SERVICE & MAINTENANCE Model 25RTS 33RTS 40RTS 3120826 March 12, 2004 AUSTRALIAN OFFICE EUROPEAN OFFICE CORPORATE OFFICE JLG INDUSTRIES, INC. P.O. Box 5119 11 Bolwarra Road Port Macquarie, Australia Telephone: 065 811111 Fax: 065 810122 JLG INDUSTRIES (EUROPE) Kilmartin Place, Tannochside Park Uddingston, Scotland, G71 5PH Telephone: 01698 811005 Main Fax: 01698 811055 Parts Fax: 01698 811455 JLG INDUSTRIES, INC. 1 JLG Drive McConnellsburg, PA.
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 maintenance personnel pay strict attention to these warnings 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.
INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS REVISON LOG Original Issue - June 1993 Revised - August 24, 1999 Revised - September 30, 1999 Revised - February 29, 2000 Revised - March 14, 2001 Revised - September 18, 2001 Revised - April 15, 2002 Revised - September 25, 2002 Revised - March 12, 2004 b – JLG Sizzor – 3120826
TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT - SECTION, PARAGRAPH PAGE NO. SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A.A A.B A.C General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS LIST OF FIGURES FIGURE NO. 1-1. 1-2. 1-3. 2-1. 2-2. 2-3. 2-4. 2-5. 2-6. 2-7. 2-8. 2-9. 2-10. 2-11. 2-12. 2-13. 2-14. 2-15. 2-16. 2-17. 2-18. 2-19. 2-20. 2-21. 2-22. 2-23. 2-24. 2-25. 2-26. 2-27. 2-28. 2-29. 2-30. 2-31. 3-1. 3-2. 3-3. 3-4. 3-5. 3-6. 3-7. ii TITLE PAGE NO. Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS LIST OF TABLES TABLE NO. 1-1 1-2 1-3 1-4 1-5 1-6 2-1 2-2 2-3 3-1 3-2 3-3 3-4 3-5 3120826 TITLE PAGE NO. Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS This page intentionally left blank.
SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 Diesel Engine CAPACITIES Manufacturer - Deutz Hydraulic Oil Tank Low RPM - 2000 Approximately 64.4 liters (17 U.S. gallons) w/15% air space High RPM - 3000 Battery - 85 Amphour, 550 Cold Cranking Amps Hydraulic System (Including Tank) Approximately 75.7 liters (20 U.S. gallons) Fuel Consumption Low RPM - 4.9 lph (1.3 gph) Fuel Tank High RPM - 6.0 lph (1.6 gph) Approximately 56.8 liters (15 U.S.
SECTION 1 - SPECIFICATIONS 1.3 PERFORMANCE DATA Machine Weight 25RTS - Approx. 3,445 kg (7,600 lb.) Travel Speed Gasoline 2 W/D - 8-10 seconds per 15 m (50 ft.) 33RTS - Approx. 3,720 kg (8,200 lb.) 40RTS - Approx. 4,175 kg (9,200 lb.) Gasoline 4 W/D - 12-14 seconds per 15 m (50 ft.) Diesel 2 W/D - 9-11 seconds per 15 m (50 ft.) Machine Height (Platform Lowered) Diesel 4 W/D - 14-16 seconds per 15 m (50 ft.) 25RTS - 2.6 m (103.5 in.
Figure 1-1.
Figure 1-2.
SECTION 1 - SPECIFICATIONS Table 1-2.
SECTION 1 - SPECIFICATIONS NOTE: Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities. If use of hydraulic oil other than Mobilfluid 424 is desired, contact JLG Industries for proper recommendations. Lubrication Specifications 1.
SECTION 1 - SPECIFICATIONS Figure 1-3. Serial Number Location 1.6 SERIAL NUMBER LOCATIONS 1.8 For machine identification, a serial number plate is affixed to the machine. 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. 1.7 NOTE: All dimensions are given in inches (in), with the metric equivalent, centimeters (cm), in parentheses.
SECTION 1 - SPECIFICATIONS 1.9 MAJOR COMPONENT WEIGHTS 1.10 CRITICAL STABILITY WEIGHTS Table 1-5.
