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Service & Maintenance Manual

1. 86 P VALVE OEN N HARNESS RELAY 5 II Duve Pi 1 2 03 87 30A 0 8 u f ge 43 wite RELAY NOTE CONNECT YEL BLK DIRECTUY 1 TO TERM 7 ON 400 RTS Wn LIFT UP DN D 87 _ WO O R LT C O OPTIONS je perda m BC II RAVERSING WELL MEE 58 WHITE BLU BLK I 21 WHT GRN 1 i BRN BLK 20 WHT ORN 1 30 STEER RELAY Bus 5 YeLLow gt lt 30 STEER RELAY Seven 11 RED BLK 1 i 87 LEFT STEER RIGHT SUI ORN BLK 87 12 sueco de RED 8LK TT LEFT REAR 55 cava BRN BLU I RIGHT REAR d RIGHT REAR MHT GRV 53 Del WHT BRN RIGHT 400879 EUROSOORTS SOORTS ERONT BRN RED GRY YEL i LIFT DOWN LIFT DOWN LONER ka UPPER 61 I BLACK BLACK BLACK LEFT FRON LE
2. Pi 5 RELAY DUMP P1 1 87 DI v una RED 30 I i BLACK 86 87 RELAY bog BROWN DI LIFT UP 87 YELLOW jse ORANGE 30 TRAVERSING 87 1 DECK RETRACT TRAVERS ING BLUE DECK EXTEND lol OPTION WHITE 1 BLU BLK Sg RIGHT REAR T STEER BRN BLK a d OPTION 1 YEL BLK 30 STEER RELAY STEER RELAY ee 39 1 RED BLK RED I STEER LEFT STEER RIGHT 5 ORN BLK YEL RED RED BLK TT Sea BLU RED t p p f3 EXTEND WHT VEL i BRN BLU 1 RIGHT REAR RIGHT REAR 4 RETRACT RICHT NHT GRY WHT ERN T 400RTS EURO 500RTS RIGHT FRON RETRACT RIGHT FRONT BRN RED 500RTS IET oun 1 EXTEND LIFT DOWN UPPER d LOWER p BLACK BLACK BLACK LEFT FRONT 1 RETRACT LEFT ERONT WHITE wire 1 WHITE i QUTRGGR Due BRAKE as i SPEED CUT OUT SW VALVE o 87 87 12 ILU RED BLACK 8 i BRAKE RELAY 30 WH
3. 7 e 5 B B 2 TBI TB2 6 2 sem swe act e 57 Frog Fat 52 fam 25 Ex VORN lt P BE EL D 26 OIL PRESSURE 51 evo dna 8 S lt MN rit Berner 31 wr FRONT EXT 29 ENGINE ROT REAR 32 Digikess tus sw wo i lt P K uva Tres m PO ast xv 37 ENABLE 9 5 nne YELLOW E FRONT w i E veo 3 5 ee 43 LIFT ort ve e xP 44 SET 4 RN KP EEL ri START a LET FRONT YELLOW 7 lt 0 29 x OPTION 8 REAR STEER BRONI lt CRo BLK BLI 1 a v n 012 Peio 5 NOTE ALL GRO SVBOLS i S ARE TO BE CONNECTED EA H TO CABLE WIRES i REF P 2 ps 16 24 13 CABLE 42 NO P CABLE 1 Noicates 16 20 P 2 CABLES N RECEPTACLE PINS B S 5 B 2 Figure 3 11 Electrical Schematic 500 RTS Ford VSG Sheet 1 of 2 3 22 JLG Sizzor 3121103 SECTION 3 TROUBLESHOOTING 3121103
4. 3121103 JLG Sizzor 3 11 SECTION 3 TROUBLESHOOTING FRONT EXTENSION SHONE FOR FRONT EXTENSION ONLY _ OPTION DUAL DECK SELECT VA 400RTS 500RTS D1 i ti STEER CYL FRONT STEER CYL REAR REAR FRONT Figure 3 1 Hydraulic Schematic Sheet 1 of 6 3 12 JLG Sizzor 3121103 SECTION 3 TROUBLESHOOTING REAR EXTENSION LEVELING JACKS LEFT FRONT RIGHT M LEVELING JACKS LEFT REAR RIGHT TO PISTON PUMP RETURN FILTER TO FRONT TO REAR B BRAKES BRAKES 1 Qi 1 1 ot 2792371 I Figure 3 2 Hydraulic Schematic Sheet 2 of 6 3121103 JLG Sizzor 3 13 SECTION 3 TROUBLESHOOTING RR DRIVE MOTOR RF DRIVE MOTOR LU 1 1 FLOW DIVIDER EB 1 Ic ull GC 3 E 2 _ 3 A LR DRIVE MOTOR LF DRIVE MOTOR DRIVE BRAKES FRONT DRIVE PUMP VARI ABLE OVER CENTER Figure 3 3 Hydraulic Schematic Sheet 3 of 6 3 14 JLG Sizzor 3121103 SECTION 3 TROUBLESHOOTING LOCK OUT VALVE ne Ei DRIVE BRAKES REAR TO THE BR PORT ON VALVE MANIFOLD 400 500RTS ONLY TO THE BF PORT ON VALVE MANIFOLD CHARGE F ILTER IK A EX 6126 TO CP VALVE MANIFOLD 2792371 Figure 3 4 Hydraulic Schematic Sheet 4 of 6 3121103 JLG Sizzor 3 15 SECTION 3 TROUBLESHOOTING 3 16 RR DRIVE MO
5. 111 Iu d 1 3 e gemens i Li 188 1 8 Bee ene 11 1 j 88 bet 3 8 7 Kus iU IR E dii 888 PP 5885 o R 1 E 545 3 225924 edi m 6 ner WHITE Ta 4 5 3 5 8 s 2 KEYSWITOH SELECTOR x Lesta KEY REMOVABLE P n PLATTOR ANO NEUTRAL 2 ENG Ci HOURMETER RELAY 8 A 9 OPTION teso DIR L H e START Lockout RELAY oss Figure 3 13 Electrical Schematic 500RTS Duetz Sheet 1 of 2 3 24 JLG Sizzor 3121103 SECTION 3 TROUBLESHOOTING 3121103 VALVE HARNESS E i MN RELAY Ub i ER hH 5 IHP ar rd orom ie BLK BLU 1 i YELLOW a 7 H me bd MD RELAY ave rea
6. MEA manne AUO IHM INEB LHM cano G L Du v YELLOW t OL meme A G 5 Le Sw m 8 nri A corem 8 RI YELLOW DASH LINES ARE EURO SPE BLU BLK RED L OPTION 2 PLAT Euro TRAVERSING E i DE e M 8 t gt RE a 3 ro RED 344 so 5 g BAT 2 591 15 Dow x 86 MAIN 2 8 b 10A BATT KEVSWITOH sevecton CO HI ENG HOURMETER KEY REMOVABLE oN z RELAY Bl 8 AND NEUTRAL i E NEC OM 2 Y wa H 8 lt st I 5 5 5 OPTION 2 EMER STOP o TRAVERSING DECK SW wo SELECI AUX PWR 4 re 6 6 u RED l e YELLOW Nc Figure 3 15 Electrical Schematic 500RTS Duetz Sheet 1 of 2 3 26 JLG Sizzor 3121103 SECTION 3 TROUBLESHOOTING 50 HARNESS RED Pi 12 suatu Dove
7. vea 1 L el Traversing GRY RED 30 DECK RETRACT BLU BLK um H TRAVERS ING WHT BRN T DECK EXTEND BRN BLK 1 ii OPTION wro ak 1 LEFT REAR RIGHT REAR WHT GRN 1 STEER ES oe ri STEER RELAY H BLU RED 86 30 STEER RELAY I i4 mo steer vert STEER RIGHT one omveuc 1 are I rm 1 d Lepr REAR RETRACT carr RUK caro mE H i d RIGHT REAR RETRACT RIGHT REAR 50085 500815 am T EXTEND 400RTS EURO k 1 Lou LIFT LIFT DON GRY WHT LOWER UPPER I RIGHT FRONT BLACK WHITE WHITE RIGHT FRONT GRY YEL EXTEND L BLACK BLACK 171 ti wire LEFT FRONT EUN LEFT FRONT 13 14 SPEED sw aru EXTEND 11 aa EU eee BLACK 1 OUTRGOR sna gt i wire i VANE i menu YELLOW i option stows SE 649 stowe PLAT EXTENSION 19 542 RATE CX SELECT wir Shu Awa cars NES RELAY T e7 16 2 05FT BLACK 1 BLACK LE mite e r gene el Tue ve MT kn H BLACK 1 i 21 22 ajz 8 OUTROOR STOWED ONLO 16 2 CABLE 5 5 BLACK Erf A Se BLACK BLACK u gt wire ourroce 16 2 CABLE 1 Stowe BLACK Er i 1 1072 CABLE 2 wirt 1 4 oUTRGOR SET oume BLACK 4672 12FT 52
8. BLU RED 2 SPD CUT OUT ro g 1 Fat 20 E ORN BLK lt D lt 5 12 VDC PLAT s Lier OM A REDE lt lt max i o DRIVE REV Eo BLACK B BLACK 9 DRIVE FORWD A pR SPD io 9 lt 11 Suma d 23 ut lt 2 anew 4 12 ta 2 g Xe ae 3 SET 2O lt raw H iex 5 OPTION t 20 Crow gt 16 HORN 17 m O 8 Tu 5 _ lt 7 17 OMAN mi ALARM E 6 19 maana 22 Wt meme BRN BLK P 2 BRN BLK 5 L a mapas DI fini fel ivo orvern lt p 2 lt ax 56 26 on BA 27 wata Teue T lt 2 5 een 29 igi mw or rici Cicer 986 jiemu YEL RE lt ei RT jit EE lt 2 max SUINA NI ORANGE 38 PUT DT ENABLE 39 er 30 AUX POWER YELLOW E E 8 vod 41 PAT BT SET uo 43 Ul YELLOW 5 4 fa ire 52 44 SET 5 5 1 2 sia 5 START Inc 17454 OUIRG R Sw 140 0 FIN G Pe 53 YELLOW 1 jg P 2 lt BLUE 29 j 9 sus 29 REAR STEER 2 Brom Brom lt IO lt eron 2 BLK BLU ki BLK BLU uva 02 OPTION si Lug HN 111 PA Back
9. Crossover relief valve low or not functioning properly Reset repair or replace valve as required Steer linkages loose Tighten linkage Steer wheel toe in not set properly Adjust toe in for 1 4 inch overall Spindle bushings badly worn Replace bushings Spindle bushings to tight Replace bushings OSCILLATING AXLE IF EQUIPPED Axle will not oscillate Defective lockout cylinder Repair or replace cylinder Lockout valve sticking Repair or replace valve Lack of lubrication on axle pin Lubricate pin Lockout valve defective Repair or replace valve Axle will not lock Air in lockout system Bleed lockout system Defective lockout valve Repair or replace valve Defective pressure reducing valve feeding lockout Repair or replace valve system 3 6 JLG Sizzor 3121103 SECTION 3 TROUBLESHOOTING Table 3 3 Chassis Troubleshooting TROUBLE PROBABLE CAUSE REMEDY ENGINE Engine will not start Station power selector switch is notin required position Actuate switch as required Circuit breaker open Determine and correct cause Reset circuit breaker Startlockout solenoid not working Replace solenoid Start switch defective Replace start switch Defective anti dieseling solenoid on carburetor Replace solenoid or carburetor Damaged wiring in ignition circuit brokenwireon repair or
10. The first rule for troubleshooting any circuit that is hydrau lically operated and electrically controlled is to determine if the circuit is lacking hydraulic oil and electrical power This can be ascertained by overriding the bypass valve mechanically or electrically so that oil is available to the function valve then overriding the function valve mechani cally If the function performs satisfactorily the problem exists with the control circuit 3 3 HYDRAULIC CIRCUIT CHECKS The first reference for improper function of a hydraulic sys tem where the cause is not immediately apparent should be the troubleshooting chart The best place to begin the problem analysis is at the power source pump Once it is determined that the pump is serviceable then a system atic check of the circuit components beginning with the control would follow For aid in troubleshooting refer to the Illustrated Parts Manual for hydraulic diagram of the various circuits JLG Sizzor 3 1 SECTION 3 TROUBLESHOOTING Table 3 1 Platform Assembly Troubleshooting TROUBLE PROBABLE CAUSE REMEDY No response to control switch Enable switch not activated Activate enable switch Function not activated within the 3 seconds after Reactivate enable switch enable switch was depressed Enable switch notfunctioning properly Replace enable switch circuit card Lift control switch inoperative Repair or replace lift
11. JLG Latino Americana Ltda Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil B 55 19 3295 0407 55 19 3295 1025 USA B 717 485 5161 amp 717 485 6417 JLG Industries UK Ltd Bentley House Bentley Avenue Middleton Greater Manchester M24 2GP England 44 0 161 654 1000 El 44 0 161 654 1001 JLG France 5 5 241 de Baulieu 47400 Fauillet France B 33 0 5 53 88 31 70 33 0 5 53 88 31 79 piu JLG Deutschland GmbH Max Planck Str 21 D 27721 Ritterhude Ihlpohl Germany B 49 0 421 69 350 20 EL 49 0 421 69 350 45 JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong B 852 2639 5783 E 852 2639 5797 JLG Industries Italia s r l Via Po 22 20010 Pregnana Milanese MI Italy B 39 029 359 5210 39 029 359 5845 JLG Europe Polaris Avenue 63 2132 JH Hoofddorp The Netherlands B 31 0 23 565 5665 31 0 23 557 2493 Dim JLG Polska Ul Krolewska 00 060 Warsawa Poland B 48 0 914 320 245 48 0 914 358 200 JLG Industries Scotland Wright Business Centre 1 Lonmay Road Queenslie Glasgow G33 4EL Scotland B 44 0 141 781 6700 EL 44 0 141 773 1907 Plataformas Elevadoras JLG Iberica S L Trapadella
12. TERMINAL TERMINAL pe BLACK SELICE nlz Se albums cW OUTRGCR STOWED o o 5 1 atack 1672 CABLE 92FT SALA AER ST BLACK OS BLACK OS 1 2 WHITE 1 OUTREGR 16 2 CABLE fil 18FT 1672 CABLE 5 10FT STONED 14 BLACK Sw RR 16 2 CABLE 2 16FT BLACK WHITE 2 Ftor 9078008 QUTRGGR BLACK 672 137 13 14 RON ilem ur TON Si 21 2 21 22 SW RF njee wire mit BLACK n 19 wie WHITE E 87 16 2 CABLE 1 A LIFT DRIVE gt 3 Nm WHITE 43 WHITE m ware wire m Ad cm 16 2 CABLE 2 21 22 21 22 CABLE 4 WHITE wire wire ar ser N 14 13 OUTRGGR SET 18 BLK RED Je SW IR GT 16 2 CABLE 5 x SW RR RELAY 4 3 An i 16 3 30 LeveL 1 5 500RTS sensor 3 40087S EURO Ce GREEN CONTROL HARNESS NOTE LEVEL SENSOR HAS BLACK NOTE CONN SUPPLIED T2VDC OUTPUT W PUP vaRrI DISP MHEN LEVEL PISTON PUMP I BROWN e NOTE PLUG 2 1S LOCATED ON THE ENGINE 4 PLUG 2 s SO mom N STARTER 9 orance B NOTE ALL GRO SYMBOLS 50 suck ARE io BE CONNECTED N gt 2 ENG DiSTRESS SCREW E 87 87A 25 2 4 3 D 8 IND f L on SOLENOID E PLUG 2 4 e 13 YELLOW 7 gt AROMI 1 gt gt 40 oaeeo lt PLUG 2 BAT CABLE 26 WAT YEL SO gt witve AUX PWR L RELAY RS RED P PRESS SENDER AUXILIAR
13. flat level surface and ensure machine is level NOTE Ensure switch mounting bracket is level and securely attached 2 Level the base of the indicator by tightening the three flange nuts Tighten each nut until bubble in the indicator is in the center of indicator 2 8 JLG Sizzor 3 Individually push down on one corner at a time there should be enough travel to cause the switch to trip If the switch does not trip in all three tests the flange nuts have been tightened too far Loosen the nuts and repeat steps 2 and 3 2 13 PRESSURE SETTING PROCEDURES Rexroth Hydraforce Valve 1 Install pressure gauge at port G on Rexroth Hydraforce Valve 2 Adjust both steer section crossover reliefs all the way in Adjust main relief cartridge out several turns 4 Activate engine and allow hydraulic system to come up to operating temperature 5 Bottom out steer function Adjust main relief to 2800 psi 193 bar 6 Bottom out front steer right and steer left functions and adjust each steer crossover relief to 1500 psi 103 bar 7 Bottom out Rear Steer Right and Steer Left functions and adjust each Steer Crossover Relief to 1500 psi 103 bar 8 Bottom out Platform Ext Extended functions and adjust each Ext Crossover Relief to 1200 psi 83 bar 9 De energize Platform Ext function shut down motor and disconnect pressure gauge 3121103 SECTION 2 PROCEDURES 2 14 DRIVE PUMP START UP PROCEDU
14. 3 Operate hydraulic functions through one com plete cycle before checking hydraulic oil level in tank Oil should be visible in ADD sight window on hyaraulic tank If oil is not visible add oil until oil is visible in both ADD and FULL sight windows on tank Do not overfill tank 4 Any time the pump coupling is removed coat splines of coupling with Texaco Code 1912 grease prior to assembly gasoline or diesel engine only 1 5 SECTION 1 SPECIFICATIONS Serial Number Stamped Serial Number Plate Figure 1 2 Serial Number Location 1 9 SERIAL NUMBER LOCATIONS For machine identification a serial number plate is affixed to the machine On gasoline or diesel powered machines the plate is located on the right front side of the frame rail In addition should the serial number plate be damaged or missing the machine serial number is stamped on the top of frame between the front wheels 1 10 MAJOR COMPONENT WEIGHTS Table 1 5 Major Component Weights Component Lb Kg Fixed Platform 180 cm x 426 1235 560 Platform Extension 275 125 Arm Assembly 500RTS Includes 8699 3946 Lift Cylinder Chassis Includes Outriggers 6052 2745 and Pneumatic Tires Chassis Includes Outriggers 6756 3065 and Foam Filled Tires 1 11 CRITICAL STABILITY WEIGHTS DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION FOR EXAMPLE FILLED TIRES
15. Drive romeo 1 12 DUMP O E Mo de CE 18 TT i 38 18 TILT ea 10 19 orive ana DE E E f 20 REAR STEER RGT E Ri X 21 REAR STEER LEFT lt lt fen 22 LIFT DWN OVERIDE A DR SPO BLACK SO 23L1FT cv LIMIT SW 24 LIFT OVERLOAD RED LIFT SW ta 25 ENG DISTRESS 2 23 Vo lt 048 26 Pressure 27 WATER TDP MQ s ore SET lt p2r krereu 412 VOC PLAT snow 29 LEFT FRONT EXT BLUE 1 vet FRONT EXT vento KOK vent 6 34 nor REAR RET OPTION 35 LEFT REAR EXT mau 57 26 LEFT s E ak mae TONI 37 EL pas M LoT anam 6a 56 i ULL CEPIT vun wa Qr O 5 tren 43 LIFT CUT OUT rid Con m OUTTROGR SET DISTRESS BATTERY ter BATTERY POS H OUTRGGR SW IST carena wo a 9 GRY WHT 2 D BLI ORANGE 5 G 1 8 5 Q9 ENABLE E H NUN 5 E a 2 3904 RGT FRONT YELLOW sie cerro 2 31 f e 3 START c 9 8 Ted ned T A ina 1S arneo Goes 57 To lt 29 4 aux REAR STEER 9 138 T oom lt lt rom 2 BLK BLU lt e
16. G 2 X stack 50 A 50 3 5 2 85 T Sor ALL GRD SYMBOLS i 888 202 UE E g g ARE TO CONNECTED l ME 25553 S SS 3 8 2 3 N TO CABLE GRND WIRES l 8 RAR P IS 16 24 3 2 So M 2 22 8 amp REF P 2 INDICATES fila A 2 3 wraps 16 20 P 2 P 2 2 Su CABLES RR OR 8 gt g 2 o b o gt 2 a e RECEPTACLE PINS H ke 223 8 8 88 8 888 233 8 2 8 8 5 8885 22 8 k 8 3 C2 G3 GRD CONT BOX a GROUND CONTROL TERM STRIP AA FASSA TA FA TA R a Fa N fa Pa s fi pasa 4 P s ERS E E CE 5 HL 3 9 jy 3 3 2 B 2 8 x om ue ten on 58 START RELAY 30 8699 LIFT jaza a 15A Tz GRD L CONT YELLOW 9 T YELLOW BATT OPTION RED TRAVERSING EXT PLAT 30A DECK N O MAIN RET __ dio RED 1 87 1 ut 8 g 8 59 HORN RELAY Tei su N o Bos 5 1 A om TER B i 9 gt OPTION EMER STOP TRAVERSING DECK NC SW Ivo SELECT AUX PWR 4 YELLOW f T 45 5 RED 9 YELLOW 3 LP v9 BLUE 1 DUEL 49 WHT ORN yo BLACKH2 1 AG WHT ORN 1 HOURMETER E Figure 3 7 Electrical Schematic 500 RT
17. 2 RELAY DUMP PI IHP er BROWN ve ET TO 10A MAIN RED i YELLON 30 LIFT UP 87A ORANGE 23 WHITE o CUT OUT 4 A Q RELAY LIFT up BLUE 0 IHP YEL BLK o WHITE TRAVERSING 37 GRY RED 30 DECK RETRACT BLU BLK 87A TRAVERSING WHT BRN DECK EXTEND BRN BLK OPTION 38 witzer veL LEFT REAR STEER RIGHT REAR 0RN BLK 21 WHT GRN lur RED 8LK 20 WHT ORN YEL RED 4 n RELAY 11 reo M Wit VEL lt 87 n STEER RIGHT STEER LI 10 omar ne 5 BRN BLU L 4 i 87 12 sum RED BLK lt LEFT REAR RETRACT leda 36 GRY GRN EXTEND ouf BRN RED 35 GRY BLK RIGHT REAR RETRACT RIGHT REAR 500875 SOORTS 34 GRY BRN EXTEND 400RTS LIFT DOWN 2d DOWN AS andar E 16 2 CABLE 40FT RIGHT FRONT BLACK wir RETRACT RIGHT FRONT 32 GRY YEL 9 EXTEND L BLACK BLACK 4 wire 31 GRY ORN LEFT FRONT RETRACT LEFT PRONT 13 14 SPEED CUT OUT sw 30 cwv nto 5 EE 29 GRV VIO BLACK lt OUTRGOR 37 BRN BLK CE WHITE 87A ww TO TERM 30 OF DUMP RELAY gEL 5 86 17 suat EE BRAKE RELAY 21 22 21 2 6 14 vercon PLAT EXTENSION OPTION OUTRGOR STONED OO E Stoned SEE REA Sr 39 16 2 CABLE 3 10FT MH SUE 16 2 CABLE BSET f sa BLACK Le mac 4 3 16 2 d RE BLACK WHITE cda MP e s WHITE ded cale
18. ENGINE DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY Table 1 6 Critical Stability Weights Component Lb Kg Tires Balasted Only 12X16 5 295 134 Engine Ford 525 238 Engine Deutz 600 272 1 6 JLG Sizzor 3121103 8 AVS S 49 AVS yeys anb oL g L oJnBiJ S19uojsej pojejd wnipeo jou op senjeA 95941 9JON SECTION 1 SPECIFICATIONS 1 7 000861 00227 00891 070 00507 5 76 0652 0952 ogle 00595 5002 95 1 097 Over 00082 0507 er ovvz 005162 000 sole oroz OOL8LL 0521 9061 0922 0891 00062 09181 zm 0252 O0SSLL 5292 206 0821 0862 00070 sest ezer OOLL 09 00 9 OSSLT 0881 006707 0022 0191 0061 0002 00996 oze 00965 06207 m 052 00696 0002 esr ooer ozel 002 8 sill 6007 078 ozi 00865 06960 over 00958 SISI SSH 080 00022 526 208 099 088 00627 09980 oez xm 00597 OOFL 0
