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D:\FMManuals\Sizzors\3120881\Drive Hub.eps

1. TILT SENSOR 2 DEI d a 16 24 CABLE FROM THE PLATFORM 21 BT RECEPTACLE PIN LETTERS 1 ENABLE 1 WXPNOHGUBARFSDKJLMTEVCQ 2 EMS STROBE LITE 2 3 LOW BATTERY 3 4 ELEVATION SWITCH 4 gt E 2 5 5 TILT 5 8 6 PUMP ENABLE 6 BLU ORN NW OM 4 tc EH 0 Lj Q C uj A ul Qc DEE uj ul LJ J LJ C e 12183124 7118 8111123 5 34541411301411811711411515111424153 9 LIFT DOWN 9 23 10 EXTENDABLE DECK 10 oN FRENCH SPEC ONLY S ORN RED 11 EXTENDABLE DECK 11 12 SUPPLY 12 5 15 TRACTION ACCEL 13 De 14 DRIVE FORWARD 14 CAPACITY 15 DRIVE REVERSE 15 BLk RED AND ORN RED 16 PUMP BY PASS 16 YEL RED HOURMETER 17 STEER LEFT 17
2. Figure 2 10 Piston Seal Kit Installation 12 Place new guidelock and hydrolock seals in the applicable outside diameter grooves of both the pis ton and the cylinder head PISTON REF Figure 2 11 Poly Pak Piston Seal Installation 13 Position the cylinder barrel in a suitable holding fix ture A 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 SPACER HEAD ASSY CAP CYLINDER SCREWS BARREL WASHER RING Figure 2 12 Rod Assembly Installation JLG Sizzor 2 9 SECTION 2 PROCEDURES 14 With the barrel clamped securely and while ade NOTE These cylinders use setscrews which should be dis quately supporting the rod insert the piston end into carded and replaced whenever they are removed the cylinder barrel Ensure that the piston loading o ring and seal ring are not damaged or dislodged 19 Remove cylinder rod from the holding fixture i AC d Go Sc 20 Place new o rings and seals in the applicable out side diameter grooves of both the piston and the 3 inder head 16 Secure the cylinder head gland using the washer zb 5 3 ring and socket head bolts 21 Eet the cylinder barrel in a suitable holding fix 17 After the cylinder has been reas
3. 95238 433282988 x x 285 5 6 sud GSSeececsszseseezecsecis gt 0 ac gt e coa gt gt meanganan OE LEE LIC CE D E E S LC RS NOTE USE ITEM 24 0100048 SILICONE COUMPOUND AS REQUIRED AT TIME ASSEMBLY OR REPLACEMENT THE FIELD RED i2 BATTERY CAPACITY 26 1 2 merum 4 fs m fs e Por rut 5 OT n a 1 15 Sas 1 SC 15 35 36 ORN BLK ORN RED BLUE 1 summer mm 39 7 GWmoum WHT BRN RED ORN bb d ud o ES 27 FOR BRAKES TILT ELEVATION 5411045 27 28 B FROM BRAKES TO SEVCON 28 29 To PLATFORM 29 3 vsroPa 32 PROXIMITY SWITCH 32 33 DRIVE CONTROLLER Ta 3 cut out __ SPEED CUT BACK 35 35 BLU RED TILT RELAY ORN BLK badd WHT BRN BLACK P veL BU 48 OR BLK Jl WHT BRN d EN DRIVE CUT OUT RELAY OPTION 3 5 Figure 3 4 Ground Control Wiring On Machines Before Serial Number 020071522 Sheet 1 of 2 JLG Sizzor 3120881 SECTION 3 TROUBLESHOOTING ST
4. 8 18 STEER RIGHT 18 19 HORN 19 BRN ORN 28 20 CONTROLLER ENABLE 20 LA 2110 B 21 22 B 22 6 AMP s mu 23 O B 23 24 B 24 25 0 B 25 WHT YEL 5 orN BLK 2 26 4 wer 27 FOR BRES TILT ELEVATION ane 27 pu OPTION 28 B FROM BRAKES TO SEVCON 28 i 29 TILT TO PLATFORM 29 30 9 VS TO PLAT 30 7 31 VS TO PLAT 51 32 SPEED SW PONER 32 33 DRIVE CONTROLLER 33 34 DRIVE CUT OUT 34 ORANGE 8 35 SPEED CUT BACK 35 eg 36 TILT ELEVATION ALARM 36 37 TILT SENSOR 37 WHT BRN 23 38 EXTENSION CUT OUT 38 3 9 e RED ORN 3d7 uh PT Se 16 5 CABLE BE S AME BROWN 9 DOL oRN BLK 2 Barre 4 27 ORANGE 2 WHT YEL 31 R 4 3 d REL A Da e ue L 4 SS RED 3 5 2g YELLOW 16 TO LIFT OVERLOAD PRESSURE SWI TOH MANUAL BRAKE RELEASE RELAY DRIVE BRAKE RELEASE RELAY ORN BLK 2 MACHINE DISABLED WHEN BRAKE BRAKE PLUG RELEASE SW HARNESS 15 PLUGGED IN EMS ARE TURNED TO THE POSITION AND KEY SW 15 24 SELECTED PLATFORM OPTION MANUEL ELETRIC BRAKE RELEASE BLK BLU 5 E REMOVE FROM 2 AND INSTAL AS SHONE WHT BRN 28 BLU RED 34 BLU RED 2g TILT ALARM ORN BLK 12 RELAY WHT BRN 23 34 53 2 24 cz 35 amp x omo m o lt Az 3 a dh DRIVE CUT OUT RELAY 3
5. ISd 0052 135 JONVIVEUFINNOS 1 6 COR WO 14 213ddn dna 3 11 Figure 3 1 Hydraulic Schematic JLGSizzor 3120881 WHT YEL DRIVE CONTROLLER 55 5 lt 25 c rz e2 gc e 95 g SA 83315 6 Nid 038 16918 43315 8 Nid 1331 83315 Nid 13389 3543 34 JAIXO 9 NY0O LHM GUVMYO4 31940 S EROEM SA 0308 Nid 30718 Nid 73999 NOIAOVMI Z Nid NMOUE Nid RA SECTION 3 TROUBLESHOOTING LHM 034 018 ana MOTI3A NMOWB SONVYO 38 134 38 318 118 9 18 13 0 7 LHM PLUG PIN LETTERS vm oO SS See e a OO ma Ss DL Sea RECEPTACLE PIN LETTERS 518 038 134 034 718 WEIER 018 439 0 118 038 018 035 3019 MOTI3A 18 018 18 134 Xv 18 NMOWB 033 118 0 033 EEN Q38 NJO 18 134 018 718 18 038 NYOH 18918 83315 1431 43315 3SH3A3H JAIXO 3AI30 1399Y 19991 OL SA 1 14 OL SA Lowalad 1914 ON31X3 114 SAN Au111V8 93N AN111V8
6. RED 24VDC 88 BLACK 16 4 1 1 2 BLUE SPEED ORANGE CUT OUT SWITCH 4932130 Figure 3 9 Ground Control Wiring On Machines After and Including Serial Number 020071522 Sheet 2 of 2 3120881 JLGSizzor 3 19 SECTION 3 TROUBLESHOOTING This page intentionally left blank 3 20 JLG Sizzor 3120881 Corporate Office JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 USA Phone 717 485 5161 Customer Support Toll Free 877 554 5438 Fax 717 485 6417 JLG Worldwide Locations JLG Industries Australia P O Box 5119 11 Bolwarra Road Port Macquarie N S W 2444 Australia Phone 61 2 65 811111 Fax 61 2 65 810122 JLG Latino Americana Ltda Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil Phone 55 19 3295 0407 Fax 55 19 3295 1025 JLG Industries Europe Kilmartin Place Tannochside Park Uddingston G71 5PH Scotland Phone 44 1 698 811005 Fax 44 1 698 811055 JLG Industries UK Unit 12 Southside Bredbury Park Industrial Estate Bredbury Stockport SK6 25 England Phone 44 870 200 7700 Fax 44 870 200 7711 JLG Europe B V Jupiterstraat 234 2132 HJ Foofddorp The Netherlands Phone 31 23 565 5665 Fax 31 23 557 2493 JLG Industries Pty Ltd Unit 1 24 Industrial Complex Herman Street Meadowdale Germiston South Africa Phone 27 11 453 133
7. NOTE Prior to cylinder assembly ensure that the proper cylinder seal kit is used NOTE Apply a light film of hydraulic oil to all components prior to assembly 1 Using a special tool pictured in the following illustra tion install a new rod seal into the applicable cylin 2 8 JLG Sizzor der head gland groove Refer to the following illustration for the proper tool size SEAL TOOL 1 7004275 1 1 2 7004276 CYLINDER 2 7002826 HEAD Figure 2 6 Rod Seal Installation A IMPORTANT IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION 2 Using a soft mallet tap a new wiper seal into the applicable cylinder head gland groove Install a new wear ring into the applicable head gland groove SEAL CYLINDER HEAD Note When installing wiper seal ensure seal are installed properly Install seal so that the flat part of seal is facing into head Figure 2 7 Wiper Seal Installation 3 Place a new o ring and back up seal in the applica ble outside diameter groove of the cylinder head CYLINDER HEAD BACKUP RING Figure 2 8 Installation of Head Seal Kit 4 Install a washer ring onto the rod then carefully install the head gland on the rod ensuring that the 3120881 SECTION 2 PROCEDURES wiper and rod seals are not damaged or dislodged Push the head along the rod to the rod end as applicable 5 Carefully slide the piston
8. 0 01 ND Ue de Cam M qvo Enos ARE Cam qvo1 LE ANOYOL dV T9 ANOYOL d D 53415 S 3215 34A 30 ve 0961 07788 9 o H o 349 dV KINO 51108 134114 9NIZ 804 SANTVA 1 5 JLG Sizzor 3120881 SECTION 1 SPECIFICATIONS This page intentionally blank 1 6 JLG Sizzor 3120881 SECTION 2 PROCEDURES SECTION 2 PROCEDURES 2 1 GENERAL 1 This section provides information necessary to per form maintenance on the sizzor lift Descriptions techniques and specific procedures are designed to provide the safest and most efficient maintenance for use by personnel responsible for ensuring the correct installation and operation of machine com ponents 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 2 The maintenance procedures included consist of servicing and component removal and installation disassembly and assembly inspection lubrication and cleaning Information on any special tools or test equipment is also provided where applicable 2 2 SERVICING AND MAINTENANCE GUIDELINES General The following information is provided to assist you in the use and application of servicing and maintena
9. Control valve not functioning properly Repair or replace control valve Steer cylinder not functioning properly Repair or replace steer cylinder Machine hard to steer or steering erratic Hydraulic system oil low Replenish oil as necessary Restricted hydraulic line or fitting Clean repair or replace hydraulic line or fitting Bentsteering linkage Repairor replace steering linkage as required Hydraulic pump not functioning properly Repair or replace hydraulic pump Steer cylinder not functioning properly Repair or replace steer cylinder Steering inoperative Wiring damaged on control switch or solenoid valve Repairor replace wiring Solenoid valve notfunctioning properly Repairor replace solenoid valve Steer control switch not functioning properly Replace steer control switch Steer cylinder not functioning properly Repair or replace steer cylinder Machine will not steer left or right Enable switch not activated Activate enable switch Function not activated within 3 seconds after enable switch was depressed Reactivate enable switch Enable switch not functioning properly Replace enable switch circuit card Wiring on steer control switch damaged Repair or replace wiring as necessary Wiring on steer solenoid valve damaged Repair or replace wiring as necessary Steer solenoid coil damaged Replace coil Bent steer cylinder r
