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Service & Maintenance Manual

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2. Figure 1 1 Lubrication Diagram Table 1 4 Lubrication Chart INDEX INTERVAL NO COMPONENT LUBE POINTS LUBE METHOD HOURS 1 Hydraulic Oil Reservoir Fill Cap Drain Plug HO Check HO Level 10 500 HO Change HO 2 Hydraulic Filter Element N A Initial Change 50 Hours 250 3 Rail Slides N A MPG Brush 100 4 Engine Crankcase Fill Cap Drain Plug Check Engine Oil Level 10 100 KEY TO LUBRICANTS MPG Multi purpose Grease EPGL Extreme Pressure Gear Lube HO Hydraulic Oil Mobil 424 A WARNING NOTE 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 3121111 JLG Lift Recommended lubricating intervals are based on machine operations under normal conditions For machines used in multi shift operations and or exposed to hostile environments or conditions lubri cation frequencies must be increased accordingly Operate hydraulic functions through one complete cycle before checking hydraulic oil level in tank Oil should be visible in ADD sight window on hydraulic tank If oil is not visible add oil until oil is visible in both ADD and FULL sight windows on tank Do not overfill tank Any time the pump coupling is removed coat splines of coupling with Texaco Code 1912 grease pr
3. 2 5 2 10 Lif Cylinder Repair 2 ae kaia taala lai were red dae 2 9 2 11 Steer Cylinder 1 2 14 2 12 Oscillation Cylinder 0 1 2 16 2 13 Magnetic Speed Pickup Cleaning Procedure 2 16 2 14 Pressure Setting 2 17 2 15 Limit Switch Adjustment ad eese E A ha fad ME RR EE 2 18 2 16 Automatic Choke Field Adjustment DF 750 2 18 2 17 Electronic Control System 2 19 2 18 Flash Codes and lt 2 21 2 19 Preventive Maintenance and Inspection 2 27 SECTION 3 TROUBLESHOOTING 3 1 General aa oaths stl eed ido eee odd Di edes deed oT te cer ears 3 1 3 2 Troubleshooting Information 1 3 1 3 3 Hydraulic Circuit Checks 1 07 3 1 3121111 JLG Lift TABLE OF CONTENTS LIST OF FIGURES FIGURE NO TITLE PAGE NO 1 1 Lubrication Diagram RR lahke a ee
4. 1 1 2 Lubrication Chart SE e req dd da es 1 3 Cylinder 4 4 1 6 Major Component 1 6 Critical Stability 12 2 2 1 6 Cylinder Component Torque 2 13 Holding Valve Torque 2 13 Help Messages and Flash Codes 2 21 Machine Model 1 2 25 Machine Configuration Programming 2 26 Preventive Maintenance and Safety 2 28 Elevation System 3 2 Chassis 0 2 3 4 Hydraulic System Troubleshooting 3 7 Electrical System 3 8 JLG Lift TABLE OF CONTENTS JLG Lift 3121111 SECTION 1 SPECIFICATIONS SECTION 1 SPECIFICATIONS 1 1 CAPA
5. rhe e 1 2 1 5 811 6 1 1 2 1 6 Pressure Settihgs va Lese et atit eeu e D Ame Seen eS 1 5 1 7 Serial Number Locations 1 5 1 8 Limit Switches occ dep DUE CRAP ae PT IU Det 1 5 1 9 Cylinder Specifications 155 11 144 eli REEL IRE REEL REEL 1 6 1 10 Major Component 1 6 1 11 Critical Stability Weights 0 0 0 0 mre 1 6 SECTION 2 PROCEDURES 2 1 General di wile uer gad ea Reda dawn es d 2 1 2 2 Servicing and Maintenance 2 1 2 3 Lubrication 22 22222 22 2 2 2 2 4 Cylinders Theory of 2 3 2 5 Valves Theory of Operation 2 3 2 6 Component Functional 2 4 2 7 Wear Pads d e deer dre does Oop weed 2 4 2 8 Cylinder Checking Procedures 2 4 2 9 Lift Cylinder Removal and Installation
6. MOTE MOTD AT AT 1304 NO LITT AX UL 1 3 0 MOTD 31814103 SISAL INNA TANA 4814 TANA E Em am 11115 NIA 7 eee s Ls uo LL ums 1 pon uuopeid Ao 1 1 LAHUS DNA anna 159 xe LINI 00 OL WOVA TINE epon puno use WINGY und wo 34 Miomo n A 4 OL WOVE 1 NMOQ WAALS LAITA 1413 LV sa CIMOIS MAAS LAHT 9114 MOTD JLG Lift Nd LITT L TANA 4n LITT TAS 4445 OL 4 TINO 8909 TINA UALS ATT HARIS XVN OL 0 3 110 HS MOTD ASUATA NIZXTY mE 048 LIINA mm TES I Tur ie LIA OL MIND TIS SAIS LIIS TUI 448 YMO AMALIVE KUOHIVIA TIS ATI i MS IIOAIVId ISAL xi MS 080049 ISAL CONT ATA 1581 SNOISHAA DOWNA ANION SAATVA KAISAS amm WOAIVTd JSWON MAING SAA ISAL WALSAS NAMI T SISILILVALDIV SIILSONIVIG
7. A 1 T am 0 L 4 at TT 22 uy Lu TANK RETURN Figure 3 3 Hydraulic Schematic Sheet 1 of 2 JLG Lift 3121111 SECTION 3 TROUBLESHOOTING REAR DRIVE MOTORS A L 8 7 A U B 4 FRONT DRIVE MOTORS FRONT BRAKES ARE USED ON 400 C E ONLY 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 Corporate Office JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 USA Phone 717 485 5161 Fax 717 485 6417 JLG Worldwide Locations JLG Industries Australia JLG Industries UK JLG Deutschland GmbH JLG Industries Italia P O Box 5119 Unit 12 Southside Max Planck Strasse 21 Via Po 22 11 Bolwarra Road Bredbury Park Industrial Estate D 27721 Ritterhude Ihlpohl 20010 Pregnana Milanese MI Port Macquarie Bredbury Bei Bremen Italy N S W 2444 Stockport Germany Phone 39 02 9359 5210 Australia SK6 25 Phone 49 421 693 500 Fax 39 02 9359 5845 Phone 61 2 65 811111 England Fax 49 421 693 5035 Fax 61 2 65 810122 Phone 44 870 200 7700 Fax 44 870 200 7711 JLG Latino Americana Ltda JLG Europe B V JLG Industries Norge AS JLG Polska Rua Eng Carlos Stevenson Jupiterstraat 234 Sofeimyrveien 12 UI Krolewska 80 Suite 71 2132 HJ Foofddorp N 1412 Sofienyr 00 060
8. p RROR RTP J3 p gt ELL 10 1 SELECT SELECT SPEED START PLUGS SELECT SELECT TILT ALARM ORN RED 44 3 BLACK 28 IR 21 MHIJRED 51 21 WHT RFD 51 3 WHT RED 57 4 i 1 E E E 4 4 EI E E 5 gt 3 E a 8 d 8 E E g E FRONT FRONT FRONTO FRONTO REAR OH REAR OH REAR REAR LEFT LEFT RIGHT e RIGHT LEFT E RIGHT RIGHT UP DOWN DOWN UP DOWN DOWN A AABA ig n BB E Dr 1 m el mp m BLACK 5 5 2 5 5 50690969 S S 8 9 b E 2 vildi gt HB SIL py 2 2 2 2 22 TILTX 18 235 ORIU RED 4 PIN4 DUAL AXIS ORN RFD 49 ANALOG TILTY 025 37 PINS TILT SENSOR NOTE BYPASS VALVES USED GND BLACK PINI ON CRT MACHINES ONLY BYPASS 1 BYPASS 2 BYPASS 3 RX VALVE VALVE VALVE 81 87A TX GND BYPASS A 30 GROUND Miis ais WHITE ELECTRONICS s RVS ORANGE 8 1 FWS ORANGE 1 1 BRS ORANGE 55 7 RTS YELLOW 10 LTS YELLOW 9 DPS 2 FUEL A DUMP STEER STEER BRAKE DRIVE DRIVE LIFT LIF i VALVE LEFT RIGHT FOR REV UP Dow d i GND E 5 g e GND 22 2 gt 2 3 12 ER 8 84 54 e gt e lt gt E amp fe fe zd E E 15 A feu ACTUATOR JA BLACK 4 V V 7 FUEL SENDER 4 BLACK I d 8 4 405 9 42 gu J m E 8 3 J E E 4 7 E LP gt SPEED valve PICK UP 5 gt GAS AUTO VALVE CHOKE I FUEL IGN PUMP SYSTEM I ES YELIR
9. 17 Position the cylinder barrel in a suitable holding fix ture IMPORTANT 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 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 inder head gland can be inserted into the barrel cyl inder 20 Secure the cylinder head gland using the washer ring and socket head bolts HEAD ASSY CYLINDER BARREL PISTON ASSY WASHER RING 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 22 If applicable install the cartridge type holding valve and fittings in the rod port block using new o rings 3121111 as applicable See Table 2 1 Cylinder Component Torque A CAUTION 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
10. PROCEDURES Valve Knob Actuator for Tow Brake Release Steer Right Brake Release Dump Valve Main Steer Right Steer Left Steer Left Figure 2 19 Valve Components 2 14 PRESSURE SETTING PROCEDURES NOTE Make all pressure adjustments with the engine oper ating and the hydraulic oil at normal operating tem perature 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 oper ating the functions from the platform control station Lift Relief Adjustments 3121111 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 From the platform control station activate the Lift Up function by selecting the lift control switch and posi tioning the joystick to the up position 4 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 Remove the pressure gauge from gauge port MP Steer Relief Adjustment 1 JLG Lift Install a pressure gauge at gauge port P2 located on the lower right side of the valve body The port is
11. dL Service amp Maintenance Manual Model 330CRT 400CRT 3121111 August 18 2004 dL 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 main tenance personnel pay strict attention to these warn ings 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 A WARNING MODIFICATION OF THE MACHINE WITHOUT CERTIFI CATION 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 consider ation when engaging in the maintenance of equip ment 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 pro vided A WARNING SINCE THE MACHINE