19. Hydraulic Schematic Sheet 2 of 6 3 13 3 3 Hydraulic Schematic Sheet 3 of 6 3 14 3 4 Hydraulic Schematic Sheet 4 Of 6 3 15 3 5 Hydraulic Schematic Sheet 5 of 6 3 16 3 6 Hydraulic Schematic Sheet 6 of 6 3 17 3 7 Electrical Schematic 500 RTS Ford LRG Sheet 1 2 3 18 3 8 Electrical Schematic 500 RTS Ford LRG Sheet 2 2 3 19 3 9 Electrical Schematic 500 RTS Ford LSG Sheet 1 2 3 20 3 10 Electrical Schematic 500 RTS Ford LSG Sheet 2 2 3 21 3 11 Electrical Schematic 500 RTS Ford VSG Sheet 1 2 3 22 3 12 Electrical Schematic 500 RTS Ford VSG Sheet 2 2 3 23 3 13 Electrical Schematic 500 Duetz Sheet 1 of 2 3 24 3 14 Electrical Schematic 500RTS Duetz Sheet 2 of 2 3 25 3 15 Electrical Schematic 500 Duetz Sheet 1 of 2 3 26 3 16 Electrical Schematic 500RTS Duetz Sheet 1 of 2 3 27 JLG Sizzor 312
20. With Deck Extended Main Deck 2 000 Ib 905 kg Extension 500 Ib 230 kg With Deck Retracted 2 000 Ib 905 kg Machine Weight Approx 15 300 6 940 kg Machine Height Platform Lowered 126 3125 in 3 15 m Machine Length 15 ft 5 in 4 72 meters Machine Width Standard Tires 7 ft 6 in 2 3 meters Foam Filled Tires 7 ft 7 in 2 3 meters 1 4 LUBRICATION Table 1 1 Hydraulic Oil HYDRAULIC SYSTEM OPERAT ING TEMPERATURE RANGE SAE VISCOSITY GRADE 0 to 23 degrees F 10W 18 to 5 degrees C 010 210 degrees F 18 to 100 degrees 10W 20 10W 30 50 to 210 degrees F 20W 20 10 to 100 degrees NOTE Hydraulic oils must have anti wear qualities at least to API Service Classification GL 3 sufficien themical stability for mobile hydraulic system ser vice JLG Industries recommends Mobil 424 hydraulic oil which has an SAE viscosity of 10W 20 and viscosity index of 152 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 Mobil 424 is desired contact JLG Industries for proper recommendations JLG Sizzor 3121103 SECTION 1 SPECIFICATIONS 1 5 LUBRICATION SPECIFICATIONS Table 1 2 Lubrication Specifications KEY SPECIFICATIONS MPG Multipurpose Grease having a mini
21. 3121103 checks are listed and defined in the following table This table is divided into two basic parts the AREA to be inspected and the INTERVAL at which the inspection is to take place Under the AREA portion of the table the various systems along with the 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 num bers 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 depending 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 Form must be completed and returned to JLG Indus tries NOTICE 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 to record
22. 8 ply pneumatic inflate to 35 PSI 2 4 bar Optional 12 16 5 NHS 6 ply foam filled Steer System Toe In Adjust to 1 4 inch 6 4 mm overall Drive Motors Hubs Brakes Drive Motor 2 48 in 3 6 3 cm3 displacement Drive Hub 2WD Gasoline and Diesel Engine Rear Hub ratio 35 1 Drive Hub 4WD Rear Hub ratio 24 1 Drive Hub Brake 4WD Front Hub ratio 24 1 brake spring applied hydraulic release release pressure 160 psi 11 bar initial 190 psi 13 bar full Drive Brake 2WD 4WD Rear Spring applied hydraulic release release pressure 150 psi 10 bar initial 170 psi 12 bar full NOTE Wheel lugs should be torqued to 80 ft Ib 109 Nm at 50 hour intervals When maintenance becomes necessary or a fas tener has loosened refer to the Torque Chart Fig ure 1 1 to determine proper torque value 3121103 JLG Sizzor 1 1 SECTION 1 SPECIFICATIONS Hydraulic Filter Inline Return Bypass Type 25 Micron Nominal 1 3 PERFORMANCE DATA Travel Speed 2 Wheel Drive 3 5 mph 5 6 kmh 4 Wheel Drive 2 8 mph 4 5 kmh Gradeability 2 Wheel Drive 25 14 4 Wheel Drive 45 24 Turning Radius Outside 2 Wheel Steer 13 ft 2 in 4 0 meters 4 Wheel Steer 6 ft 6 in 2 0 meters Lift Speed 500815 Up 65 80 seconds Down 70 80 seconds Platform Capacity Fixed Platform 2 500 Ib 1135 kg Platform Capacity Traversing Platform Extension If Equipped
23. ALL GRD SYMBOLS E wa ARE BE CONNECTED mom 2 WATER TEMP 9 PRESS VOLTAGE SEN SENDER REGULATOR od RON 4 26 WHT YEL ORANGE 12 27 BLUE H I 25 nen aLu LI ENG PRESSURE RECISION DISTRESS 3 GOVERNOR RELAY pe 879 7 CN REMOTE 7 vuo o rune d 30 Rom 7 2 gt own 83 5 Prj FORD IGNITION 87A we sj E MURI MODULE 879 6 ola ENG gt EM ee Y START i 30 10 Ere 10 FERES IR T Y recon 5 wren GOVERNOR r gt te LI START LOCKOU CARE papam U sow sO son 0 gegen aal Borek AA gt 875 87 S VELLOW 3 4 O rum me 7 H9 i REDAALU p TOO da BRN BLK a 30 g ORANGE 12 g bans B 7 COIL E e Xr 86 879 apas ts AUX S i m E il 5 RELAY Fog 8 Ry FROM 4 BAT CABLE 19 PT r MTB k i SI gi STARTER MOTOR AUXILIARY T 12 POWER on vac se ja Ws vo BLUE x SW LP GAS EL FILTR Loc 49 WHT oRN 1 VALVE o BLACK 2 12 VOLT DC gs l Par 1282341 C Figure 3 10 Electrical Schematic 500 RTS Ford LSG Sheet 2 of 2 3121103 JLG Sizzor 3 21 SECTION 3 TROUBLESHOOTING
24. MUST BE REMOVED FROM SERVICE FROST ON THE SUR FACE OF A TANK VALVES OR FITTINGS INDICATES LEAKAGE A STRONG ODOR OF LPG FUEL CAN INDICATE A LEAK 2 26 FREEWHEELING FEATURE To Disengage Torque Hubs Freewheel 1 Chock wheels securely 2 Disengage reverse disconnect caps on drive torque hubs by removing two attaching capscrews turning cap around then reinstalling and tightening capscrews 3 If desired remove chocks and using suitable equip ment for assistance move machine to an appropri ate maintenance area Again chock wheels securely To Engage Torque Hubs Engage reverse disconnect cap on both drive torque hubs by removing two attaching capscrews turning cap around then reinstalling and tightening capscrews JLG Sizzor 2 31 SECTION 2 PROCEDURES 2 21 LIMIT SWITCH ADJUSTMENT PROCEDURE Drive Cut Out Switch NOTE The drive cut out switch is set at 22 ft 6 7 m Figure 2 16 Drive Cut out Switch Drive Speed Cutout Drive speed limit switch set to actuate as soon as possible after the platform lifts beyond the stowed position and begins to elevate Switch must activate prior to a maxi mum platform height of 14 ft 4 2 m Figure 2 15 Drive Hub Disengaged Figure 2 17 Drive Speed Cutout Switch 2 32 JLG Sizzor 3121103 SECTION 2 PROCEDURES 2 28 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE a The preventive maintenance and inspection
25. NOTE Step 3 applies to the leveling jacks only 3 Fully extend leveling jacks to check 4 Shut down hydraulic system and allow machine to sit for 10 15 minutes Carefully remove hydraulic hoses from cylinder port block 5 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 cylinder repairs must be made If the retract port is leaking the piston seals are defective and must be replaced If the extend port is leaking the counterbalance valve is defective and must be replaced 6 If no repairs are necessary or when repairs have been made carefully reconnect hydraulic hoses to the appropriate ports 7 Remove lifting device from platform activate hydrau lic system and run cylinder through one complete cycle to check for leaks 2 10 CYLINDER REMOVAL AND INSTALLATION Lift Cylinder Removal 1 Place the machine on a flat and level surface Start the engine motor and raise the platform Shut down the engine motor and attach a suitable support device to the platform 2 Remove the locknut bolts flatwashers 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 3 Retract the lift cylinder rod completely 4 Tag an
26. Schematic 500 RTS Ford LRG Sheet 2 of 2 3121103 JLG Sizzor 3 19 SECTION 3 TROUBLESHOOTING GA omie _ S2 ew om car REF 1600157 e Gara wre Gyvo mr OE E GI rom Giara porn Go zona 2 Ey WE TUE E E 23802833P82223 Goron ijowax Gromu von 238532257288 25 a 3 lt 85 8 ewe ae Gemu von 8 B GO sar rum wem BLUE lt QK BLUE 8 TERMINAL AP TERMINAL Wd DESCRIPTION arance lt RKorance 9 YELLOW BLACK GRANGE 50 PLAT GRO c 2 PLAT em 4 3 IGNITION PLAT 5 REF 0610103 a 1 lt lt sum 17 3 D 8 li ORN BLK lt DK 9 SU UT 8 LIFT om RED BLK lt Q wna D B HIT pug DR SPD 10 Drive Rev 5 a s B s BLACK BR sack 50 10 pive romo b 2 e 12 STEER LEFT D 2 RED SPA _ STEER ser LIFT sw lt avv CI 14 or 3 15 ia O s O4 S 05 ourgoor SET L K mu PES lt n 17 108 B IE 5 som G A PAG mm 7 14o 19 com aux g i i BLUE PERI cm 7 19 men eis es 2 DE 27 mw 3 ORANGE DRM ALA
27. a normally closed solenoid valve and holds the platform in place when raised When activated the valve opens to permit lift down The holding valve is connected to the manual descent valve which is connected to a cable which when pulled manually opens the lift down port of the valve and allows the platform to be lowered in the event hydraulic power is lost 2 7 SLIDING WEAR PADS The original thickness of the sliding pads is 6 0 in 15 2 cm Replace sliding pads when worn to 5 7 in 14 5 cm 2 8 PUMP COUPLING LUBRICATION To insure proper operation and a long service life for the Hayes pump coupling it is necessary to lubricate the splines of the coupling any time the coupling is disassem bled or replaced Lubricate the splines with Texaco Code 1912 Pump Coupling Grease ONLY No other lubricant is recommended 2 4 JLG Sizzor 2 9 CYLINDER CHECKING PROCEDURES NOTE Cylinder checks must be performed any time a cylin der component is replaced or when improper system operation is suspected Cylinder w o Counterbalance Valves Steer Cylinder Platform Ext Cylinder Axle Lockout Cylinder If Equipped OPERATE FUNCTIONS FROM GROUND CONTROL STATION ONLY 1 Using all applicable safety precautions activate hydraulic system and fully extend cylinder to be checked Shut down hydraulic system 2 Carefully disconnect hydraulic hose from retract port of cylinder There will be initial weeping of hydra
28. a variety of single purpose grease requirements Should any question arise regarding the use of greases in maintenance stock consult your local supplier for evalua tion Refer to Section 1 for an explanation of the lubricant key designations appearing in the Lubrication Chart 2 4 CYLINDERS THEORY OF OPERATION 1 Cylinders are of the double acting type The Steer Leveling Jack and Deck Extension systems incor porate double acting cylinders A double acting inder is one that requires oil flow to operate the cylinder rod in both directions Directing oil by actu ating 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 cylin der 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 cylinder rod will retract NOTE The Lift cylinder is a single acting cylinder which take hydraulic pressure to extend and gravity to retract 2 Aholding valve is used in the Lift and Leveling Jack circuit to prevent retraction of the cylinder rod should a hydraulic line rupture or a leak develop between the cylinder and its related control valve 2 5 VALVES THEORY OF OPERATION Solenoid Control Valves Bang Bang Control valves used are four way three position solenoid valves of the sliding spool desi
29. control switch Hydraulic system oil low Replenish oil as necessary No power supply See wiring diagram Restricted or broken supply line on valve bank or hydraulic pump Clean repair or replace line Control valve not functioning properly Repair or replace valve Defective dump valve on cylinder Repair or replace dump valve Lift cylinder not functioning properly Repair or replace lift cylinder Hydraulic pump not functioning properly Repair or replace hydraulic pump Platform will not raise Enable switch not activated Activate enable switch Function not activated within the 3 seconds after enable switch was depressed Reactivate enable switch Enable switch not functioning properly Replace enable switch circuit card Load capacity exceeded Personnel and or equip ment Reduce load Refer to capacity placard Hydraulic system oil low Replenish oil as necessary Broken or binding pivot pin Repair or replace pivot pin Restricted or broken hydraulic line or fitting Clean repair or replace line or fitting Control valve not functioning properly Repair or replace control valve Lift cylinder not functioning properly Repair or replace lift cylinder Pump does not respond when lift control switch is moved to the up position Refer to electrical troubleshooting table No electrical signal being sentto lift up control valve ca
30. d An Oshkosh Truck Corporation Company Service amp Maintenance Manual Model 500RTS 3121103 November 14 2007 AZ Lt An Oshkosh Truck Corporation Company INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS SECTION A INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS A A GENERAL This section contains the general safety precautions which must be observed during maintenance of the aerial platform It is of utmost importance that main tenance personnel pay strict attention to these warn ings and precautions to avoid possible injury to themselves or others or damage to the equipment A maintenance program must be followed to ensure that the machine is safe to operate A WARNING MODIFICATION OF THE MACHINE WITHOUT CERTIFI CATION BY A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST AS SAFE AS ORIGINALLY MANUFACTURED IS A SAFETY VIOLATION The specific precautions to be observed during maintenance are inserted at the appropriate point in the manual These precautions are for the most part those that apply when servicing hydraulic and larger machine component parts Your safety and that of others is the first consider ation when engaging in the maintenance of equip ment Always be conscious of weight Never attempt to move heavy parts without the aid of a mechanical device Do not allow heavy objects to rest in an unstable position When raising a portion of the equipment ensure
31. into mesh with cluster gears in carrier If ring gear is on correctly the X marking a shoulder bolt hole should face up Make sure punch marks on cluster gears remain in their correct positions when installing ring gear Place carrier assembly and ring gear together into mesh with internal gear Align shoulder bolt hole in ring gear marked with an X over one of the shoulder bolt holes in the hub Ring gear may be lifted off hub to align shoulder bolt holes Ring gear and carrier need to be installed together initially only so that punch marks on carrier remain aligned Oil all exposed surfaces inside hub Place thrust spacer onto input shaft assembly Place thrust washer into counterbore in carrier Assemble cover as follows a Place o ring onto cover cap so it rests against flange of cover cap b Insert o ring into groove inside cover cap c Insert disconnect rod into cover cap d Place cover cap into cover Align pipe plug hole in cover cap over pipe plug hole in cover e Place two cover cap bolts into any two bolt holes 180 apart on cover cap and tighten f Using a torque wrench apply 36 49 in Ib 4 5 Nm torque to both bolts g With large end down place disconnect cap onto cover Align pipe plug hole in disconnect cap over pipe plug hole in cover cap h Place two remaining bolts into bolt holes in dis connect cap and tighten i Using a torque wrench apply 36 49 in Ibs 4 5 Nm torque to both
32. spring and retain with snap ring Remove 3 8 N C nut 3 8 x 3 1 4 capscrew and two washers 6 Install pivot spider and piston assemblies in piston block assembly 7 Lubricate thrust race and install in housing assem bly 8 Install piston block assembly in housing assembly Piston shoes must contact thrust race Be sure all parts are in their proper position 9 Install new needle bearing in backplate if necessary 10 Install new o ring on backplate 11 Install backplate on housing 12 Install six capscrews and torque to 15 18 ft lbs 20 24 Nm 3121103 2 21 DRIVE TORQUE HUB 2WD 4WD REAR TORQUE HUB UNITS SHOULD ALWAYS BE ROLL AND LEAK TESTED BEFORE DISASSEMBLY AND AFTER ASSEMBLY TO MAKE SURE THAT THE UNITS GEARS AND SEALANTS ARE WORKING PROPERLY NOTICE WHEN REBUILDING A UNIT USE NEW SEALS AND O RINGS NEVER RE USE SEALS AND O RINGS AS THIS WOULD CAUSE UNIT TO LEAK A CAUTION WEAR SAFETY GLASSES WHEN PERFORMING THE FOLLOWING STEP BE AWARE THAT SPRING AND SPACERS COMPRESSED BY RETAINING RING MAY POP SUDDENLY OFF SHAFT WHEN RETAINING RING IS REMOVED USING RETAINING RING PLIERS REMOVE RETAINING RING FROM GROOVE ON INPUT SHAFT 1 Remove one spacer one spring and other spacer from input shaft 2 Remove thrust washer from around spindle 3 Lift internal gear out of hub A CAUTION BEWARE OF SHARP EDGES IN COUNTERBORE WHEN REMOV ING O RING 4 Remove o ring from counterbore in hub Disca
33. stamp inspection dates Notify dealer if inspection is over due d The inspection and maintenance code numbers are as follows 1 Check for proper 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 for eign material 7 Check for proper operation and freedom of movement 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 pump motor 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 necessary 15 Check for proper inflation 16 Check Inspection Decal for current inspec tion stamp JLG Sizzor 2 33 SECTION 2 PROCEDURES Table 2 3 Preventive Maintenance and Safety Inspection AREA INTERVAL 10Hours Daily 50 Hours Weekly 200 Hours Monthly 500 Hours 3 Month 1000 Hours 6 Month PLATFORM 1 Controller 1 11 2 Switches 1 11 3 Placards and Decals 12 4 Control Tags 12 5 Hoses and Cables 48 6 Wear Pads 7 Handrails and Chains CHASSIS 1 Engine Oil 2 Battery 3