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11. 2 9 FEATURES Features in Traction Mode Maximum Speed Control The controller incorporates a function to limit the maxi mum speed of the machine to a percentage of maximum possible speed The function operates in such a manner as to control vehicle speed by limiting the percentage on of the switching device to keep the machine speed below the maximum permitted value or if required to apply vari able plug braking to restrict machine speed when travel ing down a grade The speed is controlled based on the percentage of accelerator input Features in Pump Mode 1 Proportional Control of Pump Motor Speed The pump motor speed shall be controlled by varying the percentage on of the switching element in rela tion to a separate pump accelerator input 2 Soft Start The pump motor speed control incorpo rates a soft start facility by applying acceleration delay to changes in the applied percentage on of the switching element 2 4 JLG Sizzor 3120881 SECTION 2 PROCEDURES General Features Diagnostics To obtain flash code depress enable switch and repeat operation which caused fault After fault occurs maintain function position and read flash code NOTE Flash code repeats after pause Flash code readings must be taken from platform control box with unit switched to platform Table 2 1 Flash Codes Code Description LED On Controller Operational L
12. dL Service and Maintenance Manual Model 3369electric 3969electric 3120881 June 13 2000 1509001 REGISTERED COMPANY 015 MG 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 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
13. JLG Sizzor 1 1 SECTION 1 SPECIFICATIONS Machine Width 3369 electric 1 80 m 69 in 3969 electric 1 80 m 69 in Wheelbase 3369 electric 1 98 m 77 in 3969 electric 1 98 m 77 in Ground Clearance 3369 electric 17 8 cm 7 in 3969 electric 17 8 cm 7 in Maximum Tire Load 3369 electric 1388 kg 3060 Ib 3969 electric 1427 kg 3145 Ib NOTE Hyaraulic oils must have anti wear qualities at least to API Service Classification GL 3 and sufficient chemical stability for mobile hydraulic system ser vice JLG Industries recommends Mobilfluid 424 hydraulic oil which has an SAE viscosity of 10W 20 and a viscosity index of 152 When temperatures remain consistently below 7 2 F recommends the use of Mobil DTE 11 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 Maximum Bearing Pressure KEY SPECIFICATIONS 3369 electric 3 9 bar 56 psi EPGL Extreme Pressure Gear Lube oil meeting API service classification GL 5 or MIL Spec MIL L 2105 3969 electric 3 9 bar 58 psi HO Hydraulic Oil API service classification Gl 3 e g Mobil 424 or BP Energol S
14. SettihgS s E i i Eet ie 1 2 1 7 Cylinder 5 1 4 1 8 Major Component 5 1 4 1 9 Critical Stability Weights 2 1 1 4 1 10 Relays Circuit 5 1 4 1 11 Serial Number 1 4 SECTION 2 PROCEDURES 2 1 Gerleral Caes ath at o Tareas E Rl 2 1 2 2 Servicing and Maintenance Guidelines 2 1 2 3 Lubrication 2 2 2 4 Cylinders Theory of Operation 2 3 2 5 Valves Theory of 2 3 2 6 Component Functional Description 2 4 2 7 WearPads ue UI DAT RR peed has see eee 2 4 2 8 Motor Controller Modes of 2 4 2 9 Features uos erum DRE e doit CR RE la 2 4 2 10 Cylinder Checking 2 5 2 11 Lif
15. place Under the AREA of the table the various systems along with components that make up that system are listed The INTERVAL portion of the table is divided into five columns representing the various inspection time periods The numbers listed within the interval column represent the applicable inspection code for which that component is to be checked The checks and services listed in this schedule are not intended to replace any local or regional regulations that may pertain to this type of equipment nor should the lists be considered as all inclusive Variances in interval times may occur due to climate and or conditions and depend ing on the location and use of the machine JLG Industries requires that a complete annual inspection be performed in accordance with the Annual Machine Inspection Report form Forms are supplied with each new machine and are also available from JLG Customer Service Forms must be completed and returned to JLG Industries 2 16 JLG Sizzor A IMPORTANT JLG INDUSTRIES REQUIRES THAT A COMPLETE ANNUAL INSPECTION BE PERFORMED IN ACCORDANCE WITH THE ANNUAL MACHINE INSPECTION REPORT FORM NOTE This machine requires periodic safety and mainte nance inspections by a JLG Dealer A decal located on the frame affords a place record stamp inspection dates Notify dealer if inspection is over due The inspection and maintenance code numbers are as fol lows 1 Check for proper
16. 5 AMP Figure 3 8 Ground Control Wiring On Machines After and Including Serial Number 020071522 Sheet 1 of 2 JLG Sizzor 3120881 SECTION 3 TROUBLESHOOTING NOTE USE ITEM 24 0100048 SILICONE COUMPOUND AS REQUIRED AT TIME ASSEMBLY OR REPLACEMENT IN THE FIELD 8 BRN BLK 2 RED BLK Ij BLK ORN ENS 2 WHT BRN LEFT REAR 23 BLK BLU GRN BRAKE 5 BLU RED WHT 5 HORN LEVEL PIN2 24 wHT BRN BLK mn OPTION 2 8 Wi BLK RED STEER LEFT m YEL RED STEER RIGHT PIN 2 RIGHT 8 BRN ORN LIFT UP SE 8 YEL ORN LIFT DOWN o EE NOTE CUT 20 GA SEVCON WIRES TERMINATE AND INSTALL AS SHOWN OPTION god 9 EXT DECK EXT C d RED YEL EXT DECK RET TACH L 14 MM 24 wHT BRN L RED pe 23 wHT BRN 6 DEUS EXISTING 2 24 WHT BRN 2 ON SE SEVCON LT 3 0 H 18 2 SHIELDED CABLE 2 116 2 SS Bi BLACK OPTION Ld tok mis 21 MOTION ALARM Ges 24 WHT BRN OPTION SHIELD WHT BRN RED PIN 4 TACH DRIVE __ BLK PIN 3 TACH DRIV
17. 93N A8111V8 dn 1411 NMG 1301 119 011111 1399v 14911 380515 S3 318YN3 110 102 3A1Y0 OL Ai 3 81N OL MS A313 JLG Sizzor 3120881 Figure 3 2 Platform Wiring On Machines Before Serial Number 020071522 Sheet 1 of 2 3 12 SECTION 3 TROUBLESHOOTING s SPEED CONTROL 5 WHT YEL rd aad gt D a m gt gt en a 5 N Doy K D N N 25 ce BEND RESISTOR WIRES NOTE OVER DOUBLE AND INSTALL INTO TERM S FOR CRIMPING CONTROL ENABLE WHT YEL CONTACT BLOCK BLOCK 2 EA x gt gt 2 c J Q SUE D e Ca 4 x amp amp a toy a a zm en 5 5 EM em mem e D Rae cpi 0 0 R Si s TWIST LOCK RECEPTACLE 4932657D Figure 3 3 Platform Wiring On Machines Before Serial Number 020071522 Sheet 2 of 2 3120881 JLGSizzor 3 13 SECTION 3 TROUBLESHOOTING 3 14 16 24 CABLE FROM THE PLATFORM RECEPTACLE PIN LETTERS WXPNOHGUBARFSDKJLMTEVCO
18. and carefully disconnect hydraulic hose from cylinder extend port Activate hydraulic system and activate cylinder retract function Check extend port for leakage If extend port leakage is less than 6 8 drops per minute carefully reconnect hose to extend port then activate cylinder through one complete cycle and check for leaks If leakage continues at a rate of 6 8 drops per minute or more cylinder repairs must be made Cylinders With Single Counterbalance Valve Lift Cylinder A IMPORTANT OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY 1 JLG Sizzor Using all applicable safety precautions activate hydraulic system Raise platform completely and place a suitable over head lifting device approximately 2 5 cm 1 in below the platform After completing the above shut down hydraulic system and allow machine to sit for 10 15 minutes This is done to relieve pressure in the hydraulic lines Carefully remove hydraulic hoses from appro priate cylinder port block 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 following cylinder repairs must be made If the retract port is leaking the piston is leaking the piston seals are defective and must be replaced If the extend port is leaking the counterb
19. cylinder port block Dis 5 Remove the bolt locknut and keeper shaft securing card o rings 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 BARREL CLAMP 6 Carefully remove the cylinder from the sizzor lift and Bes cw place in a suitable work area PROTECTED ROD CLAMP Lift Cylinder Installation SUPPORT 1 Install lift cylinder in place using a suitable slings RN TABLE aligning barrel end attaching pin mounting holes on lower arm assembly 2 Using a suitable drift drive the barrel end attach pin Figure 2 1 Barrel Support through the mounting holes in the lift cylinder and the lower arm assembly Secure in place with bolt 3 Place the cylinder barrel into a suitable holding fix locknut and keeper shaft ture 3 Remove cylinder port plugs and hydraulic line caps and correctly attach lines to cylinder ports 4 Extend the cylinder rod until the attach pin hole CAPSCREWS 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 holes with the hole on the arm assem bly Secure the pin in place with bolt locknut keeper shaft 5 Lower platform to stowed position and shut down motor Check hydraulic fluid level and adjust accord ingly F
20. ensure that adequate support is pro vided WARNING SINCE THE MACHINE 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 3120881 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 WARNING FAILURE 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 CH
21. it is necessary to start the system in a sub zero environment it will be necessary to heat the oil with a low density 100VAC heater to a minimum temperature of 26 C 3 The only exception to the above is to drain and fill the system with Mobil DTE13 oil or its equivalent This will allow start up at temperatures down to 29 C However use of this oil will give poor perfor mance at temperatures above 49 C Systems using DTE13 oil should not be operated at temperatures above 94 C under any condition Changing Hydraulic 1 Use of any of the recommended hydraulic oils elimi nates the need for changing the oil on a regular basis However filter elements must be changed after the first 40 hours of operation and every 250 hours thereafter If it is necessary to change the oil use only those oils meeting or exceeding the specifi cations appearing in this manual If unable to obtain the same type of oil supplied with the machine con sult local supplier for assistance in selecting the proper equivalent Avoid mixing petroleum and syn thetic base oils JLG Industries recommends chang ing the hydraulic oil annually 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 filter and replace the cartridge any time the system oil is changed 3 While