12. i 3 Lift Speed Fuel Consumption Low RPM 1 3 gph 4 9 Table 1 1 Lift Speeds High RPM 2 4 gph 9 Iph Model Lift Up Sec Lift Down Sec Horsepower 24 5 3600 RPM 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 Ib 455 kg 400 CRT 800 Ib 365 kg Platform Extension Capacity 1 5 LUBRICATION Table 1 2 Hydraulic Oil All Models 250 Ib 120 kg Machine Weight 330CRT Approx 9 320 Ib 4 228 kg 440CRT Approx 10 070 Ib 4 568 kg Machine Height Fully Extended 330 CRT 33 ft 10 m 400 CRT 40 ft 12 m Machine Platform Height Platform Lowered HYDRAULIC SYSTEM OPERATING SAE VISCOSITY GRADE TEMPERATURE RANGE Oto 23 degrees F 10W 18 to 5 degrees 0 to 210 degrees F 10W 20 10W 30 18 to 100 degrees C 50 to 210 degrees F 20W 20 10 to 100 degrees 330 CRT 66 5 in 1 7 m 400 CRT 68 25 in 1 7 m Machine Length 10 ft 2 in 3 Machine Width 69 in 1 8 m 1 4 TORQUE REQUIREMENTS All wheel lugs must be torqued at 105 ft Ib 142 ft Ib every 50 hours 1 2 JLG Lift NOTE Hyaraulic oils must have anti wear qualities at least to Service Classification GL 3 and sufficient chemical stability
13. 3 2 Chassis Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Drive System No response to drive controller Joystick not activated within three sec onds 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 Machine drives erratically Microcircuit on controller improperly adjusted Adjust microswitch on controller for proper operation Machine will not travel forward Joystick not activated within three sec onds after drive switch is activated Activate drive switch then activate joy stick within three seconds Hydraulic system oil low Replenish oil as necessary Restricted or broken hydraulic line or fit ting Clean repair or replace line or fitting Control valve not functioning properly Repair or replace valve Drive motor not functioning properly Repair or replace motor Brake not func
14. CID 206 3A139314 4 7 0101 48113 31150 C97 adaon COU HOLNA ANOYOL 553515 VIO 328 13898 419 134908 4108 3121111 JLG Lift 1 4 SECTION 1 SPECIFICATIONS Serial Number Stamped Serial Number Plate Figure 1 2 Serial Number Location 1 6 PRESSURE SETTINGS 1 8 LIMIT SWITCHES Main Relief 3300 psi 50 psi 228 bar 3 4 bar The machine is equipped with the following limit switches Steer Relief Left max 2600 psi 1 79 bar High Drive Speed Cut Out High drive speed is cut out when platform is raised above stowed fully lowered posi Steer Relief Right max 1600 psi 110 bar tion Lift Pressure 330CRT 2300 psi 159 bar 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 oper Leveling Jacks Valve If Equipped 1200 psi 83 bar ated on a 3 slope with the platform completely lowered only the warning light is illuminated 400CRT 2500 psi 172 bar Rr TT em Drive Cut Out 400CRT only Drive function is cut out 1 7 SERIAL NUMBER LOCATIONS when the machine reaches a preset height of 30 ft 0 8 m For machine identification a serial number plate is affixed to the machine The p
15. F TOP VIEW TOP COVER SCREW VACUUM CONNECTION eet VACUUM PULL OFF POSITIVE CONNECTION SIDE VIEW HORIZONTAL ADJUSTING iris AIR mic Figure 2 20 Automatic Choke Adjustment DF 750 3121111 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 required Diesel Engine 3121111 NOTE Never run the fuel tank dry Diesel engines cannot be restarted after running out of fuel until the fuel system has been air 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 con troller 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 back wards 2 Power up the Control System by turning the lower key to the platf
16. MANUFACTURER HAS NO DIRECT CONTROL OVER THE FIELD INSPECTION AND MAINTENANCE SAFETY IN THIS AREA RESPON SIBILITY OF THE OWNER OPERATOR A B HYDRAULIC SYSTEM SAFETY It should be noted that the machines hydraulic sys tems operate at extremely high potentially danger ous pressures Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of the system 3121111 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 A WARNING 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 DUR ING 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 CAU TIONS ON MACHINE AND IN SERVICE MANUAL KEEP OIL GREASE WATER ETC WIPED FROM STANDING SURFACES AND HAND HOLDS USE CAUTION WHEN CHECKING A HOT PRESSUR IZED COOLANT SYSTEM NEVER WORK UNDER AN ELEVATED BOOM U
17. ae 1 3 1 1 Torge Chame ier Boy ete Aa aa ae ee MEA IUS 1 4 1 2 Serial Number 1 5 2 1 Arms and Platform Positioning and Support Cylinder Repair 2 6 2 2 SS0GRT Lift Gylinider eld dan Petes hal ot a dk ast oe ae 2 7 2 3 AOOCRT Lift Cylinder eo dy ioe eo a et EWES ASE were eae 2 8 2 4 Cylinder Barrel 2 9 2 5 Gapscrew Removal cei ierse esegue imer eR Edu ued la aaa 2 9 2 6 aair panice Sade me eed Bs ah 2 9 2 7 Tapered Bushing 1 4 3 4 4 2 10 2 8 Rod Seal Installation 2 11 2 9 Wiper Seal Installations 2 1 od s epe Bie ea bated Meda 2 11 2 10 Installation of Head Seal 2 11 2 11 Piston Seal 4 2 12 2 12 Bushing Installation 11 2 12 2 13 Seating the Tapered Bearing 2 12 2 14 Poly
18. 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 10 11 12 3121111 JLG Lift Continue pushing the rod into the barrel until the cyl inder head gland can be inserted into the barrel cyl inder If applicable secure the cylinder head retainer using a suitable chain wrench 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 If applicable install the cartridge type holding valve and fittings in the port block using new o rings as applicable SECTION 2 PROCEDURES 1 Barrel 7 O Ring 13 Head 2 Check Restrictor Valve 8 Spacer 14 Seal 3 Locknut 9 Bacp Up Ring 15 Wiper 4 Wear Ring 10 O Ring 16 Rod 5 Seal 11 Wear Ring 17 Garmax Bushing 6 Piston 12 O ring Figure 2 3 400CRT Cylinder 2 8 JLG Lift 3121111 SECTION 2 PROCEDURES 2 10 LIFT CYLINDER REPAIR Disassembly IMPORTANT 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 IMPORTANT DO NOT FULLY EXTEND CYLINDER TO END OF STROKE RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES SURE 2 Operate the hydraulic power source an
19. divided into five columns representing the various inspec 5 tion time periods The numbers listed within the interval column represent the applicable inspection code for 6 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 8 be considered as all inclusive Variances in interval times may occur due to climate and or conditions and depend 9 ing on the location and use of the machine 10 JLG Industries requires that a complete annual inspection 11 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 12 Service Form must be completed and returned to JLG Industries 13 IMPORTANT 14 JLG INDUSTRIES REQUIRES THAT A COMPLETE ANNUAL INSPECTION BE PERFORMED IN ACCORDANCE WITH THE ANNUAL MACHINE INSPECTION REPORT FORM 16 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 over due 3121111 JLG Lift 15 The inspection and maintenance code numbers are as fol lows Check for proper and secure installation Check for visible damage and legibility Check for proper fluid level Check for an
20. 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 3 Loosen the 3 top cover screws and rotate the top cover till the choke butterfly is closed with 1 32 in 2 18 JLG Lift space between the plate and the wall of the carbure tor 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 carburetor Remember LP fuel needs no choke all the way open 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
21. identified by a stamping on the valve body Activate the Steer Right function and check Steer pressure If necessary adjust Steer pressure to 1600 psi 110 bar Activate the Steer Left function and check Steer pressure If necessary adjust Steer pressure to 2600 psi 179 bar Remove the pressure gauge from gauge port P2 2 17 SECTION 2 PROCEDURES 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 have been pre set to operate between 20 and 100 with little or no adjustment If the machine will be operated for pro long use outside these temperature ranges adjust ments could be made to improve performance of the engine 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
22. is a grav ity down machine A holding valve is used in the Lift circuit to prevent retrac tion 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 acti vated and the control valve solenoid energizes the spool is shifted and the corresponding work port opens to per mit oil flow to the component in the selected circuit with the opposite work port opening to reservoir Once the cir cuit 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 spring loaded to center position therefore when the control is released the spool automatically returns to neutral pro hibiting any flow through the circuit Proportional Control Valves The proportional control valves provide a power output match