34. 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 5 Use bolts of proper length A bolt which is too long will bottom before the head is tight against its related part If 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 6 Unless specific torque requirements are given within the text standard torque values should be used on heat treated bolts studs and steel nuts in accor dance with recommended shop practices Hydraulic Lines and Electrical Wiring Clearly mark or tag hydraulic lines and electrical wiring as well as their receptacles when disconnecting or removing them from the unit This will assure that they are correctly reinstalled Hydraulic System 1 Disassemble and reassemble parts on clean work surface Clean all metal parts with non flammable cleaning solvent Lubricate components as required to aid assembly 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
35. to see if brake has reset itself If brake has reset roll checker should not be able to turn h Remove roll checker from spindle brake i Remove hyaraulic line from its brake port j Remove bleeder valve from its brake port Leak test unit at a pressure of 5 psi 0 4 bar for 2 to 3 minutes Remove the twelve grade 8 bolts and four shoulder bolts from cover Remove flat washers from cover Remove cover from hub If necessary disassemble cover as follows a Remove pipe plug from cover if it has not already been removed b Set cover down so that its open end faces up Remove o ring from counterbore in cover Dis card o ring c Turn cover over Remove two bolts that hold dis 21 connect cap in place d Remove disconnect cap from cover e Remove two remaining bolts that hold cover cap 22 in place f Remove cover cap from cover 23 g Remove disconnect rod from cover cap 24 h Remove o ring from groove inside cover cap 25 Discard o ring i Remove o ring from outside of cover cap 26 Remove thrust washer from carrier assembly 37 Remove thrust spacer from input shaft assembly 28 Remove ring gear from mesh with carrier assembly JLG Sizzor 11 12 13 14 15 16 17 18 19 20 Remove carrier assembly from hub If necessary disassemble carrier assembly as fol lows a Locate roll pin in carrier housing Drive roll pin down into planet shaft until it bottoms against carrier hou
36. top of needle rollers d Line remaining half of cluster gear with 16 nee dle rollers e Insert a planet shaft into one of the planet shaft holes in the carrier housing which has a roll pin hole End of planet shaft that does not have a roll pin hole should be inserted into carrier hous ing first f Place one thrust washer onto end of planet shaft which has been inserted through planet shaft hole Notice that thrust washer has a tang on it Tang should point straight so as to fit in slot on inside edge of planet shaft hole g Following thrust washer place cluster gear with needle rollers onto planet shaft Large end of cluster gear should go onto shaft first h Following cluster gear place one more thrust washer onto planet shaft Align thrust washer in same manner as described in step f 3121103 SECTION 2 PROCEDURES 13 14 15 16 17 18 19 3121103 i Insert planet shaft through opposite planet shaft hole in carrier housing Use an alignment punch or similar tool to align roll pin holes in carrier housing and planet shaft j Drive roll pin down into aligned roll pin holes Repeat steps a through j to install two remain ing cluster gears Set carrier assembly on work surface so that large end of cluster gears face up Locate punch marks on face of each cluster gear and position them at 12 o clock With squared shoulder side down place ring gear
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38. 1103 TABLE CONTENTS TABLE NO 3121103 LIST TABLES TITLE PAGE NO Hydraulic 6 tte ep pat man Bike Y dera 1 2 Lubrication 4 1 3 Cylinder Specifications 1 3 Lubrication Charts iiu Ma Oe UO aou e de exeo et bp 1 5 Major Component 1 6 Critical Stability Weights 4 1 6 Cylinder Piston Nut Torque 2 7 Holding Valve Torque Specifications 2 7 Preventive Maintenance and Safety 2 34 Platform Assembly Troubleshooting L ernennen ner ern reren 3 2 Chassis Troubleshooting 2 3 4 Chassis Troubleshooting 2252 2 2 4 nace theo ne 3 7 Hydraulic System 0 4 3 8 Electrical System 0 3 9 JLG Sizzor TABLE OF CONTENTS This page left blank intentionally JLG Sizzor 3121103 SECTION 1 SPECIFICATIONS SECTION 1 SPECIFICAT
39. 13 14 LIFT ORIVE i E ser T 21 22 21 22 SW RF wire 1 NE wore wire mee ely aly t 87 Piga 16 2 1 w Wen wire e were LR wire 1672 came 2 aje MooB nja Adler wire i wire LE wire E fe Ru CAT RELY YELLOW WHITE 30 LI aa 1 5500018 H Sensor CONTRO HARNESS H NOTE LEVEL SENSOR HAS Fe H NOTE CONN SUPPLIED OUTPUT THEN LEVEL PISTON PUMP LL om NOTE PLUG 2 15 LOCATED ON THE ENGINE PLUG 2 i nl ORANGE 0 ARE To CONNECTED gt d mites BLAGK 3 H a ENG DISTRESS 22 fo oo Screw EA H m 2 H BAT reo 30 H I FUEL H SOLENOID L gue 42 CY i S BROWN 1 l gt gt ORN RED l PLUG 2 i SO gt wr vec on Press SENDER i bg l T BRN RED e 1 m 8 BATTERY DI CONNECT ti i em H wire I 5 l so H mr neo TAR bg ha 4 H GREEN E YELLOW 1 RED 10 i ur Er i CONTROL NOTE ALL UNSPECIFIED CONDUCTORS EQUIVALENT TO 1 5mm2 CONDUCTORS SPECIFIED 1 von TP 3 0m 4 5mm 6 1281974 L Figure 3 14 Electrical Schematic 500RTS Duetz Sheet 2 of 2 JLG Sizzor 3 25 SECTION 3 TROUBLESHOOTING REF 1600157 DRIVE 2 5 TERMINA
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42. 6 Remove complete piston block assembly from housing assembly 7 Remove piston assemblies spider and pivot from piston block assembly 8 The piston block assembly need not be disassem bled unless pins or spring are damaged A CAUTION THE FOLLOWING PROCEDURE SHOULD BE USED IF THE SPRING IS TO BE REMOVED FROM THE PISTON BLOCK THE SPRING IS HIGHLY COMPRESSED AND THE SNAP RING SHOULD NOT BE REMOVED WITHOUT COMPRESSING THE SPRING JLG Sizzor 3121103 SECTION 2 PROCEDURES 3121103 Inspection Wash all parts thoroughly in a suitable solvent Examine needle bearings in housing and backplate If needles are free of excessive play and remain in bearing cage there is no need to replace bearing Inspect thrust washers and thrust bearing All sur faces should be free of any signs of wear or fretting Inspect spider and pivot Conical surfaces should be free of wear and score marks Inspect pistons The O D surface should be smooth and free of scoring Shoes should be snug fit to pis ton Face of shoes should be flat and free of scoring and flaking Do not lap piston shoes Inspect piston block bores should be free of scor ing Surface that contacts backplate should be smooth and free of grooves or metal build up Do not lap piston block JLG Sizzor Inspect thrust race surface should show no signs of scoring or grooves Inspect flat surface on backplate it should be free of excessive scor
43. Air Cleaner 4 Exhaust System c 5 Engine Mounts 6 Hydraulic Pump 7 Valves 8 Hydraulic Filter See Lubrication Chart 5 14 9 Hydraulic Hoses and Tubing 10 Hydraulic Oil Tank 4 1 Hydraulic Tank Breather 6 14 12 Fuel Tank 3 5 13 Lift Cylinder 1 12 5 6 13 14 Limit Switch 17 15 Tilt Alarm Switch 4 6 Placards and Decals 4 7 Wheel and Tire Assemblies 8 9 4 8 Drive Motors 1 5 6 4 9 Drive Brakes 1 6 20 Drive Torque Hubs 1 3 5 6 21 Steer Cylinder 5 6 13 22 Steer Components 4 6 23 Wheel Bearings 2 Wheel Drive 24 Sizzor Arms 14 25 Safety Props 14 26 Sliding Wear Pads 27 Pivot Pins Bolts 14 7 8 28 Switches Ground Control 1 11 29 Control Tags 12 Inspection and Maintenance Code 10 to be performed annually 2 34 JLG Sizzor 3121103 SECTION 3 TROUBLESHOOTING 3121103 SECTION 3 TROUBLESHOOTING 3 1 GENERAL This section contains troubleshooting information to be used for locating and correcting most of the operating problems which may develop in the aerial platform If a problem should develop which is not presented in this section or which is not corrected by listed corrective actions technically qualified guidance should be obtained before proceeding with any m
44. 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 1 Refer to Section 1 for recommendations for viscosity ranges 2 JLG recommends Mobil 424 hydraulic oil which has an SAE viscosity of 10W 20 and a viscosity index of 152 3121103 SECTION 2 PROCEDURES 3121103 NOTE Start up of hydraulic system with oil temperatures below 15 F 26 C is not recommended If it is necessary to start the system in a sub zero environ ment it will be necessary to heat the oil with a low density 100 heater to a minimum temperature of 15 F 26 C 3 The only exception to the above is to drain and fill the system with Mobil DTE 11 oil or its equivalent This will allow start up at temperatures down to 20 F 29 C However use of this oil will give poor per formance at temperatures above 120 F 49 C Sys tems using DTE 11 oil should not b
45. FT FRONT GO cnv nto Dr nemen 5 EXTEND NE WHITE WHITE 29 crv vio QUTRGOR 37 BRN BLK i DP BRAKE 5 em ra BRAKE 2 SPEED CUT OUT Sw 37 a urn 5 BLACK 17 aureo SYLT V arme RELAY 30 WHITE OPTION 41 WHITE b OUTREER STONED 21 22 QUTROOR QE Back 1 SW NE STOWED 6 16 2 SSFT m RENE AZ BLACK RAN sa 6 E OL 16 2 95F 400 DOM RTS ci obs OPTION OUTRGGR sTOWED 32 2 ajz 16 2 7 116 2 CABLE di p CM N 6 pa m E leva tante Ge u 0 40 Ges t 6 QUTRGGR BLACK 1 16 2 12FT to NN 43 lt w 19 WHITE OM LIFT ORIVE OUTRGGR TAN M OUTRGOR SET T 4 were GROUND BLACK 5 42 av 22 16 2 CABLE 3 21 22 RF Mi TE CONTROL i 400 DOM RTS Ml ii L 0 m ra 3 CUT OUT BOX WHITE OPTION 825 845 z wie Be 400 DOM RTS E ri i 118672 ome Hi OPTION ios WHITE 116 2 CABLE 2 acia ON 87 2 i WHITE E 87 TILT OUTRGGR SET 1174 5140 QUTROOR 18pucneo A RELAY ND SW RR ELLOW 35 WHITE a loss __400 DOM RTS OPTION a 65 E I 7777 BENSOR 1 5 500RTS 8 I ENGINE 3 7A00RTS GREEN ENGINE ORTS EURO n tL SENSOR HAS BLACK I 12 02 OUTPUT VARI DISP WHEN LEVEL BROWN 1 ae PISTON PUMP NOTE CONN SUPPLIED 8 1 A 9 ORANGE I C gt BROW 50 Brack BLACK 12 2 t BROWN 1 NOTE
46. GH ENGINE LIMIT SWITCH LOW ENGINE SLIDE PIN 2 Figure 2 6 Throttle Adjustments Deutz F3L1011 2 14 JLG Sizzor 3121103 SECTION 2 PROCEDURES The inlet line leading from the reservoir to the pump must be filled prior to start up Check the inlet line for property tightened fittings and make sure it is free of restrictions and air leaks NOTE In most cases the reservoir is above the pump inlet so that the pressure head created by the higher oil level helps to keep the inlet pressures within an acceptable range and prevent high vacuum levels However due to hose routing or low reservoir loca tions there may be air trapped within this line It is important to assure that the air is bled from this line This can be accomplished by loosening the hose at the fitting closest the pump When oil begins to flow the line is full the air has been purged and the fitting can be retightened to its specified torque If the tank needs to be pressurized in order to start the flow of oil a vacuum reading should be taken at the inlet of the pump during operation in order to verify that the pump is not being asked to draw an inlet vacuum higher than it is capable of Be certain to fill the pump and or motor housing with clean hydraulic fluid prior to start up Fill the housing by pouring filtered oil into the upper case drain port NOTE It is highly recommended to use the highest possible case drain port this ensures that
47. IONS 1 1 CAPACITIES Hydraulic Oil Tank Approximately 36 5 U S gallons 138 17 liters w 1096 air space Hydraulic System Including Tank Approximately 44 U S gallons 166 56 liters Fuel Tank Approximately 15 U S gallons 56 8 liters Engine Crankcase Gasoline Engine 3 4 quarts 3 2 liters w filter 2 9 quarts 2 7 liters w o filter Diesel Engine 6 34 quarts 6 0 liters w filter 5 8 quarts 5 5 liters w o filter Coolant Capacity Gasoline Engine 3 5 U S gallons 13 2 liters 1 2 COMPONENT DATA Gasoline Engine Displacement 4 5 liter Manufacturer Model Ford LRG 425 Oil Capacity 4 5 quarts 4 3 liters w filter 4 0 quarts 3 8 liters w o filter Low RPM 750 Mid RPM 2200 High RPM 3000 Alternator 55 Amp external Battery 85 Amphour 550 Cold Cranking Amps Fuel Consumption Low RPM 1 8 gph 6 7 Iph High RPM 3 0 gph 11 4 Iph Horsepower 70 2800 RPM Coolant Capacity 3 5 U S gallons 13 2 liters Diesel Engine Manufacturer Model Deutz F3L 101 1 Oil Capacity 6 34 quarts 6 0 liters w filter 5 8 quarts 5 5 liters w o filter Mid RPM 2000 High RPM 3000 Alternator 60 Amphour Battery 60 Amphour 1000 Cold Cranking Amps Fuel Consumption Low RPM 1 9 gph 7 19 Iph High RPM 2 5 gph 9 46 Iph Horsepower 42 3000 RPM Drive Steer System Tires Standard 12 x 16 5 NHS 8 ply pneumatic inflate to 45 PSI 3 1 bar Optional 31 15 5 x 15 NHS
48. IRES l 33 da 8 8 1 5 16 24 ll 1 885 33 8 B8 er 2 2 INDICATES 8 8 E 16 20 P 2 CABLES T 9 Q 9 Q E 8 9 9 939 R y 3 AT RECEPTACLE PINS RE 2 5 2 2 if 8558 a a 8 5 lt 7m amp EE OB RE IE ME 5 3 5 3 55 85885 555 8 8 EN 88 8 8 8 8 x FEE 222 8 8 e II i oe BH kg 3 g 620301 DA e8 5 8 G 2 05 GRD CONT BOX GROUND CONTROL TERM STRIP 8 5 HE er ae ge E SE ES 5 3 X RE gt 3 5 3 E Jai ie 24252 5 b 5 Bm B VOLTMETER x l 2 s x 5 E x 3 gt 15A VW GRD 1 T Sr lt 1 30A m MAIN RED 1 HI ENG saat 86 PM t a SI 4 8 8 i es 2 u DRIVE START al kerato vol CUT OUT 5 RELAY wa sro eno si TRAVERS ING DECK H lt SELECT AUX PWR 4 YELLOW BRNVBLK RED YELLOW T NO RELAY E 8 8 7430 Figure 3 9 Electrical Schematic 500 RTS Ford 156 Sheet 1 of 2 3 20 JLG Sizzor 3121103 SECTION 3 TROUBLESHOOTING
49. ITE l OPTION PLAT EXTENSION WHITE 16 2 95 SELECT BLACK abs us 1 BLA Wire OUTRESR STOWED SWAR O OUTRGGR STOWED i 116 2 55 13 4 16 2 CABLE 3 WHITE L BLACK BLACK L 1 1 I di 1 16 2 95 OUTRGGR 5 5 9 5418 Oc CABLE 4 16 2 CABLE 1 SW LR 4 16 2 CABLE 5 Loss Tm 116 2 CABLE 2 rt BLACK sls BLA K l l STOWED BLACK 16 2 12FT PIS re aly uper H 2 OUTRGGR SET QUTRGGR GROUND BACK us ir 4421672 CABLE Se WHITE CONTROL A 87 7A KIET DRIVE BOX I s 38 CUT OUT RELAY I WHITE z B wire 6 T 30 11672 CABLE 1 16 2 WHITE CABLE 4 116 2 CABLE 2 a 22 16 2 CABLE 5 als WHITE WHITE WHITE gt 87 m OUTRGOR SET ILL wOUTRGOR SET 8 aeRELAY I WHITE 163 LEVEL me aso GREEN ENGINE 7 H YEL LOW i MARINES NOTE LEVEL SENSOR HAS BLACK 12706 OUTPUT ALTERNATOR Ns CERA l 1 n FUEL 11 8 2 BLACK 12 STARTER ii NOTE CONN SUPPLIED Y MOTOR NOTE ALL GRD SYMBOLS WPP ARE TO BE CONNECTED T TO GND SCREW T L mu 10 T GRND BLACK 12 l H 9 2 CABLE l YELLOW 12 BROWN 1 t BATT lt T 660 40 AUX POWER H IGN K RED GRN RELAY Acc LX 12 0 BATTERY sr AUXILIARY
50. Inner Spring Outer Spring Housing Return Plate Pin 1 2 3 4 5 6 7 8 9 2 30 Separator Case Seal Washer Head Cap Screw Cover Bleeder Screw Retainer Ring Guide Spring Dowel Pin Back Up Ring Figure 2 13 Drive Brake 2WD 4WD Rear JLG Sizzor O Ring Back Up Ring O Ring Disc Rotor Friction Disc Stator Piston Pipe Plug O Ring Gasket 3121103 SECTION 2 PROCEDURES 2 24 SPARK ARRESTOR MUFFLER The multiple discs on these mufflers will require frequent cleaning if used with oily or sooty exhaust such as a die sel engine or on malfunctioning engines as evidenced by visible exhaust 2 25 DUAL FUEL LPG SYSTEM IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THE OTHER WITHOUT ALLOWING THE ENGINE TO STOP EXTREME CARE MUST BE TAKEN AND THE FOLLOWING INSTRUCTIONS MUST BE FOLLOWED Changing From Gasoline to LP Gas 1 Start engine from ground control station 2 Open hand valve on LP gas supply tank by turning valve counterclockwise A CAUTION BE SURE ALL GASOLINE IS EXHAUSTED BEFORE SWITCHING TO LP GAS 3 While engine is operating place the three position LPG GASOLINE switch at ground control station to center OFF position Allow engine to operate with out load until engine begins to stumble from lack of gasoline 4 As engine begins to stumble place switch to LPG position allowing LP fuel to be sent to the f
51. L 28 r STRIP TERMINAL 2 S 10 NO DESCRIPTION 8 50 PLAT GRO SE vens 1 IGNITION PLAT mo LOO saves PGP oin Eos RECEPTACLE PINS 2 SPD cur our P 4 START ORANGE 5 12 VDC PLAT 5 LIFT DIN DRIVE CONNECT TO TERMINAL 87 E z LIFT UP Week SUTRIGGERSCARE INSTALLED 3 9 DRIVE REV 5 hi sue TO mur LG 5 YELLOW 1 11 STEER LEFT f once O sue an 87 DRIVE 14 GN LIFT 9 60 E 9 INTERLOCK py ORN Bureo B e wnto 17 19 io 50 3 17 COMM AUX TO 18 1 8078 TILT i lt lt 9 19 DRIVE CUT OUT 20 REAR STEER RED 8LK ec 1 21 REAR STEER T 22 LIFT DWN OVERID BLACK lt lt 50 23LiFT LIMIT SW Di pone 24 LIFT OVERLOAD Om PES Ye suus lt u u aa 26 pressure 27 WATER OUTRGGR SET lt 2 Qua 28 12 VDC PLAT LITE 29 LEFT FRONT EXT 6 2 ALARM Hg option 31 RGT FRONT EXT PN OPTION vee vsa 7 3 Rot FRONT fe Tier 33 ROT REAR EXT YEL RED 08 2 AUS 8 34 REAR RET T 35 LEFT REAR EXT 36 LEFT REAR RE oe sm su 2 Donau MES DIE lt G OUTREGR SW 25 par DI E 9 emen Ora se 39 RETA gt Brows L 41 PLAT EXT SELECT pes our ni o