22. 2 o clock straight up from each planet pin With shoulder side of ring gear facing down place ring gear over into mesh with cluster gear Be sure that punch marks remain in correct location during installation The side of the ring gear with an stamped on it should be up While holding ring gear and cluster gear in mesh place small side of cluster gear into mesh with the internal gear and sun gear On the ring gear locate the hole marked X over one of the marked coun terbored holes in hub NOTE If gears do not mesh easily or carrier assembly does 10 11 12 13 14 15 16 not rotate freely then remove the carrier and ring gear and check the cluster gear timing Sun gear is installed meshing with the teeth of the large diameter cluster gear The counterbore on the sun gear locates on the shoulder of the input spacer This is to be a slip fit and should operate freely Thrust washer is installed onto the sun gear and should locate on the gear teeth shoulder Thrust washer is installed into the counterbore of the carrier Place o ring into input cover counterbore Use petro leum jelly to hold o ring in place The input cover is now installed on this assembly Taking care to correctly align pipe plug hole with those in the hub usually 90 to one another locate the four counterbore holes in housing marked in step 3 and install four shoulder bolts A tap with a hammer may be n
23. 3 Holding Valve Torque Specifications 2 10 2 4 Preventive Maintenance and Inspection Schedule 2 17 3 1 Platform Assembly 0 1 4 3 2 3 2 Chassis Troubleshooting 3 4 3 3 Hydraulic System 3 6 3 4 Electrical System 3 7 3 5 Flash Code Troubleshooting 3 8 3 6 Control Module Settings for Machines After and Including Serial Number 020071522 3 9 3 7 Control Module Settings for Machines Before Serial Number 020071522 3 9 JLG Sizzor 3120881 SECTION 1 SPECIFICATIONS SECTION 1 SPECIFICATIONS 1 4 CAPACITIES Hydraulic Oil Tank 41 6 liters 11 0 gallons Hydraulic System Approximately 50 0 liters 13 2 gallons Torque Hubs 2 0 5 liters 17 ounces 1 2 COMPONENT DATA Battery Charger Input 110 VAC 60 HZ Output 48 VDC 23 Amp Batteries 8 Standard 6 Volt 225 AmpHour High Output 6 Volt 370 AmpHour Drive System Drive Motor 36 VDC 4 1 1880 rpm continuous rotation reversible Drive Brake 24 VDC spring applied elect
24. 4 Fax 27 11 453 1342 JLG Deutschland GmbH Max Planck Strasse 21 D 27721 Ritterhude Ihlpohl Bei Bremen Germany Phone 49 421 693 500 Fax 49 421 693 5035 JLG Industries Norge AS Sofeimyrveien 12 N 1412 Sofienyr Norway Phone 47 6682 2000 Fax 47 6682 2001 Plataformas Elevadoras JLG Iberica S L Trapadella 2 Castellbisbal Sur 08755Castellbisbal Spain Phone 34 93 77 24700 Fax 34 93 77 11762 JLG Industries Italia Via Po 22 20010 Pregnana Milanese MI Italy Phone 39 02 9359 5210 Fax 39 02 9359 5845 JLG Polska UI Krolewska 00 060 Warsawa Poland Phone 48 91 4320 245 Fax 48 91 4358 200 JLG Industries Sweden Enkopingsvagen 150 Box 704 SE 175 27 Jarfalla Sweden Phone 46 8 506 59500 Fax 46 8 506 59534
25. E 1 PIN 2 SPARE 4 PIN PLUG 53 BRN ORN 1 PIN 1 SPEED SWITCH POWER 1 8 ORN BLU PIN 1 PUMP BY PASS 6 YEL BLU PIN 2 PUMP ENABLE 5 BLU RED 1 PIN 3 TILT SENSOR INPUT 4 WITE PIN 4 ELEVATION LIMIT SWITCH INPUT 4 BRN BLU PIN 5 DRIVE FORWARD INPUT 13 BRN RED PIN 6 DRIVE REVERSE INPUT 2 PIN 7 OUTPUT FOR BRAKES ELEVATION LIMIT SWITCHES amp TILT SENSOR 238 BRN ORN 8 RETURN FROM BRAKES 4 ORN RED 1 PIN 9 CONTROLLER ENABLE I3 RED PIN 10 SUPPLY Z RED ORN PIN 11 PUMP ACCEL 15 PIN PLUG 13 BLU ORN PIN 12 TRACTION ACCEL 23 WHT BRN 1 PIN 13 GROUND WHITE 14 BATTERY CHARGER LOCKOUT WHITE PIN 15 BATTERY CHARGER LOCKOUT BLACK 10 4 p RED 10 BATTERY CHARGER WHITE I PLATFORM WORK LITES OPTION 16 2 9 WHITE t 28 BLACK 3 16 2 DRIVE p CUT OUT c WITE SWITCH Lech BLACK 2 WHITE 27706 54 BLACK LIFT T 16 2 16 2 N C TOP LIFT CYL 83
26. ECKING A HOT PRESSUR IZED COOLANT SYSTEM NEVER WORK UNDER AN ELEVATED BOOM UNTIL 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 DUR ING REPLACEMENT OF ELECTRICAL COMPONENTS KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS STOWED IN THEIR PROPER PLACE USE ONLY APPROVED NONFLAMMABLE CLEANING SOLVENTS JLG Sizzor a INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS REVISON LOG Original Issue March 25 1999 This manual was part of complete manual 3120835 Revised March 13 2000 Page 1 1 Updated June 13 2000 Page 2 11 Updated June 13 2000 JLG Sizzor 3120881 5 TABLE CONTENTS SUBJECT SECTION PARAGRAPH PAGE NO SECTION A INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS AA EE Hydraulic System a a A C Maintenance secca nk a a SECTION 1 SPECIFICATIONS 1 1 lee EE EE eb eed et o En doa 1 1 1 2 Component AIR ia WM ee d 1 1 1 3 Performance o c Lee RE ES ELA EEG 1 1 1 4 Torque Specifications recesso eere ee pese asd E a wae RA ER Reg 1 2 1 5 KOU cL 1 2 1 6 Pressure
27. ED Off Internal fault or power not turned on 1 Flash Internal fault 2 Flashes Procedure fault 3 Flashes Motor permanently low 4 Flashes Motor permanently high 5 Flashes Motor neither low nor high Open circuit 6 Flashes Faulty drive hand controller 7 Flashes Low battery voltage 8 Flashes Thermal cutback controller 10 Flashes Tachometer fault 11 Flashes Tachometer out of calibration NOTE Refer to Troubleshooting Section 3 for specific flash code troubleshooting information 2 10 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 Without Counterbalance Valves Steer 1 3120881 Using all applicable safety precautions activate hydraulic system and fully extend cylinder to be checked Shut down hydraulic system 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 initial discharge there should be no further leakage from the retract port Activate hydraulic system and activate cylinder extend function If cylinder retract port leakage is less than 6 8 drops per minute carefully reconnect hose to retract port and retract cylinder If leakage continues at a rate of 6 8 drops per minute or more cylinder repairs must be made With cylinder fully retracted shut down motor
28. EER LEFT STEER RIGHT NOTE CUT 20 GA SEVCON WIRES TERMINATE AND INSTALL AS SHOWN OPTION b n EXT DECK EXT EXT DECK RET TACH Dam Ner 14 18 2 SHIELDED CABLE x WIE 1 16 2 BEACON 3 t OPTION 1 1 PIN 4 TACH DRIVE PIN 3 TACH DRIVE PIN 2 SPARE 4 PIN PLUG PIN 1 PROXIMITY SWITCH WHTALK GRN 20 PIN 1 PUMP BY PASS PIN 2 PUMP ENABLE PIN 3 TILT SENSOR INPUT 7 PIN 4 ELEVATION LIMIT SWITCH INPUT i 41 PIN 5 DRIVE FORWARD INPUT is PIN 6 DRIVE REVERSE INPUT PIN 7 OUTPUT FOR BRAKES ELEVATION LIMIT SWITCHES amp TILT SENSOR PIN 8 RETURN FROM BRAKES PIN 9 CONTROLLER ENABLE PIN 10 B SUPPLY PIN 11 PUMP ACCEL 15 PIN PLUG PIN 12 TRACTION ACCEL PIN 13 GROUND PIN 14 BATTERY CHARGER LOCKOUT PIN 15 BATTERY CHARGER LOCKOUT WHITE SPEED E BUE CUT OUT PROXIMITY NOTE REF Fi SWITCH RIGA SPEED CUTOUT INSTL 4932658 Figure 3 5 Ground Control Wiring On Machines Before Serial Number 020071522 Sheet 2 of 2 3120881 JLGSizzor 3 15 SECTION 3 TROUBLESHOOTING 3 16 ELEV SW TO MTB ELEV SW TO PLAT DRIVE CUT OUT ENABLE EMS ON STROBE LIGHT PUMP ACCEL TILT TO PLAT LIFT DIN LIFT UP BATTERY NEG BATTERY NEG BATTERY NEG PLAT EXTEND PLAT RETRACT VS TO PLAT VS TO PLAT TRACTION ACCEL DRIVE FORWARD DRIVE REVERSE STEER LEFT STEER RIGHT HORN Figure 3 6 Platform Wiring On Machin
29. HS46 LL Synthetic Lithium Lubricant Gredag 741 Grease 1 4 TORQUE SPECIFICATIONS Table 1 1 Torque Specifications DESCRIPTION TORQUE VALUE INTERVAL HOURS DRY Torque Hub 75 ft Ibs 500 102 NM Wheel Bolts 90 ft Ibs 50 122 NM NOTE When maintenance becomes necessary or a fas tener has loosened refer to the Torque Chart to determine proper torque value 1 5 LUBRICATION Table 1 2 Hydraulic Oil Hydraulic System Operating Temper SAE Viscosity Grade ature Range 0 F to 23 18 C to 5 10W 0 F to 210 F 18 C to 99 C 10W 20 10W 0 50 F to 210 F 10 C to 99 C 20W 20 Updated 11 16 99 1 2 JLG Sizzor MPG may be substituted for these lubricants if neces sary but service intervals will be reduced NOTE Refer to Lubrication Chart for specific lubrication pro cedures 1 6 PRESSURE SETTINGS Lift Up Relief 3369ES 172 bar 2500 psi 3969ES 186 bar 2700 psi Lift Down Relief 69 bar 1000 psi Steer Relief 82 7 bar 1200 psi NOTE Main Relief at Pump 186 2 bar 2700 psi 3120881 SECTION 1 SPECIFICATIONS NOTE 100 Hrs 3 months 200 Hrs 6 months 400 Hrs 1 year 800 Hrs 2 years Figure 1 1 Lubrication Ch
30. METERS 1 5 2 1 Barrel Suppott ea Eau eh 2 6 2 2 VE Rule TEE 2 6 2 3 leie Re DD RR nds Ms 2 7 2 4 Tapered Bushing 2 7 2 5 Oil lite Bearing Installation 2 0 2 8 2 6 Rod Seal 5 2 8 2 T Wiper Seal Installation eR RE EE RE EU e ei Ron bord bd 2 8 2 8 Installation of Head Seal 2 8 2 9 Tapered Bushing Installation 2 9 2 10 Piston Seal Kit 2 9 2 11 Poly Pak Piston Seal 2 9 2 12 Rod Assembly 2 9 2 13 Pressure Setting Procedures 2 12 2 14 Drive Torque Hub 2 14 2 15 Drive Brake 2 15 3 1 Hydraulic Schemalic UR edo ess dose SR ues 3 11 3 2 Platform Wiring On Machines Before Serial Number 020071522 Sheet 1 of 2 3 12 3 3 Platform
31. Software 104 104 Max Current 400 400 Acc Delay 1 5 1 5 Dec Delay 0 5 0 5 Off Level Creep 0 0 Max Speed 85 85 Cut Back 1 Elev 13 10 Cut Back 2 Slope 60 60 Pump Acc 3 3 Pump Threshold 20 20 Password 73461829 Table 3 7 Control Module Settings for Machines Before Serial Number 020071522 SETTING 3369E 3969E Software 102 102 Max Current 400 400 Acc Delay 1 5 1 5 Dec Delay 0 5 0 5 OffLevel Creep 0 0 Max Speed 85 85 Cut Back 1 Elev 13 10 Cut Back 2 Slope 60 60 Pump Acc 3 3 Pump Threshold 20 20 Password 73461829 3120881 JLGSizzor 3 9 SECTION 3 TROUBLESHOOTING This page intentionally left blank 3 10 JLG Sizzor 3120881 SECTION 3 TROUBLESHOOTING 90806166 31114 110 1292561 31819373 164 00 2 ta 91 51408 1 31 3 3 8VON31X3 43315 LYWHO 33S Q3LYY 021 1311 01 03811039 340 344 OL 331138 1317 135 Hel 1 JONVIVEUSINNOD 1 9
