Jlg 400CRT ANSI Service Manual- Manuals

Jlg 400CRT ANSI Service Manual– User Manual in PDF format online.

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User Manual

User Manual Jlg 400CRT ANSI Service Manual

Summary

Page 3 - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS; – JLG Lift –; SECTION A. INTRODUCTION - MAINTENANCE SAFETY; A.B HYDRAULIC SYSTEM SAFETY

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS 3121111 – JLG Lift – a SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A.A GENERAL This section contains the general safety precautionswhich must be observed during maintenance of theaerial platform. It is of utmost importance that main-tenance ...

Page 4 - REVISON LOG

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS b – JLG Lift – 3121111 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

Page 5 - TABLE OF CONTENTS

TABLE OF CONTENTS 3121111 – JLG Lift – i TABLE OF CONTENTS SUBJECT - SECTION, PARAGRAPH PAGE NO. SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A.A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

Page 6 - ii; LIST OF FIGURES

TABLE OF CONTENTS ii – JLG Lift – 3121111 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 1-1. Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1-1. Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . ....

Page 7 - LIST OF TABLES

TABLE OF CONTENTS 3121111 – JLG Lift – iii LIST OF TABLES TABLE NO. TITLE PAGE NO. 1-1 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1-2 Lubrication Specifications . . . . . . . . . . . . . . . . ...

Page 8 - iv

Page 9 - SECTION 1 - SPECIFICATIONS; SECTION 1. SPECIFICATIONS; Model

SECTION 1 - SPECIFICATIONS 3121111 – JLG Lift – 1-1 SECTION 1. SPECIFICATIONS 1.1 CAPACITIES Hydraulic Oil Tank Ap p roxim ate ly 1 6 U.S . gallons (6 0.6 lit ers ) w/1 5% airspace. Hydraulic System (Including Tank) Approximately 20 U.S. gallons (75.7 liters) Fuel Tank Approximately 13 U.S. gallons ...

Page 10 - NOTE: Hydraulic oils must have anti-wear qualities at least; KEY

SECTION 1 - SPECIFICATIONS 1-2 – JLG Lift – 3121111 Platform Capacity - Fixed Platform 330CRT - 1,000 lb. (455 kg) 400 CRT - 800 lb. (365 kg) Platform Extension Capacity All Models - 250 lb (120 kg) Machine Weight 330CRT - Approx. 9,320 lb. (4,228 kg) 440CRT - Approx. 10,070 lb. (4,568 kg) Machine H...

Page 11 - EPGL - Extreme Pressure Gear Lube

SECTION 1 - SPECIFICATIONS 3121111 – JLG Lift – 1-3 4 Extends from front of machine 1 2 3 Note: 500 Hrs. = 3 months1000 Hrs. = 6 months2000 Hrs. = 1 year4000 Hrs. = 2 years Table 1-4. Lubrication Chart INDEX NO COMPONENT NUMBER/TYPE LUBE POINTS LUBE METHOD INTERVAL HOURS 1 Hydraulic Oil Reservoir Fi...

Page 13 - PRESSURE SETTINGS; The machine is equipped with the following limit switches:; Serial Number Plate

SECTION 1 - SPECIFICATIONS 3121111 – JLG Lift – 1-5 1.6 PRESSURE SETTINGS Main Relief - 3300 psi ± 50 psi (228 bar ± 3.4 bar) Steer Relief (Left) - max 2600 psi (179 bar) Steer Relief (Right) - max 1600 psi (110 bar) Lift Pressure - 330CRT - 2300 psi (159 bar) 400CRT - 2500 psi (172 bar) Leveling Ja...

Page 14 - CYLINDER SPECIFICATIONS; Component

SECTION 1 - SPECIFICATIONS 1-6 – JLG Lift – 3121111 1.9 CYLINDER SPECIFICATIONS NOTE: All dimensions are given in inches (in), with the met- ric equivalent, centimeters (cm), in parentheses. 1.10 MAJOR COMPONENT WEIGHTS 1.11 CRITICAL STABILITY WEIGHTS DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ...

Page 15 - SECTION 2 - PROCEDURES; SECTION 2. PROCEDURES

SECTION 2 - PROCEDURES 3121111 – JLG Lift – 2-1 SECTION 2. PROCEDURES 2.1 GENERAL This section provides information necessary to performmaintenance on the scissor lift. Descriptions, techniquesand specific procedures are designed to provide the saf-est and most efficient maintenance for use by perso...

Page 16 - NOTE: Metal particles may appear in the oil or filters of new

SECTION 2 - PROCEDURES 2-2 – JLG Lift – 3121111 3. If a bearing is found to be serviceable, apply a lightcoat of oil and wrap it in clean (waxed) paper. Do notunwrap reusable or new bearings until they areready to install. 4. Lubricate new or used serviceable bearings beforeinstallation. When pressi...