52. Limit Switches ex 1 8 Cylinder Specifications 1 9 Serial Number 1 10 Major Component Weights 1 11 Critical Stability SECTION 2 PROCEDURES 2 1 Generali perc 2 2 Servicing and Maintenance Guidelines 2 8 Lubrication 2 4 Cylinders Theory of Operation 2 5 Valves Theory 2 6 Component Functional Description 2 7 Sliding Wear Pads i cues RES ERRARE PR RUE MEER 2 8 Pump Coupling Lubrication 2 9 Cylinder Checking 2 10 Cylinder Removal and Installation 2 11 Cylinder 2 12 SWitch 2 1 et ate RI ehe an Bt h sss deis 2 13 Pressure Setting Procedures 2 14 Drive Pump Start up Procedure 2 15 Throttle Checks and Adjustments Ford 2 16 Throttle Checks and Adjustments Deutz F3L1011 2 17 Hydraulic Component Start Up Procedures and Recommendations 2 18 Oscillating Axle Lockout Cylin
53. NTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES NOTE 10 11 12 13 2 6 With the barrel clamped securely apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel Using suitable protection clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible On the Steer Cylinder the rod and piston are all one unit Remove the set screw s if applicable and nut which attach the piston to the rod and remove the piston Discard nylon point set screws Remove the piston rings Remove and discard the piston o rings seal rings and backup rings Remove the set screw if applicable piston spacer and wear ring if applicable from the rod Remove the rod from the holding fixture Remove the cylinder head gland and retainer if applicable Discard the o rings back up rings rod seals and wiper seals Cleaning and Inspection 10 11 12 13 14 15 16 17 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 excessive dam age Dress threads as necessary Inspect inner surface of cylinder barrel tube for scor ing or other damage Check insi
54. OM WHITE 16 5 LEVEL d d oF kay E SENSOR 1 5 500RTS 3 400RTS EURO NOTE LEVEL SENSOR HAS us YARI DISP o LEVEL OT i PISTON PUMP BROWN 1 1 lt SE 8 NOTE CONN SUPPL IED n OX BLACK 12 TO GRD SCREW A 2 BLACK 12 m BLACK 2 BLACK 1 1 ENGINE Gr war TES que Eee mI E VRS lt GRAY 18 pine lt TEMBER mnm a x lt GRY RED 18 HT A GOVERNOR ECT2 lt GRN RED 18 s f ACTUATOR OCT2 lt YEL BLK 185 RED 3 4 cake Z Pressure TAN WHT 18 PHASE A SWITCH E wiT GRN TAN ORN 1 PHASE B F WHT GRN RED GRN 1 VEL 8 Ah p B ELECTRONIC SPARK CONTROL ORN BLK 1 4360405 8 pad a OVERSPEED att RED GRN RED GRN 18 DISTRIBUTORLESS RELAY START LOCKOUT BLACK 12 8 IGNITION COIL YELLOW ss WHT BLK 42 RED GRN 1 U WHT BLK 1 BRN BLK 71 YELLOW 12 7 RED 10 5 RECTIFER 3 B STATOR gt gt WATER TEMP PRESS SRESER SENDER l a FROM TERM 40 OF M T B ven sq LPP zi i 2 TIsl AUXILIARY 90 AMP gt POWER CARB ALTERNATOR 5 M MOTOR 7 CHOKE 500 1 REGULATOR vacui SENSING LP GAS SWITCHING H FILTR Loc CIRCUITS Li HReog2 00 VALVE i 1 GAS 1282366 Figure 3 8 Electrical
55. P SCREWS 2 Remove case seal from housing then remove bleeder screw from end cover 3 Remove piston from end cover 4 Remove o ring back up ring o ring and back up ring from piston 5 Remove separators from housing 6 Remove stack assembly consisting of stator friction discs return plate and rotor discs from housing 2 27 SECTION 2 PROCEDURES Figure 2 11 Torque Hub Cover Pipe Plug Alignment 7 Remove dowel pins springs and spring retainer from housing NOTE Not all models use the same number of springs or spring pattern Record this information for assembly purposes 8 Remove retaining ring from housing 9 Remove shaft by pressing or using a soft mallet on male end of shaft 10 Remove retaining ring and bearing from shaft 11 Press rotary oil seal from housing Assembly NOTE Lubricate all rubber components from repair kit with clean hydraulic fluid of the type used in the system 1 Clean all parts thoroughly before assembly 2 Press new rotary oil seal into housing Note direction of seal 3 Install new bearing and retaining ring on shaft 4 Insert shaft assembly and retaining ring in housing 2 28 JLG Sizzor 5 Insert dowel pins spring guide and springs in hous ing OPEN RED BLUE Figure 2 12 Spring Loading 3121103 SECTION 2 PROCEDURES NOTE NOTE 10 3121103 Be sure to use the same number of springs and same spring p
56. R l 457 24 IT om oven YeLLow oom near ou noon Sw 26 LIFT even 104 27 ENG DISTRESS 49 CONNECT YEL WIRE TO ita GE 2 Pressure TERM 2 ON 400 DOM RTS gt 29 WATER TEMP OPTION W O OPTIONS oryza lt P K A55 35 voc Pear fis 33 LEFT FRONT ext TIL IGHT YEL BLK 32 LEFT FRONT RET T A T 33 RGT FRONT EXT os FRONT ner RGT REAR OUTRGOR SW 35 ROT REAR EXT 36 ROT REAR RET N ivo Form p DE 54 55 nom 38 LEFT REAR RET tog orram lt Okoa 53 39 bows ORANGE ea 3 T RAT EXT 1 HORN PLAT RET EMER 37 Nox POWER YELLOW Se 8 42 Ext SELECT 2 M RGT FRONT OUTRGGR SW 43 areae pe lio y LIFT ra YeLLow T 51 GUTTAGOR ser 1 Ivory rel lt lt 2 RN crv oRnN lt P DY D EE ss ote START tee Pd n LFT FRONT OUTRGOR SW 120 0 i wo cRY RED lt P LDKORaNCE 450 Q 1 Lo cay vio O lt 29 Ge 3 E OPTION AUX 8 REAR STEER FRONT E Brom Brom lt lt 2 EXTNSN ene di vy 5 TA aa BLK BLU BLK BLU N BUBU 2 SA 85 MI f mene BLACK 50 9 9 NU 1 A s z 2 2 gg 387 a NOTE ALL CRD SYMBOLS Sg 2383383 282 vii 3 2 N fa ARE BE CONNECTED i 3 2 a tl 5 5 ES m z m TO CABLE W
57. RE NOTICE THE FOLLOWING PROCEDURE SHOULD ALWAYS BE PER FORMED WHEN STARTING A NEW PUMP OR WHEN RESTARTING AN INSTALLATION IN WHICH EITHER THE PUMP OR MOTOR HAVE BEEN REMOVED FROM THE SYSTEM A WARNING THE FOLLOWING PROCEDURE MAY REQUIRE THE MACHINE TO BE DISABLED WHEELS RAISED OFF THE GROUND DRIVE FUNCTION DISCONNECTED ETC WHILE PERFORMING THE PROCEDURE IN ORDER TO PREVENT INJURY TO TECHNICIAN AND OTHER PERSONNEL TAKE NECESSARY SAFETY PRECAU TIONS BEFORE MOVING THE MACHINE 1 Prior to installing pump and or motor inspect unit s for damage incurred during shipping and handling Make certain all system components reservoir hoses valves fittings heat exchanger etc are clean prior to filling with hydraulic fluid 2 Fill reservoir with recommended hydraulic fluid which should be passed through a 10 micron nomi nal no bypass filter prior to entering the reservoir The use of contaminated fluid will cause damage to components which may result in unexpected machine movement 3 The inlet line leading from the reservoir to the pump should be filled prior to start up Check inlet line for properly tightened fittings and make sure it is free of restrictions and air leaks 4 Be certain to fill pump and or motor housing with clean hydraulic fluid prior to start up Fill housing by pouring filtered oil into upper case drain port 5 Install a 0 to 50 psi 0 to 35 bar pressure gauge in the charge pressure gauge po
58. RMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA 1 Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting A WARNING DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES SURE 2 Operate the hydraulic power source and extend the cylinder Shut down and disconnect the power source Adequately support the cylinder rod if appli cable A WARNING CYLINDERS WITH DOUBLE HOLDING VALVES BEFORE REMOV ING HOLDING VALVES CRACK BLEEDER TO RELEASE PRES SURE 3 If applicable remove the cartridge type holding valve and fittings from the cylinder port block Dis card o rings JLG Sizzor 2 5 SECTION 2 PROCEDURES 4 NOTE 6 Place the cylinder barrel into a suitable holding fix ture Tap around outside of cylinder head retainer with a suitable hammer to shatter loctite Using a suitable spanner wrench loosen the der head retainer if applicable and or cylinder head gland and remove from cylinder barrel Steer Cylinder has two head retainers at each end of cylinder Platform Ext Cylinder has a snap ring in barrel end of cylinder Remove snap ring before withdraw of the rod Attach a suitable pulling device to the cylinder rod port block end or cylinder rod end as applicable A WARNING EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL INDER ROD HEAD AND PISTON AVOID PULLING THE ROD OFF CE
59. S Ford LRG Sheet 1 of 2 3 18 JLG Sizzor 3121103 SECTION 3 TROUBLESHOOTING 86 Pi BLK BLU DUMP RELAY DUMP PI lo 87 ire BLK BLU RED RED i RED 30 H BLACK ec oo STA RELAY I 1 LIFT UP YEL BLK 87 YELLOW mA vet ORANGE GRY RED 30 TRAVERSING 87A DECK RETRACT TRAVERS ING BLUE WHT BRN L DECK EXTEND i 4 WHITE LEFT REAR BLU BLK STEER RIGHT REAR WHT GRN t i DUM BRN BLK WHT ORN YEL BLK 30 STEER RELAY YELLON ORN BLK 82 KA 30 STEER RELAY RED BLK H RED BLK 83 onwnen 8i 4 LEFT STEER RIGHT ORN BLK ORN BLK YEL RED 84 m 87 nep RED BLK BLU RED 85 I 4 25 20 86 oRr RED l MH
60. Sun 7 8 hex M20 x 1 5 thds 30 35 ftlb 41 48Nm Sun 1 1 8 hex 1 14 UNS thds 45 50ftlb 61 68 Sun 1 1 4 hex M36 x 2 thds 150 153ftlb 204 207Nm Racine 1 1 8 hex 1 1 16 12 thds 50 55 ftlb 68 75Nm Racine 1 3 8 hex 1 3 16 12 thds 75 80 ftlb 102 109Nm Racine 1 7 8 hex 1 5 8 12 thds 100 110ftlb 136 149Nm T Carefully slide the piston spacer on the rod If appli cable align the oil holes in the rod and the spacer Secure the spacer if applicable If applicable correctly place a new o ring and back up rings in the inner piston diameter groove NOTE Carefully place the piston on the cylinder rod ensur ing that the o ring and back up rings are not dam aged or dislodged 8 9 10 11 JLG Sizzor Push the piston onto the rod until it abuts the spacer end apply locktite 242 and install the attaching nut Refer to Table 2 1 Cylinder Piston Nut Torque Specifications On the Steer Cylinder the rod and piston are all one unit Prior to setscrew installation spot drill rod before installing the setscrew s which secure the piston attaching nut to the diameter groove Remove the cylinder rod from the holding fixture Place new o rings and seals in the applicable out side diameter grooves of both the piston and the inder head Position the cylinder barrel in a suitable holding fix ture SECTION 2 PROCEDURES CARE SHOULD TAKEN
61. T 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 REVISION LOG Original Issue January 12 2000 Revised February 29 2000 Revised July 3 2003 Revised September 16 2004 Revised November 14 2007 JLG Sizzor 3121103 TABLE CONTENTS TABLE OF CONTENTS SUBJECT SECTION PARAGRAPH SECTION A INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS General sir eli OE nee ee AN A B Hydraulic System A C ue irr t o e era V E RACER SECTION 1 SPECIFICATIONS 1 1 Gapacities i Leite Leda NE rar 1 2 Component 1 3 Performance Data u RE 1 4 Lubrication u d apie ae tige st feed 1 5 Lubrication Specifications 1 6 Pressure Setlinigs ts u u E rn du etu 1 7
62. T VIO 20 isi Rena pian oa GRY BRN 1 f LI EXTEND 11 i WHT BRN RIGHT FRONT S981S EURO SOORTS RIGHT FRONT GRYZYEL EXTEND GRY ORN i ROT BLACK BLACK BLACK i RETRACT LEFT FRONT GRY RED f I EXTEND faite WE 7 emn Age DI BRAKE 13 14 SPEED CUT OUT SW BRN BLK T VALVE 9 E TERM 30 OF DUMP RELAY 987 eunte BLACK GA ave se y NN rear gt 30 WHITE PLAT EXT BLAT EXTENSION OPTION RELAY I 87 WE 16 2 95FT E BLACK OUTRGGR 5 19 55 OUTRGOR STOWED 9 430 R CORE SW LF ge 16 2 CABLE 3 gl SUR e WHITE 1 BLACK BLACK L ak 1 1 BLACK 1 I d d BLACK 16 2 95FT 16 2 WHITE I as PI OUTRGOR STOWED N o BLACK SW LR au 16 2 CABLE 45 Au 4 BLACK BLACK 4 16 2 CABLE 2 st A STOWED BLACK 16 2 12FT SW RR t WHITE LIFT ORIVE mm i 2 CUT OUT SW OUTRCOR_SET QuTRGGR GROUND succ BE tone a Ser 6 ware wire CONTROL WHITE 2 2 3 87 LIFT DRIVE BOX ale sh VELLOM 87 007 007 RELAY I WHITE E PI 6 I WALE Fr 16 2 CABLE 1 16 2 30 CABLE 16 2 CABLE 2 21 22 16 2 CABLE 5 ala WHITE T 1 WH TE 5 87 Fat 1 7 OUTRGOR SET BLK RED mE SW LR SW RR 6 G YELL
63. TEM MOTOR RESS OPTION ALT TACH YEL BLK 4 I m TACH YEL Ld Ii I BRN RED 1 31 1 HORN T Uv vl CONTROLLER 5 gt 7123141816 8 T B 30 VEL hd RED BLU YEL BLK 83 I 1 I pet 5 RER H N C Q d DIS COIL BLKA H SWITCH 15 PSI lt H 1 2 H l YELLOW 7 T ib VAGUIM vo BLUE LP GAS l 3 FILTR LOC DUEL 86 WHT ORN e j REDj2 o VALVE BEC lwo BLACK 2 PM i ao GAS SHUTOFF GAS VALVE Figure 3 12 JLG Sizzor 1281973 F Electrical Schematic 500 RTS Ford VSG Sheet 2 of 2 3 23 SECTION 3 TROUBLESHOOTING 6 meum S 6 mov 0 cem ax come _ 21 ZO asa 5 8 seww Ho 8 me 822 8 ie rm Wen Mm Gi 4 men 000 30A MAIN REF 1600157 DRIVE 5 Els E 8 TERMINAL Tr B23 8h 822598 558 so PLAT ORD T IGNITION PLAT 9 9 3 ies 3 23 5 12 voc PLAT s LIFT om 7 wum DRIVE REV fs
64. TOR 1 1 mE DRIVE MOTOR DRIVE PUMP VARIABLE OVER CENTER EN Y RETURN 1 H FILTER peor ud psy LEJ LI Figure 3 5 Hvdraulic Schematic Sheet 5 of 6 JLG Sizzor 3121103 SECTION 3 TROUBLESHOOTING LOCK OUT VALVE E i x ca DRIVE MOTOR OSCL RAA out CIRCUIT BRAKES 20 THE 96 POR ON VALVI MANIFOLD 400 500 RTS CHARGE PUMP FILTER x TO CP ON VALVE MANIFOLO 400 500RTS ONLY 2792371 Figure 3 6 Hydraulic Schematic Sheet 6 of 6 3121103 JLG Sizzor 3 17 SECTION 3 TROUBLESHOOTING 9 GG smua E owon 2 orror REF 1600157 GI wa 25 GI 3 mrzer m 9 mom 2 29 55 orv meo wre E 3355 304 3 zegege 8255 do TO TERM 30 OF PLAT EXT RELAY I 29 2 rem 39 orv 2 33ESi 35553 18 24 30 36 orvon 42 90 6066 4 2 5 35 emo BLUE lt Q lt BLUE STRIP TERMINAL orae 8 onance 9 51 PLAT GRD YELLOW am 50 PLAT GRD BLU RED 1 IGNITION PLAT
65. The unit has a leak if the pressure gauge reading on the air checker starts to fall once the unit has been pressurized Leaks will most likely occur at main seal or wherever o rings or gaskets are located The exact location of a leak can usually be detected by brushing a soap and water solution around the main seal and where o rings or gaskets meet the exterior of the unit then checking for air bubbles If a leak is detected in a seal o ring or gasket the part must be replaced Assembly BEWARE OF SHARP EDGES IN COUNTERBORE WHEN INSTALL ING O RING 1 Assemble hub spindle assembly as follows NOTE Make sure cup sits square with counterbore before pressing a Set hub onto its large end Press bearing cup into counterbore in small end of hub b Press nine studs into stud holes in hub c Apply a light coat of Never Seize to two pipe plugs and tighten them into two pipe plug holes in side of hub NOTE Make sure cup sits square with counterbore before pressing d Turn hub over onto its small end Press bearing cup down into counterbore in deep end of hub e Set hub onto its large end Place bearing cone into bearing cup f Press seal into small end of hub g Oil spindle then lower hub small end down onto spindle h Press bearing cone onto spindle in hub i Place spacer onto spindle in hub NOTE Make sure the retaining ring is securely seated in groove in spindle j Place retaining ring over spa
66. This will hold punch marks in position while installing carrier into hub Place carrier assembly and ring gear together into mesh with internal gear aligning X marked shoulder bolt in ring gear over one of the shoulder bolt holes in hub Mark location of shoulder bolt holes on out side of ring gear and hub Ring gear may be lifted off hub to align shoulder bolt holes Ring gear and carrier were installed together only to keep punch marks on carrier in place With internal splines facing up counterbore end fac ing down place input gear into mesh with carrier assembly Oil all exposed surfaces inside hub Place thrust washer into counterbore in top of carrier assembly 17 Assemble cover as follows a JLG Sizzor Using disconnect rod push o ring into groove inside cover cap Place o ring onto cover cap so it rests against flange of cover cap Insert disconnect rod into cover cap Set cover on table exterior side up Place cover cap onto cover aligning pipe plug hole in cover cap over pipe plug hole in cover Place two cover cap bolts into any two bolt holes 180 degrees apart on cover cap then tighten bolts Torque both bolts to 36 49 in Ibs 4 5 Nm With large end down place disconnect cap onto cover cap aligning pipe plug hole in disconnect cap over pipe plug hole in cover cap Place two remaining bolts into bolt holes in dis connect cap and tighten bolts Torque both bolts to 36 49 i
67. 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 12 With barrel clamped securely and while adequately supporting the rod insert the piston end into the barrel cylinder Ensure that the piston loading o ring and seal ring are not damaged or dislodged 18 Continue pushing the rod into the barrel until the cyl inder head gland can be inserted into the barrel cyl inder 14 If applicable secure the cylinder head retainer using a suitable spanner type wrench 15 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 16 If applicable install the cartridge type holding valve and fittings in the port block using new o rings as applicable Refer toTable 2 2 Holding Valve Torque Specifications 2 12 TILT ALARM SWITCH NOTE The machine may be equipped with a tilt alarm switch sensor which is factory set to activate at 2 that will sound an alarm and illuminate a warning light on the platform control console Consult factory for tilt sensor adjustment The only field adjustment necessary is leveling the switch on the spring loaded studs A CAUTION PERFORM TILT ALARM SWITCH LEVELING PROCEDURE A MINI MUM OF EVERY SIX MONTHS TO ENSURE PROPER OPERATION AND ADJUSTMENT OF SWITCH Manual Adjustment 1 Park the machine on