32. Sun Spacer Input Washer Thrust Washer Thrust Bolt Hex Bolt Shoulder Plug Pipe 3120881 SECTION 2 PROCEDURES Inspection 1 Inspect the friction plate and the mating surfaces on the armature and mounting plate for wear and or damage Examine the compression spring Examine the friction plate and the shaft for wear and or damage to the spline 1 Magnet and Coil Assembly 2 Armature 3 Shaft 4 Plate Mounting 5 Plate Friction Solid 6 Not Used 7 Plate Outer 8 Spacer 9 Bolt Metric Socket Head 10 Spring Compression 11 Bearing Ball 12 Ring Retainer External 13 Ring Retainer Internal 14 Manual Release Assembly 15 Not Used 16 Not Used 17 Not Used 18 Not Used 19 O Ring 20 Shim 21 Connector Electrical 22 O Ring Examine the pole faces of the magnet and the arma ture for bruises swellings or damage Any bruises swellings or damage should be stoned flat Examine input and output splines of shaft for wear and or damage Check ball bearing for axial float and or wear It is essential when replacing the friction plate that spacers are also replaced Figure 2 15 Drive Brake Assembly Assembly 3120881 Clean all parts thoroughly Reverse disassembly procedure above taking par ticular care with the assembly sequence of the fric tion plate NOTE Assemble friction plate with two center punches fac ing to
33. Wiring Machines Before Serial Number 020071522 Sheet 2 of 2 3 13 3 4 Ground Control Wiring On Machines Before Serial Number 020071522 Sheet 1 of 2 3 14 3 5 Ground Control Wiring On Machines Before Serial Number 020071522 Sheet 2 of 2 3 15 3 6 Platform Wiring On Machines After and Including Serial Number 020071522 Sheet 1 of 2 3 16 3 7 Platform Wiring On Machines After and Including Serial Number 020071522 Sheet 2 of 2 3 17 3 8 Ground Control Wiring On Machines After and Including Serial Number 020071522 Sheet 1 of 2 3 18 3 9 Ground Control Wiring On Machines After and Including Serial Number 020071522 Sheet 2 of 2 3 19 LIST OF TABLES TABLE NO TITLE PAGE NO 1 1 ele e ee EE 1 2 1 2 Hydraulic RO Gad I usta 1 2 1 3 Lubrication 5 1 2 1 4 Lubrication Chatt Fut idet edt e hu ka uvae ee ars 1 8 1 5 Cylinder Specifications 1 4 1 6 Major Component 5 1 4 1 7 Critical Stability 1 4 2 1 Flash Codes ae re eu ERIS EPUM He does Roe ed 2 5 2 2 Cylinder Piston Nut Torque 2 10 2
34. ach covered separately within this section These groups are as follows elevation system chassis assembly hydraulic system and electrical system 2 Each malfunction within an individual group or sys tem is followed by a listing of probable causes which will enable determination of the applicable remedial action The probable causes and the remedial action should where possible be checked in the order listed in the tables 3 It should be noted that there is no substitute for a thorough knowledge of the equipment and related systems 4 It should be recognized that the majority of the prob lems 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 possi ble treatment In the remaining machine groups only those problems which are symptomatic of greater problems which have more that one proba ble cause and remedy are included This means that problems for which the probable cause and remedy may be immediately obvious are not listed in this section 5 The first rule for troubleshooting any circuit that is hydraulically operated and electrically controlled is to determine if the circuit is lacking hydraulic oil and electrical control power This can be ascertained by overriding the bypass valve mechanically or electri cally so that oil is available to the function valve then overriding
35. achine will not travel in reverse Motor controller reverse contactor defective Repair or replace contactor See machine will not travel forward Machinetravels very slow below horizontal Defective hand controller Check flashcode on Sevcon 6 flashes Sevon controller not programmed properly Reprogram Sevcon Drive system very jerky Sevcon controller defective Check flashcode Machine will speed up in forward or reverse Wires loose or broken from Tach Drive system to Sevcon controller Check flashcode on Sevcon Repair or replace wire as necessary Tach Drive shaft broke off Replace Tach Drive shaft Tach Drive defective Check flashcode 3 4 JLG Sizzor 3120881 SECTION 3 TROUBLESHOOTING Table 3 2 Chassis Troubleshooting TROUBLE PROBABLE CAUSE REMEDY STEER SYSTEM to control Enable switch not activated Activate enable switch Function not activated within seconds after Reactivate enable switch Enable switch was depressed Enable switch not functioning properly Replace enable switch circuit card Hydraulic system low Replenish oil as necessary Damaged wiring on control switch or solenoid valve Repair or replace wiring as necessary Control switch not functioning properly Replace switch Resrticted or broken hydraulic line on steer valve or hydraulic pump Clean repair or replace hydraulic line
36. alance is defective and must be replaced If no repairs are necessary or when repairs have been made carefully reconnect hydraulic hoses to the appropriate ports Remove lifting device from platform activate hydrau lic system and run cylinder through complete cycle to check for leaks and operation 2 5 SECTION 2 PROCEDURES 2 11 LIFT CYLINDER REMOVAL AND 2 12 LIFT CYLINDER REPAIR INSTALLATION NOTE The following are general procedures that apply to all of the cylinders on this machine Procedures that Lift Cylinder Removal apply to a specific cylinder will be so noted 1 Place the machine on a flat and level surface Start the motor and raise the platform Shut down the motor and attach a suitable lifting device to the plat form A IMPORTANT DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA Disassembly 2 Remove the bolt locknut and keeper shaft 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 1 Operate the hydraulic power source and extend the cylinder Shut down and disconnect the power 3 Retract the cylinder rod completely source Adequately support the cylinder rod if nec essary 4 Tag and disconnect then cap the lift cylinder hydraulic lines and ports 2 If applicable remove the cartridge type holding valve and fittings from the
37. and secure installation 2 Check for visible damage and legibility 3 Check for proper fluid level 4 Check for any structural damage cracked or broken welds bent or warped surfaces Check for leakage 6 Check for presence of excessive dirt or foreign material 7 Check for proper operation and freedom of move ment 8 Check for excessive wear or damage 9 Check for proper tightness and adjustment 10 Drain clean and refill 11 Check for proper operation while engine is running 12 Check for proper lubrication 13 Check for evidence of scratches nicks or rust and for straightness of rod 14 Check for condition of element replace as neces sary 15 Check for proper inflation 16 Clean or replace suction screen 3120881 SECTION 2 PROCEDURES Table 2 4 Preventive Maintenance and Inspection Schedule AREA INTERVAL PLATFORM 10 HOURS DAILY 50 HOURS WEEKLY 200 HOURS MONTHLY 500 HOURS 3 MONTHS 1000 HOURS 6 MONTHS 1 Controller 1 11 2 Switches 1 11 3 Placards and Decals 1 2 4 Control Tags 1 2 5 Hoses and Cables 1 4 8 6 Wear Pads 7 and Chains CHASSIS 1 Batteries 2 Battery Charger 3 Hydraulic Pump Motor 4 Valves 5 Hydraulic Filter 6 Hydraulic Hoses and Tubing 7 Hydraulic Oil Tank 8 Breather Hydraulic Tank 9 Li
38. art Table 1 4 Lubrication Chart INDEX NO TYPE LUBE INTERVAL NUMBER COMPONENT POINTS LUBE METHOD HOURS COMMENTS 1 Hydraulic Oil Fill Cap Drain Plug HO Mobil 424 8 800 Check oil every 8 hours of operation Change oil every 800 hours of operation 2 Torque Hub Fill Plug Half Full EPGL SAE 90 2000 Check oil level at side plug on hub 3 Wheel Bearings N A MPG Repack 800 2 years 4 Sliding Pads Wear Pads 8 MPG Brush 50 N A 5 notshown Hydraulic Filter Element N A Replaceable Element 40 250 Replace filter element after first 40 hours of operation then every 250 hours thereafter KEY TO LUBRICANTS Hydraulic Oil Mobil 424 EPGL Extreme Pressure Gear Lube 3120881 NOTE Be sure to lubricate like items on each side of the machine 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 cating frequencies must be increased accordingly JLG Sizzor 1 3 SECTION 1 SPECIFICATIONS 1 7 CYLINDER SPECIFICATIONS Table 1 5 Cylinder Specifications 1 9 CRITICAL STABILITY WEIGHTS Table 1 7 Critical Stability Weights DESCRIPTION BORE STROKE RODDIA COMPONENT Lift Cylinder 10 16cm 37 29 cm 6 35cm LBS KG Steer Cylinder 5 08 7 62cm 3 18cm Double Rod each direction each rod Pan
39. chanical assistance is required All slings chains cables etc should be parallel to each other and as near perpendicular as possible to top of part being lifted 2 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 degrees 3 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 sequence Do not partially disassemble or assemble one part then start on another Always recheck your work to assure that nothing has been overlooked Do not make any adjustments other than those recommended without obtaining proper approval Pressure Fit Parts When assembling pressure fit parts use an anti seize or molybdenum disulfide base compound to lubricate the mating surface Bearings 1 When 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 3120881 JLG Sizzor 2 1 SECTION 2 PROCEDURES 3 bea