SECTION 2 - PROCEDURES SECTION 2. PROCEDURES 2.1 GENERAL This section provides information necessary to perform maintenance on the sizzor lift. Descriptions, techniques and specific procedures are designed to provide the safest and most efficient maintenance for use by personnel responsible for ensuring the correct installation and operation of machine components and systems.
SECTION 2 - PROCEDURES 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. 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 bearing 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.
SECTION 2 - PROCEDURES NOTE: Metal particles may appear in the oil or filters of new machines due to the wear-in of meshing components. Hydraulic Oil 1. Refer to Section 1 for recommendations for viscosity ranges. 2. JLG recommends Mobilfluid 424 oil, which has an SAE viscosity of 10W-30 and a viscosity index of 152. NOTE: Start-up of hydraulic system with oil temperatures below -26° C (-15° F). is not recommended.
SECTION 2 - PROCEDURES Relief Valves 2.7 Main relief valves are installed at various points within the hydraulic system to protect associated systems and components 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.
SECTION 2 - PROCEDURES 2. Carefully disconnect hydraulic hose from retract port of cylinder. There will be initial weeping of hydraulic fluid which can be caught in a suitable container. After the initial discharge, there should be no further leakage from the retract port. 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.
SECTION 2 - PROCEDURES 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 DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1. Place the cylinder barrel into a suitable holding fixture. Figure 2-3. Bottom Lift Cylinder Pin Location 6. Carefully remove the cylinder from the Sizzor lift and place in a suitable work area.
SECTION 2 - PROCEDURES Figure 2-5.
SECTION 2 - PROCEDURES 4. If applicable, remove the cartridge-type holding valve and fittings from the cylinder port block. Discard o-rings. Figure 2-6. Holding Valve and Fitting Removal Figure 2-7. Cylinder Rod Support 5. Tap around outside of cylinder head retainer with a suitable hammer to shatter loctite. 6. Using a suitable chain wrench, loosen the cylinder head retainer, if applicable, and/or cylinder head gland, and remove from cylinder barrel. 7.
SECTION 2 - PROCEDURES Cleaning and Inspection Assembly 1. Clean all parts thoroughly in an approved cleaning solvent. NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. 2. Inspect the cylinder rod for scoring, tapering, ovality, or other damage. If necessary, dress rod with Scotch Brite or equivalent. Replace rod if necessary. Apply a light film of hydraulic oil to all components prior to assembly. 3. Inspect threaded portion of rod for excessive damage.
SECTION 2 - PROCEDURES 4. Carefully slide the piston spacer on the rod. If applicable, align the oil holes in the rod and the spacer. Secure the spacer, if applicable. 5. Carefully place the piston on the cylinder rod, ensuring that the o-ring is not damaged or dislodged. 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.
SECTION 2 - PROCEDURES Figure 2-14. Lift Cylinder 11. Remove the cylinder rod from the holding fixture. 12. Position the cylinder barrel in a suitable holding fixture. 14. Continue pushing the rod into the barrel until the cylinder head gland can be inserted into the barrel cylinder. 15. If applicable, secure the cylinder head retainer using a suitable chain wrench. EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, HEAD, AND PISTON.
SECTION 2 - PROCEDURES 2.12 TILT ALARM SWITCH NOTE: The machine is equipped with a tilt alarm switch factory set to activate at 3° and will sound an alarm and illuminate a warning light on the platform control console. Consult factory for tilt switch adjustment. The only field adjustment necessary is leveling the switch on the spring loaded studs. There are two methods of adjustment, a manual adjustment and an adjustment using a voltmeter.
SECTION 2 - PROCEDURES Figure 2-16. Tilt Alarm Switch - Voltmeter Adjustment 2.13 LIMIT SWITCH ADJUSTMENT PROCEDURE 2.14 DRIVE PUMP START-UP PROCEDURE NOTE: The high drive limit switch is located on top of the frame at the front of the machine. 1. With the machine in the stowed position raise the platform until the arms break away from each other.