68. Y 4 dew OPTION 12voc 58 t US 1 MOTOR BATTERY HORN 87A SWITCH EURO BROWN M 430 87A vel 5 30 RNA o 87A 9 4 30 ORN GRN GREEN YELLOW 1 RED 10 GRAY voc BLACK Ne qe i BLACK 12 A 88 GROUND BLACK CONTROL NOTE ALL UNSPECIFIED CONDUCTORS 3121103 EQUIVALENT TO 1 5mm CONDUCTORS SPECIFIED 12 3 0mm 10 4 5mm2 9 6 0mm 1283064 Figure 3 16 Electrical Schematic 500RTS Duetz Sheet 1 of 2 JLG Sizzor 3 27 SECTION 3 TROUBLESHOOTING ES NOTES 3 28 JLG Sizzor 3121103 CALIFORNIAN PROPOSITION 65 BATTERY WARNING Battery posts terminals and related accessories contain lead and lead compounds chemical known to the State of Califormia to cause cancer and reproductive harm WASH HANDS AFTER HANDLING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm 1702961 Oshkosh Truck Corporation Company Corporate Office JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 JLG Worldwide Locations JLG Industries Australia P O Box 5119 11 Bolwarra Road Port Macquarie N S W 2444 Australia B 61265811111 EL 61 2 65 810122
69. achine will not travel forward High speed function does not operate Loose or damaged wiring between controller and high speed switch Ensure proper connection of wires Using suitable test meter perform continuity test on wiring between controller and switches Repair or replace wires as necessary Defective high speed control switch Replace switch Loose or damaged wire in control box wire har ness Ensure proper connection of wire atthe control switch Using suitable test meter perform continu ity teston wire repair or replace harness as neces sary 3 4 JLG Sizzor 3121103 SECTION 3 TROUBLESHOOTING Table 3 2 Chassis Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Loose or damaged wire between platform and Ensure proper connection of wire atthe platform high speed solenoid andatthehigh speed solenoid Using suitable test meter perform continuity test on wire repair or replace harness as necessary High speed solenoid not functioning properly Replace e solenoid Loose or damaged wires between high sped relay Ensure proper connection of wires between high and high speed limit switch speed relay and high speed limit switch Using suitable test meter perform continuity test on wire repair or replace harness as necessary High speed limit switch not functioning properly Repair or replace limit switch Loose or damaged wire in valve wiring
70. aintenance Troubleshooting and maintenance information pertaining to the prime mover engine motor that are not contained in this manual are contained in the applicable engine maintenance manual 3 2 TROUBLESHOOTING INFORMATION The troubleshooting procedures applicable to the aerial platform are listed and defined in Tables 3 1 through 3 4 As an aid to table use the platform sizzor is divided into 4 major groups each covered separately within this section These groups are as follows Platform chassis hydraulic system and electrical system Each malfunction within an individual group or system is followed by a listing of probable causes which will enable determination of the applicable remedial action The prob able causes and remedial action should where possible be checked in the order listed in the tables It should be noted that there is no substitute for a thor ough knowledge of the equipment and related systems It should be recognized that the majority of the problems arising in the machine will be centered in the hydraulic and electrical systems For this reason every effort has been made to ensure that all likely problems in these areas are given the fullest possible treatment In the remaining machine groups only those problems which have more than one probable cause and remedy are included This means that problems for which the proba ble cause and remedy may be immediately obvious are not listed in this section
71. attern as recorded during disassem bly Position new large diameter return plate in housing with tabs guided by dowel pins until disc rests on springs Rotor discs and stator friction discs should remain dry during installation No oil residue should be allowed to contaminate disc surfaces Place a new friction disc on shaft until it contacts return plate Add additional new stator discs and new rotor discs as required to complete assembly Insert separators in holes of return plate Install new o ring new back up ring new o ring and new back up ring on piston Note order of o rings and back up rings Insert piston into end cover being careful not to shear o rings or back up rings 12 13 NOTE 14 JLG Sizzor Install case seal in housing then install bleeder Screw in end cover Position end cover on housing aligning dowel pins with holes in end cover Install washer head cap screws and tighten evenly to draw end cover to housing Torque washer head cap screws to 55 ft Ibs 75 Nm If available a hydraulic press will simplify installation of end cover on housing Clamp cover in position while tightening washer head cap screws If hydrostatic bench testing is done on brake assem bly release pressure should not exceed 2000 psi 138 bar unless two additional bolts are used for supplemental clamping 2 29 SECTION 2 PROCEDURES Seal Bearing Retaining Ring Shaft
72. bolts j Grease o ring JLG Sizzor k Place o ring into counterbore around edge of cover A CAUTION BEWARE OF BURRS AND SHARP EDGES AROUND COUNTER BORE WHEN INSTALLING O RING NOTE O rings may be stretched to fit counterbore If an o ring has been stretched too much simply squeeze o ring together bit by bit while placing it around coun terbore It can be made to fit exactly I Apply a light coat of never seize to pipe plug m Tighten pipe plug into pipe plug hole in cover 20 Place cover assembly onto ring gear Align pipe plug holes in cover and hub as shown in Figure 2 10 Make sure shoulder bolt holes in cover and ring gear are aligned 21 Place sixteen flatwashers on top of bolt holes in cover assembly 22 Place shoulder bolts into four shoulder bolt holes in cover and tighten by hand 23 Place grade 8 bolts into twelve bolt holes in cover and tighten 24 Apply 18 25 ft lbs 25 35 Nm of torque to all bolts 25 Leak test unit at a pressure of 5 psi 0 4 bar for 2 3 minutes 2 23 DRIVE BRAKE 2WD 4WD REAR Disassembly 1 Remove end cover from housing by removing washer head cap screws A CAUTION END COVER IS UNDER SPRING TENSION OF APPROXIMATELY 2000 LBS 907 KG THE FOUR WASHER HEAD CAP SCREWS SHOULD BE LOOSENED EVENLY TO RELIEVE THIS FORCE IF A HYDRAULIC PRESS IS AVAILABLE 3000 LBS MIN 1361 KG MINIMUM COVER CAN BE HELD IN POSITION WHILE REMOVING WASHER HEAD CA
73. cer onto spindle in hub 2 Grease o ring and place it into counterbore in hub JLG Sizzor 2 21 SECTION 2 PROCEDURES NOTE O ring may be stretched or pinched together to make it fit counterbore exactly Oil all exposed surfaces inside hub Place internal gear into hub so that its internal splines mesh with external splines of spindle Oil internal gear Place thrust washer around spindle so that it rests on bottom of internal gear Stand input shaft on its splined end Place one spacer onto smooth end of input shaft Place one spring onto smooth end of input shaft Place other spacer onto smooth end of input shaft A CAUTION SAFETY GLASSES MUST BE WORN DURING THE FOLLOWING STEP BE AWARE THAT SPRING AND SPACERS COMPRESSED BY RETAINING RING MAY POP SUDDENLY OFF SHAFT IF RING IS RELEASED BEFORE IT IS PROPERLY IN PLACE 9 10 11 12 13 14 NOTE 15 16 2 22 Using retaining ring pliers insert retaining ring into groove on input shaft by compressing spring and spacers together With large splined end down place input shaft assembly into spindle Place thrust spacer onto input shaft Set carrier assembly on work surface so that large ends of cluster gears face up Locate punch marks on face of each cluster gear and position them at 12 o clock Refer to Figure 2 9 Torque Hub Carrier Timing With X marked side facing up place ring gear around cluster gears NOTE
74. ch Unplug ground control box harness from platform receptacle check wire from applicable pin in plug to control box power switch for proper connection Using suitable test meter perform continuity test onwire Repair or replace harness as necessary 3121103 JLG Sizzor 3 9 SECTION 3 TROUBLESHOOTING Table 3 5 Electrical System Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Defective Platform Ground select switch Replace Platform Ground select switch No voltage e present at function control switch Checkwiring from power switch to function control switch for proper connection or damage Repair or replace wiring as necessary Defective function control switch Replace function control switch No voltage present at applicable control valve coil Check applicable wire for proper connection at terminal strip valve harness plug pin valve har ness receptacle pin and valve coil Using suitable test meter perform continuity test on wire Repair or replace harness as necessary No voltage supplied to motor from start relay Check battery cable from relay to motor for proper connection or damage Repair or replace cable as necessary Defective motor pump assembly Replace motor pump assembly ENGINE STARTER SYSTEM Engine will not crank Discharged battery or loose battery terminals Check and charge battery or replace battery as necessary Clean and secur
75. d disconnect then cap the lift cylinder hydraulic lines and ports 5 Remove the bolts lockwashers and flatwashers securing the barrel end attach pin to the lower arm assembly Using a suitable brass drift drive out the barrel end attach pin from the arm assembly 6 Carefully remove the cylinder from the Sizzor lift and place in a suitable work area 3121103 Lift Cylinder Installation 1 Install lift cylinder in place using suitable slings or supports aligning barrel end attach pin mounting holes on lower arm assembly 2 Using a suitable drift drive the barrel end attach pin through the mounting holes in the lift cylinder and the lower arm assembly Secure in place with the bolts flatwashers and lockwashers 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 aligns with those in the upper arm assembly Using a suitable drift drive the cylinder rod attach pin through the aligned holes Secure the pin in place with the bolts lockwashers and flatwashers 5 Lower platform to stowed position and shut down motor engine Check hydraulic fluid level and adjust accordingly 2 11 CYLINDER REPAIR NOTE The following are general procedures that apply to all of the cylinders on this machine Procedures that apply to a specific cylinder will be so noted Disassembly NOTICE DISASSEMBLY OF THE CYLINDER SHOULD BE PERFO
76. de 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 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 seal and o ring grooves in head for burrs and sharp edges Dress applicable surfaces as nec essary If applicable inspect cylinder head retainer or end cap for surface or thread damage Repair or replace as necessary Inspect cylinder head outside diameter for scoring or other damage and ovality and tapering Replace as necessary If applicable inspect thread ring for scoring or other damage Dress threads or applicable surfaces as necessary If applicable inspect rod and barrel bushings for signs of correct lubrication and excessive wear Replace as necessary Inspect travel limiting collar or spacer for burrs and sharp edges If necessary dress inside diameter surface with Scotch Brite or equivalent If applicable inspect port block fittings and holding valve Replace as necessary Inspect the oil ports for blockage or the presence of dirt or other foreign material Repair as necessary If applicable inspect piston rings for c
77. der Bleeding Procedure If Equipped 2 19 Lockout Cylinder 2 20 Piston Drive Motor 2WD amp 4WD 2 21 Drive Torque Hub 2WD AWD 2 22 Drive Torque Hub Brake AWD 2 23 Drive Brake 2WD AWD 2 24 Spark Arrestor 2 25 Dual Fuel LPG System 2 26 Freewheeling 2 27 Limit Switch Adjustment Procedure 2 28 Preventive Maintenance and Inspection Schedule SECTION 3 TROUBLESHOOTING 3 1 General iss eee eh ah 3 2 Troubleshooting 3 3 Hydraulic Circuit 3121103 JLG Sizzor PAGE NO TABLE CONTENTS LIST OF FIGURES FIGURE NO TITLE PAGE NO 1 1 Lubrication SEP quu ER VERI EP EAS 1 4 1 2 Serial Number 3 0 1 6 1 3 Torque ooo a C e heb ELENA 1 7 2 1 Poly Pak Seal Installation 2 7 2 2 Pressure Adjustment Locations Prior t
78. der not functioning properly Repair or replace cylinder Tire pressure low Correct tire pressure Bent or seized spindle Replace spindle Steering inoperative Damaged wiring on controller or solenoid valve See proper wiring diagram Solenoid valve not functioning properly Repair or replace valve Controller not functioning properly Replace controller Relief valve improperly set or not functioning prop erly Reset repair or replace valves as required Steer cylinder not functioning properly Repair or replace steer cylinder 3121103 JLG Sizzor SECTION 3 TROUBLESHOOTING Table 3 2 Chassis Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Machine will not steer left or right Enable switch not activated Activate enable switch Function not activated within the 3 seconds after Reactivate enable switch enable switch was depressed Enable switch not functioning properly Replace enable switch circuit card Wiring on controller is damaged Repair or replace wiring Wiring on solenoid valve is damaged Repairor replace wiring Coil in solenoid is damaged Replace coil Bentoylinder rod Repair or replace cylinder Damaged steer linkage Repair or replace steer linkage Crossover relief valve stuck Repair or replace crossover relief valve Pressure setting incorrect Reset pressure setting Machine wanders steering not firm
79. droop CCW as far as it will go Then turn screw slot CW until vertical Droop should not need further adjustment Turn idle adjusting screw on carburetor CCW all the way out CCW until there is a gap between the screw and stop plate Start engine and allow it to come up to operating temperature Remove wire from no 7 connector on controller which will switch engine speed to HIGH Adjust speed screw until engine runs at 3000 rpm If engine surges turn gain screw one or two degrees CCW until surging stops no more Replace wire no 7 connector on controller which will return engine to LOW speed Adjust remote until engine runs at 2200 rpm Recheck speeds When satisfied apply a drop of fin gernail polish to all trimpot screws Replace cover 2 16 THROTTLE CHECKS AND ADJUSTMENTS NOTE 2 12 DEUTZ F3L1011 Never run fuel tank dry Diesel engines cannot be restarted after running out of fuel until fuel system has been air vented or bled of air See Deutz Oper ators Manual for procedure Disconnect actuator cable from the throttle lever With the aid of an assistant start the engine and allow it to come up to operating temperature Adjust throttle lever stop until engine runs at 2000 rpm Shut down engine Reattach actuator cable to throt tle lever making sure that low engine setting remains the same Restart engine and check set tings If necessary adjust slide pin to contact low engine limit switch at 2000 r
80. e NOTE Making sure that machine is on a level surface and rear wheels are blocked then disengage drive hubs Optional 4WD all drive hubs must be unlocked 1 Making sure that machine is on a level surface and rear wheels are blocked then disengage drive hubs Optional 4WD all drive hubs must be disengaged 2 Activate machine hydraulic system from platform control station 3121103 JLG Sizzor 2 15 SECTION 2 PROCEDURES NOTE Start the engine and place engine speed and drive speed control switches to their respective low posi tions Depress the enable switch and activate drive con troller to forward position Using a suitable lifting equipment lift front of machine up and place an 8 in 20 cm high block under left front wheel With the drive controller activated and engine at idle crack open both fittings at lockout cylinder one at a time and close when all air is dissipated bled Using a suitable lifting equipment lift front of machine and remove the 8 in 20 cm block Transfer the 8 in 20 cm high block to right front wheel and repeat steps 1 through 6 substituting the word right for left in step 5 After lockout cylinders are bled be sure to engage drive hubs before removing stop block from rear wheels To check lockout cylinder after bleeding perform the LOCKOUT CYLINDER CHECK in paragraph 2 19 2 19 LOCKOUT CYLINDER CHECK NOTE 2 16 Ensure platform is completely lowered prio
81. e battery terminals Starter relay faulty or faulty relay connections Using a test meter check relay coil terminals for presence of electrical power and for energization of relay coil Also check relay terminals for correct switching of contacts Replace relay as necessary Malfunctioning starter solenoid or motor Replace solenoid or motor in accordance with applicable manufacturer s manual Defective start lockout solenoid Replace start lockout solenoid Malfunctioning ignition switch Using a test meter check ignition switch for cor rect switching of contacts replace switch as nec essary Faulty ignition and or starter circuit wiring Check wiring continuity refer to wiring diagram Defective ring gear or flywheel Replace ring gear INSTRUMENTS AND INDICATORS Ammeter inoperative Damaged wiring in circuits Repair or replace wiring Ammeter not functioning properly Replace ammeter Alternator not charging Repair or replace alternator Travel warning horn inoperative Circuit breaker open Determine and correct cause Damaged wiring in horn circuit Replace horn Damaged wiring in hourmeter circuit Repair or replace wiring Inoperative hourmeter Replace hourmeter 3 10 JLG Sizzor 3121103 SECTION 3 TROUBLESHOOTING 2 NOTES