40. ctioning prop erly Repair or replace lift down control cartridge Lift cylinder not functioning properly Repair or replace lift cylinder 3 2 JLG Sizzor 3120881 SECTION 3 TROUBLESHOOTING Table 3 1 Platform Assembly Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Platform raises or lowers erratically Enable switch notactivated Activate enable switch Function not activated within 3 seconds after Reactivate enable switch enable switch was depressed Enable switch notfunctioning properly replace enable switch circuit card Hydraulic system low replenish oil as necessary Restricted or broken hydraulic line or fitting Clean repair or replace as necessary Control valve notfunctioning properly Repair or replace valve Worn sealsin lift cylinder Replace seals Cylinder not functioning properly Repair or replace cylinder Platform drifts down Worn sealsin lift cylinder Replace seals Manual descent valve open Close manual descent valve High drive does not operate below horizontal Damaged wiring on limit switch Repair or replace wiring Damagedlimit switch Replace limit switch 3120881 JLGSizzor 3 3 SECTION 3 TROUBLESHOOTING Table 3 2 Chassis Troubleshooting TROUBLE PROBABLE CAUSE REMEDY DRIVESYSTEM to control Enable switch not activate
41. d Activate enable switch Function not activated within 3 seconds after Reactivate enable switch enable switch was depressed Enable switch not functioning properly Replace enable switch circuit card Drive motor s not functioning properly Repair or replace drive motors Damaged wiring onhand controller See wiring schematic repair or replace wiring as necessary Sevcon overheated Check flashcode Defective hand controller Repair or replace hand controller Damaged wiring on motor controller See wiring schematic repair or replace wiring as necessary Defective enable switch Repair or replace enable switch Defective motor controller Check flashcode Replace motor controller Defective motor controller contactors Repair or replace contactors Low battery Check flashcode on sevcon Machine will not travel forward Enable switch not activated Activate enable switch Function not activated within 3 seconds after Reactivate enable switch enable switch was depressed Enable switch not functioning properly Replace enable switch circuit card Drive motor s not functioning properly Repair or replace drive motors Brake s not releasing Repair or replace electric brake Motor Pump will not respond when drive control moved to forward Refer to electrical system troubleshooting Motor controller forward contactor defective Repair or replace contactor M
42. d for burrs and sharp edges Dress applicable surfaces as nec essary 2 7 SECTION 2 PROCEDURES 12 Inspect cylinder head outside diameter for scoring or other damage and ovality and tapering Replace as necessary 13 applicable inspect rod and barrel bearings for signs of correct lubrication and excessive wear If necessary replace bearings as follows a Thoroughly clean steel bushing hole 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 or bar rel as applicable must be replaced c Lubricate inside of steel bushing with WD 40 prior to bearing installation d Using arbor of the correct size carefully press the bearing into the steel bushing NOTE Install the cylinder pin into the Oll lite bearing dry Lubrication is not required with chrome pins and bearings STEEL BUSHING OIL LITE BUSHING ARBOR Figure 2 5 Oil lite Bearing Installation 14 Inspect travel limiting collar or spacer for burrs and sharp edges If necessary dress inside diameter surface with Scotch Brite or equivalent 15 If applicable inspect port block fittings and holding valve Replace as necessary 16 Inspect the oil ports for blockage or the presence of dirt or other foreign material Repair as necessary 17 If applicable inspect piston rings for cracks or other damage Replace as necessary Assembly
43. ecessary to align shoulder bolt with hub counterbore Install bolts into remaining holes Pipe plugs are to be installed into input cover using a lubricant seal Torque bolts 28 amp 29 to 31 36 NM 23 27 ft lbs Fill unit one half full with EP90 lubricant 2 18 DRIVE BRAKE ASSEMBLY Disassembly 1 JLG Sizzor After removing brake from its installation place brake on a clean dry work bench with mounting plate uppermost Unscrew the socket head bolts in equal increments to ensure the spring pressure within the brake is reduced gradually and evenly Remove and lay aside the shaft and mounting plate sub assembly Should it be necessary to replace ball bearings retainer rings and press bearing off Remove friction plate and spacers and set aside Spacers are factory set for each brake to obtain required air gap and not interchangeable between brakes Armature and compression springs can be removed and set aside 2 13 SECTION 2 PROCEDURES Spindle Seal Lip Cup Bearing Outer Cone Bearing Outer Cup Bearing Inner Cone Bearing Inner Housing Washer Thrust Ring Retaining 0 Plug Pipe Stud Wheel Plug Pipe Gear Internal Carrier Washer Tanged Thrust Bearing Needle Spacer Thrust Shaft Planet Gear Cluster Roll Pin Figure 2 14 Drive Torque Hub Assembly JLG Sizzor Gear ring O Ring Cover Input Gear
44. emoving retaining rings and sliding off the rod Inspection 1 Inspect the head wiper rod seal o ring and wear ring for wear scratches and damage Clean or replace both heads 2 check both spacer tubes for damage to inner bore and deformed ends Replace if damaged 3 Inspect the rod for wear or scratches Clean polish or replace 4 Check seal of head for wear or damage Clean or replace 5 Inspect rod o ring for wear or damage Clean or replace 6 Inspect cam roller for smooth turning Clean or replace Assembly 1 Lightly lubricate rod and slide piston with seal to locate over o ring at center of rod 2 Lock piston into place with two retaining rings 3 Slide spacer tubes from both ends of rod to rest on retaining rings 4 Carefully insert rod with piston and spacers into bar rel 5 Slide heads with wiper rod seal o ring and wear ring onto rod from both ends 6 Apply loctite 222 to barrel threads of both ends 3120881 and install retainer caps Tighten with strap wrench Test for leakage 2 14 TILT SWITCH INDICATOR LEVELING PROCEDURE A CAUTION PERFORM TILT SWITCH LEVELING PROCEDURE A MINIMUM OF EVERY SIX MONTHS TO ENSURE PROPER OPERATION AND ADJUSTMENT OF SWITCH Manual Adjustment 1 NOTE Park the machine on a flat level surface Be sure it is as level as possible with tires filled to rated pres sure Ensure switch mounting is level and securely attached Tighten the t
45. er rod should a hydraulic line rupture or leak develop between the cylinder and its related control valve 2 5 VALVES THEORY OF OPERATION Control Valves It consists of cartridge type valves in an anodized alumi num manifold The cartridge valves provide for control of flow volume of flow and pressure in the hydraulic system The directional control valves are solenoid operated three position 4 way sliding spool type valves One valve is pro vided for each of the two functions Energizing one of the electrical coils on a valve will divert the supply of hydraulic oil to provide motion of that function in one direction Energizing the other coil will divert the oil for motion in the other direction When neither coil is energized the supply of hydraulic oil is blocked Flow control valves in the lift circuits provide for control of the rate of flow when the oil is flowing out of the cap ends of the cylinders the load is being lowered An adjusting screw on each cartridge flow control valve allows the rate of flow speed to be adjusted When oil is flowing into the cap end of the lift cylinders an internal check valve feature allows unrestricted flow Pressure relief valves limit the pressure in the steer circuit and the rod end of each lift cylinder When the pressure in one of those circuits reaches the set point of the valve the valve opens allowing enough flow to return to the reser voir so that the set pressure is not
46. es After and Including Serial Number 020071522 Sheet 1 of 2 BRN BLK RED BLK BLK LU YEL BLU ORN RED BLU RED BRON ORANGE BLACK YEL BLK BLU BLK YELLOW BLUE RED LU RED Bum BRN LU BRN RED BLK RED YEL RED BLK ORN JLG Sizzor i i WHT BRN E BLU ORN i YEL BLU x BRN BLU lt BRN RED BLK RED YEL RED 7 i i i e ORANGE BROIN i i 5 M i a 8l BLU RED 0 R Sc x 5 a E BLK ORN i N S 55 1 BLU RED WHT BRN i RED BLU i RED i i H z WHT YEL i i i i i i 1 H 5 1 8 1 1 T 1 i 1 5 1 i 1 1 R i i EJ 1 1 1 i 5 RED BLK i i i 5 RED ORN i
47. exceeded An adjusting Screw on each cartridge relief valve allows the set pres sure to be adjusted The aluminum manifold provides the passages through which the hydraulic oil is diverted to provide the desired movement of the actuators No moving parts of the valves slide against the manifold and so it is not subject to wear JLG Sizzor 2 3 SECTION 2 PROCEDURES 2 6 COMPONENT FUNCTIONAL DESCRIPTION Hydraulic Pump The single stage gear pump is attached to the electric motor located on the right rear of frame Manual Descent Pump The manual operated hand pump is located on the right rear of frame behind ground control station 2 7 WEAR PADS The original thickness of the sliding wear pads is 12 7 mm 5 in Replace sliding pads when worn to 11 9 mm 4 7 in 2 8 MOTOR CONTROLLER MODES OF OPERATION Traction Motor Drive Drive in either forward or reverse will start only if the fol lowing conditions are satisfied 1 Function switches off 2 No procedure or diagnostic faults present 3 TEB operate The function is selected in a 3 second window after the TEB has been momentary closed The function is selected in a 10 second window after the TEB has been permanently closed Another function was operated less than 3 seconds before 4 FWD or REV selected as appropriate Once in drive mode activating a function switch shall not cause drive mode to be exited the pump