23. scoring and for distortion Dress piston surface or replace piston as necessary 10 11 12 13 14 15 16 17 JLG Lift Inspect threaded portion of piston for damage Dress threads as necessary Inspect seal and o ring grooves in piston for burrs and sharp edges Dress applicable surfaces as nec essary Inspect cylinder head inside diameter for scoring or other damage and for ovality and tapering Replace as necessary Inspect threaded portion of head for damage Dress threads as necessary Inspect seal and o ring grooves in head for burrs and sharp edges Dress applicable surfaces as nec essary Inspect cylinder head outside diameter for scoring or other damage and ovality and tapering Replace as necessary 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 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 Inspect travel limiting collar or spacer for burrs and sharp edges If necessary dress inside diameter surface with Scotch Brite or equivalent If applicable inspect port block fitt
24. suction line Clean repair or replace line Ollinreserve low Replenish oil to proper level Restricted reservoir air vent Clean vent Oil viscosity to high Drain system and replace with recommended oil Refer to hydraulic oils Leak in suction line or manifold Repair or replace line or manifold as necessary System overheating Oil viscosity too high Drain system and replace with recommended oil Refer to hydraulic oils Restricted or blocked hydraulic line Repair or replace line Machine overloaded Check weight in platform Main relief valve set too high Reset valve as required Hydraulic system oil low Replenish oil as necessary Pump not delivering oil Restricted suction line Clean repair or replace line Air entering system through broken line or fitting suction side Replace or repair line or fitting Oil level too low Replenish oil to proper level Plugged strainer in tank Clean strainer Pump coupling defective Replace pump coupling Broken pump drive shaft Repair or replace pump System pressure too low Main relief valve set too low Reset valve as required Main relief valve stuck in open position Clean repair or replace valve Check system oil for contamination Hydraulic pump not functioning properly Repair or replace pump Leak in component line or fitting Repair or replace component line or fitting Scored valv
25. 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 1 1 260 CRT 0 Model 2 330 CRT 3 400 CRT 2 0 750 Dual Fuel 0 Engine Selection 1 905 Diesel 2 1105 Diesel 3 0 No Cutout 0 Tilt 1 Cutout lift up and drive if tilted and elevated Required for AUS and BRZ markets 4 0 No drive cutout switch installed 0 Drive Cutout 1 Cuts out drive when deckis elevated above a predetermined elevation Default for 400 CRT 5 0 FWD amp LIFT up 0 Control Direction 1 FWD amp LIFT dn for future use 6 0 No 0 Leveling Jacks 1 Yes 7 0 Domestic amp CE Fixed 2 Axle Type 1 DOmestic Oscillating 2 CE Oscillating 2 26 JLG Lift 3121111 SECTION 2 PROCEDURES 2 19 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE 1 The preventive maintenance and inspection checks are listed and defined in the following table This table is 2 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 4 systems along with the components that make up that system are listed The INTERVAL portion of the table is
26. the cylinder mounting block clears the mounting slot in the bot 1 Barrel 2 Locknut 3 Seal 4 Piston 5 O Ring 6 Back Up tom of the axle then slowly remove the cylinder from the axle and place it in a suitable work area Disassembly IMPORTANT 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 fix ture Using a suitable chain wrench carefully remove the cylinder head retainer from one end of the cylinder barrel Attach a suitable pulling device to one end of the cylinder rod 7 Wear Ring 8 Guide 9 Wiper 10 O Ring 11 Retaining Ring 12 Rod Figure 2 16 Steer Cylinder Assembly 2 14 JLG Lift 3121111 SECTION 2 PROCEDURES IMPORTANT EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL INDER ROD SPACER AND PISTON AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES 4 10 With the barrel clamped securely apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel 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 O ring and wear ring Using suitable protection clamp the cylinder rod in a vise or similar holding fixtur
27. 12 5 6 13 14 Limit Switch 1 7 15 Tilt Alarm Switch 16 Placards and Decals 17 Wheel and Tire Assemblies 8 9 18 Drive Motors 1 5 6 19 Drive Brakes 1 6 20 Drive Torque Hubs 1 3 5 6 21 Steer Cylinder 5 6 13 22 Steer Components 46 23 Wheel Bearings 2 Wheel Drive 12 24 Sizzor Arms 1 4 25 Safety Props 1 4 26 Sliding Wear Pads 27 Pivot Pins Bolts 1 4 7 8 28 Switches Ground Control 1 11 29 Control Tags 1 2 Inspection and Maintenance code 10 to be performed annually 2 28 JLG Lift 3121111 SECTION 3 TROUBLESHOOTING 3121111 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 thr
28. 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 Torque Value p w Loctite Tapered Bushing Retaining Screws Lift Cylinder 80 ftlb 108 Nm Head Retaining Screws Lift Cylinder 9ftlb 12 Nm Table 2 2 Holding Valve Torque Specifications Description Torque Value Sun 7 8 hex M20 x 1 5 thds 30 35 16 41 48Nm Sun 1 1 8 hex 1 14 UNS thds 45 50 ftlb 61 68Nm Sun 1 1 4 hex M36 x 2thds 150 153ftlb 204 207Nm Racine 1 1 8hex 1 1 16 12 thds 50 55 ftlb 68 75Nm Racine 1 3 8 hex 1 3 16 12 thds 75 80 ftlb 102 109Nm Racine 1 7 8 hex 1 5 8 12 thds 100 110ftlb 136 149Nm 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
29. 3 8 JLG Lift 3121111 SECTION 3 TROUBLESHOOTING Table 3 4 Electrical System Troubleshooting TROUBLE PROBABLE CAUSE REMEDY No voltage present at function control switch Check wiring from power switch to function control switch for proper connection or damage Repair or replace wiring as necessary Defective function control switch Replace function control switch No voltage present at applicable control valve Check applicable wire for proper connection at terminal strip valve harness plug pin valve har ness receptacle pin and valve coil Using suitable test meter perform continuity test on wire Repair or replace harness as necessary No voltage supplied to motor from start relay Check battery cable from relay to motor for proper connection or damage Repair or replace cable as necessary Defective motor pump assembly Replace motor pump assembly ENGINE STARTER SYSTEM Engine will not crank Discharged battery or loose battery terminals Checkand charge battery or replace battery as necessary Clean and secure battery terminals Starter relay faulty or faulty relay connections Usinga test meter check relay coil terminals for presence of electrical power and for energization of relay coil Also check relay terminals for correct switching of contacts Replace relay as necessary Malfunctioning starter solenoid or motor Replace solenoid or
30. Battery voltage above 16V Check battery and alternator 5 5 ENGINE SHUTDOWN OVERSPEED The engine speed exceeded 4500 RPM for more than 2 seconds Check throttle actuator for debris or interference which pre vents free movementof actuator Recycle power to clear the fault and restart ENGINE SHUTDOWN OIL PRES COOLANT TEMP The engine oil pressure was too low or the engine coolant temperature was too high for more than 10 seconds Check engine fluid levels Recycle power to clear fault and restart 2 22 JLG Lift 3121111 SECTION 2 PROCEDURES 2 23 2 Jo 199465 12 2 911614 11266 QHOMSSVd H31N3 LSNIN 5 1631 N3LSAS OL H3QHO NI uondo x uondo M RN NI MO uondo x ad 4 0 44 ANC MLO L A UO T UH uondo HUO L ad 0TH WOT AjuQ jan jand x NO 0 uuopeld ur 1591 x xNO 9 0 34 NON L dil TWO a pU Eoo NOUO 14 juo uondo 2d UO i Yousior not 1 sMOlsuo uondo xx EE p SCHO EPON uuopeld 1591 sei 8804 us 2 en ee WV Wis EIDEM cue t LIT WIS 2 133HS OL MOTIIV TTL SISSVHO L
31. CITIES 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 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 Diesel Engine Manufacturer Kubota 1105 Low RPM 1500 High RPM 3000 Alternator 40 Amp Fuel Consumption Low RPM 0 93 gph 3 5 High RPM 1 7 gph 6 6 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 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 Alternator 40 Amp external 7 ft 2 m Battery 85 Amphour 700 cold cranking amps 0 F
32. D BLK BRN 5 YEL RED 2 2 A A A A A YELIRED 2 4 ii n E 5 LIFT A 563 cL d z START GLOW UP DOWN ee PLUSS 9888888592892289989 40020 65 BLACK 1 GND 4 4 1 DNG ESTOP Cj MUN UPG AT GROUND WHT YFI 48 6 lt 1 lt CONTROL WHT YFL 48 1 5 GENS YEL RED 2 1 lt Q TD STRG pue Pool GROUND RED I 5 RED 1 1 B 01 B D ELECTRONICS lt 02 1 lt 8188 E GLOW WATLYEL 48 1 lt 09 28 lt LPV GLUIS 4 5 PLUG 12VDC OUTPUT ELEV 4 LOCATED RELAY gr WHEN PLATFORM ELEVATION LIMIT 4 0 9 e 4 1 FULLY LOWERED SWITCH 4 3 ENGINE d 01180161 4 3 i 30 12VDC OUTPUT DTE WHEN BELOW THE we 5 DRIVE CUTOUT ULIS pave 8 T 2 YEL RED 2 5 a YEL RED 2 5D V PLUGS OPTIONAL 02 5 IGN 5 e 5 amp 8 E 2 ci Die E 5 x 4 55558 9 2 A fl fe Ale E e X xx e RED 1 1 22 TERMINATES WITH V y V BRN WHT 47 6 CICUIT Y 8 BLACK AT JI 22 OR JI 23 d 1 Soe S 1 i OSC AXLE EI ENGINE 4 PRESS SW 2 LOW OIL PRESS