82. e operated at temperatures above 200 F 94 C under any con dition Changing Hydraulic Oil 4 Use of any of the recommended crankcase or hydraulic oils eliminates the need for changing the oil on a regular basis However filter elements must be changed after the first 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 specifications appearing in this man ual If unable to obtain the same type of oil supplied with the machine consult local supplier for assis tance in selecting the proper equivalent Avoid mix ing petroleum and synthetic base oils JLG Industries recommends changing the hydraulic oil annually 5 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 6 While the unit is shut down a good preventive main tenance measure is to make a thorough inspection of all hydraulic components lines fittings etc as well as a functional check of each system before placing the machine back in service Lubrication Specifications Specified lubricants as recommended by the component manufacturers are always the best choice however multi purpose greases usually have the qualities which meet
83. ed end down place input shaft gears seem to roll hard as long as they roll with consis assembly into spindle brake tency 10 Place thrust spacer onto input shaft Leak Test 11 With internal splines facing up place input gear into mesh with input shaft assembly The purpose of the leak test is to make sure the unit is air l tight The unit has a leak if the pressure gauge reading on 12 Assemble carrier as follows the air checker starts to fall once the unit has been pres surized Leaks will most likelv occur at main seal or wher ever o rings or gaskets are located The exact location of a leak can usually be detected by brushing a soap and water solution around the main seal and where o rings or gaskets meet the exterior of the unit then checking for air bubbles If a leak is detected in a seal o ring or gasket the part must be replaced Assembly 1 Grease o ring 2 Place o ring into counterbore in hub A CAUTION BEWARE OF SHARP EDGES AND BURRS IN COUNTERBORE WHEN INSTALLING O RING NOTE O rings may be stretched to fit counterbore If an o ring has been stretched too much simply squeeze o ring together bit by bit while placing it around coun terbore It can be made to fit exactly 3 Oil exposed surfaces inside hub 2 26 JLG Sizzor a Apply grease to inside of one cluster gear b Line one half of cluster gear with 16 needle roll ers c Place one thrust spacer inside cluster gear so it rests on
84. equivalent centimeters cm in parentheses Table 1 3 Cylinder Specifications Description Bore Stroke RodDia Lift Cylinder 5 0 78 5 3 5 400RTS 500RTS 12 7 199 8 9 Steer Cylinder 3 0 7 5 15 7 6 19 05 3 8 Lockout Cylinder 3 0 3 75 1 25 Oscillating Axle 7 6 9 5 3 2 Leveling Jack 3 0 18 75 2 0 Cylinder 7 6 47 6 5 0 Traversing Platform Cylinder 1 5 3 8 48 1 00 121 2 5 500 5 Tilt Alarm A horn is sounded and a warning light is illuminated when the machine is operated on a slope that exceeds 2 with the platform raised If the machine is operated on a 2 slope with the platform completely lowered only the warn ing light is illuminated JLG Sizzor 1 3 SECTION 1 SPECIFICATIONS JLG Sizzor Figure 1 1 Lubrication Diagram 3121103 SECTION 1 SPECIFICATIONS Table 1 4 Lubrication Chart INDEX INTERVAL NO COMPONENT NUMBER TYPE LUBE POINTS LUBE METHOD HOURS 1 Oscillating Axle Pivot Point Optional 1 Grease Fitting MPG Pressure Gun 100 2 Lockout Cylinders Optional 2 Grease Fittings 1 each cylinder MPG Pressure Gun 100 3 Front Steering Spindles 2 W D 2 Grease Fittings MPG Pressure Gun 100 4 Front Steering Spindles 4 W D 2 Grease Fittings MPG Pressure Gun 100 Optional 5 Tow Bar Hitch Optional 1 Grease Fitting MPG Pressure Gun 100 6 Wheel Bearing
85. er not properly adjusted Correctly adjust controller Hydraulic pump not functioning properly Repair or replace pump Restricted or broken pump supply line Clean repair or replace line Restricted or broken line on valve bank Clean repair or replace line Drive motor s not functioning properly Repairor replace motor s Damaged wiring on controller Repair or replace wiring Controller not functioning properly Repair or replace controller Drive brake not releasing Determine cause and repair or replace brake Machine drives erratically Microswitch on controller improperly adjusted Adjust microswitch on controller for proper opera tion Machine will nottravel forward Enable switch not activated Activate enable switch Function not activated within the 3 seconds after enable switch was depressed Reactivate enable switch Enable switch not functioning properly Replace enable switch circuit card Hydraulic system oil low Replenish oil as necessary Restricted or broken hydraulic line or fitting Clean repair or replace line or fitting Controller not adjusted properly Correctly adjust controller Control valve not functioning properly Repair or replace valve Drive motor s not functioning properly Repair or replace motor s Defective controller Repair or replace controller Machine will nottravel in reverse See M
86. f spindle brake Using a soft punch and hammer remove bearing cup from deep end of hub 3121103 SECTION 2 PROCEDURES 1 Hub Spindle Brake Assy 101 Brake Assembly 501 Spindle 502 Spacer 503 Stationary Disc 504 Rotating Disc 505 Back Up Ring 506 O Ring 507 Back Up Ring 508 O Ring 509 Piston 510 Spring 511 O Ring 512 Cover 513 Socket Head Bolt 514 Expander 102 Lip Seal 103 Bearing Cone 104 Bearing Cup 105 Bearing Cup 106 Bearing Cone 107 Hub Figure 2 10 108 Tongued Flatwasher 109 Tongued Lockwasher 110 Lock Nut 111 Pipe Plug 112 Wheel Stud 113 Pipe Plug Internal Gear Carrier Assembly 201 Carrier Housing 202 Tongued Thrust Washer 203 Needle Roller 204 Thrust Spacer 205 Cluster Gear 206 Planet Shaft 207 Roll Pin Internal Gear O Ring Cover Assembly 301 Cover 302 Cover Cap 303 Bolt 304 Disconnect Cap 305 Disconnect Rod 306 O Ring 307 O Ring 308 Pipe Plug 309 I D Plate Input Shaft Assembly 401 Shaft 402 Retaining Ring 403 Spring 404 Thrust Spacer 8 Input Gear 9 Thrust Spacer 10 Thrust Spacer 11 Thrust Washer 12 Bolt 13 Shoulder Bolt 14 Flatwasher 16 15 Gasket 17 16 Coupling 19 17 Retainer Ring 21 18 Thrust Washer 22 Drive Torque Hub Brake 4WD Front JLG Sizzor 2 25 SECTION 2 PROCEDURES NOTE When using punch be very careful not to strike 4 counterbore of hub w
87. forward and reverse for at least five minutes 11 Shut down prime mover remove gauges and plug ports Check reservoir level and add fluid if neces sary JLG Sizzor 2 9 SECTION 2 PROCEDURES ADJUST DECK EXT ADJUST MAIN RELIEF ADJUST FRONT STEER ADJUST LIFT DOWN SPEED ADJUST REAR STEER NOTE Pressure on deck Ext Retract Leveling Jacks Lift Up and Overload all work off of System Pressure Figure 2 2 Pressure Adjustment Locations Prior to S N 107516 2 10 JLG Sizzor 3121103 SECTION 2 PROCEDURES 1 STEER 3 DECK 2 MAIN LIFT UP 4 LIFT DOWN Figure 2 3 Pressure Adjustment Locations S N 107516 to Present 3121103 JLG Sizzor 2 11 SECTION 2 PROCEDURES 2 15 THROTTLE CHECKS AND ADJUSTMENTS FORD ENGINE Throttle Checks 12 Check that anti dieseling solenoid is operating If solenoid is operating an audible click should be heard when the ignition is switched ON and OFF 18 Check throttle linkage for smooth operation by rotat ing throttle lever by hand to full throttle position then slowly back to idle position feeling closely for stick ing or binding Throttle Adjustments In Sequence NOTE 1 NOTE Steps 1 and 2 are preliminary settings Remove cover from controller With engine shut down turn gain CCW as far as it will go then turn screw slot CW until vertical Gain may need fine tun ing Turn
88. gn When a circuit is acti vated and the control valve solenoid energizes the spool is shifted and the corresponding work port opens to per mit oil flow to the component in the selected circuit with the opposite work port opening to reservoir Once the cir cuit is deactivated control returned to neutral the valve spool returns to neutral center and oil flow is then directed through the valve body and returns to reservoir A typical control valve consists of the valve body sliding spool and two solenoid assemblies The spool is machine fitted in the bore of the valve body Lands on the spool divide the bore into various chambers which when the spool is shifted align with corresponding ports in the valve body open to common flow At the same time other ports would be blocked to flow The spool is spring loaded to center position therefore when the control is released the spool automatically returns to neutral pro hibiting any flow through the circuit Relief Valves Main relief valves are installed at various points within the hydraulic system to protect associated systems and com ponents against excessive pressure Excessive pressure can be developed when a cylinder reaches its limit of travel and the flow of pressurized fluid continues from the system control The relief valve provides an alternate path for the continuing flow from the pump thus preventing rupture of the cylinder hydraulic line or fitting Complete failure
89. harness Ensure proper connection of wires at the terminal strip Using suitable test meter perform continuity test on wire repair or replace harness as neces sary STEERING SYSTEM No response to control Enable switch not activated Activate enable switch Function not activated within the 3 seconds after Reactivate enable switch enable switch was depressed Enable switch not functioning properly Replace enable switch circuit card Hydraulic system oil low Replenish oil as necessary Damaged wiring on control switch or solenoid valve See proper wiring diagram Controller not functioning properly Replace controller Restricted or broken hydraulic line on valve bank or hydraulic pump Clean repair or replace line Control valve not functioning properly Repair or replace valve Steer cylinder not functioning properly Repair or replace steer cylinder Machine hard to steer or steering is erratic Hydraulic system oil low Replenish oil as necessary Restricted hydraulic line or fitting Clean repair or replace line or fitting Lack of lubrication Lubricate as required refer to lubrication chart Restricted crossover relief valve pressure low Clean or replace valve Steer system pressure low Adjust pressure Bent steering linkage Repair or replace linkage as required Hydraulic pump not functioning properly Repair or replace pump Steer cylin
90. here cup is located Mark four shoulder bolt holes on hub so for align ment with shoulder bolt holes in ring gear and cover 29 Usi ft h and h basti 5 Place internal gear into hub so its internal splines mesh with external splines of spindle brake cup from shallow end of hub internal gear NOTE This cup can be reached by putting punch into small access hole in bottom of hubs deep end 7 Place thrust washer onto spindle brake so it rests on bottom of internal gear 30 Remove two pipe plugs from pipe plug holes in side 8 Assemble input shaft as follows of hub l a Place one thrust spacer spring and other 31 Remove two magnetic pipe plugs from pipe plug spacer IN THAT ORDER onto smooth end of holes in flange of hub shaft 32 Hammer out nine wheel studs A CAUTION Roll Test SAFETY GLASSES SHOULD BE WORN DURING FOLLOWING PROCEDURE The purpose of a roll test is to determine if the units gears are rotating freely and properly Gears should be able to b Place retaining ring onto input shaft Using be rotated by applying a constant force to the roll checker retaining ring pliers insert retaining ring into If more drag is felt in the gears only at certain points then groove on input shaft by compressing spring the gears are not rolling freely and should be examined for and spacers together proper installation or defects Some gear packages roll with more difficulty than others Do not be concerned if 9 With large splin
91. his section provides information necessary to perform maintenance on the sizzor lift Descriptions techniques and specific procedures are designed to provide the saf est and most efficient maintenance for use by personnel responsible for ensuring the correct installation and oper ation of machine components and systems A CAUTION WHEN AN ABNORMAL CONDITION IS NOTED AND PROCEDURES CONTAINED HEREIN DO NOT SPECIFICALLY RELATE TO THE NOTED IRREGULARITY WORK SHOULD BE STOPPED AND TECHNICALLY QUALIFIED GUIDANCE OBTAINED BEFORE WORK IS RESUMED The maintenance procedures included consist of servic ing and component removal and installation disassembly and assembly inspection lubrication and cleaning Infor mation on any special tools or test equipment is also pro vided where applicable 2 2 SERVICING AND MAINTENANCE GUIDELINES General The following information is provided to assist you in the use and application of servicing and maintenance proce dures contained in this chapter Safety and Workmanship Your safety and that of others is the first consideration when engaging in 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 se
92. ing or metal build up Do not lap backplate Inspect drive shaft for fretting in bearing areas Check spline area for twisted or broken teeth If keyed shaft check for cracked or chipped keyway SECTION 2 PROCEDURES Snap Ring 2 Shaft Seal 3 Washer 4 Snap Ring 5 Thrust Washer 6 Thrust Bearing 7 Drive Shaft 8 Needle Bearing 2 18 9 Housing Assembly 10 Thrust Face 11 Piston Assembly 12 Spider 13 Pivot 14 Piston Block 15 Pin Keeper 16 Pin Figure 2 7 Piston Drive Motor JLG Sizzor 17 Washer 18 Spring 19 Snap Ring 20 Needle Bearing 21 O Ring 22 Backplate 23 Cap Screw 3121103 SECTION 2 PROCEDURES Assembly NOTE Use filtered system oil to lubricate all critical moving parts before assembly 1 Install one snap ring in rear groove of drive shaft Install one thrust washer thrust bearing and second thrust washer on drive shaft Install second snap ring in front groove on drive shaft 2 Replace needle bearing in housing if necessary Install shaft in housing assembly and install washer Oil 1 0 of new shaft seal and press into position Retain with snap ring 3 Compress pin keeper and install in spline area of piston block 4 Install three pins in special grooves of spline with head end of pin toward inside of block 5 Install one washer spring and second washer Use two 3 8 1 0 washers 3 8 N C nut and 3 8 x 3 1 4 capscrew to compress
93. ir or replace line or fitting Lack of lubricant on lift cylinder attach pins Lubricate as required Refer to lubrication chart Counterbalance valve on lift cylinder improperly Replace valve adjusted or not functioning properly Control valve not functioning properly Repair or replace valve Sizzor arm pins not properly lubricated Lubricate as necessary Worn seals in lift cylinder Replace seals Cylinder not functioning properly Repair or replace lift cylinder Platform drifts down Manual lowering valve notfunctioning properly Repair or replace valve Worn seals in lift cylinder Replace seals Holding valve on lift cylinder not functioning prop erly Repair or replace holding valve High drive does not operate below set height Damaged wiring on limit switch Repair or replace wiring Damage limit switch Replace limit switch 3121103 JLG Sizzor SECTION 3 TROUBLESHOOTING Table 3 2 Chassis Troubleshooting TROUBLE PROBABLE CAUSE REMEDY DRIVE SYSTEM Noresponse to control Enable switch not activated Activate enable switch Function not activated within the 3 seconds after Reactivate enable switch enable switch was depressed Enable switch not functioning properly Replace enable switch circuit card Hydraulic system oil low Replenish oil as necessary Drive hubs disengaged Engage hubs Controll
94. m lines at the motor s Continue to run the engine at low idle and tighten the system lines as soon as oil is observed to leak from them When oil is observed to leak at the motor the line is full the air has been purged and the system hoses should be retightened to their specified torque Once charge pressure has been established increase speed to normal operating RPM Charge pressure should be as indicated in the pump model code If charge pres sure is inadequate shut down and determine the cause for improper pressure A WARNING INADEQUATE CHARGE PRESSURE WILL AFFECT THE OPERA TOR S ABILITY TO CONTROL THE MACHINE Shut down the engine and connect the external control input signal Also reconnect the machine function s if disconnected earlier Start the engine checking to be cer tain the pump remains in neutral With the engine at nor mal operating RPM slowly check for forward and reverse machine operation Charge pressure may slightly decrease during forward or reverse operation Continue to cycle slowly between for ward and reverse for at least five minutes Shut down engine remove gauges and plug ports Check reservoir level and add filtered fluid if needed The machine is now ready for operation 2 18 OSCILLATING AXLE LOCKOUT CYLINDER BLEEDING PROCEDURE IF EQUIPPED NOTE Ensure platform is fully lowered to open the cam valve prior to beginning oscillating axle lockout cylin der bleeding procedur
