Service & Maintenance Manual Models 400RTS 500RTS 3120696 November 12, 2007
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 REVISION LOG Original Issue - June 1993 Revised - May 19, 1999 Revised - September 26, 2003 Revised - August 31, 2006 Revised - November 12, 2007 b – JLG Sizzor – 3120696
TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT - SECTION, PARAGRAPH PAGE NO. SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A.A A.B A.C General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-a Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-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. 3-1. 3-2. 3-3. 3-4. 3-5. 3-6. 3-7. 3-8. 3-9. 3-10. 3-11. 3-12. 3-13. 3-14. 3-15. 3-16. 3-17. 3-18. 3-19. 3-20. 3-21. 3-22. 3-23. 3-24. 3-25. 3-26. 3-27. 3-28. 3-29. 3-30. 3-31. 3-32. 3-33. 3-34. ii TITLE PAGE NO. 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 2-4 3-1 3-2 3-3 3-4 3-5 3120696 TITLE PAGE NO. Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS This page left blank intentionally.
SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 Diesel Engine CAPACITIES Manufacturer/Model - Deutz F3L-1011 Hydraulic Oil Tank Approximately 36.5 U.S. gallons (138.17 liters) w/10% air space. Hydraulic System (Including Tank) Approximately 44 U.S. gallons (166.56 liters). Fuel Tank Approximately 15 U.S. gallons (56.8 liters) Oil Capacity 6.34 quarts (6.0 liters) w/filter 5.8 quarts (5.
SECTION 1 - SPECIFICATIONS NOTE: Wheel lugs should be torqued to 80 ft lb (112 Nm) at 50 hour intervals. When maintenance becomes necessary or a fastener has loosened, refer to the Torque Chart, Figure 1-1, to determine proper torque value. Hydraulic Filter - Inline Return - Bypass Type 25 Micron Nominal With Deck Retracted 400RTS - 1,500 lb (680 kg) 500RTS - 2,000 lb (907 kg) Platform Capacity - Wide Deck, Dual Extensions (500RTS Only) 500RTS - 1500 lb (680 kg) Machine Weight 400RTS - Approx.
SECTION 1 - SPECIFICATIONS than Mobil 424 is desired, contact JLG Industries for proper recommendations. 1.7 LIMIT SWITCHES The machine is equipped with the following limit switches: 1.5 High Drive Speed Cut-Out LUBRICATION SPECIFICATIONS High drive speed is cut out when platform is raised above stowed (fully lowered) position. Table 1-2. Lubrication Specifications KEY SPECIFICATIONS Lift Cut-Out (If Equipped) Multipurpose Grease having a minimum dripping point of 350 degrees F.
Figure 1-1.
SECTION 1 - SPECIFICATIONS Table 1-3.
SECTION 1 - SPECIFICATIONS Figure 1-2. Serial Number Location 1.8 SERIAL NUMBER LOCATIONS 1.9 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.
SECTION 1 - SPECIFICATIONS 1.10 MAJOR COMPONENT WEIGHTS 1.11 CRITICAL STABILITY WEIGHTS Table 1-5. Major Component Weights Component Lb Kg Fixed Platform (180 cm x 426 cm). 1235 560 Platform Extension. 275 125 Arm Assembly - 400RTS - Includes Lift Cylinder. 7750 3515 Arm Assembly - 500RTS - Includes Lift Cylinder.
Figure 1-3.
SECTION 2 - PROCEDURES SECTION 2. PROCEDURES 2.1 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 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. If it becomes necessary to hand-fabricate a gasket, use gasket material or stock of equivalent material and thickness.
SECTION 2 - PROCEDURES 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 environment, it will be necessary to heat the oil with a low density, 100VAC 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).
SECTION 2 - PROCEDURES failure of the system pump is also avoided by relieving circuit 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 pressure of the component is reached.
SECTION 2 - PROCEDURES assembly. Using a suitable brass drift, drive out the barrel end attach pin from the arm assembly. WHEN WORKING ON THE LIFT CYLINDER, RAISE THE PLATFORM COMPLETELY AND SUPPORT THE PLATFORM USING A SUITABLE OVERHEAD LIFTING DEVICE. 2. Raise platform completely and place a suitable overhead lifting device or prop approximately 1 in. (2.5 cm) below the platform. NOTE: Step (3) applies to the leveling jacks only. 3. Fully extend leveling jacks to check. 4.
SECTION 2 - PROCEDURES CYLINDERS WITH DOUBLE HOLDING VALVES. BEFORE REMOVING HOLDING VALVES CRACK BLEEDER TO RELEASE PRESSURE. 13. 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 3. If applicable, remove the cartridge-type holding valve and fittings from the cylinder port block. Discard o-rings. 1. Clean all parts thoroughly in an approved cleaning solvent. 4.