33. DS A MAXIMUM PRESSURE 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 3121111 SECTION 2 PROCEDURES 2 18 FLASH CODES AND DESCRIPTIONS Table 2 3 Help Messages and Flash Codes FLASH CODE HELP MESSAGE AND DESCRIPTION No Flash Code ALARM SOUNDING TILTED 8 ABOVE ELEVATION Platform is elevated and the chassis is not level DIFFERENT FUNCTION SELECTED amp IGNORED A function i e Drive Lift etc is active and the operator has selected another function The system has ignored the new selec tion DRIVING AT CUTBACK ABOVE ELEVATION Platform is elevated and the machine is in the drive mode of operation FUNCTION SELECTED BUT TRIGGER SWITCH OPEN A function i e Drive Lift etc has been selected by the operator but the trigger switch is not active closed JOYSTICK MOVED BUT NO FUNCTION SELECTED The joystick was moved out of the center position before a function was selected DRIVE PREVENTED Above drive cutout height 2 1 STARTUP Anew system power up has occurred since the last help message 2 2 FUNCTIONS LOCKED OUT SHORT TO PLATFORM ROW INPUT DETECTED Battery power has been detected ona row input pins J1 8 J1 9 or J1 13 FUNCTION PROBLEM Horn permanently selected FUNCTION PROBLEM DRIVE PERMANENTLY S
34. ED 2 5 1870118 Figure 3 2 Electrical Schematic Sheet 2 of 2 3121111 JLG Lift 3 11 SECTION 3 TROUBLESHOOTING ONLY ll ET LiT NG CHECK En DI HOLDING CHECK 1 e AXLE LOCK OUT CIRCUIT 400CRT ONLY 1 20 qe VE gt 5 STEER P T STEER A LEFT ipud RIGHT P T RELEASE E e PRESSURE SWITCH 13 AVAILABLE WITH CE OSC AXLE ONLY 3 12 a 7 Ney EE TT Xx SP PI MP G P2 PS D gt FLOW DU T Si T a 1 25 MBL
35. ELECTED Drive select switch in the platform control box closed at start up or for more than ten seconds Release switch to clear fault FUNCTION PROBLEM LIFT PERMANENTLY SELECTED Lift select switch in the platform control box closed at start up or for more than ten seconds Release switch to clear fault FUNCTION PROBLEM O R PERMANENTLY SELECTED An outrigger select switch in the platform control box closed at start up or for more than ten seconds Release switch to clear fault FUNCTION PROBLEM START PERMANENTLY SELECTED Start switch in the platform control box closed at start up Release switch to clear fault FUNCTION PROBLEM GLOW PLUG PERMANENTLY SELECTED Glow plug switch in the platform control box closed at start up Release switch to clear fault FUNCTION PROBLEM STEERLEFT PERMANENTLY SELECTED Steer left switch in the 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 inputis outside the acceptable voltage range The wiper wire being off the wiper wire shorted to battery power or the wiper wire shorted 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 shortin the steer switch wiring or a fail
36. LITY Table 1 7 Critical Stability Weights Component Lb Kg Tires Balasted Only 246 111 Gas DF Engine Dry with flywheel and hous 136 62 ing Diesel Engine Dry with flywheel and hous 256 116 ing 1 6 JLG Lift 3121111 SECTION 2 PROCEDURES SECTION 2 PROCEDURES 21 GENERAL This section provides information necessary to perform maintenance on the scissor lift Descriptions techniques and specific procedures are designed to provide the saf est and most efficient maintenance for use by personnel responsible for ensuring the correct installation and oper ation of machine components and systems A CAUTION 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 servic ing and component removal and installation disassembly and assembly inspection lubrication and cleaning Infor mation on any special tools or test equipment is also pro vided 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 proce dures contained in this chapter Safety and Workmanship Your safety and that of others is the first consideration when engaging in t
37. Lift Figure 2 10 Installation of Head Seal Kit 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 Carefully slide the piston spacer on the rod If applicable correctly place new o ring in the inner piston diameter groove The backup ring side fac ing the O ring is grooved 2 11 SECTION 2 PROCEDURES 7 NOTE 8 10 NOTE 11 2 12 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 pis ton is recommended to install the solid seal The backup rings for the solid seal have a radius on one side This side faces the solid seal See magni fied 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 PISTON BACKUP SPLIT SEAL RINGS T RING SPLIT BACKUP RING SPLIT SEAL Figure 2 11 Piston Seal Kit Installation Using suitable protection clamp the cylinder rod in a vise or similar holding fixture as close to piston as possible Carefully thread the piston on the cylinder rod hand tight ensuring that the o ring and back up rings are not damaged or dislodged Thread piston onto rod until it abuts the spacer end and install the tapered bushing When installing t
38. NTIL BOOM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING OR BOOM SAFETY PROP HAS BEEN ENGAGED BEFORE MAKING ADJUSTMENTS LUBRICATING OR PERFORMING ANY OTHER MAINTENANCE SHUT OFF ALL POWER CONTROLS BATTERY SHOULD ALWAYS BE DISCONNECTED DURING REPLACEMENT OF ELECTRICAL COMPO NENTS KEEP ALL SUPPORT EQUIPMENT AND ATTACH MENTS STOWED IN THEIR PROPER PLACE USE ONLY APPROVED NONFLAMMABLE CLEANING SOLVENTS 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 JLG Lift 3121111 TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT SECTION PARAGRAPH PAGE NO SECTION A INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS AA Generales iio ed tel oases dda anda ads des del wags pe poer 1 Hydraulic System Safety 1 1 eee PRI doa CEU ahs CS E RE ge 1 SECTION 1 SPECIFICATIONS 1 1 aie oi de ee ae 1 1 1 2 Component Data iR DERI RUE hee ds eed bee BN we 1 1 1 3 uice ames Rea hea et ale 1 1 1 4 Torque Requirements
39. Pak Piston Seal Installation r rr rrereerereea 2 13 2 15 Rod Assembly 4143 2 13 2 16 Steer 2 14 2 17 Magnetic Speed Pickup 2 2 2 16 2 18 Magnetic Speed Pickup 2 16 2 19 Valve Component 22 socer pue ei iia D P ed Poen 2 17 2 20 Automatic Choke Adjustment 750 2 18 2 21 Analyzer Flow Chart Sheet 1 2 2 23 2 22 Analyzer Flow Chart Sheet 2 2 2 24 3 1 Electrical Schematic Sheet 1 2 3 10 3 2 Electrical Schematic Sheet 2 2 3 11 3 3 Hydraulic Schematic Sheet 1 2 1 3 12 3 4 Hydraulic Schematic Sheet 2 2 3 13 JLG Lift 3121111 TABLE OF CONTENTS TABLE NO 3121111 LIST OF TABLES TITLE PAGE NO Hydraulid ead etre Ri Sache etnies tdeo uae t Me 1 2 Lubrication Specifications
40. URE Su E E SWITCH 8PSI amp RELAY 87 87A S 4 gt 5 HOUR METER S d 25 Ka 00000 OIL CH ENGINE i PRESSURE MA B HIGH TEMPERATURE IA 14 SWITCH XXX ME 42514443 rm D 2144 4 GN ENGINE 3 od 54 d TEMP 2 205035 lt ALT LAMP GENE CHARGE e PRESSURE N 0 70 TEMPERATURE BLACK 6 SWITCH Na UE IGN ALTERNATOR ANI lt LAMP lt PEWS Figure 3 1 Electrical Schematic Sheet 1 of 2 3 10 JLG Lift 3121111 SECTION 3 TROUBLESHOOTING ORN WHT 55 6 ORN WHT 55 ORN WHT 55 4 ORN WHT 55 WHT YEL 48 4 BLU ORN 52 1 NHT YEL 48 1 WHT YF 48 2 IAN 55 2 ORANGE 55 1 IK OHM POT W 150 OHM CURRENT LIMITING RESISTORS GND J35 BLAEE R Epis 4 5V OUTPUT cow 32 12 V Y V T2 3V 0 CENTER GAS KOE Fone a ti ow 9 LO LA E E DRIVE P LIFT ENGINE PI HORN GLOW FUEL FLOR P FROR
41. Warsawa 13092 310 Campinas SP The Netherlands Norway Poland Brazil Phone 31 23 565 5665 Phone 47 6682 2000 Phone 48 91 4320 245 Phone 55 19 3295 0407 Fax 31 23 557 2493 Fax 47 6682 2001 Fax 48 91 4358 200 Fax 55 19 3295 1025 JLG Industries Europe JLG Industries Pty Ltd Plataformas Elevadoras JLG Industries Sweden Kilmartin Place Unit 1 24 Industrial Complex JLG Iberica S L Enkopingsvagen 150 Tannochside Park Herman Street Trapadella 2 Box 704 Uddingston G71 5PH Meadowdale Castellbisbal Sur SE 175 27 Jarfalla Scotland Germiston 08755Castellbisbal Sweden Phone 44 1 698 811005 South Africa Spain Phone 46 8 506 59500 Fax 44 1 698 811055 Phone 27 11 453 1334 Phone 34 93 77 24700 Fax 46 8 506 59534 Fax 27 11 453 1342 Fax 34 93 77 11762
42. X 19 3 NOU SIA ON ON TANA WAT OSL IAN 092 d ANIONA TOW TOW SDIATAIS 11266 41115 4 SSIIIV LASHS 3121111 JLG Lift 2 24 SECTION 2 PROCEDURES Table 2 4 Machine Model Adjustment Adjustment Adjustment range Default Values Gas Default Values Diesel DRIVE Accel 1 0to 5 0 sec 4 4 Decel 1 0to 5 0 sec 2 2 FWD MIN 010 100 21 21 FWD MAX 010 100 48 48 FWD ELEV 01035 30 30 REV MIN Oto 100 21 21 REV MAX Oto 100 52 52 REV ELEV 0103596 30 30 LOMAX 35 to 65 50 50 ENGINE SPD 2800 to 3800 RPM 3600 3000 GAIN 010999 180 50 DROOP 010999 200 250 STABILITY 010999 170 125 Accel 0 2 05 0 4 4 Decel 0 2 05 0 0 5 0 5 UP MIN ENG 1400 TO 2200 RPM 2000 2000 UP MAX ENG 2600 to 3600 RPM 3000 3000 LOMAX 35 to 55 50 50 GAIN 010999 150 10 DROOP 010999 220 240 STABILITY 010999 125 70 IDLE ENGINE SPEED 1200 1500 rpm 1500 1500 GAIN 010999 150 10 DROOP 010 999 250 85 5 010 999 100 90 070 100 19 25 MAXACT L D 070 100 60 100 IDLE 070 100 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
