JLG 330CRT Service Maintenance Manual
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JLG 330CRT Service Maintenance Manual

JLG 330CRT Service Maintenance Manual

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Service & Maintenance Manual
Model
330CRT
400CRT
3121804
April 7, 2004

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Summary of Contents for JLG 330CRT

  • Page 1 Service & Maintenance Manual Model 330CRT 400CRT 3121804 April 7, 2004...

  • Page 3: Hydraulic System Safety

    • USE ONLY APPROVED, NONFLAMMABLE CLEANING ous pressures. Every effort should be made to SOLVENTS. relieve any system pressure prior to disconnecting or removing any portion of the system. 3121804 – JLG Lift –...
  • Page 4 INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS REVISON LOG Original Issue - April 13, 2000 Revised - August 17, 2000 Revised - September 28, 2001 Revised - October 18, 2002 Revised - April 7, 2004 – JLG Lift – 3121804...

  • Page 5: Table Of Contents

    Hydraulic Circuit Checks ............3-1 3121804 – JLG Lift –...
  • Page 6 330CRT Lift Cylinder ........
  • Page 7 Electrical System Troubleshooting..........3-8 3121804 – JLG Lift –...
  • Page 8 TABLE OF CONTENTS This page left blank intentionally. – JLG Lift – 3121804...

  • Page 9: Section 1. Specifications

    7 ft. (2 m) Fuel Consumption Lift Speed Low RPM - 4.9 lph (1.3 gph) Lift up - 330CRT - 36-40 seconds High RPM - 9 lph (2.4 gph) 400CRT - 53-55 seconds Horsepower - 24.5 @ 3600 RPM Lift down - 330CRT - 36-40 seconds...

  • Page 10: Torque Requirements

    SAE viscosity index of152. 400 CRT - 1.7 m (68.25 in.) NOTE: Aside from JLG recommendations, it is not advisable Machine Length to mix oils of different brands or types, as they may 3 m (10 ft. 2 in.) not contain the same required additives or be of comparable viscosities.
  • Page 11 MAINTENANCE REQUIRING PLATFORM TO BE ELEVATED. Any time the pump coupling is removed, coat NOTE: Be sure to lubricate like items on each side splines of coupling with Texaco Code 1912 grease prior to assembly. 3121804 – JLG Lift –...
  • Page 12 SECTION 1 - SPECIFICATIONS – JLG Lift – 3121804...

  • Page 13: Pressure Settings

    Steer Relief (Right) - max 110 bar (1600 psi) tion. Lift Pressure - 330CRT - 159 bar (2300 psi) Tilt Alarm - 3° - A horn is sounded and a warning light is illuminated when the machine is operated on a slope that 400CRT - 172 bar (2500 psi) exceeds 3°...

  • Page 14: Cylinder Specifications

    1.25 (6.4) (18.1) (3.2) 1.10 MAJOR COMPONENT WEIGHTS Table 1-5. Major Component Weights Component Fixed Platform Platform Extension Arm Assembly- 330CRT 3200 1452 (Includes Lift Cylinder) Arm Assembly- 400CRT 3900 1769 (Includes Lift Cylinder) Chassis with Foam Filled Tires 4980 2259 –...

  • Page 15: Section 2. Procedures

    2. Discard bearings if the races and balls (or rollers) order to function properly. are pitted, scored, or burned. 3121804 – JLG Lift –...

  • Page 16: Lubrication Information

    When recommended lubricants are nents. not available, consult your local supplier for an equivalent that meets or exceeds the specifications listed. – JLG Lift – 3121804...

  • Page 17: Cylinders - Theory Of Operation

    2. JLG recommends Mobilfluid 424, which has an SAE Should any question arise regarding the use of greases in viscosity of 10W-30 and a viscosity index of 152.

  • Page 18: Component Functional Description

    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. – JLG Lift – 3121804...