SECTION 2 - PROCEDURES 17. If applicable, inspect piston rings for cracks or other damage. Replace as necessary. 6. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible. Assembly Table 2-1. Cylinder Piston Nut Torque Specifications NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. Refer to the Illustrated Parts manual.
SECTION 2 - PROCEDURES 11. Position the cylinder barrel in a suitable holding fixture. NOTICE EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES. 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. 13.
SECTION 2 - PROCEDURES 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 500 psi (34 bar). 9. De-energize Platform Ext. function, shut down motor, and disconnect pressure gauge. 2.
SECTION 2 - PROCEDURES ADJUST DECK EXT TO 34 BAR (500PSI) ADJUST MAIN RELIEF TO 156 BAR (2250 PSI) ON 400RTS AND 193 BAR (2800 PSI) ON 500RTS PRESSURE PORT ADJUST FRONT STEER TO 90 BAR (1300 PSI) ADJUST REAR STEER TO 90 BAR (1300 PSI) ADJUST LIFT DOWN SPEED TO 70-60 SECONDS. ON 400RTS AND 80-70 SECONDS ON 500RTS NOTE: Pressure on deck ext./retract, leveling jacks, lift up, and overload all work off of system pressure Figure 2-2.
SECTION 2 - PROCEDURES 2.16 THROTTLE CHECKS AND ADJUSTMENTS - FORD ENGINE 2.17 THROTTLE CHECKS AND ADJUSTMENTS - DEUTZ F3L1011 Throttle Checks 1. 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. 2. Check throttle linkage for smooth operation by rotating throttle lever by hand to full throttle position, then slowly back to idle position, feeling closely for sticking or binding.
SECTION 2 - PROCEDURES Figure 2-3. Throttle Checks and Adjustments - Ford VSG 413 Figure 2-4.
SECTION 2 - PROCEDURES Figure 2-5.
SECTION 2 - PROCEDURES 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 cylinder bleeding procedure. 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. 4.
SECTION 2 - PROCEDURES Figure 2-6.
SECTION 2 - PROCEDURES Assembly 9. Disassemble the piston block as follows: NOTE: The following parts will be needed to disassemble the piston block: 2 ea. 3/8 I.D. x 1-1/8 O.D. flat washers 1 ea. 3/8 x 3-1/4 N.C. capscrew 1 ea. 3/8 N.C. nut a. Place one of the flatwashers over the 3/8 x 3-1/4 capscrew and place this through the center of the piston block. b. Place the other washer over the capscrew and let it rest on the three pins. c.
SECTION 2 - PROCEDURES Figure 2-7.
SECTION 2 - PROCEDURES Disassembly 1. Turn hub over on to its side. Remove coupling from wide end of spindle. NOTE: If roll pin isn’t driven all the way into the planet shaft, carrier could be damaged when planet shaft is removed from carrier. 2. Mark location of shoulder bolt holes on outside of ring gear and hub for easy re-alignment when rebuilding. Remove four shoulder bolts and twelve bolts from cover. b.
SECTION 2 - PROCEDURES c. Remove retaining ring from around spindle in hub.Remove spacer from around spindle in hub. Set hub, small end/spindle facing down, up on something 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. d.
SECTION 2 - PROCEDURES 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. Using retaining ring pliers, insert retaining ring into groove on input shaft by compressing spring and spacers together. 15. With internal splines facing up, counterbore end facing down, place input gear into mesh with carrier assembly. 16. Oil all exposed surfaces inside hub.
SECTION 2 - PROCEDURES 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. BEWARE OF SHARP EDGES IN COUNTERBORE WHEN INSTALLING O-RING. b. Install a bleeder valve into tapered brake port. 18. Set cover assembly on table, interior side up. Grease o-ring and place it into counterbore around edge of cover. c. Insert roll checker into spindle/brake.
SECTION 2 - PROCEDURES Figure 2-9.
SECTION 2 - PROCEDURES 8. Remove thrust washer from carrier assembly. 9. Remove thrust spacer from input shaft assembly. 10. Remove ring gear from mesh with carrier assembly. 26. Using a slide hammer, remove seal from small end of hub. Discard seal. 27. Lift bearing cone off of spindle/brake. 28. Using a soft punch and hammer, remove bearing cup from deep end of hub. 11. Remove carrier assembly from hub. 12. If necessary, disassemble carrier assembly as follows: a. Locate roll pin in carrier housing.