43. 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 pres sure of the component is reached Crossover Relief Valves Crossover relief valves are used in circuits where the actu ator requires an operating pressure lower than that sup plied to the system When the circuit is activated and the required pressure at the actuator is developed the cross over relief diverts excess pump flow to the reservoir Indi vidual 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 func tions and provides a maximum output of 7 6 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 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 2 4 JLG Lift cable is connected to the valve which when pulled manu ally opens the lift down port and allows the platform to be low
44. are necessary or when repairs have been made carefully reconnect hydraulic hoses to the appropriate ports 6 Remove lifting device from platform activate hydrau lic 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 plat form 3121111 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 Retract the lift cylinder rod completely Tag and disconnect the hydraulic lines then cap the lift cylinder hydraulic lines and ports Remove the bolt and locknut securing the barrel end attach pin to the lower arm assembly Using a suit able brass drift drive out the barrel end attach pin from the arm assembly Carefully remove the cylinder from the scissor lift and place in a suitable work area Installation 1 JLG Lift Install lift cylinder in place using suitable slings aligning barrel end attach pin mounting holes on lower arm assembly 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 Remove cylinder port plugs and hydraulic l
45. assword is displayed press ENTER The access level should display the following if the pass word 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 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 set tings 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 set tings Password 33271 will give you access to level 1 which will permit you to change all machine person ality settings A WARNING CHANGING THESE SETTINGS MAY ADVERSELY AFFECT THE PERFORMANCE OF YOUR MACHINE IMPORTANT IT IS A GOOD PRACTICE TO AVOID PRESSURE WASHING ELEC TRICAL ELECTRONIC COMPONENTS SHOULD PRESSURE WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRI CAL ELECTRONIC COMPONENTS JLG INDUSTRIES INC REC OMMEN
46. d If it is necessary to start the system in a sub zero environ ment it will be necessary to heat the oil with a low density 100 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 per formance at temperatures above 120 F 49 C Sys tems using DTE 11 oil should not be operated at temperatures above 200 F 94 C under any condi tion 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 man ual If unable to obtain the same type of oil supplied with the machine consult local supplier for assis tance in selecting the proper equivalent Avoid mix ing 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 contami nants from the service container Always clean the mesh element of the filt
47. d extend the cylinder Shut down and disconnect the power source Adequately support the cylinder rod if nec essary 3 If applicable remove the cartridge type holding valve and fittings from the cylinder port block Dis card o rings 4 Place the cylinder barrel into a suitable holding fix ture SUPPORT TABLE Figure 2 4 Cylinder Barrel Support 5 Mark cylinder head and barrel with a center punch for easy realignment Using an allen wrench loosen 3121111 the cylinder head retainer cap screws and remove cap screws from cylinder barrel CAPSCREWS w WASHER BST 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 IMPORTANT EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL INDER ROD HEAD AND PISTON AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES 8 With the barrel clamped securely apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel ROD SUPPORT X SUPPORT 7 2 TABLE 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 a
48. d while ade quately 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 dam aged or dislodged 9 Continue pushing the rod assembly into the cylinder barrel until the cylinder rod is approximately cen tered in the barrel 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 3 Reconnect the hydraulic hoses to the applicable cyl ind
49. e Carefully remove the head from the cylinder rod and remove and discard the wiper rod seal o ring and wear ring 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 Carefully remove the piston from the cylinder rod Remove and discard the T seal and o ring Remove the cylinder rod from the holding fixture Cleaning and Inspection 1 3121111 Clean all parts thoroughly in an approved cleaning solvent 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 neces sary Inspect the threaded portion of the rod for excessive damage Dress the threads as necessary Inspect the inner surface of the cylinder barrel tube for scoring or other damage Check the inside diam eter for tapering or ovality Replace the barrel if nec essary Inspect the piston surface for damage scoring and distortion Dress the piston surface or replace the piston as necessary Inspect the seal and o ring grooves in the piston for burrs and sharp edges Dress applicable surfaces as necessary Inspect the inside diameter of the spacers and heads for scoring or other damage and for ovality and tapering Replace as necessary 8 Inspect the seal and o ring grooves in the heads for burrs and sharp edges Dress applicable surfaces a
50. e function valve mechani cally 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 sys tem 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 system atic 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 JLG Lift 3 1 SECTION 3 TROUBLESHOOTING Table 3 1 Elevation System Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Platform Elevation System No Response to Control Lift not performed within three seconds after lift function switch 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 bank or pump Clean repair or replace line 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 P
51. e spool Scored cylinder Replace valve Replace cylinder System s operate erratically Sticking or binding valve spools piston rod etc Clean repair or replace components as required Hydraulic oil nota toptimum operating tempera ture Allow oil sufficient time to warm up Pump drive slipping Repair or replace drive 3121111 JLG Lift 3 7 SECTION 3 TROUBLESHOOTING Table 3 4 Electrical System Troubleshooting TROUBLE PROBABLE CAUSE REMEDY HAND CONTROLLER Regardless of which way handle is moved only one function occurs Improper or loose wiring to the solenoid s Check all wiring for proper connections Directional valve stuck in one direction Repair or replace valve Valve will not function when handle is moved in either direction Joystick not activated within the 3 seconds after function switch was depressed Reactivate function switch No electrical power to handle Check electrical input to hand controller 12V No electrical power to valve Check electrical output of printed circuit board and electrical signal at the valve Improper ground Check for proper grounding of handle Defective controller Repair or replace controller Microswitches on controller bad or need adjust ment Adjust or replace switches CONTROL SWITCHES No response to a function control switch Emergenc
52. ed steer switch can cause this FUNCTION LOCKED OUT JOYSTICK NOT CENTERED Selected function is not allowed because the joystick is not centered Return joystick to center and reselect function FUNCTION PROBLEM TRIGGER PERMANENTLY CLOSED Trigger switch in the platform control box closed at start up Release switch to clear fault TRIGGER CLOSED TOOLONG WHILE IN NEUTRAL Trigger switch in the platform control box closed for more than ten seconds while the joystick is in the neutral position Release switch to clear fault 3121111 JLG Lift 2 21 SECTION 2 PROCEDURES Table 2 3 Help Messages and Flash Codes 2 3 FUNCTION PROBLEM LIFT PERMANENTLY SELECTED Lift switch up or down in the ground control box closed at start up Release switch to clear fault FUNCTION PROBLEM START PERMANENTLY SELECTED Start switch in the ground control box closed at start up Release switch to clear fault FUNCTION PROBLEM GLOW PLUG PERMANENTLY SELECTED Glow plug switch in the ground control box closed at start up Release switch to clear fault NO DATA FROM TILT SENSOR NOT CONNECTED OR FAULTY No signal from the tilt switch Check wiring and plug connections at the level sensor and at the ground control board 2 5 DRIVE amp LIFT UP PREVENTED Oscillating axle not set 4 4 BATTERY VOLTAGE TOO LOW Battery voltage below 8 0V Check battery and alternator BATTERY VOLTAGE TOO HIGH