95. mething that will support hubs flange while it lifts hub up so spindle is not resting on anything Carefully press or hammer spindle down out of hub If seal and bearing cone come out of hub and rest on spindle remove these parts from spindle and set them aside Discard seal If seal and bearing cone did not come out of small end of hub when spindle was pressed out of hub remove seal and bearing cone from small end of hub Discard seal Bearing cone should be lying loose in wide end of hub Remove bearing cone from inside hub ammer and punch are used to remove bearing cups make sure counterbore is not struck with punch when removing bearing cup f g h Roll Test 3121103 Remove bearing cup from counterbore in small end of hub Turn hub over and lift it out of flange support Remove bearing cup from wide end of hub Press nine studs out of stud holes in hub The purpose of a roll test is to determine if the units gears are rotating freely and properly Gears should be able to be rotated by applying a constant force to the roll checker If more drag is felt in the gears only at certain points then the gears are not rolling freely and should be exam ined for proper installation or defects Some gear packages roll with more difficulty than oth ers Do not be concerned if gears seem to roll hard as long as they roll with consistency Leak Test The purpose of the leak test is to make sure the unit is air tight
96. mple if model number is W1BFF0335 then roll unit 35 times in each direction Leak test unit at a pressure of 5 psi 0 4 bar for 2 3 minutes 2 22 DRIVE TORQUE HUB BRAKE 4WD FRONT TORQUE HUB UNITS SHOULD ALWAYS BE ROLL AND LEAK TESTED BEFORE DISASSEMBLY AND AFTER ASSEMBLY TO MAKE SURE THAT THE UNITS GEARS AND SEALANTS ARE WORKING PROPERLY Disassembly Remove pipe plug from cover and drain oil from unit Inspect spindle brake as follows a Examine two brake ports on bottom of spindle brake Bottom of one is tapered and bottom of other one is flat Install hydraulic line of a hand pump into flat brake port b Install a bleeder valve into tapered brake port 2 23 SECTION 2 PROCEDURES 2 24 c Insert roll checker into spindle brake If brake is not working properly roll checker should not turn d Set hand pump to PUMP e Increase hydraulic pressure in brake by pump ing gradually At the same time try to turn roll checker If brake is set correctly roll checker should turn when pump pressure reaches 140 to 160 psi 10 11 bar f Roll test brake in both clockwise and counter clockwise directions Perform same number of turns in each direction as ratio of unit This num ber is the same as the last two digits of the model number found on the units ID tag For example if units model number is W1BJ4U318 then it should be rolled 18 times in both direc tions g Set hand pump to RELEASE and check
97. mum dripping point of 350 degrees F Excellent water resistance and adhesive qualities and being of extreme pres sure type Timken OK 40 pounds minimum EPGL Extreme Pressure Gear Lube oil meeting API ser vice classification GL 5 or MIL Spec MIL L 2105 EO Engine crankcase Oil Gas API SF SG class MIL L 2104 Diesel API CC CD class MIL L 2104B MIL L 2104C HO Hydraulic Oil API service classification GL 3 e g Mobil 424 NOTE Refer to Figure 1 2 for specific lubrication proce dures 1 6 PRESSURE SETTINGS NOTE All pressures are given in pounds per square inch psi with the metric equivalent bar in parentheses 500RTS Rexroth Hydraforce Valve Main Relief 2800 psi 193 bar Steer Relief 1500 psi 103 bar Steer Relief 4 W S If Equipped 1500 psi 103 bar Platform Extension If Equipped 1200 psi 83 bar 3121103 1 7 LIMIT SWITCHES The machine is equipped with the following limit switches High Drive Speed Cut Out High drive speed is cut out when platform is raised above stowed fully lowered position Lift Cut Out If Equipped Lift is cut out at 22 ft 6 8 m when leveling jacks are in the stowed position Drive Cut Out If Equipped Drive is cut out when platform is at 22 ft 6 8 m above stow position or when leveling jacks are in the set posi tion 1 8 CYLINDER SPECIFICATIONS NOTE All dimensions are given in inches in with the met ric
98. n Ibs 4 5 Nm Apply a light coat of Never Seize to pipe plug and tighten it into pipe plug hole in cover 3121103 SECTION 2 PROCEDURES POSITION PUNCH MARKS AT 12 O CLOCK FOR CORRECT TIMING Figure 2 9 Torque Hub Carrier Timing A CAUTION BEWARE OF SHARP EDGES IN COUNTERBORE WHEN INSTALL ING O RING 18 NOTE O ring may be stretched or pinched together to make it fit counterbore exactly 19 Place cover assembly onto ring gear aligning pipe plug holes in cover and hub according to applicable assembly print Also make sure shoulder bolt holes in cover and ring gear are aligned 20 Place four flat washers on top of bolt holes in cover assembly 21 Place shoulder bolts into four shoulder bolt holes in cover and tighten by hand 22 Place remaining twelve flat washers onto remaining bolt holes in cover 1 23 Place twelve bolts into remaining bolt holes in cover 2 and tighten 24 Torque shoulder bolts to 18 25 ft Ib 25 34 Nm Torque bolts to 18 25 ft Ib 25 34 Nm 25 Turn hub over on to its side Insert coupling into end of spindle 3121103 JLG Sizzor Set cover assembly on table interior side up Grease o ring and place it into counterbore around edge of cover 26 27 Roll test unit in both clockwise and counter clock wise directions Perform same number of turns in each direction as ratio of unit Ratio is last two digits of model number on units ID tag For exa
99. n sS eer ES 44 OUTTRGGR SE ENGINE 45 BATTERY POS ur 46 BATTERY POS ep OUTRGGR SW GRY 8RN 2 Keruak L34 wo lt 2 lt 35 ORANGE ea ENABLE HORN E ROT FRONT f OUTRGOR Sw TA E a lt 2 OK snow 52 o orv omn lt 2 EX veucon 31 5 2 ila Bla 55 E s START 1 ES am LFT FRONT oe OUTRGOR Sw VELLOW 4 3 4 gt re OK orano Go 3 n lt 5 t ELLOW lt X sus 29J 6 Y a 5 REAR STEER um Brom som lt lt arom 2 EXTNSN sh i g ale BLK BLU I lt lt 8 2 A Sq HI OPTION Hie P HEAOZTAIL LIGHTS r slack lt P 2 8 50 3 NOTE ALL GRD SYMBOLS 5 E e g g 358 P E ARE TO CONNECTED 5 k 2 2 lt lt a a 3 2 208 8 TO CABLE GRND WIRES 3 8 3 2 93 Du 8 5 5 8 528 2 16 24 22 E P 2 INDICATES A A CABLE 2 16 20 P 2 5 5 NO INDICATES R 5959 959 R 3 3 3 8 lt 4 ame 99 P im N a GROUND CONTROL TERM STRIP 08D CONT BOX 26 XA 5 28 5 1 14 45 45 4 7 12 38 39 2 41 40 3 16 2 T omnc mena 5 79
100. o S N 107516 2 10 2 3 Pressure Adjustment Locations S N 107516 to Present 2 11 2 4 Throttle Checks and Adjustments Ford VSG 413 2 13 2 5 Precision Governor Adjustments 2 13 2 6 Throttle Adjustments Deutz 11011 2 14 2 T Piston Drive Motor sma a OR SU ecce ena RR Bote nta 2 18 2 8 Drive Torque Hub 2WD 4WD rear 2 20 2 9 Torque Hub Carrier 0 2 2 23 2 10 Drive Torque Hub Brake AWD 2 2 25 2 11 Torque Hub Cover Pipe Plug 2 28 2 12 Spring Loading rio dara n dere PRI E E e 2 28 2 13 Drive Brake 2WD 4WD 2 30 2 14 Drive Hub Engaged e a LE e nip 2 32 2 15 Drive Hub Disengaged ERO RE RE E 2 32 2 16 Drive Cutout Switch dew a pee pravi dudas a ad eee ine 2 32 2 17 Drive Speed Cutout 2 32 3 1 Hydraulic Schematic Sheet 1 of 6 3 12 3 2
101. of the system pump is also avoided by relieving cir JLG Sizzor 2 3 SECTION 2 PROCEDURES cuit pressure The relief valve is installed in the circuit between the pump outlet pressure line and the cylinder of the circuit generally as an integral part of the system valve bank Relief pressures are set slightly higher than the load requirement with the valve diverting excess pump delivery back to the reservoir when operating pres sure of the component is reached Crossover Relief Valves Crossover relief valves are used in circuits where the actu ator requires an operating pressure lower than that sup plied to the system When the circuit is activated and the required pressure at the actuator is developed the cross over relief diverts excess pump flow to the reservoir Indi vidual integral reliefs are provided for each side of the circuit 2 6 COMPONENT FUNCTIONAL DESCRIPTION Piston Hydraulic Pump The Sundstrand piston hydraulic pump is attached to and driven by the gasoline or diesel engine The pump is a 2 8 in 45 9 cm displacement piston pump that powers the drive motors Gear Hydraulic Pump The John Barnes gear pump is piggy backed to the piston pump and operates all machine functions except drive The gear pump has a displacement of 0 6 in 10 5 cm Manual Descent Valve If Equipped The manual descent valve is located on top of the holding valve on the lift cylinder The holding valve is
102. place coupler Defective pump bearing Repair or replace pump Oil filter s dirty Clean and or replace filter s as necessary Pump cavitating Vacuum in pump due to oil star vation Restricted suction line Clean repair or replace line Ollinreserve low Replenish oil to proper level Restricted reservoir air vent Clean vent Oil viscosity to high Drain system and replace with recommended oil Referto hydraulic oils Leakin suction line or manifold Repair or replace line or manifold as necessary System overheating Oil viscosity to high Drain system and replace with recommended oil Refer to hydraulic oils Restricted or blocked hydraulic line Repair or replace line Machine overloaded Check weightin platform Main relief valve settoo high Reset valve as required Hydraulic system oil low Replenish oil as necessary Pump not delivering oil Restricted suction line Clean repair or replace line Air entering system through broken line or fitting suction side Replace or repair line or fitting Oil level too low Replenish oil to proper level Plugged strainer in tank Clean strainer Pump coupling defective Replace pump coupling Broken pump drive shaft Repair or replace pump System pressure too low Main relief valve set too low Reset valve as required Main relief valve stuck in open position Clean repair o
103. pm Shut down engine 2 With the aid of an assistant start engine from plat form and allow it to come up to operating tempera ture Disconnect modular dump valve wire Activate HIGH ENGINE switch Activate and Drive Controller and hold it in full drive position Adjust slide pin to contact high engine limit switch at 3000 rpm Shut off all switches and controllers Reconnect modular control dump valve wire NOTE Actuator cable travel must stop slightly before lever makes contact with throttle lever stop Failure to do so will burn out actuator 2 17 HYDRAULIC COMPONENT START UP PROCEDURES AND RECOMMENDATIONS From a hydrostatic component standpoint the goal at system start up is to put into functional operation the hydrostatic system in such a way as to preserve the designed life span of the system The following start up procedure should be adhered to whenever a new pump or motor is initially installed into a machine or a system is restarted after either a pump or motor has been removed and or replaced A WARNING THE FOLLOWING PROCEDURE MAY REQUIRE THE MACHINE TO BE DISABLED WHEELS RAISED OFF THE GROUND WORK FUNCTIONS DISCONNECTED ETC WHILE PERFORMING THE PROCEDURE IN ORDER TO PREVENT INJURY TAKE NECES SARY SAFETY PRECAUTIONS BEFORE MOVING THE VEHICLE MACHINE Prior to installing the pump and or motor inspect the unit s for damage that may have been incurred during shipping and handling Make certain that all sys
104. printed circuit board and electrical signal atthe valve Improper ground Checkfor proper grounding of handle Defective controller Repair or replace controller Microswitches on controller bad or need adjust ment Adjust or replace switches CONTROL SWITCHES No response to a function control switch Emergency stop switch not positioned properly Place emergency stop switch to on Platform Ground select switch not positioned properly Place switch to platform or ground as necessary Circuit breaker open Determine and correct cause Reset circuit breaker No voltage present at emergency stop switch Check battery cable from battery to emergency stop switch for proper connection or damage Repair or replace cable as necessary Emergency stop switch not functioning properly Replace switch No voltage supplied to start relay from emergency stop switch Check battery cable from switch to relay for proper connection or damage Repair or replace cable as necessary No voltage input at terminal strip Check wire from battery to terminal strip for proper connection or damage Repair or replace cable as necessary No voltage present at circuit breaker Check wire from terminal strip to battery for proper connection or damage Repair or replace cable as necessary Defective circuit breaker Replace circuit breaker No voltage present at Platform Ground select swit
105. r replace valve Checksystem oil for contamination Hydraulic pump not functioning properly Repair or replace pump Leakin component line or fitting Repair or replace component line or fitting Scored valve spool Scored cylinder Replace valve Replace cylinder System s operate erratically Sticking or binding valve spools piston rod etc Clean repair or replace components as required Hydraulic oil not a t optimum operating tempera ture Allow oil sufficient time to warm up Pump drive slipping Repair or replace drive 3 8 JLG Sizzor 3121103 SECTION 3 TROUBLESHOOTING Table 3 5 Electrical System Troubleshooting TROUBLE PROBABLE CAUSE REMEDY HAND CONTROLLER Regardless of which way handle is moved only one function occurs Improper or loose wiring to the solenoid s Checkall wiring for proper connections enable switch was depressed Directional valve stuck in one direction Repair or replace valve Valve will not function when handle is moved in either direction Enable switch not activated Activate enable switch Function not activated within the 3 seconds after Reactivate enable switch Enable switch not functioning properly Replace enable switch circuit card No electrical power to handle Check electrical inputto hand controller 12V No electrical powerto valve Checkelectrical outputof
106. r to begin ning lockout cylinder check Place a 8 in 20 cm high block with ascension ramp in front of left front wheel Activate machine hydraulic system from platform control station Place engine speed and drive speed control switches to their respective low positions Place drive controller to forward position and care fully drive machine up ascension ramp until left front wheel is on top of the 8 in 20 cm high block Raise machine platform approximately 2 ft 0 6 m ensure lockout cylinder cam valve is free of sizzor arm trip bar Place drive controller to reverse position and care fully drive machine off block and ramp Have an assistant check to see that left front wheel remains locked in position off the ground Lower machine platform lockout cylinder should then release the wheel and allow it to rest on the ground Transfer the 8 in 20 cm high block to front of right front wheel and repeat steps 1 through 8 substitut ing the word right for left in steps 1 4 and 7 10 If lockout cylinder does not function properly have qualified personnel correct the malfunction prior to any further operation 2 20 PISTON DRIVE MOTOR 2WD amp 4WD Disassembly 1 Clean outside of unit thoroughly 2 Clamp drive shaft in a protected jaw vise with back plate end up 3 Remove six cap screws from backplate 4 Use a plastic mallet and tap the backplate to loosen it 5 Remove o ring from backplate
107. racks or other damage Replace as necessary 3121103 SECTION 2 PROCEDURES Assembly NOTE Prior to cylinder assembly ensure that the proper cylinder seal kit is used Refer to the Illustrated Parts manual Apply a light film of hydraulic oil to all components prior to assembly WHEN INSTALLING NEW POLY PAK PISTON SEALS AXLE LOCKOUT CYLINDER ENSURE SEALS ARE INSTALLED PROP ERLY REFER TO FIGURE 2 1 FOR CORRECT SEAL ORIENTA TION IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION 6 Using suitable protection clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible Table 2 1 Cylinder Piston Nut Torque Specifications PISTON REF 3121103 Figure 2 1 Poly Pak Seal Installation Place a new wiper seal and rod seal into the applica ble cylinder head gland grooves Carefully install the head gland on the rod ensuring that the wiper and rod seals are not damaged or dis lodged Push the head along the rod to the rod end as applicable Description Nut Torque Setscrew Value torque Value Lift Cylinder 400 ftib 100in Ib 542 Nm 12Nm Lockout Cylinder N A N A Level Cylinder 400 ftlb 100 542 12 Nm Platform Ext Cylinder N A N A Steer Cylinder N A N A Table 2 2 Holding Valve Torque Specifications Description Torque Value
