Jlg 400CRT Service Manual User Manual

Service & Maintenance ManualModel330CRT400CRT3121804April 7, 2004

SECTION 1 - SPECIFICATIONS1-2 – JLG Lift – 3121804Platform Capacity330CRT - 450 kg (1,000 lb.)400 CRT - 360 kg (800 lb.)Platform Extension CapacityAl

SECTION 1 - SPECIFICATIONS3121804 – JLG Lift – 1-3 H[WHQGVIURPIURQWRIPDFKLQH1231RWH+UV PRQWKV+UV PRQWKV+

SECTION 1 - SPECIFICATIONS1-4 – JLG Lift – 3121804Figure 1-1. Torque Chart

SECTION 1 - SPECIFICATIONS3121804 – JLG Lift – 1-51.6 PRESSURE SETTINGSMain Relief - 228 bar ± 3.4 bar (3300 psi ± 50 psi)Steer Relief (Left) - max 1

SECTION 1 - SPECIFICATIONS1-6 – JLG Lift – 31218041.9 CYLINDER SPECIFICATIONSNOTE: All dimensions are given in inches (in), with the met-ric equivalen

SECTION 2 - PROCEDURES3121804 – JLG Lift – 2-1SECTION 2. PROCEDURES2.1 GENERALThis section provides information necessary to performmaintenance on th

SECTION 2 - PROCEDURES2-2 – JLG Lift – 31218043. If a bearing is found to be serviceable, apply a lightcoat of oil and wrap it in clean (waxed) paper.

SECTION 2 - PROCEDURES3121804 – JLG Lift – 2-3Hydraulic Oil1. Refer to Section1 for recommendations for viscosityranges.2. JLG recommends Mobilfluid 4

SECTION 2 - PROCEDURES2-4 – JLG Lift – 3121804Proportional Control ValvesThe proportional control valves provide a power outputmatching that required

SECTION 2 - PROCEDURES3121804 – JLG Lift – 2-53. Activate motor and activate cylinder extend function.Check retract port for leakage.4. If cylinder le

SECTION 2 - PROCEDURES2-6 – JLG Lift – 3121804.Figure 2-1. Arms and Platform Positioning and Support, Cylinder Repair

SECTION 2 - PROCEDURES3121804 – JLG Lift – 2-76. Remove the cylinder rod from the holding fixture.7. Position the cylinder barrel in a suitable holdin

SECTION 2 - PROCEDURES2-8 – JLG Lift – 3121804Figure 2-3. 400CRT LIft Cylinder

SECTION 2 - PROCEDURES3121804 – JLG Lift – 2-92.10 LIFT CYLINDER REPAIRDisassemblyIMPORTANTDISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ONA CLEAN W

SECTION 2 - PROCEDURES2-10 – JLG Lift – 312180411. Insert the cap screw(s) in the threaded holes in theouter piece of the tapered bushing. Progressive

SECTION 2 - PROCEDURES3121804 – JLG Lift – 2-11AssemblyNOTE: Prior to cylinder assembly, ensure that the propercylinder seal kit is used. See your JLG

SECTION 2 - PROCEDURES2-12 – JLG Lift – 3121804NOTE: The backup rings for the solid seal have a radius onone side. This side faces the solid seal.(See

SECTION 2 - PROCEDURES3121804 – JLG Lift – 2-1310. Position the cylinder barrel in a suitable holding fix-ture.IMPORTANTEXTREME CARE SHOULD BE TAKEN W

SECTION 2 - PROCEDURES2-14 – JLG Lift – 31218042.11 STEER CYLINDER REPAIRRemovalBefore beginning this procedure, ensure that the parkingbrake is engag

SECTION 2 - PROCEDURES3121804 – JLG Lift – 2-15IMPORTANTEXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL-INDER ROD, SPACER, AND PISTON. AVOID PULLIN

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS3121804 – JLG Lift – aSECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSA.A GENERALThis section co

SECTION 2 - PROCEDURES2-16 – JLG Lift – 312180410. Carefully install one of the cylinder heads on oneend of the cylinder rod and push the head onto th

SECTION 2 - PROCEDURES3121804 – JLG Lift – 2-17.2.14 PRESSURE SETTING PROCEDURESNOTE: Make all pressure adjustments with the engine oper-ating and the

SECTION 2 - PROCEDURES2-18 – JLG Lift – 31218042.15 LIMIT SWITCH ADJUSTMENTSpeed Cutout SwitchThe speed cutout switch is located on the right side of

SECTION 2 - PROCEDURES3121804 – JLG Lift – 2-19Diesel EngineNOTE: Never run the fuel tank dry. Diesel engines cannotbe restarted after running out of

SECTION 2 - PROCEDURES2-20 – JLG Lift – 3121804Changing the Access Level of the Hand Held Analyzer: When the analyzer is first connected, you will be

SECTION 2 - PROCEDURES3121804 – JLG Lift – 2-212.18 FLASH CODES AND DESCRIPTIONSTable 2-3. Help Messages and Flash CodesFLASH CODE HELP MESSAGE AND DE

SECTION 2 - PROCEDURES2-22 – JLG Lift – 3121804FUNCTION PROBLEM - START PERMANENTLY SELECTEDStart switch in the ground control box closed at start up.