53. er and replace the cartridge any time the system oil is changed 3 While the unit is shut down a good preventive main tenance 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 3121111 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 evalua tion 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 cyl inder rod will retract The lift cylinder is a single acting type It does not require oil when the cylinder is being retracted The CRT
54. er ports 2 12 OSCILLATION CYLINDER BLEEDING NOTE Park the machine on a firm and level surface with the rear wheels blocked before starting the bleeding pro cedure 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 2 16 JLG Lift 2 13 MAGNETIC SPEED PICKUP CLEANING PROCEDURE 1 Locate the magnetic speed pickup on the bell hous ing on the right side of the motor 4 Magnetic Pickup Lad 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 ooo p A 1 7 m 7 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 fin ger 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 3121111 SECTION 2
55. ered 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 replaced or when improper system operation is suspected Cylinder w o Counterbalance Valves Steer Cylinder IMPORTANT OPERATE FUNCTIONS FROM GROUND CONTROL STATION ONLY DO NOT FULLY EXTEND CYLINDER TO END OF STROKE RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES SURE 1 Using all applicable safety precautions activate motor and fully extend cylinder to be checked Shut down motor 2 Carefully disconnect hydraulic hose from retract port of cylinder There will be initial weeping of hydraulic fluid which can be caught in a suitable container After the initial discharge there should be no further leakage from the retract port 3 Activate motor and activate cylinder extend function Check retract port for leakage 4 If cylinder leakage is 6 8 drops per minute or more piston seals are defective and must be replaced If cylinder retract port leakage is less than 6 8 drops per minute carefully reconnect hose to retract port and retract cylinder 5 With cylinder fully retracted shut down motor and carefully disconnect hydraulic hose from cylinder extend port 6 Activate motor and activate cylinder retract fu
56. et or notfunction ing properly Reset repair or replace valve as neces sary Steer cylinder not functioning properly Repair or replace cylinder Machine will not steer left or right Steer switch on controller not functioning properly Replace controller Wiring on steer control switch is dam aged Repair or replace wiring 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 settoo low or not functioning properly Reset repair or replace valve as neces sary Steer linkage loose Tighten linkage Spindle bushings badly worn Replace bushings 3 6 JLG Lift 3121111 SECTION 3 TROUBLESHOOTING Table 3 3 Hydraulic System Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Hydraulic pump noisy Air entering system through broken line or fitting Repair or replace line or fitting Air bubbles in oil Replenish oil as required Faulty pump coupler Replace coupler Defective pump bearing Repair or replace pump Oil filter s dirty Clean and or replace filter s as necessary Pump cavitating Vacuum in pump due to oil star vation Restricted
57. f menu items may be offered If for example you choose Personal ities 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 can cel 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 pass word to advance to a lower level This ensures that a set ting 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 exam ple 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 pass word 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 p
58. for mobile hydraulic system ser vice 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 Indus tries for proper recommendations Lubrication Specifications Table 1 3 Lubrication Specifications KEY SPECIFICATIONS MPG Multipurpose Grease having a minimum dripping point of 350 degrees F Excellent water resistance andadhesive qualities and being of extreme pres sure type Timken OK 40 pounds minimum EPGL Extreme Pressure Gear Lube oil meeting API ser vice classification GL 5 or MIL Spec MIL L 2105 EO Engine crankcase Oil Gas API SF SG class MIL L 2104 Diesel API CC CD class MIL L 2104B MIL L 2104C HO Hydraulic Oil API service classification GL 3 e g Mobil 424 3121111 SECTION 1 SPECIFICATIONS Note 500 Hrs 3 months 1000 Hrs 6 months 2000 Hrs 1 year 4000 Hrs 2 years 4 Extends from front of machine
59. he 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 Cleanliness 1 The most important single item in preserving the long service life of a machine is to keep dirt and for eign materials out of the vital components Precau tions 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 discon nected clear adjacent areas as well as the openings and fittings themselves As soon as a line or compo nent is disconnected cap or cover all openings to prevent entry of foreign matter 3 Clean and inspect all parts during servicing or main tenance 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 contain ers until they are ready to be used Components Removal and Installation 4 Use adjustable lifting devices whenever possible if mechanical assistance is reguired All slings chains cables etc should be parallel to each other and as near perpendicular as poss
60. he tapered bushing piston and mat ing end of rod must be free of oil Assemble the tapered bushing loosely into the pis ton and insert JLG capscrews not vendor cap 12 13 14 JLG Lift screws through the drilled holes in the bushing and into the tapped holes in the piston PISTON TAPERED _ BUSHING CAP SCREWS Figure 2 12 Tapered Bushing Installation Tighten the capscrews evenly and progressively in rotation to the specified torque value See Table 2 1 Cylinder Component Torque 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 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 PISTON TAPERED BUSHING BRASS SHAFT Figure 2 13 Seating the Tapered Bearing Re torque the capscrews evenly and progressively in rotation to the specified torque value See Table 2 1 Cylinder Component Torque 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 PISTON REF Figure 2 14 Poly Pak Piston Seal Installation
61. ible 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 eye bolt 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 com plete the procedural steps in seguence 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
62. igh speed solenoid not functioning properly Replace solenoid Loose or damaged wiring between high speed relay and high speed limit switch Ensure proper connection of wires between high speed relay and high speed limit switch Using suitable test meter per form continuity test on wires Repair or replace wires as necessary High speed limit switch not functioning properly Repair or replace limit switch Loose or damaged wiring in valve wiring harness Ensure proper connection of wires at ter minal strip Using suitable test meter per form continuity test on wires Repair or replace wires as necessary Steering System No response to steer control switch on controller Steer switch on controller not functioning properly Repair or replace switch 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 Ensure proper connection of wires at con trol switch or solenoid valve Using suit able test meter perform continuity test on wires Repair or replace wires as neces sary Restricted or broken hydraulic line on valve bank or hydraulic pump Clean repair or replace line Control valve not functioning properly Repair or replace valve Steer cylinder not functioning properly Repair or replace cylinder Machine hard to steer or s
63. ine caps and correctly attach lines to cylinder ports 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 Lower platform to stowed position and shut down motor Check hydraulic fluid level and adjust accord ingly SECTION 2 PROCEDURES WITH SAFETY PROPS BLOCKING OR OVERHEAD SLING amp WARNING NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL IT HAS BEEN RESTRAINED FROM MOVEMENT STRAP SAFETY PROP Figure 2 1 Arms and Platform Positioning and Support Cylinder Repair 2 6 JLG Lift 3121111 SECTION 2 PROCEDURES 1 Barrel 7 O Ring 2 Check Restrictor Valve 8 Spacer 3 Locknut 9 Bacp Up Ring 4 Wear Ring 10 O Rin 5 Seal 11 Wear Bing 6 Piston 12 O ring Figure 2 2 330CRT Lift Cylinder 6 Remove the cylinder rod from the holding fixture 7 Position the cylinder barrel in a suitable holding fix ture IMPORTANT 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
