534

JLG 400CRT Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

A.A GENERAL

A.B HYDRAULIC SYSTEM SAFETY

A.C MAINTENANCE

SECTION 1. SPECIFICATIONS

1.1 CAPACITIES

Hydraulic Oil Tank

Hydraulic System (Including Tank)

Fuel Tank

Engine Crankcase

Gasoline Engine

Diesel Engine

Drive/Steer System

1.2 COMPONENT DATA

1.3 PERFORMANCE DATA

Travel Speed

Gradeability

Turning Radius (Inside)

Lift Speed

Platform Capacity - Fixed Platform

Platform Extension Capacity

Machine Weight

Machine Height (Fully Extended)

Machine Platform Height (Platform Lowered)

Machine Length

Machine Width

1.5 LUBRICATION

1.4 TORQUE REQUIREMENTS

Lubrication Specifications

1.6 PRESSURE SETTINGS

1.7 SERIAL NUMBER LOCATIONS

1.8 LIMIT SWITCHES

1.9 CYLINDER SPECIFICATIONS

1.10 MAJOR COMPONENT WEIGHTS

1.11 CRITICAL STABILITY WEIGHTS

SECTION 2. PROCEDURES

2.1 GENERAL

2.2 SERVICING AND MAINTENANCE GUIDELINES

General

Safety and Workmanship

Cleanliness

Components Removal and Installation

Component Disassembly and Reassembly

Pressure-Fit Parts

Bearings

Gaskets

Bolt Usage and Torque Application

Hydraulic Lines and Electrical Wiring

Hydraulic System

Lubrication

Batteries

Lubrication and Servicing

2.3 LUBRICATION INFORMATION

Hydraulic System

Hydraulic Oil

Changing Hydraulic Oil

Lubrication Specifications

2.4 CYLINDERS - THEORY OF OPERATION

2.5 VALVES - THEORY OF OPERATION

Solenoid Control Valves (Bang-Bang)

Proportional Control Valves

Relief Valves

Crossover Relief Valves

2.6 COMPONENT FUNCTIONAL DESCRIPTION

Hydraulic Pump

Lift Cylinder Counterbalance/Manual Descent Valve

2.7 WEAR PADS

Sliding Pads

2.8 CYLINDER CHECKING PROCEDURES

Cylinder w/o Counterbalance Valves - Steer Cylinder

Installation

2.9 LIFT CYLINDER REMOVAL AND INSTALLATION

Removal

2.10 LIFT CYLINDER REPAIR

Disassembly

Cleaning and Inspection

Assembly