  • Page 19: Lift Cylinder Removal And Installation

    If leakage continues at a rate of 6-8 5. Lower platform to stowed position and shut down drops per minute or more, the counterbalance valve motor. Check hydraulic fluid level and adjust accord- is defective and must be replaced. ingly. 3121804 – JLG Lift –...
  • Page 20 SECTION 2 - PROCEDURES Figure 2-1. Arms and Platform Positioning and Support, Cylinder Repair – JLG Lift – 3121804...
  • Page 21 SECTION 2 - PROCEDURES Figure 2-2. 330CRT Lift Cylinder 6. Remove the cylinder rod from the holding fixture. 9. Continue pushing the rod into the barrel until the cyl- inder head gland can be inserted into the barrel cyl- 7. Position the cylinder barrel in a suitable holding fix- inder.
  • Page 22 SECTION 2 - PROCEDURES Figure 2-3. 400CRT LIft Cylinder – JLG Lift – 3121804...

  • Page 23: Lift Cylinder Repair

    9. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible. 10. Loosen and remove the cap screw(s), if applicable, which attach the tapered bushing to the piston. 3121804 – JLG Lift –...
  • Page 24 Replace if necessary. 5. Inspect threaded portion of barrel for damage. Dress threads as necessary. 6. Inspect piston surface for damage and scoring and for distortion. Dress piston surface or replace piston as necessary. 2-10 – JLG Lift – 3121804...
  • Page 25 NOTE: Prior to cylinder assembly, ensure that the proper groove. cylinder seal kit is used. See your JLG Parts Manual. Apply a light film of hydraulic oil to all components prior to assembly.
  • Page 26 4. Assemble the tapered bushing loosely into the pis- ton and insert JLG capscrews (not vendor cap- Figure 2-13. Seating the Tapered Bearing screws) through the drilled holes in the bushing and into the tapped holes in the piston.
  • Page 27 Figure 2-15. Rod Assembly Installation 14. 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. 3121804 – JLG Lift – 2-13...

  • Page 28: Steer Cylinder Repair

    3. Attach a suitable pulling device to one end of the cylinder rod. 4. Carefully lift the steer cylinder until the cylinder mounting block clears the mounting slot in the bot- Figure 2-16. Steer Cylinder Assembly 2-14 – JLG Lift – 3121804...
  • Page 29 9. Continue pushing the rod assembly into the cylinder heads for scoring or other damage and for ovality barrel until the cylinder rod is approximately cen- and tapering. Replace as necessary. tered in the barrel. 3121804 – JLG Lift – 2-15...

  • Page 30: Oscillation Cylinder Bleeding

    NOTE: Flats on the magnetic pickup must be oriented verti- 4. Tighten the bleeder screw then push the raised cally. wheel down and repeat the process for the opposite level cylinder. 5. Replace the jam nut and tighten. 2-16 – JLG Lift – 3121804...

  • Page 31: Pressure Setting Procedures

    3. Bottom out the Lift Up function and adjust the Lift Up 2.14 PRESSURE SETTING PROCEDURES relief to 159 bar (2300 psi) on the 330CRT and 172 bar (2500 psi) on the 400CRT. NOTE: Make all pressure adjustments with the engine oper- ating and the hydraulic oil at normal operating tem- 4.

  • Page 32: Limit Switch Adjustment

    90% may improve the performance of the machine. and support bracket securely making sure the choke moves freely. No adjustment is normally required. 2-18 – JLG Lift – 3121804...

  • Page 33: Electronic Control System

    If there was no fault detected during power up, the display will read: HELP: EVERYTHING OK 3121804 – JLG Lift – 2-19...
  • Page 34 SECTION 2 - PROCEDURES Changing the Access Level of the Hand Held NOTE: Refer to the appropriate Machine Personality Set- tings Table, and the Machine Setup Table in the JLG Analyzer: Service Manual for the recommended factory set- When the analyzer is first connected, you will be in access tings.