64. ing 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 differ ence between the load and pump outlet pressure and varies the pump displacement to keep the difference con 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 cavi tation 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 com ponents 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 cir cuit pressure The relief valve is installed in the circuit between the pump outlet pressure line
65. ings and holding valve Replace as necessary Inspect the oil ports for blockage or the presence of dirt or other foreign material Repair as necessary If applicable inspect piston rings for cracks or other damage Replace as necessary 3121111 SECTION 2 PROCEDURES Assembly NOTE Prior to cylinder assembly ensure that the proper cylinder seal kit is used See your JLG Parts Manual Apply a light film of hydraulic oil to all components prior to assembly A special tool is used to install a new rod seal into the applicable cylinder head gland groove ROD SEAL SEAL TOOL SMOOTH SIDE CYLINDER HEAD Figure 2 8 Rod Seal Installation IMPORTANT WHEN INSTALLING POLY PAK PISTON SEALS ENSURE SEALS ARE INSTALLED PROPERLY REFER TO WIPER SEAL INSTALLA TION 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 CYLINDER HEAD MALLET Note When installing wiper seal ensure seal are installed properly Install seal so that the flat part of seal is facing into head 3121111 Figure 2 9 Wiper Seal Installation e Place a new o ring and back up seal in the applica ble outside diameter groove of the cylinder head CYLINDER HEAD 7 JLG
66. ior to assembly SECTION 1 SPECIFICATIONS yeys 71 SM3U9S 4 9 qaividNn KINO Sr108 d31V 1d INIZ 804 SANTVA 8 AVS S AQVYS AVS si9ua sej pajejd winipes Ajdde jou op senjeA anbio 9JoN 0 26 00088 5066 80 0992 09546 00007 0066 77 6 049 000406 00248 0086 006 ei 2111 oroe 00409 5 76 OtSc O9EC 09 6 00892 50406 99 1 097 06 00087 osor 9 OOGLEL 000 69 04 0402 00726 00181 084 908 09022 089 00081 08 61 006 cb 2111 0 008414 5492 706 081 0860 000970 GEGL 4206 000 OOvL 00109 0881 9 088 006201 004 0 9 OOSL 0004 00996 OOEL 06 OvcL 00969 08 07 0062 vh 0811 00696 0002 098 028 007228 841 600L 078 OZLL 00868 0696 0 1 0861 00998 474 SSLL 080L 000 4826 208 099 088 005 7 09580 06211 g L Orch 0059 00 060 096 0861 00 89 0 8 471 009 008 00 lt 06920 1 816 00699 001 96 Ord 0001 00469 SEL 9 068 007 00227 06990 000 7 998 00909 066 289 089 006 005 58 9 9 648 08v Ov9 0098 09090 8 S 9 0060S SZL ves 00S 099 00867 OZS Scy 056 0 7 00946 06040 05 80 vl 8 2 989 00297 099 68 09 009 009v 56 986 066 Otv 00964 00970 6 00 00616 SOV 966 oze 007 00966 066 894 OCT 006 008 lt 0 0 0 005 0 9 596 007 lt lt 007 LOE 0842 086 00 06 582 Ove 004 092 OOELC o
67. late 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 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 Dia Lift Cylinder 4 0 63 7 2 75 330CRT 10 2 161 8 7 0 Upper Lift Cylinder 3 0 58 1 2 75 400CRT 7 62 147 6 7 0 Lower Lift Cylinder 4 0 58 1 2 75 400CRT 10 2 147 6 7 0 Lockout Cylinder 3 0 3 75 1 25 Oscillating Axle 7 6 9 5 3 2 Leveling Jack 2 0 14 0 1 25 Cylinder 5 1 35 6 3 2 Steer Cylinder 2 5 7 1 1 25 6 4 18 1 8 2 1 10 MAJOR COMPONENT WEIGHTS Table 1 6 Major Component Weights Component Lb Kg Fixed Platform 569 258 Platform Extension 230 104 Arm Assembly 330CRT 3200 1452 Includes Lift Cylinder Arm Assembly 400CRT 3900 1769 Includes Lift Cylinder Chassis with Foam Filled Tires 4980 2259 1 11 CRITICAL STABILITY WEIGHTS A WARNING 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 STABI
68. latform will not raise Joystick not activated within three sec onds after lift switch is activated Activate lift switch then activate joystick within three seconds Load capacity exceeded Personnel and or equipment on platform Reduce load Refer to capacity placard Hydraulic system oil low Replenish oil as necessary Restricted or broken hydraulic line or fit ting Clean repair or replace line or fitting 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 Refer to Electrical System Troubleshoot ing Noresponseto control switch No electrical signal being sentto lift up control valve cartridge Refer to Electrical System Troubleshooting No response to control switch Platform will not lower Joystick not activated within three sec after lift switch is activated Depress lift switch then activate control ler within three seconds No electrical signal sent to lift down con trol valve cartridge Refer to Electrical System Troubleshoot ing No response to control switch Lift down control valve cartridge not functioning properly Repair or replace lift down control valve cartridge Lift cylinder not functioning properly Repair or replace lift cylinder Engine does not
69. matter entering a system can cause wear or damage to the components and generally results in faulty opera tion 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 speci fied intervals required in the Lubrication Chart in Section 1 and the Preventive Maintenance and Inspection Chart in this section Always examine fil ters for evidence of metal particles 3 Cloudy oils indicate a high moisture content which permits organic growth resulting in oxidation or cor rosion If this condition occurs the system must be drained flushed and refilled with clean oil 4 t is not advisable to mix oils of different brands types except as recommended as they may not contain the same required additives or be of compa rable viscosities Good grade mineral oils with vis cosities 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 compo nents 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 26 is not recommende
70. motor in accordance with applicable manufacturer s manual Defective start lockout solenoid Replace start lockout solenoid Malfunctioning ignition switch Using a test meter check ignition switch for cor rect switching of contacts replace switch as nec essary Faulty ignition and or starter circuit wiring Check wiring continuity refer to wiring diagram Defective ring gear or flywheel Replace ring gear INSTRUMENTS AND INDICATORS Ammeter inoperative Damaged wiring in circuits Repairor replace wiring Ammeter not functioning properly Replace ammeter Alternator not charging Repair or replace alternator Travel warning horn inoperative Circuit breaker open Determine and correct cause Damaged wiring in horn circuit Replace horn Hourmeter inoperative Damaged wiring in hourmeter circuit Repair or replace wiring Inoperative hourmeter Replace hourmeter 3121111 JLG Lift 3 9 SECTION 3 TROUBLESHOOTING YEL RED 2 38 ARAA PLATFORM DISPLAY 002 GND JEDE cou Ten cove manc 0003 TED 014 manc cous TED BLACK YEL RED 2 ESTOP 501 YELIRED 2 2 COLO YELIRED 2 3 1 2 4 2 2 d d E Ag VEL RED 2 13 ds add a TRIGGER d SWITCH gt B 62 CH 13 ORN RED BLK YEL BLK ORN BLK BLU BLK BLK RED YEL RED ORN RED BLU RE
71. nction 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 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 IMPORTANT OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY 1 Using all applicable safety precautions activate hydraulic system A WARNING WHEN WORKING ON THE LIFT CYLINDER RAISE THE PLAT FORM 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 PRES SURE 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 5 f no repairs
72. nd remove the cap screw s if applicable which attach the tapered bushing to the piston JLG Lift 2 9 SECTION 2 PROCEDURES 11 12 13 14 15 16 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 Remove the bushing from the piston PISTON TAPERED BUSHING CAP SCREWS Figure 2 7 Tapered Bushing Removal Screw the piston CCW by hand and remove the piston from cylinder rod Remove and discard the piston o rings seal rings and backup rings Remove piston spacer if applicable from the rod Remove the rod from the holding fixture Remove the cylinder head gland and retainer plate if applica ble Discard the o rings back up rings rod seals and wiper seals Cleaning and Inspection 1 2 10 Clean all parts thoroughly in an approved cleaning solvent Inspect the cylinder rod for scoring tapering ovality or other damage If necessary dress rod with Scotch Brite or eguivalent Replace rod if necessary Inspect threaded portion of rod for excessive dam age Dress threads as necessary Inspect inner surface of cylinder barrel tube for scor ing or other damage Check inside diameter for tapering or ovality Replace if necessary Inspect threaded portion of barrel for damage Dress threads as necessary Inspect piston surface for damage and