Page 17 - NOTE: Start-up of hydraulic system with oil temperatures

SECTION 2 - PROCEDURES 3121111 – JLG Lift – 2-3 Hydraulic Oil 1. Refer to Section1 for recommendations for viscosityranges. 2. JLG recommends Mobilfluid 424, which has an SAEviscosity of 10W-30 and a viscosity index of 152. NOTE: Start-up of hydraulic system with oil temperatures below -15° F (-26° ...

Page 18 - NOTE: Cylinder checks must be performed any time a cylin-; IMPORTANT

SECTION 2 - PROCEDURES 2-4 – JLG Lift – 3121111 st ant . This diffe rent ial pr es sur e is applie d across t hevalve’s meter-in spool, with the effect that pump flow isdetermined by the degree of spool opening, independentof load pressure. Return lines are connected together,simplifying routing of ...

Page 19 - Removal; Retract the lift cylinder rod completely.; Installation

SECTION 2 - PROCEDURES 3121111 – JLG Lift – 2-5 minute, carefully reconnect hose to extend port,then activate cylinder through one complete cycleand check for leaks. Cylinders w/Single Counterbalance Valves - Lift Cylinder IMPORTANT OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATIONONLY. 1. Using all...

Page 21 - Remove the cylinder rod from the holding fixture.

SECTION 2 - PROCEDURES 3121111 – JLG Lift – 2-7 6. Remove the cylinder rod from the holding fixture. 7. Position the cylinder barrel in a suitable holding fix-ture. IMPORTANT EX TR EME CARE SHO UL D BE TAKE N W HEN INS TAL LI NG T HECYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE RODOFF-CENTER, WH...

Page 23 - LIFT CYLINDER REPAIR

SECTION 2 - PROCEDURES 3121111 – JLG Lift – 2-9 2.10 LIFT CYLINDER REPAIR Disassembly IMPORTANT DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ONA CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1. Connect a suitable auxiliary hydraulic power sourceto the cylinder port block fitting. IMPORTANT D O N O...

Page 24 - Cleaning and Inspection

SECTION 2 - PROCEDURES 2-10 – JLG Lift – 3121111 11. Insert the cap screw(s) in the threaded holes in theouter piece of the tapered bushing. Progressivelytighten the cap screw(s) until the bushing is looseon the piston. 12. Remove the bushing from the piston. 13. Screw the piston CCW, by hand, and r...

Page 25 - Assembly; NOTE: Prior to cylinder assembly, ensure that the proper; Carefully slide the piston spacer on the rod.; Figure 2-10. Installation of Head Seal Kit

SECTION 2 - PROCEDURES 3121111 – JLG Lift – 2-11 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 componentsprior to assembly. 1. A special tool is used to install a new rod seal intothe...

Page 26 - NOTE: The backup rings for the solid seal have a radius on; Figure 2-11. Piston Seal Kit Installation

SECTION 2 - PROCEDURES 2-12 – JLG Lift – 3121111 7. If applicable, correctly place new seals and guidelock rings in the outer piston diameter groove. (Atube, with I.D. slightly larger than the O.D. of the pis-ton is recommended to install the solid seal.) NOTE: The backup rings for the solid seal ha...

Page 27 - Tapered Bushing Retaining Screws - Lift Cylinder; Table 2-2. Holding Valve Torque Specifications

SECTION 2 - PROCEDURES 3121111 – JLG Lift – 2-13 15. Remove the cylinder rod from the holding fixture. 16. Place new guide locks and seals in the applicableoutside diameter grooves of the cylinder piston.(See Figure 2-11., Piston Seal Kit Installation) 17. Position the cylinder barrel in a suitable ...

Page 28 - STEER CYLINDER REPAIR

SECTION 2 - PROCEDURES 2-14 – JLG Lift – 3121111 2.11 STEER CYLINDER REPAIR Removal Before beginning this procedure, ensure that the parkingbrake is engaged and the rear wheels are chocked. 1. Tag and disconnect the hydraulic lines to the steercylinder, then cap the steer cylinder hydraulic linesand...

Page 30 - NOTE: Park the machine on a firm and level surface with the; MAGNETIC SPEED PICKUP CLEANING; NOTE: Flats on the magnetic pickup must be oriented verti-; Figure 2-18. Magnetic Speed Pickup Removal

SECTION 2 - PROCEDURES 2-16 – JLG Lift – 3121111 10. Carefully install one of the cylinder heads on oneend of the cylinder rod and push the head onto therod until it is snug against the end of the cylinderbarrel. 11. Install one of the cylinder head retainers on the endof the cylinder barrel and tig...