108. rd o ring 5 If necessary disassemble hub spindle assembly as follows NOTE Start with large end of hub facing up large end of spindle facing down JLG Sizzor 9 19 SECTION 2 PROCEDURES 2 20 e i Z 1 Hub Spindle Assembly 101 102 103 104 105 106 107 108 109 110 111 Spindle Seal Bearing Cone Bearing Cup Wheel Bolt Pipe Plug Hub Bearing Cup Bearing Cone Spacer Retaining Ring Internal Gear Carrier Assembly 201 Carrier Figure 2 8 Drive Torque Hub 2WD 4WD rear 202 Planet Shaft 203 Roll Pin 204 Thrust Washer 205 Needle Roller 206 Spacer 207 Cluster Gear Ring Gear O Ring Cover Assembly 301 Cover 302 O Ring 303 Cover Cap 304 O RIng 305 Disconnect Rod 306 Disconnect Cap JLG Sizzor 8 9 307 Bolt 308 Pipe Plug Input Shaft 401 Shaft 402 Spacer 403 Spring 404 Retaining Ring Input Gear Thrust Spacer 10 Thrust Spacer 11 Thrust Washer 12 Bolt 13 Shoulder Bolt 14 Coupling 15 Flatwasher 3121103 SECTION 2 PROCEDURES CAUTION WEAR SAFETY GLASSES WHILE PERFORMING THE FOLLOWING Remove retaining ring from around spindle in hub Remove spacer from around spindle in hub c Remove retaining ring from around spindle in STEP a b d e NOTE If h hub Remove spacer from around spindle in hub Set hub small end spindle facing down up on so
109. replace wiring starter Ignition switch not functioning properly Replace switch Defective ignition module Replace ignition module Ignition circuit shorted to ground Repair circuit card as required Battery cable s not making contact Clean and tighten cables Engine will not star Ignition No fuel Replenish fuel as necessary Restricted or broken fuel line Clean or replace line Battery defective or requires charging Charge or replace battery as required Engine will not accelerate above low speed Damaged wiring on speed control switch on gover Repair or replace wiring nor solenoid Speed control switch not functioning properly Replace switch Defective precision governor Ford Repair or replace governor Defective Adeco throttle actuator Deutz Repair or replace actuator Governor not functioning properly Repair or replace governor Defective electronic governor Replace governor Engine will not decelerate below high speed See engine will not accelerate above low speed 3121103 JLG Sizzor 3 7 SECTION 3 TROUBLESHOOTING Table 3 4 Hydraulic System Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Hydraulic pump noisy Air entering system through broken line or fitting Repair or replace line or fitting Air bubbles in oil Replenish oil as required Faulty pump coupler Re
110. rt to monitor charge pressure during start up 6 It is recommended that the external control input signal electrical connections be disconnected at the pump control until after initial start up This will allow the pump to remain in its neutral position 7 Jog or slowly rotate prime mover until charge pres sure starts to rise Start prime mover and run at the lowest possible RPM until charge pressure has been established Excess air may be bled from high pres sure lines through high pressure gauge ports 3121103 A WARNING DO NOT START PRIME MOVER UNLESS PUMP IS IN NEUTRAL POSITION 0 DEGREES SWASHPLATE ANGLE TAKE PRECAU TIONS TO PREVENT MACHINE MOVEMENT IN CASE PUMP IS ACTUATED DURING INITIAL START UP 8 Once charge pressure has been established increase speed to normal operating RPM Charge pressure should be approximately 22 psi 15 5 bar minimum If charge pressure is incorrect shut down and determine cause for improper pressure A WARNING INADEQUATE CHARGE PRESSURE WILL AFFECT THE OPERA TORS ABILITY TO CONTROL THE MACHINE 9 Shut down prime mover and connect external con trol input signal start prime mover checking to be certain pump remains in neutral with prime mover at normal operating speed slowly check for forward and reverse machine operation 10 Charge pressure should remain at 22 psi to 24 psi 15 5 bar to 16 9 bar minimum during forward or reverse operation Continue to cycle slowly between
111. rtridge Refer to electrical troubleshooting table Platform will not raise above 25 ft 7 6 m Leveling jacks notin contact with the ground to set limit switches Setleveling jacks Leveling jack limit switches not functioning prop erly Repair or replace limit switch Machineis on an unlevel surface Lower platform and level machine No power supply See wiring diagram Platform will not lower Enable switch not activated Activate enable switch Function not activated within the 3 seconds after Reactivate enable switch enable switch was depressed Enable switch not functioning properly Replace enable switch circuit card Pump does not respond when lift control switch is moved to the down position Refer to electrical troubleshooting table 3 2 JLG Sizzor 3121103 SECTION 3 TROUBLESHOOTING Table 3 1 Platform Assembly Troubleshooting TROUBLE PROBABLE CAUSE REMEDY No electrical signal being sentto lift down control valve cartridge Referto electrical troubleshooting table Lift down control valve cartridge not functioning properly Repair or replace lift down control valve cartridge Liftcylinder not functioning properly Repair or replace lift cylinder Platform raises and lowers erratically Hydraulic system low Replenish hydraulic oil as required Restricted or broken hydraulic line or fitting Clean repa
112. rvice life of a machine is to keep dirt and for eign materials out of the vital components Precau tions have been taken to safeguard against this Shields covers seals and filters are provided to keep air fuel and oil supplies clean however these items must be maintained on a scheduled basis in order to function properly 2 At any time when air fuel or oil lines are discon nected clear adjacent areas as well as the openings and fittings themselves As soon as a line or compo 3121103 nent is disconnected cap or cover all openings to prevent entry of foreign matter 3 Clean and inspect all parts during servicing or main tenance and assure that all passages and openings are unobstructed Cover all parts to keep them clean Be sure all parts are clean before they are installed New parts should remain in their contain ers until they are ready to be used Components Removal and Installation 4 Use adjustable lifting devices whenever possible if mechanical assistance is required All slings chains cables etc should be parallel to each other and as near perpendicular as possible to top of part being lifted 5 Should it be necessary to remove a component on an angle keep in mind that the capacity of an eye bolt or similar bracket lessens as the angle between the supporting structure and the component becomes less than 90 6 If a part resists removal check to see whether all nuts bolts cables bracket
113. s 2 W D N A MPG Repack 2000 7 Wheel Drive Hub 4 W D Optional Fill Plug EPGL SAE 90 500 8 Hydraulic Oil Reservoir Fill Cap Drain Plug HO Check HO Level See note 4 10 500 Change HO 9 Hydraulic Filter Element N A Initial Change 40 Hours 250 10 Wheel Drive Hub Fill Plug EPGL SAE 90 500 11 Rear Steering Spindles 4 W S 2 Grease Fittings MPG Pressure Gun 100 Optional 12 500 RTS Sizzor Arm Pivot Pins 38 Grease Fittings 500RTS MPG Pressure Gun 100 13 Rail Slides N A MPG Brush 100 14 Platform Extension Slides Optional N A MPG Brush 100 15 Lift Cylinder 4 Grease Fittings MPG Pressure Gun 100 16 Engine Crankcase Fill Cap Drain Plug Check Engine Oil Level 10 100 KEY TO LUBRICANTS MPG Multi purpose Grease EPGL Extreme Pressure Gear Lube HO Hydraulic Oil Mobil 424 Torque Hubs should be 1 2 full of lubricant JLG Industries recommends replacing the hydraulic filter after the first 40 hours of operation hours thereafter A WARNING TO AVOID PERSONAL INJURY USE SAFETY MAINTENANCE REQUIRING PLATFORM TO BE ELEVATED 3121103 NOTE and every 250 PROP FOR ALL JLG Sizzor 1 Be sure to lubricate like items on each side 2 Hecommended 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 lubrication frequencies must be increased accord ingly
114. s 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 a bearing is removed cover it to keep out dirt and abrasives Clean bearings in nonflammable cleaning solvent and allow to drip dry Compressed air can be used but do not spin the bearing 2 Discard bearings if the races and balls or rollers are pitted scored or burned 3 If bearing is found to be serviceable apply a light coat of oil and wrap it in clean waxed paper Do not unwrap reusable or new bearings until they are ready to install JLG Sizzor 2 1 SECTION 2 PROCEDURES 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
115. sing If roll pin is not completely driven into planet shaft damage to carrier could occur when shaft is removed b Drive roll pin out of planet shaft Roll pin must come out through side of planet shaft that it orig inally went into c Remove planet shaft from carrier housing Two tongued thrust washers and cluster gear will slide off d Remove needle rollers and spacer from inside cluster gear e Repeat steps a through d to remove two remaining cluster gears Remove input gear from input shaft assembly Remove thrust spacer from input shaft assembly Remove input shaft assembly from spindle brake If necessary disassemble input shaft as follows a Remove retaining ring from input shaft Discard retaining ring b Slide thrust spacer spring and other thrust spacer off of input shaft Remove thrust washer from bottom of internal gear Remove internal gear from hub Remove o ring from counterbore in hub Discard o ring Using screwdriver or chisel and hammer straighten out tang on lock washer which has been bent into notch in locknut Using an N 13 locknut wrench tool no T 141863 loosen locknut Remove locknut from spindle brake and discard Remove lock washer from spindle brake and dis card Remove tongued washer from spindle brake Lift bearing cone out of hub Lift hub off of spindle brake Using a slide hammer remove seal from small end of hub Discard seal Lift bearing cone off o
116. tem com ponents reservoir hoses valves fittings heat exchanger etc are clean prior to filling with fluid Fill the reservoir with recommended hydraulic fluid This fluid should be passed through a 10 micron nominal no bypass filter prior to entering the reservoir The use of contaminated fluid will cause damage to the components which may result in unexpected vehicle machine move ment NOTE If a pump or motor is being replaced due to internal damage the remaining units pump or motors need to be inspected for damage and contamination and the entire hydraulic system will need to be flushed and the fluid replaced Failure to do so may cause considerable damage to the entire system JLG Sizzor 3121103 SECTION 2 PROCEDURES 3121103 THROTTLE ROD LINKAGE d PRECISION GOVERNOR dl E THROTTLE LEVER M IDLE SPEED l ADJUSTMENT SCREW Figure 2 4 Throttle Checks and Adjustments Ford VSG 413 e STARTER LOCKOUT SPEED ADJUST MAIN SPEED ADJUST 4 ADJUST O __ GAIN ADJUST ADJUST MID SPEED ADJUST Figure 2 5 Precision Governor Adjustments JL G Sizzor 2 13 SECTION 2 PROCEDURES ACTUATOR CABLE THROTTLE LEVER STOP ACTUATOR CABLE LIMIT SWITCH p NR HI
117. that adequate support is pro vided A 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 3121103 Relieve system pressure by cycling the applicable control several times with the engine stopped and ignition on to direct any line pressure back into the reservoir Pressure feed lines to system components can then be disconnected with minimal fluid loss A C MAINTENANCE A WARNING FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION MAY RESULT IN MACHINE DAMAGE PERSONNEL INJURY OR DEATH AND IS SAFETY VIOLATION NO SMOKING IS MANDATORY NEVER REFUEL DUR ING ELECTRICAL STORMS ENSURE THAT FUEL CAP IS CLOSED AND SECURE AT ALL OTHER TIMES REMOVE ALL RINGS WATCHES AND JEWELRY WHEN PERFORMING ANY MAINTENANCE DO NOT WEAR LONG HAIR UNRESTRAINED OR LOOSE FITTING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME CAUGHT ON OR ENTANGLED IN EQUIPMENT OBSERVE AND OBEY ALL WARNINGS AND CAU TIONS ON MACHINE AND IN SERVICE MANUAL KEEP OIL GREASE WATER ETC WIPED FROM STANDING SURFACES AND HAND HOLDS USE CAUTION WHEN CHECKING A HO
118. the housing con tains as much oil as possible and offers the greatest amount of lubrication to the internal components NOTE In initial start up conditions it may be convenient to fill the housing just prior to installing the case drain line Component especially motor location may be such that access to the case drain port after installa tion is not realistic NOTE Make certain that the oil being used to fill the compo nent housing is as clean as possible and store the fill container in such a way as to prevent it from becoming contaminated Install a 60 bar or 1000 psi pressure gauge in the charge pressure gauge port in order to monitor the charge pres sure during start up It is recommended that the external control input signal electrical connections for EDC be disconnected at the pump control until after initial start up This will ensure that the pump remains in its neutral position A WARNING DO NOT START THE ENGINE UNLESS PUMP IS IN THE NEUTRAL POSITION 0 DEGREES SWASHPLATE ANGLE TAKE PRECAU TIONS TO PREVENT MACHINE MOVEMENT IN CASE PUMP IS ACTUATED DURING INITIAL START UP Jog or slowly rotate the engine until charge pressure starts to rise Start the engine and run at the lowest possi ble RPM until charge pressure has been established Excess air should be bled from the system lines as close to the motors as possible NOTE With the engine on low idle crack loosen don t remove the syste
119. this manual at the specified intervals When recommended lubricants are not available consult your local supplier for an equivalent that meets or exceeds the specifications listed 2 2 JLG Sizzor 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 e g using inadequate hydraulic oil allowing moisture grease filings sealing components sand etc to enter when performing maintenance or by permitting the pump to cavitate due to insufficient system warm up or leaks in the pump supply suc tion lines 2 The design and manufacturing tolerances of the component working parts are very close therefore even the smallest amount of dirt or foreign matter entering a system can cause wear or damage to the components and generally results in faulty opera tion Every precaution must be taken to keep hydraulic oil clean including reserve oil in storage Hydraulic system filters should be checked cleaned and or replaced as necessary Always examine filters for evidence of metal particles 3
120. uel regu lator Changing From LP Gas to Gasoline 1 With engine operating on LP under a no load condi tion throw LPG GASOLINE switch at ground control station to GASOLINE position 2 If engine stumbles because of lack of gasoline place switch to LPG position until engine regains smoothness then return switch to GASOLINE posi tion 3 Close hand valve on LP gas supply by turning clock wise 3121103 Using Liquid Petroleum LP Gas A WARNING CLOSE FUEL VALVE ON TANK WHEN PARKING SIZZOR LIFT MORE THAN MOMENTARILY WHEN REFUELING LPG POWERED SIZZOR LIFTS ALWAYS FOL LOW MANUFACTURERS SPECIFICATIONS AND OR APPLICABLE REGULATIONS 1 If machine is to be left overnight or longer it must be parked outside or the LPG tank removed and stored outside 2 LPGis extremely flammable No smoking 3 Only trained and authorized personnel are permitted to operate filling equipment 4 Fill LPG tanks outdoors Stay at least 50 ft 15 m from buildings motor vehicles electrical equipment or other ignition sources Stay at least 15 ft 4 5 m from LPG storage tanks 5 During transfer of LPG metal components can become very cold Always wear gloves when refilling or changing tanks to prevent freeze burns to skin 6 Do not store LPG tanks near heat or open flame For complete instructions on the storage of LPG fuels refer to ANSI NEPA 58 amp 505 A WARNING DO NOT USE AN LPG TANK THAT 15 DAMAGED A DAMAGED TANK
121. ulic fluid which can be caught in a suitable container After the initial discharge there should be no further leakage from the retract port 3 Activate hydraulic system and activate cylinder extend function Check retract port for leakage 4 If cylinder leakage is 6 8 drops per minute or more piston seals are defective and must be replaced If cylinder retract port leakage is less than 6 8 drops per minute carefully reconnect hose to retract port and retract cylinder 5 With cylinder fully retracted shut down hydraulic system and carefully disconnect hydraulic hose from cylinder extend port 6 Activate motor and activate cylinder retract function Check extend port for leakage 7 If cylinder leakage is 6 8 drops per minute or more piston seals are defective and must be replaced If extend port leakage is less than 6 8 drops per minute carefully reconnect hose to extend port then activate cylinder through one complete cycle and check for leaks Cylinders w Single Counterbalance Valves Lift Cylinder Leveling Jacks If Equipped 1 Using all applicable safety precautions activate hydraulic system A WARNING WHEN WORKING ON THE LIFT CYLINDER RAISE THE PLAT FORM COMPLETELY AND SUPPORT THE PLATFORM USING A SUITABLE OVERHEAD LIFTING DEVICE 3121103 SECTION 2 PROCEDURES 2 Raise platform completely and place a suitable over head lifting device or prop approximately 1 in 2 5 cm below the platform

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Service & Maintenance Manual