73. orm position and pulling both emer gency 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 dis play will scroll the fault across the screen If there was no fault detected during power up the display will read In plattorm mode HELP EVERYTHING OK In ground mode GROUND MODE OK If ENTER is pressed again the display moves to the fol lowing 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 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 o
74. ough 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 prob able 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 thor ough 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 proba ble cause and remedy may be immediately obvious are not listed in this section The first rule for troubleshooting any circuit that is hydrau lically 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 th
75. ree o OL OCT 00937 892 voc 081 0006 06 ESL OEL 041 0069 09520 05290 8l 8 012 00927 Ove 081 041 Occ 086046 591 Sel OLL OSL 007 09620 bb 59 006042 061 061 041 0628 Sel 601 06 Oct 086421 06020 296 0 8l 946 SSL 004281 59 661 OLL 081 00 9 Oc 96 08 OLL 00911 02810 cb 0664 SEL 801 06 ozL 00 00 08 S9 06 00 0 66810 0005 0 0c 21 OLL 06 02 96 08 OLL 0472 98 89 99 GL 0506 61010 l GL OL8LL 06 02 09 08 00 0 09 0S 99 0331 18110 5 60 02 911 02 06901 08 69 SS 01 0846 64 Sv GE 08 0089 89010 vb 03 0828 99 Sr 56 0S 0062 Ov ce SC Ge 0095 8280 0 05 60 vc g c 0341 09 Ok ge Sr 0002 ge 9c 06 06 57200 9 14 0089 06 SC 0 Sc 02648 LE ZL vi 6L 007 08500 2160 ve SC OvcS oe cc 8l SC 0227 6L 9 L ZL Opee 500 14781 14 81 14781 14781 13 91 14 81 14781 14781 vl 0 96 98 021 89 0846 Sel 98 021 0664 9 0 0 00520 9c L 0816 09 801 vv 098c 50 GL 96 0202 8 00 0c m LS 89 0081 96 6v S8cL 000000 0060 OL 09 0881 TE ev 04 0 094 00 ve ce 0261 e LE 0 6 7 00 09910 96 8 m LE kr 092 TC 06 006 007 00 26 6L 9 06 eb 8L 019 810100 0861 0 07 9 ZL ec 028 e 9 084 6060070 m OL 009 EX 1 6 007 99000 02110 8v p 6 cL 075 9 8 08 709000 07 lS 06927007 8 45 2
76. respond when lift switch is moved to down position Refer to Electrical System Troubleshoot ing No response to control switch 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 ting Clean repair or replace line 3 2 JLG Lift 3121111 SECTION 3 TROUBLESHOOTING Table 3 1 Elevation System Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Counterbalance valve on lift cyl improp rely adjusted or not functioning properly Replace valve 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 Platform drifts down Manual lowering valve not functioning properly Repair or replace valve Worn seals in lift cylinder Replace seals Holding valve on lift cylinder not function ing properly Repair or replace valve High Drive does not operate below horizontal Damaged wiring on limit switch Repair or replace wiring Damaged limit switch Replace limit switch 3121111 JLG Lift 3 3 SECTION 3 TROUBLESHOOTING Table
77. s 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 dis lodged 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 fix ture IMPORTANT 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 an
78. teering is erratic Hydraulic system oil low Replenish oil as necessary Restricted or broken hydraulic line or fit ting Clean repair or replace line or fitting 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 dance with Lubrication Chart 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 Repair or replace switch Hydraulic system pressure too low Adjust pressure Loose or damaged wiring on control switch or solenoid valve Ensure proper connection of wires at con trol switch or solenoid valve Using suit able test meter perform continuity test on wires Repair or replace wires as neces sary Solenoid valve not functioning properly Repair or replace valve Restricted or broken hydraulic line on valve bank or hydraulic pump Clean repair or replace line Relief valve improperly s
79. 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 bear ing 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 accor dance 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 rub ber particles is fo
80. tioning properly Repair or replace brake Engine will not respond when enable switch is activated and drive controller is activated Refer to Electrical System Troubleshoot ing No response to control switch No electrical signal being sentto the drive valve cartridge Refer to Electrical System Troubleshoot ing No response to control switch Machine will not travel in reverse See Machine will nottravel forward High Speed Drive function does not operate 3 4 JLG Lift 3121111 SECTION 3 TROUBLESHOOTING Table 3 2 Chassis Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Loose or damaged wiring between drive controller and High Speed switch Ensure proper connection of wires Using suitable test meter perform continuity test wiring between switches Repair or replace wires as necessary Defective high speed control switch Replace high speed control switch Loose or damaged wiring in control box wire harness Ensure proper connection of wires at the control switch Using suitable test meter perform continuity test on wires Repair or replace harness as necessary Loose or damaged wiring between plat form and high speed solenoid Ensure proper connection of wires at the platform and atthe high speed solenoid Using suitable test meter perform conti nuity test on wires Repair or replace wires as necessary H
81. und 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 2 2 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 JLG Lift 1 The primary enemy of a hydraulic system is contam ination 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 suc tion lines 2 The design and manufacturing tolerances of the component working parts are very close therefore even the smallest amount of dirt or foreign
82. y stop switch not positioned properly Place emergency stop switch to on Platform Ground select switch not positioned properly Place switch to platform or ground as necessary Circuit breaker open Determine and correct cause Reset circuit breaker No voltage present at emergency stop switch Check battery cable from battery to emergency stop switch for proper connection or damage Repair or replace cable as necessary Emergency stop switch not functioning properly Replace switch No voltage supplied to start relay from emergency stop switch Check battery cable from switch to relay for proper connection or damage Repair or replace cable as necessary No voltage input atterminal strip Check wire from battery to terminal strip for proper connection or damage Repair or replace cable as necessary No voltage present at circuit breaker Check wire from terminal strip to battery for proper connection or damage Repair or replace cable as necessary Defective circuit breaker Replace circuit breaker No voltage present at Platform Ground select switch Unplug ground control box harness from platform receptacle check wire from applicable pin in plug to control box power switch for proper connection Using suitable test meter perform continuity test on wire Repair or replace harness as necessary Defective Platform Ground select switch Replace Platform Ground select switch
83. y structural damage cracked or broken welds bent or warped surfaces Check for leakage Check for presence of excessive dirt or foreign material Check for proper operation and freedom of move ment Check for excessive wear or damage Check for proper tightness and adjustment Drain clean and refill Check for proper operation while pump motor is running Check for proper lubrication Check for evidence of scratches nicks or rust and for straightness of rod Check for condition of element replace as neces sary Check for proper inflation Check Inspection Decal for current inspection stamp 2 27 SECTION 2 PROCEDURES Table 2 6 Preventive Maintenance and Safety Inspection AREA INTERVAL 10Hours Daily 50 Hours Weekly 200 Hours Monthly 500 Hours 3 Month 1000 Hours 6 Month PLATFORM 1 Controller 1 11 2 Switches 1 11 3 Placards and Decals 1 2 4 Control Tags 1 2 5 Hoses and Cables 48 6 Wear Pads 7 Handrails and Chains CHASSIS 1 Engine Oil 2 Battery 3 Air Cleaner 14 4 Exhaust System wl 5 Engine Mounts 6 Hydraulic Pump 7 Valves 8 Hydraulic Filter See Lubrication Chart 5 14 9 Hydraulic Hoses and Tubing 10 Hydraulic Oil Tank 11 Hydraulic Tank Breather 6 14 12 Fuel Tank 3 5 13 Lift Cylinder 1

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