SECTION 2 - PROCEDURES 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. 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. Install a 0 to 35 bar (0 to 500 psi) pressure gauge in the charge pressure gauge port to monitor charge pressure during start-up.
SECTION 2 - PROCEDURES Figure 2-18. Throttle Checks and Adjustments - Ford E-301 GAIN SPEED (LOW ENGINE) SPEED (HI ENGINE) Figure 2-19.
SECTION 2 - PROCEDURES GAIN E - 401H Figure 2-20.
SECTION 2 - PROCEDURES 2.16 THROTTLE CHECKS AND ADJUSTMENTS - DEUTZ NOTE: 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 Operators Manual for procedure.) c. Adjust the cover to open the choke plate 1 /32". Readjust for ambient temperature by rotating the cover one (1) mark per 5°F from 70° F. Rotate CCW (lean) if warmer than 70°F, CW (rich) if colder than 70°F.
SECTION 2 - PROCEDURES 2.18 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.
SECTION 2 - PROCEDURES NOTE: With the engine on low idle, "crack", (loosen-don’t remove), the system 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.
SECTION 2 - PROCEDURES Figure 2-21.
SECTION 2 - PROCEDURES 4. De-energize jack function and shut down engine. Remove pressure gauge. 2.20 PRESSURE SETTING PROCEDURES (4 W/S) Racine Three Stack Valve (If Equipped) 1. Install pressure gauge at quick connect on Racine Two Stack Valve. 2. Adjust both Steer Section Crossover Relief’s all the way in. 2.21 OSCILLATING AXLE LOCKOUT CYLINDER BLEEDING PROCEDURE NOTE: Ensure platform is fully lowered to open the cam valve prior to beginning oscillating axle lockout cylinder bleeding procedure. 3.
SECTION 2 - PROCEDURES Figure 2-24.
SECTION 2 - PROCEDURES 2. Activate machine hydraulic system from platform control station. 3. Place Engine Speed and Drive Speed control switches to their respective “LOW” positions. 3. Start the Engine and place Engine Speed and Drive Speed control switches to their respective “LOW” positions. 4. Place Drive controller to “FORWARD” position and carefully drive machine up ascension ramp until left front wheel is on top of 20 cm (8 in.) high block. 4.
SECTION 2 - PROCEDURES 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. 9. Disassemble the piston block as follows: NOTE: The following parts will be needed to disassemble the piston block: 6. Inspect piston block; bores should be free of scoring. Surface that contacts back plate should be smooth and free of grooves or metal build-up. Do not lap piston block.
SECTION 2 - PROCEDURES 4. Install three pins in special grooves of spline with head end of pin toward inside of block. 7. Lubricate thrust race and install in housing assembly. 5. Install one washer, spring, and second washer. Use two 3/8 I.D. washers, 3/8 N.C. nut and 3/8 x 3-1/4 cap screw to compress spring and retain with snap ring. Remove 3/8 N.C. nut, 3/8 x 3-1/4 cap screw and two washers. 8. Install piston block assembly in housing assembly. Piston shoes must contact thrust race.
SECTION 2 - PROCEDURES Figure 2-26.
SECTION 2 - PROCEDURES 2.24 DRIVE TORQUE HUB - 2WD/4WD REAR 7. Remove thrust washer from counter bore in top of carrier assembly. 8. Remove input gear from middle of carrier assembly . TORQUE HUB UNITS SHOULD ALWAYS BE ROLL AND LEAK TESTED BEFORE DISASSEMBLY AND AFTER ASSEMBLY TO MAKE SURE THAT THE UNIT’S GEARS AND SEALANTS ARE WORKING PROPERLY. WHEN REBUILDING A UNIT, USE NEW SEALS AND O-RINGS. NEVER RE-USE SEALS AND O-RINGS, AS THIS WOULD CAUSE UNIT TO LEAK. Disassembly 9. Lift ring gear off of hub.