Page 31 - PRESSURE SETTING PROCEDURES; NOTE: Make all pressure adjustments with the engine oper-; Lift Relief Adjustments; Remove the pressure gauge from gauge port MP.; Steer Relief Adjustment; Remove the pressure gauge from gauge port P2

SECTION 2 - PROCEDURES 3121111 – JLG Lift – 2-17 . 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 operatedfrom the platform control station in order to achieve...

Page 32 - LIMIT SWITCH ADJUSTMENT; NOTE: All automatic choke assemblies have been pre-set to; Adjustments; NOTE: If the choke rod is binding make sure the support; SIDE VIEW

SECTION 2 - PROCEDURES 2-18 – JLG Lift – 3121111 2.15 LIMIT SWITCH ADJUSTMENT Speed Cutout Switch The speed cutout switch is located on the right side of theframe of the machine. When activated, the switch cuts outthe high drive function. Adjust the switch to activate whenthe platform is raised abov...

Page 33 - Reassembly; NOTE: If the machine starts and stalls immediately or if it is; Diesel Engine; NOTE: Never run the fuel tank dry. Diesel engines cannot; ELECTRONIC CONTROL SYSTEM; NOTE: The cable has a four pin connector at each end of

SECTION 2 - PROCEDURES 3121111 – JLG Lift – 2-19 Reassembly Reassemble the air horn making sure the choke is notbinding, t es t to ins ur e t hat none of the s et tings hav emoved and the choke is not binding. The vacuum pull off should be set such that when vacuumis applied to the choke system the ...

Page 34 - NOTE: Refer to the appropriate Machine Personality Set-

SECTION 2 - PROCEDURES 2-20 – JLG Lift – 3121111 view what the last fifteen faults were. Use the right and leftarrow keys to scroll through the fault logs. To return to thebeginning, press ESC two times. When a top level menu is selected, a new set of menuitems may be offered; If for example you cho...

Page 35 - FLASH CODES AND DESCRIPTIONS; FLASH CODE; FUNCTION PROBLEM - Horn permanently selected

SECTION 2 - PROCEDURES 3121111 – JLG Lift – 2-21 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 & ABOVE ELEVATIONPlatform is elevated and the chassis is not level. DIFFERENT FUNCTION SELECTE...

Page 38 - gure

SECTION 2 - PROCEDURES 2-24 – JLG Lift – 3121111 B Y PR E S SI N G TH E S E A R R O W K E Y S ( ) Y O U CA N S C RO LL TH RO U G H TH E TO P LE V E L M E N U S . - T o p L e v e l M e n u - S u b L e v e l M e n u - I te m t o b e V ie w e d o r C h a n g e d (P ro mp t b e fo re C a lib ra tion ) (...

Page 40 - NOTE: When configuring a CRT scissors machine, the; Table 2-5. Machine Configuration Programming Information

SECTION 2 - PROCEDURES 2-26 – JLG Lift – 3121111 NOTE: When configuring a CRT scissors machine, the machine configuration must be completed beforeany personality settings can be changed. Changingthe personality settings first and then changing themodel number of the machine configuration willcause t...

Page 41 - PREVENTIVE MAINTENANCE AND; NOTE: This machine requires periodic safety and mainte-

SECTION 2 - PROCEDURES 3121111 – JLG Lift – 2-27 2.19 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE The preventive maintenance and inspection checks arelisted and defined in the following table. This t able isdivided into two basic parts, the “AREA” to be inspectedand the “INTERVAL” at which the in...

Page 43 - SECTION 3 - TROUBLESHOOTING; SECTION 3. TROUBLESHOOTING; GENERAL

SECTION 3 - TROUBLESHOOTING 3121111 – JLG Lift – 3-1 SECTION 3. TROUBLESHOOTING 3.1 GENERAL This section contains troubleshooting information to beused for locating and correcting most of the operatingproblems which may develop in the aerial platform. If aproblem should develop which is not presente...

Page 52 - GROUND

SECTION 3 - TROUBLESHOOTING 3-10 – JLG Lift – 3121111 GROUND ELECTRONICS Figure 3-1. Electrical Schematic - Sheet 1 of 2

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Page 58 - JLG Worldwide Locations; Corporate Office

JLG Worldwide Locations Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA Phone: (717) 485-5161 Fax: (717) 485-6417 JLG Industries (Australia)P.O. Box 511911 Bolwarra RoadPort MacquarieN.S.W. 2444AustraliaPhone: (61) 2 65 811111Fax: (61) 2 65 810122 JLG Industries (...