SECTION 2 - PROCEDURES3121804 – JLG Lift – 2-23 (Press Escape Twice to Return to Help)*(Outrigger Option Only)*(Test in Ground Mode)**(Diesel Engine O

SECTION 2 - PROCEDURES2-24 – JLG Lift – 3121804BY PRESSING THESE ARROW KEYS ( ) YOU CAN SCROLL THROUGH THE TOP LEVEL MENUS. (Prompt bef

SECTION 2 - PROCEDURES3121804 – JLG Lift – 2-25Table 2-4. Machine Model AdjustmentAdjustment Adjustment range Default Values - Gas Default Values - D

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSb – JLG Lift – 3121804REVISON LOGOriginal Issue - April 13, 2000Revised - August 17, 2000Revised - Septem

SECTION 2 - PROCEDURES2-26 – JLG Lift – 3121804NOTE: When configuring a CRT scissors machine, themachine configuration must be completed beforeany per

SECTION 2 - PROCEDURES3121804 – JLG Lift – 2-272.19 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULEThe preventive maintenance and inspection checks are

SECTION 2 - PROCEDURES2-28 – JLG Lift – 3121804Table 2-6. Preventive Maintenance and Safety InspectionAREA INTERVAL10Hours(Daily)50 Hours(Weekly)200 H

SECTION 3 - TROUBLESHOOTING3121804 – JLG Lift – 3-1SECTION 3. TROUBLESHOOTING3.1 GENERALThis section contains troubleshooting information to beused f

SECTION 3 - TROUBLESHOOTING3-2 – JLG Lift – 3121804.Table 3-1. Elevation System TroubleshootingTROUBLE PROBABLE CAUSE REMEDYPlatform Elevation SystemN

SECTION 3 - TROUBLESHOOTING3121804 – JLG Lift – 3-3Counterbalance valve on lift cyl. improp- rely adjusted or not functioning properly. Replace valve.

SECTION 3 - TROUBLESHOOTING3-4 – JLG Lift – 3121804 Table 3-2. Chassis TroubleshootingTROUBLE PROBABLE CAUSE REMEDYDrive SystemNo response to drive co

SECTION 3 - TROUBLESHOOTING3121804 – JLG Lift – 3-5Loose or damaged wiring between drive controller and High Speed switch. Ensure proper connection of

SECTION 3 - TROUBLESHOOTING3-6 – JLG Lift – 3121804Machine hard to steer or steering is erratic (cont.)Lack of lubrication on steer components. Lubri

SECTION 3 - TROUBLESHOOTING3121804 – JLG Lift – 3-7Table 3-3. Hydraulic System TroubleshootingTROUBLE PROBABLE CAUSE REMEDYHydraulic pump noisyAir ent

TABLE OF CONTENTS3121804 – JLG Lift – iTABLE OF CONTENTSSUBJECT - SECTION, PARAGRAPH PAGE NO.SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTION

SECTION 3 - TROUBLESHOOTING3-8 – JLG Lift – 3121804Table 3-4. Electrical System TroubleshootingTROUBLE PROBABLE CAUSE REMEDYHAND CONTROLLERRegardless

SECTION 3 - TROUBLESHOOTING3121804 – JLG Lift – 3-9No voltage present at function control switch Check wiring from power switch to function control sw

SECTION 3 - TROUBLESHOOTING3-10 – JLG Lift – 3121804GROUNDELECTRONICSFigure 3-1. Electrical Schematic - Sheet 1 of 2

SECTION 3 - TROUBLESHOOTING3121804 – JLG Lift – 3-11GROUNDELECTRONICS1870118_IFigure 3-2. Electrical Schematic - Sheet 2 of 2

SECTION 3 - TROUBLESHOOTING3-12 – JLG Lift – 3121804Figure 3-3. Hydraulic Schematic - Sheet 1 of 2

SECTION 3 - TROUBLESHOOTING3121804 – JLG Lift – 3-132792397 EFigure 3-4. Hydraulic Schematic - Sheet 2 of 2

SECTION 3 - TROUBLESHOOTING3-14 – JLG Lift – 3121804This page intentionally left blank.

JLG Worldwide LocationsCorporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USAPhone: (717) 485-5161Fax: (717) 485-6417JLG Ind

TABLE OF CONTENTSii – JLG Lift – 3121804LIST OF FIGURESFIGURE NO. TITLE PAGE NO.1-1. Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS3121804 – JLG Lift – iiiLIST OF TABLESTABLE NO. TITLE PAGE NO.1-1 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTSiv – JLG Lift – 3121804This page left blank intentionally.

SECTION 1 - SPECIFICATIONS3121804 – JLG Lift – 1-1SECTION 1. SPECIFICATIONS1.1 CAPACITIESHydraulic Oil TankApproximately 60.6 liters (16 U.S. gallons