SECTION 2 - PROCEDURES Leak Test BEWARE OF SHARP EDGES IN COUNTER BORE WHEN REMOVING O-RING. 18. Remove o-ring from counter bore in hub. Discard oring. 19. If necessary, disassemble hub-spindle assembly as follows: NOTE: Start with large end of hub facing up, large end of spindle facing down. The purpose of the leak test is to make sure the unit is air tight. The unit has a leak if the pressure gauge reading on the air checker starts to fall once the unit has been pressurized.
SECTION 2 - PROCEDURES 3. Apply a light coat of “Never-Seize” to two pipe plugs and tighten them into two pipe plug holes in side of hub. 6. Press seal into small end of hub. 7. Oil spindle, then lower hub, small end down, onto spindle. NOTE: Make sure cup sits square with counter bore before pressing. 4. Turn hub over onto its small end. Press bearing cup down into counter bore in deep end of hub. 8. Press bearing cone onto spindle in hub. 5. Set hub onto its large end.
SECTION 2 - PROCEDURES NOTE: Make sure retaining ring is securely seated in groove in spindle. 14. Place thrust washer around spindle so that it rests on bottom of internal gear. 10. Place retaining ring over spacer onto spindle in hub. 15. Stand input shaft on its splined end. Place one spacer onto smooth end of input shaft. 11. Grease o-ring and place it into counter bore in hub. 16. Place one spring onto smooth end of input shaft.
SECTION 2 - PROCEDURES 17. Place other spacer onto smooth end of input shaft. 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. 20. Place thrust spacer onto input shaft. 21. With internal splines facing up (counterbore end facing down), place input gear into mesh with input shaft sub-assembly. 18.
SECTION 2 - PROCEDURES Assemble carrier as follows: 1. Apply grease to the inside of one cluster gear and line one half of cluster gear with 16 needle rollers. 6. Following the thrust washer, place cluster gear, large end toward roll pin hole in carrier housing, onto planet shaft. 2. Place one spacer inside cluster gear so that it rests on top of the needle rollers. 3. Line the remaining half of cluster gear with 16 needle rollers. 7.
SECTION 2 - PROCEDURES 10. Repeat steps 1-9 to assemble and install the two remaining cluster gears. 11. 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 as shown in diagram below. NOTE: 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. 14. Oil all exposed surfaces inside hub.
SECTION 2 - PROCEDURES 8. Place two remaining bolts into bolt holes in disconnect cap, and tighten bolts. 3. Insert disconnect rod into cover cap. 4. 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. 9. Torque both bolts to 4 - 5 Nm (36 - 49 in. lbs.). 10. Apply a light coat of “Never-Seize” to pipe plug and tighten it into pipe plug hole in cover. BEWARE OF SHARP EDGES IN COUNTER BORE WHEN INSTALLING O-RING. 11.
SECTION 2 - PROCEDURES 12. 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. 18. Turn hub over on to its side. Insert coupling into end of spindle. 19. Roll test unit in accordance with paragraph b in both clockwise and counterclockwise directions. Perform same number of turns in each direction as ratio of unit.
SECTION 2 - PROCEDURES Figure 2-27.
SECTION 2 - PROCEDURES h. Remove roll checker from spindle/brake. 13. Remove input gear from input shaft assembly. i. Remove hydraulic line from its brake port. 14. Remove thrust spacer from input shaft assembly. j. Remove bleeder valve from its brake port. 3. Leak test unit at a pressure of 0.4 bar (5 psi) for 2 to 3 minutes. 15. Remove input shaft assembly from spindle/brake. 16. If necessary, disassemble input shaft as follows: 4. Remove the twelve grade 8 bolts and four shoulder bolts from cover.
SECTION 2 - PROCEDURES Roll Test The purpose of a roll test is to determine if the unit’s 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 be examined for proper installation or defects. Some gear packages roll with more difficulty than others.
SECTION 2 - PROCEDURES 13. 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 as shown in diagram below. i. Using a torque wrench, apply 4 - 5 Nm (36 - 49 in. lbs. ) torque to both bolts. j. Grease o-ring. k. Place o-ring into counter bore around edge of cover. BEWARE OF BURRS AND SHARP EDGES AROUND COUNTER BORE WHEN INSTALLING O-RING. NOTE: O-rings may be stretched to fit counter bore.