48. ft Cylinder 10 Limit Switch 17 11 Placards and Decals 1 2 12 Wheel and Tire Assemblies 8 9 13 Drive Motors 1 5 6 14 Drive Torque Hubs 1 3 5 6 15 Drive Brakes 1 6 16 Steer Cylinder 5 6 13 17 Steer Components 4 6 18 Wheel Bearings 19 Sizzor Arms 1 4 20 Safety Prop 1 4 21 Wear Pads 22 Pivot Pins Bolts 1 4 7 8 23 Switches Ground Control 1 11 24 Control Tags 12 25 Hoseand Cable 1 4 8 Inspection and Maintenance Code 10 to be performed annually 3120881 JLG Sizzor 2 17 SECTION 2 PROCEDURES 2 18 This page intentionally left blank JLG Sizzor 3120881 SECTION 3 TROUBLESHOOTING 3120881 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 If a problem should develop which is not presented in this section or which is not corrected by listed corrective actions technically qual ified guidance should be obtained before proceeding with any maintenance 3 2 TROUBLESHOOTING INFORMATION 1 The troubleshooting procedures applicable to the aerial platform are listed and defined in Tables 3 1 through 3 4 As an aid to table use the aerial plat form is divided into four major groups e
49. hree flange nuts with a socket wrench Each nut should be tightened approximately one quarter of its spring s travel Using bubble level on top of indicator tighten or loosen the three flange nuts until indicator is level Individually push down on one corner at a time There should be enough travel to cause the indica tor to trip If the indicator does not trip in all three tests the flange nuts have been tightened too far 2 15 LIMIT SWITCHES Drive Cut Out Limit Switch This switch is located on the front of the machine frame Adjust cam to trip limit switch when platform is elevated to 8 m 26 ft 2 5 in High Speed Drive Cut Out High drive speed is cut out when platform is raised above stowed fully lowered position NOTE JLG Sizzor There is no adjustment to be made to the Platform Ext limit switch which bolts on the bottom of the plat form If Equipped Updated 6 13 00 2 11 SECTION 2 PROCEDURES 2 16 PRESSURE SETTING PROCEDURES Main Relief at Pump 1 Install pressure gauge at port on the control valve 2 Activate and bottom out Lift Up Adjust Main Relief to 186 bar 2700 psi Lift UP Relief 1 With pressure gauge at port on the control valve activate and bottom out Lift Up 2 Adjust Lift Relief to 172 bar 2500 psi on the 3369ES and 186 bar 2700 psi on the 3969ES Lift Down Relief 1 With pressure gauge at
50. i f gt WHT BRN i ORN 8LU i i i i i i i 3120881 SECTION 3 TROUBLESHOOTING BLACK PIN 1 GROUND BROWN PIN 2 TRACYION ACCEL VIOLET PIN 3 TRIGGER BLUE PIN 4 BOARD VS WHT ORN PIN 5 DRIVE FORWARD ORANGE PIN 6 DRIVE REVERSE YELLOW PIN 7 STEER RIGHT GREEN PIN 8 STEER LEFT DES EEN RED PIN 9 STEER VS lt S M c 5 BLU RED i gt e 41 5 TIMIH T3A 1HM TAM 4 rat 8 E 1H911 DND e D 288 gt FE RAAI Ss 1 P lt z X e aL Sa WHT BRN 1 17 8 2 T 5 3 5 BLK BLU PIN2 BLUE YEL PIN 3 RED ORN PIN 4 BRN BLK 220w PIN 1 ORN YEL a PIN 5 WHITE m S 2 o 2 E m som 228 885 gen 252 de RE 288 5 gt 4933121 zr 5 Figure 3 7 Platform Wiring On Machines After and Including Serial Number 020071522 Sheet 2 of 2 3120881 JLGSizzor 3 17 SECTION 3 TROUBLESHOOTING 3 18
51. igure 2 2 Capscrew Removal 2 6 JLG Sizzor 3120881 SECTION 2 PROCEDURES 4 To aid in realignment mark cylinder head and barrel with a center punch Using a suitable spanner wrench loosen the span ner nut retainer and remove the spanner nut from the cylinder barrel Attach a suitable pulling device to the cylinder rod port block or cylinder rod end as applicable A 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 Figure 2 3 Rod Support 8 With the barrel clamped securely apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel 9 Using suitable protection clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible 10 If applicable loosen and remove the nut which attaches the piston to the rod then remove the pis ton from the rod 11 If applicable loosen and remove the cap screw s securing the tapered bushing to the piston 12 Insert the capscrew 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 then remove the bushing from the pis ton 13 Screw the piston counter clockwise by hand and remove the piston from the cylinder rod 14 Remove and discard the
52. inder has been reassembled the rod should be pushed the way fully retracted prior to the reinstallation of any holding valves Sun 7 8 hex M20 x1 5 thds 30 35 ft Ib 41 48 27 f applicable install the cartridge type holding valve and fittings in the rod port block using new o rings Sun 1 1 8 hex 1 14 UNS thds 45 50 ft Ib as applicable Refer to Table 2 3 Holding Valve 61 68 Nm Torque Specifications for proper torque Sun 1 1 4 hex M36 x 2 thds 150 160 ft 6 204 207 Nm CAUTION IF THE CYLINDER IS BE TESTED PRIOR TO INSTALLATION ON TDI HG sete NT THE MACHINE EXTREME CARE SHOULD BE USED TO INSURE THAT THE OUTER END OF THE ROD IS SUPPORTED USE Racine 1 3 8 hex 1 3 16 12thds 75 80 ft lb EITHER A TRAVELING OVERHEAD HOIST FORKLIFT OR OTHER 102 109 Nm MEANS TO SUPPORT THE OVERHANGING WEIGHT OF THE EXTENDING ROD Racine 1 7 8 hex 1 5 8 12 thds 100 110 ftlb 136 149 Nm 2 10 JLG Sizzor 3120881 SECTION 2 PROCEDURES 2 13 STEER CYLINDER DISASSEMBLY AND ASSEMBLY Disassembly 1 Remove cylinder retainer caps on both ends by turn ing clockwise with a strap wrench to loosen 2 Remove heads of both ends by pushing on rod in both directions and sliding off of rod 3 Remove rod from barrel carefully so as not to dam age inner surface of barrel 4 Remove spacer tubes by sliding towards both ends of the rod 5 Remove piston from rod by r
53. king parts are very close therefore even the smallest amount of dirt or foreign matter entering a system can cause wear or damage to the components and generally results in faulty 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 at the specified intervals required in Section 1 Always examine filters for evi dence 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 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 Good grade mineral oils with viscosities suited to the ambient temperatures in which the machine is oper ating 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 Hydraulic Oil JLG Sizzor 1 Refer to Lubrication Specification Table for recom mendations for viscosity ranges 2 JLG recommends Mobil Fluid 424 Hydraulic Oil which has an SAE viscosity of 10W 20 and a viscos ity index of 152 3120881 SECTION 2 PROCEDURES NOTE Start up of hydraulic system with oil temperatures below 26 C is not recommended If
54. motor pump assembly Drive motors will not function when hand controller is activated Motor controller 200 Amp fuse blown Check flashcode on Sevcon and determine cause and repair Replace fuse Hydraulic pump motor will not run Batteries require charging or will not charge Charge or replace batteries as required Motor controller contactors not functioning prop erly Repair or replace contactors Pump motor not functioning properly Repair or replace pump motor Motor controller malfunctioning column Referto flash code troubleshooting chart 3120881 JLGSizzor 3 7 SECTION 3 TROUBLESHOOTING Table 3 5 Flash Code Troubleshooting Messages CODE MESSAGE REMEDY 1Flash Internal fault Replace MOS90 2 Flashes Checkenable wiring Retry Check for correct start up sequence Retry Checkthatboth directions are not selected Selectonly one direction 3Flashes Check power and control wiring for shorts Rectify Replace controller 4Flashes Check direction contactor tips Free change tips Check power wiring for shorts Rectify Check motor for armature to field shorts Rectify Check for shorts to frame and battery leakage Rectify Replace controller 5 Flashes Check contactor tips Repair replace Check contactor for mechanical operation and coil Repair replace check power and control wiring Rectify Check motor Rectify Replace cont
55. nce proce dures contained in this chapter Safety and Workmanship Your safety and that of others is the first consideration when engaging in the maintenance of equipment Always be conscious of weight Never attempt to move heavy parts without the aid of a mechanical device Do not allow heavy objects to rest in an unstable position When raising a portion of the equipment ensure that adequate support is provided 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 oil supplies clean however these items must be maintained on a scheduled basis in order to func tion properly 2 At any time when hydraulic 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 Component Removal and Installation 1 Use adjustable lifting devices whenever possible if me
56. od Repair or replace cylinder Damaged steer linkage Repair or replace steer linkage 3120881 JLGSizzor 3 5 SECTION 3 TROUBLESHOOTING Table 3 3 Hydraulic System Troubleshooting TROUBLE PROBABLE CAUSE REMEDY HYDRAULIC SYSTEM GENERAL Hydraulic pump noisy Air bubbles in oil Reservoir oil level low Replenish oil as neces sary OU filter dirty Replace oil filter Pumpcavitating Vacuum in pump duetooil starvation Oil in reservoir low Replenish oil as necessary Restricted reservoir air vent Clean air vent Oil viscosity too high Drain hydraulic system and replace with recom mended oil Leak in suction line Repairor replace suction line System overheating Oil viscosity too high Drain hydraulic system and replace with recom mended oil Hydraulic oil low in reservoir Replenish oilto proper level Extended driving periods Do not drive machine for extended periods Pump not delivering oil Defective motor on pump Repair or replace motor System pressure too low Leak in component line or fitting Repair or replace component line or fitting Hydraulic pump not functioning properly Repair or replace pump Defective valve cartridge Replace cartridge Systems operate erratically Sticking or binding valve cartridge piston rod etc Clean repair or replace components as req