  • Page 35: Flash Codes And Descriptions

    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. FUNCTION PROBLEM - LIFT PERMANENTLY SELECTED Lift switch (up or down) in the ground control box closed at start up. Release switch to clear fault 3121804 – JLG Lift – 2-21...
  • Page 36 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 – 3121804...
  • Page 37 SECTION 2 - PROCEDURES 3121804 – JLG Lift – 2-23...
  • Page 38 à W y à y à ‰ à i  ‰ à G ‚ à ‡ à G ƒ ‚ € à U … à ˆ ‡ r à T à D ‚ à à 2-24 – JLG Lift – 3121804...
  • Page 39 0 to 999 DROOP 0 to 999 STABILITY 0 to 999 MIN ACT 0 T0 100% MAX ACT L/D 0 T0 100% MAX ACT IDLE 0 T0 100% CUT ACT 200 TO 2800 RPM 3121804 – JLG Lift – 2-25...
  • Page 40 No drive cutout switch installed. (Drive Cutout) Cuts out drive when deck is elevated above a predetermined elevation (Default for 400 CRT) FWD & LIFT up (Control Direction) FWD & LIFT dn (for future use) (Leveling Jacks) 2-26 – JLG Lift – 3121804...

  • Page 41: Preventive Maintenance And Inspection Schedule

    11. Check for proper operation while pump/motor is Inspection Report” form. Forms are supplied with each running. new machine and are also available from JLG Customer Service. Form must be completed and returned to JLG 12. Check for proper lubrication.
  • Page 42 23. Wheel Bearings (2 Wheel Drive) 24. Sizzor Arms 25. Safety Props 26. Sliding Wear Pads 27. Pivot Pins/Bolts 28. Switches, Ground Control 1,11 29. Control Tags * Inspection and Maintenance code 10 to be performed annually 2-28 – JLG Lift – 3121804...

  • Page 43: Section 3. Troubleshooting

    For aid in troubleshooting, refer to the Illustrated Parts Manual for hydraulic diagram of the various circuits. 3121804 – JLG Lift –...
  • Page 44 - 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- Clean, repair or replace line. ting. – JLG Lift – 3121804...
  • Page 45 Holding valve on lift cylinder not function- Repair or replace valve. ing properly. High Drive does not operate below horizontal Damaged wiring on limit switch. Repair or replace wiring. Damaged limit switch. Replace limit switch 3121804 – JLG Lift –...
  • Page 46 No electrical signal being sent to the drive Refer to Electrical System Troubleshoot- valve cartridge. ing - No response to control switch. Machine will not travel in reverse See: Machine will not travel forward. High-Speed Drive function does not operate – JLG Lift – 3121804...
  • Page 47 Repair or replace cylinder. Machine hard to steer or steering is erratic Hydraulic system oil low. Replenish oil as necessary. Restricted or broken hydraulic line or fit- Clean, repair or replace line or fitting. ting. 3121804 – JLG Lift –...
  • Page 48 Repair or replace steer linkage. Machine wanders; steering not firm Crossover relief valve set too low or not Reset, repair or replace valve as neces- functioning properly. sary. Steer linkage loose. Tighten linkage. Spindle bushings badly worn. Replace bushings. – JLG Lift – 3121804...
  • Page 49 Sticking or binding valve spools, piston rod, etc Clean, repair or replace components as required Hydraulic oil not a t optimum operating tempera- Allow oil sufficient time to warm up ture Pump drive slipping Repair or replace drive 3121804 – JLG Lift –...
  • Page 50 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 – JLG Lift – 3121804...
  • Page 51 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 3121804 – JLG Lift –...
  • Page 52 SECTION 3 - TROUBLESHOOTING GROUND ELECTRONICS Figure 3-1. Electrical Schematic - Sheet 1 of 2 3-10 – JLG Lift – 3121804...
  • Page 53 SECTION 3 - TROUBLESHOOTING GROUND ELECTRONICS 1870118_I Figure 3-2. Electrical Schematic - Sheet 2 of 2 3121804 – JLG Lift – 3-11...
  • Page 54 SECTION 3 - TROUBLESHOOTING Figure 3-3. Hydraulic Schematic - Sheet 1 of 2 3-12 – JLG Lift – 3121804...
  • Page 55 SECTION 3 - TROUBLESHOOTING 2792397 E Figure 3-4. Hydraulic Schematic - Sheet 2 of 2 3121804 – JLG Lift – 3-13...
  • Page 56 SECTION 3 - TROUBLESHOOTING This page intentionally left blank. 3-14 – JLG Lift – 3121804...
  • Page 58 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.

This manual is also suitable for:

400crt

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