SECTION 2 - PROCEDURES Figure 2-28.
SECTION 2 - PROCEDURES Assembly 2.26 DRIVE BRAKE - 2WD/2WS REAR NOTE: Lubricate all rubber components from repair kit with clean hydraulic fluid of the type used in the system. Disassembly 1. Remove end cover from housing by removing washer head cap screws. 1. Clean all parts thoroughly before assembly. 2. Press new rotary oil seal into housing. Note direction of seal. END COVER IS UNDER SPRING TENSION OF APPROXIMATELY 2000 LBS. (907 KG.
SECTION 2 - PROCEDURES NOTE: Be sure to use the same number of springs and same spring pattern as recorded during disassembly. 8. Add additional new discs and new friction discs as required to complete assembly. 9. Insert separators in holes of return plate. 6. Position new large diameter return plate in housing with tabs guided by dowel pins until disc rests on springs. 10. 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.
SECTION 2 - PROCEDURES Figure 2-29.
SECTION 2 - PROCEDURES 11. Install case seal in housing, then install bleeder screw in end cover. 2.28 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. 12.
SECTION 2 - PROCEDURES To Disengage Torque Hubs (Freewheel) 2. LPG is extremely flammable. No smoking. 3. Only trained and authorized personnel are permitted to operate filling equipment. 1. Chock wheels securely. 4. Fill LPG tanks outdoors. Stay at least 15 m (50 ft) from buildings, motor vehicles, electrical equipment or other ignition sources. Stay at least 5 m (15 ft) from LPG storage tanks. 5. During transfer of LPG, metal components can become very cold.
SECTION 2 - PROCEDURES 2.30 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE The preventive maintenance and inspection checks are listed and defined in the following table. This table is divided into two basic parts, the “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.
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 1,2 4. Control Tags 1,2 5. Hoses and Cables 4,8 6. Wear Pads 8 7. Handrails and Chains 1,4 CHASSIS 1. Engine Oil 3 5 2. Battery 3 5 3. Air Cleaner 1 14 4. Exhaust System 1 1,5 5. Engine Mounts 1 6.
SECTION 2 - PROCEDURES This page left blank intentionally.
SECTION 3 - TROUBLESHOOTING 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 maintenance.
SECTION 3 - TROUBLESHOOTING Table 3-1.
SECTION 3 - TROUBLESHOOTING Table 3-1.
SECTION 3 - TROUBLESHOOTING Table 3-2.
SECTION 3 - TROUBLESHOOTING Table 3-2. Chassis Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Loose or damaged wire between platform and high speed solenoid Ensure proper connection of wire at the platform and at the high speed solenoid. Using suitable test meter, perform continuity test on wire. repair or replace harness as necessary.
SECTION 3 - TROUBLESHOOTING Table 3-2.
SECTION 3 - TROUBLESHOOTING Table 3-3. Chassis Troubleshooting TROUBLE PROBABLE CAUSE REMEDY ENGINE Engine will not start Station power selector switch is not in required position Actuate switch as required Circuit breaker open Determine and correct cause.
SECTION 3 - TROUBLESHOOTING Table 3-4.
SECTION 3 - TROUBLESHOOTING Table 3-5.
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 present at function control switch Check wiring from power switch to function control switch for proper connection or damage.
SECTION 3 - TROUBLESHOOTING 2792368 A Figure 3-1.
SECTION 3 - TROUBLESHOOTING 2792368 A Figure 3-2.
SECTION 3 - TROUBLESHOOTING 2792368 A Figure 3-3.
SECTION 3 - TROUBLESHOOTING Figure 3-4.
SECTION 3 - TROUBLESHOOTING Figure 3-5.
SECTION 3 - TROUBLESHOOTING Figure 3-6.
SECTION 3 - TROUBLESHOOTING Figure 3-7.
SECTION 3 - TROUBLESHOOTING This page intentionally left blank.
Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA Phone: (717) 485-5161 Customer Support Toll Free: (877) 554-5438 Fax: (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W.