57. on n gt Platform Extension 320 145 1 8 MAJOR COMPONENT WEIGHTS Foam Filled Tires 150 68 Table 1 6 Major Component Weights Battery Each 71 m COMPONENT 3369 ELECTRIC 3969 ELECTRIC LBS KG LBS KG 1 10 RELAYS CIRCUIT BREAKERS Platform 761 345 761 345 Platform Extension 320 145 320 145 Console Box Arm Assembly Includes Lift 3393 1539 3903 1770 Relay Potter amp Brumfield P N K10P 11D15 48 48VDC Cylinders Circuit Breaker Wood Electric Corp P N W58 x BIA4 A 5 Chassis Includes Battery 3662 1661 3662 1661 Box and Foam filled Tires Machine Complete GVW 8000 3629 8800 3992 1 11 SERIAL NUMBER LOCATIONS For machine identification a serial number plate is affixed to the front of the frame If the serial number plate is dam aged or missing the machine serial number is stamped on the right front of the machine frame Serial Number Stamped Serial Number Plate Figure 1 2 Serial Number Location 1 4 JLG Sizzor 3120881 SECTION 1 SPECIFICATIONS 8 avs 5 33vs9 JYS
58. oning properly Check Sevcon control contactors for proper func tioning Low battery voltage Check voltage and charge batteries or replace batteries as necessary Platform will not raise Enable switch not activated Activate enable switch Function not activated within seconds after enable switch was depressed Reactivate enable switch Enable switch notfunctioning properly Replace enable switch circuit card Load capacity exceeded Personnel and or equipment on platform Reduce load to recommended capacity Hydraulic oil system low Replenish oil as necessary Restricted or broken oil line or fitting Clean repair or replace as necessary Control valve notfunctioning properly Repair or replace valve Lift cylinder not functioning properly Repair or replace lift cylinder Motor Pump does not respond when lift control switch is moved to the up position Refer to the electrical schematic and or electrical system troubleshooting chart No electrical signal being sentto lift up control valve cartridge Refer to the electrical schematic and or electrical system troubleshooting chart Pressure set to low on pump Check pressure and reset as necessary Platform will not lower No electrical signal being sent to lift down control valve cartridge Refer to the electrical schematic and or electrical system troubleshooting chart Lift down control cartridge not fun
59. piston o rings back up rings guidelock rings and hydrolock seals 15 If applicable remove the piston spacer from the rod 3120881 16 PISTON TAPERED BUSHING CAP SCREWS Figure 2 4 Tapered Bushing Removal Remove the rod from the holding fixture Remove the cylinder head and retainer plate from the rod Cleaning and Inspection 1 10 11 JLG Sizzor 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 equivalent Replace rod if necessary Inspect threaded portion of rod for damage 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 scoring and for distortion Dress piston surface or replace piston as necessary 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 hea
60. placement is necessary the bearing cups can be removed with a slide hammer puller or driven out with a punch To remove the cluster gears from the carrier drive the roll pin into the planet shaft The planet shaft may now be tapped out of the carrier After planet shaft has been removed the roll pin can be driven out The cluster gear can now be removed from the car rier The tanged thrust washer will be removed from the cluster gear The needle bearings and thrust spacer are now removed from cluster gear When rebuilding or repairing the unit the retaining ring 9 o rings 22 and seal 2 should always be replaced Assembly 1 3120881 With the hub shaft sub assembly resting on the shaft install internal gear The spline of the internal gear bore will mesh with the spline of the output shaft Thrust washer 27 is installed on the face of the out put shaft Sufficient grease or petroleum jelly should be used to hold thrust washer in place Place o ring into hub counterbore Use petroleum jelly to hold in place Locate and mark the four counter beamed holes in the face of the housing This is for identification later in the assembly Thrust spacer 25 is installed into the bore of the output shaft This should be a slip fit and the thrust spacer should rotate in this location Place carrier assembly on a flat surface with the gear cluster up Find the punch marked tooth on each large gear and locate at 1
61. port on the control valve activate and bottom out Lift Down 2 Adjust Lift Relief to 62 bar 900 psi Steer Relief 1 2 12 With pressure gauge at port on the control valve activate and bottom out steer left or right LIFT DOWN RELIEF ADJUST TO 900 PSI 62 BAR LIFT UP RELIEF ADJUST TO 2500 PSI 172 4 BAR STEER RELIEF ADJUST TO 1200 PSI 82 7 BAR 2 3 Adjust Steer Relief to 82 7 bar 1200 psi Shut down hydraulic system and remove pressure gauge 2 17 DRIVE TORQUE HUB Disassembly 1 gg p 5 Loosen all cover bolts 28 amp 29 and drain from unit Remove the cover bolts 28 amp 29 and lift off input cover Remove and discard o ring from counterbore of input cover Remove sun gear and thrust washer Lift out the carrier and thrust washer Remove input spacer Lift out internal gear and thrust washer While wearing eye protection remove the retaining ring from the output shaft and discard Remove thrust washer from the output shaft The output shaft may now be pressed out of the housing Figure 2 13 Pressure Setting Procedures JLG Sizzor 3120881 SECTION 2 PROCEDURES 10 NOTE 11 12 13 The bearing cups will remain hub as will the inner bearing cone The outer bearing cone will remain on the output shaft The lip seal will be automatically removed during this procedure If bearing re
62. rically released Steer System Tires ST205 75R15 Load Range C 6 Rating Poly Filled Toe In Adjust to 6 4 mm 1 4 in overall Hydraulic Filter 3120881 Return 25 Micron Hydraulic Pump Electric Motor Assembly Motor 48 VDC 5 5 2500 rpm Pump 1 6 cm 3 rev 0 098 in 3 rev Pump Output 4 13 Ipm 1 09 137 9 Bar 2000 psi 1 3 PERFORMANCE DATA Travel Speed 3369 3969 electric 4 8 kmh 3 0 mph High Drive for rev sec 15 2 m 11 13 sec Creep Drive for rev sec 15 2 m 50 60 sec Gradeability 2596 Turning Radius Inside 3369 electric 1 52 m 60 in 3969 electric 1 52 m 60 in Turning Radius Outside 3369 electric 3 81 m 149 in 3969 electric 3 81 m 149 in Platform Lift Speed 3369 electric Lift Up 75 80 seconds 3369 electric Lift Down 50 60 seconds 3969 electric Lift Up 75 80 seconds 3969 electric Lift Down 50 60 seconds Platform Capacity 3369 electric 455 kg 1000 16 3969 electric 340 kg 750 Ibs Platform Extension Capacity 3369 electric 230 kg 500 Ibs 3969 electric 230 kg 500 Ibs Machine Weight 3369 electric 3629 kg 8 000 165 3969 electric 3992 kg 8 800 Ibs Machine Height w Rails Folded Down 3369 electric 1 85 m 73 in 3969 electric 2 01 m 79 in Machine Length Stowed 3369 electric 2 77 m 109 in 3969 electric 2 77 m 109 in Updated 6 13 00
63. ring is found to be serviceable apply a light coat of oil and wrap it in clean waxed paper Do not unwrap reusable or new bearings until they are ready to be installed 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 a
64. roller 6 Flashes Check operation of hand controller with Test Sequence Rectify replace Check pot operation with voltmeter for voltage at minimum Adjust as necessary or replace setting Replace controller 7 Flashes Check battery voltage with voltmeter Change charge battery Check power connections fuses etc Repair or replace Check for battery leakage to frame Rectify Replace controller 8 Flashes Check current draw Rectify Check mounting and heat sinking of controller Rectify 10 Flashes Check tachometer wiring Repair Check speed tachometer Rectify Replace tachometer 11 Flashes Recycle emergency stop switch Replace tachometer PC board Check pin voltage NOTE If the machine is operated at a very slow speed or stalled when climbing a grade of 20 or greater a 10 flash fault will occur recycle the emergency stop switch to recover NOTE All flash codes must be checked with unit switched to platform control If speed switch is turned 25 50 toward full speed Sevcon controller will give a 2 flash fault indicating a procedure fault If while 2 flash fault is being indicated the speed control knob is turned to less then 25 the 2 flash fault will stop and LED will come on steady indicating controller operational 3 8 JLG Sizzor 3120881 SECTION 3 TROUBLESHOOTING Table 3 6 Control Module Settings for Machines After and Including Serial Number 020071522 SETTING 3369E 3969E
65. sembled the rod e ie AIMPORTANT VE EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE 18 If applicable install the cartridge type holding valve CYLINDER ROD HEAD AND PISTON AVOID PULLING THE ROD and fittings in the port block using new o rings as applicable OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES 22 With barrel clamped securely and while adequately WARNING supporting the rod insert the piston end into the WHEN REBUILDING THE LIFT CYLINDERS APPLY LOCTITE 242 inder barrel Ensure that the piston loading o ring TO PISTON NUT AND SETSCREWS and seal ring are not damaged or dislodged 23 Continue pushing the rod into the barrel until the cyl inder head gland can be inserted into the barrel cyl Table 2 2 Cylinder Piston Nut Torque Specifications inder or if applicable until the cylinder head threads engage the barrel threads Description Nut Torque Value Setscrew Torque Wet Value Dry 24 If applicable apply loctite 222 and secure the cyl inder head retainer using a suitable chain wrench Lift Cylinder 400 ft Ibs 100in Ibs 542 NM 12NM NOTE Step 25 applies to the Steer Cylinder Steer Cylinder N A N A 25 Insert the other cylinder head gland into the barrel cylinder Secure the cylinder head retainer using a suitable chain wrench Table 2 3 Holding Valve Torque Specifications 26 After the cyl
66. spacer onto the rod 6 If applicable correctly place a new o ring and back up rings in the inner piston diameter groove 7 Using suitable protection clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible 8 Carefully thread the piston on the cylinder rod hand tight ensuring that the o ring and back up rings are not damaged or dislodged 9 Thread the piston onto the rod until it abuts the spacer end and install the tapered bushing NOTE When installing the tapered bushing the piston and mating end of the rod must be free of oil TAPERED BUSHING Figure 2 9 Tapered Bushing Installation WARNING WHEN REBUILDING THE LIFT CYLINDER APPLY LOCTITE 242 TO TAPERED BUSHING BOLTS THEN TIGHTEN BOLTS SECURELY REFER TO TABLE 2 2 CYLINDER PISTON NUT TORQUE SPECIFICATIONS AND TABLE 2 3 HOLDING VALVE TORQUE SPECIFICATIONS FOR PROPER BOLT TORQUE VAL UES 10 Install the bolts into the bushing using Loctite 242 Refer to Cylinder Component Torque Specifications Table for proper bolt torque values 11 Remove the cylinder rod from the holding fixture A IMPORTANT WHEN INSTALLING NEW POLY PAK TYPE PISTON SEALS ENSURE SEALS ARE INSTALLED PROPERLY SEE FIGURE 2 11 FOR CORRECT SEAL ORIENTATION IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION 3120881 GUIDE LOCK RING SEAL 4 GUIDE LOCK RING BACK UP
67. ssure that they are correctly reinstalled Hydraulic System 1 Keep the system clean If evidence of metal or rub ber particles are found in the hydraulic system drain and flush the entire system 2 Disassemble and reassemble parts on clean work surface Clean all metal parts with non flammable cleaning solvent Lubricate components as required to aid assembly Lubrication Service applicable components with the amount type and grade of lubricant recommended in this manual at the specified interval 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 1 The primary enemy of a hydraulic system is contam ination Contaminants enter the system by various means inadequate hydraulic oil allowing mois ture grease filings sealing components sand etc to enter when performing maintenance or by per mitting the pump to cavitate due to insufficient sys tem warm up 2 The design and manufacturing tolerances of the component wor
68. t Cylinder Removal and 8 2 6 2 12 Lift Cylinder de ecce de dc et s Da e ce ds 2 6 2 13 Steer Cylinder Disassembly and Assembly 2 11 2 14 Tilt Switch Indicator Leveling 2 11 2 15 Limit SWitches uem t dre eee Ideo ate ipt Ade CUR e 2 11 2 16 Pressure Setting Procedures 2 12 2 17 Drive Torque es 2 12 2 18 Drive Brake Assembly EEN Ak 2 13 2 19 Free Wheeling Procedure mm m 2 16 2 20 Preventive Maintenance and Inspection 2 16 SECTION 3 TROUBLESHOOTING 3 1 General We oe A dE PER e 3 1 3 2 Troubleshooting 3 1 3 3 Hydraulic Circuit CHECKS i wg e e Gee 3 1 3120881 JLG Sizzor LIST FIGURES FIGURE NO TITLE PAGE NO 1 1 Lubrication Chart uu LE eae E M E 1 3 1 2 1 etek Pee age eee eck we ee 1 4 1 3 Torque E mae aus paket ati Pane
69. the function valve mechanically If the function performs satisfactorily the problem exists with the control circuit 3 3 HYDRAULIC CIRCUIT CHECKS The reference for improper function of a hydraulic system where the cause is not immediately apparent should be the Troubleshooting Chart The best place to begin the problem analysis is at the power source pump Once it is determined that the pump is serviceable then a 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 diagrams of the various circuits JLGSizzor 3 1 SECTION 3 TROUBLESHOOTING Table 3 1 Platform Assembly Troubleshooting enable switch was depressed TROUBLE PROBABLE CAUSE REMEDY PLATFORM ELEVATION SYSTEM Noresponseto control switch Enable switch notactivated Activate enable switch Function not activated within 3 seconds after Reactivate enable switch Enable switch notfunctioning properly Replace enable switch circuit card Lift control switch inoperative Replace control switch Hydraulic oil system low Replenish oil system necessary Restricted or broken supply line on valve or pump Clean repair or replace as necessary Control valve not functioning properly Repair or replace valve Lift cylinder not functioning properly Repair or replace lift cylinder Hydraulic pump not functi
70. 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 3120881 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 requirements Should any question arise regarding the use of greases in mainte nance stock consult your local supplier for evaluation Refer to Section 1 for an explanation of the lubricant key designations appearing in the Lubrication Chart 2 4 CYLINDERS THEORY OF OPERATION 1 Oylinders are of the double acting type The Lift and Steer systems incorporate double acting cylinders A double acting cylinder is one that requires oil flow to operate the cylinder rod in both directions Direct ing 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 cylin der rod will retract 2 Holding valves are used in the lift circuits to prevent retraction of the cylind
71. traction con tactor drive shall not be energized it will be left at the trac tion position If a function switch is selected during traction a procedure fault will occur when neutral is selected remaining until a function switch and both direc tions are no longer selected When neutral is selected the controller will control smooth stopping of the machine using plug braking before the electric brake is allowed to operate If a function switch is activated in neutral when the vehicle has stopped and the brake is applied then pump mode will become operational Pump Motor Drive Pump motor drive will start only if the following conditions are satisfied 1 FWD and REV switch off 2 Traction mode off brake applied 3 TEB operate The function is selected in a 3 second window after the TEB has been momentarily CLOSED The function is selected in a 10 second window after the TEB has been permanently CLOSED Another function was operated less than 3 seconds before Pump drive shall only be enabled when the direction selector inputs are in neutral and the machine is station ary Once pump drive mode has been entered then the status of the direction selector inputs shall no longer inter lock pump operation If a direction switch is selected dur ing pump drive a procedure fault will occur when the function switch is no longer selected remaining until both directions and the function switch are no longer selected
72. uired Hydraulic notat operating temperature Allow oil sufficient time to warm up JLG Sizzor 3120881 SECTION 3 TROUBLESHOOTING Table 3 4 Electrical System Troubleshooting TROUBLE PROBABLE CAUSE REMEDY ELECTRICAL SYSTEM Hand controller No electric power to hand controller Check electrical inputto hand controller Control valve will not function when thumb No electric power to valve Check electric output and electrical signal atthe Switch is moved in either direction valve Improper ground Check for proper grounding Noresponseto a function control switch Emergency stop switch no positioned properly Place emergency stop switch to on position Platform Ground select switch not positioned properly Place Platform Ground select switch to proper position Batteries defective or require charging Check batteries for serviceability Replace or charge batteries as necessary No voltage supplied to drive motors Check motor controller and contactors for proper functioning Repair or replace as neces sary Defective function switch Replace switch Defective circuit breaker Replace circuit breaker No voltage presentat applicable control valve Check applicable wire for proper connection Using suitabletest meter perform continuity test on wire Repair or replace wire as necessary Defective motor pump assembly Replace
73. voc 6599 07 40 LL 244 8026 852 ai Le 8228 81 9k 905 95190 sei 8k a 012 9 78 vec 88 6 6662 9 ecr 60 ebl zozo 8690 96 660 68 10 97 2699 9 88 22 mm 19070 ooz 159 59 05 60 6 6926 SLL 26 S col 90950 CL ZOL 56 60 18 89 89 SL Seve SI0 0 02 96 228 60 68 GZ SZ 19 8r 89 5806 00220 v 89 5965 GZ 9 8r 89 esse 79 vt 8 OVS 06220 ezoso 70 ge 9 89 8r 19 8r 8 le ly lee 69610 9 Ze 92 7 vt IS 1292 6c 6L 92 8 9 EVO 22 0 P LIEZ x 0 Gz Wiz 9 lt lt 500 Leen 8 99 2 6L o 2901 92600 82 py 8L e 9L 6 LL 916 80800 04 9 8 218 9 288 8090 0 ce 1 m e 905 57700 SSO sc O G 668 9 2200 4 9 S 5 6 95500 MO 8 z 85200 4 2 ae eoz 25000 20900 9 L L L 16 5900 9v xi e z s esoo P WN 90 INN INN WN WN WN WN WN 9 9991 SP LLZ 80 272 b b
74. wards mounting plate gt JLG Sizzor If a new plate has been fitted then new spacers will have to be adjusted for air gap of 0 35 0 60 mm 0 014 0 024 in After checking air gap connect power supply Switch on power supply and ensure brake fully releases 2 15 SECTION 2 PROCEDURES 6 The brake can be adjusted for friction plate wear by removing spacers and machining them to maintain the correct air gap Length of all three spacers should be within 0 025 mm 0 001 in 2 19 FREE WHEELING PROCEDURE Use the following procedures ONLY for emergency move ment to a suitable maintenance area 1 Chock all wheels securely 2 Engage the mechanical release on both brakes by loosening completely reversing towards drive motor and tightening the three nuts on each brake 3 Connect suitable equipment remove chocks and move machine 4 After moving machine position on a firm level sur face 5 Chock wheels securely 6 Disengage the mechanical release on both drive brakes by loosening completely reversing towards torque hub and tightening the three nuts on each brake 7 Remove chocks from wheels as desired 2 20 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE The preventive maintenance and inspection checks are listed and defined in the following table This table is divided into two basic parts the to be inspected and the INTERVAL at which the inspection is to take

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