SECTION 2 - PROCEDURES g. Following thrust washer, place cluster gear, with needle rollers, onto planet shaft. Large end of cluster gear should go onto shaft first. NOTE: O-rings may be stretched to fit counterbore. If an oring has been stretched too much, simply squeeze oring together bit by bit while placing it around counterbore. It can be made to fit exactly. h. Following cluster gear, place one more thrust washer onto planet shaft. Align thrust washer in same manner as described in step (f). 3.
SECTION 2 - PROCEDURES h. Place two remaining bolts into bolt holes in disconnect cap and tighten. 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. i. Using a torque wrench, apply 36 - 49 in lbs (4 - 5 Nm) torque to both bolts. j. Grease o-ring. k. Place o-ring into counterbore around edge of cover. 21.
SECTION 2 - PROCEDURES 3. Install new bearing and retaining ring on shaft. 2.23 DRIVE BRAKE - 2WD/4WD REAR 4. Insert shaft assembly and retaining ring in housing. Disassembly 5. Insert dowel pins, guide retainer, and springs in housing. 1. Remove end cover from housing by removing washer head cap screws. 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.
SECTION 2 - PROCEDURES Figure 2-11.
SECTION 2 - PROCEDURES Using Liquid Petroleum (LP) Gas 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 diesel engine, or on malfunctioning engines, as evidenced by visible exhaust. CLOSE FUEL VALVE ON TANK WHEN PARKING SIZZOR LIFT MORE THAN MOMENTARILY. WHEN REFUELING LPG POWERED SIZZOR LIFTS, ALWAYS FOLLOW MANUFACTURERS SPECIFICATIONS AND/OR APPLICABLE REGULATIONS. 2.
SECTION 2 - PROCEDURES 2.27 LIMIT SWITCH ADJUSTMENT PROCEDURE Drive Cut-Out Switch The drive cut-out switch is set at the following heights. Table 2-3. Drive Cutout Heights Model Cut-Out 400 RTS Not Required 400 RTS w/31 x 15.5 - 15 Tires 32 ft (9.8 m) 500RTS 22 ft (6.7 m) Figure 2-12. Drive Hub Engaged 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. Figure 2-14.
SECTION 2 - PROCEDURES d. The inspection and maintenance code numbers are as follows: 2.28 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE a. 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 2-4. 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 NOTES: 2-32 – JLG Sizzor – 3120696
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 e present at function control switch Check wiring from power switch to function control switch for proper connection or damage.
SECTION 3 - TROUBLESHOOTING NOTES: 3120696 – JLG Sizzor – 3-11
SECTION 3 - TROUBLESHOOTING Figure 3-1.
SECTION 3 - TROUBLESHOOTING Figure 3-2.
SECTION 3 - TROUBLESHOOTING 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 Figure 3-8.
SECTION 3 - TROUBLESHOOTING Figure 3-9.
SECTION 3 - TROUBLESHOOTING Figure 3-10.
SECTION 3 - TROUBLESHOOTING Figure 3-11.
SECTION 3 - TROUBLESHOOTING 1283067 D Figure 3-12.
SECTION 3 - TROUBLESHOOTING 1283067 D Figure 3-13.
SECTION 3 - TROUBLESHOOTING NOTES: 3120696 – JLG Sizzor – 3-25
SECTION 3 - TROUBLESHOOTING Figure 3-14.
SECTION 3 - TROUBLESHOOTING Figure 3-15.
SECTION 3 - TROUBLESHOOTING Figure 3-16.
SECTION 3 - TROUBLESHOOTING Figure 3-17.
SECTION 3 - TROUBLESHOOTING Figure 3-18.
SECTION 3 - TROUBLESHOOTING Figure 3-19.
SECTION 3 - TROUBLESHOOTING Figure 3-20.
SECTION 3 - TROUBLESHOOTING Figure 3-21.
SECTION 3 - TROUBLESHOOTING Figure 3-22.
SECTION 3 - TROUBLESHOOTING 1283066 C Figure 3-23.
SECTION 3 - TROUBLESHOOTING 1283066 C Figure 3-24.
SECTION 3 - TROUBLESHOOTING NOTES: 3120696 – JLG Sizzor – 3-37
SECTION 3 - TROUBLESHOOTING Figure 3-25.
SECTION 3 - TROUBLESHOOTING Figure 3-26.
SECTION 3 - TROUBLESHOOTING Figure 3-27.
SECTION 3 - TROUBLESHOOTING 1282341 C Figure 3-28.
SECTION 3 - TROUBLESHOOTING Figure 3-29.
SECTION 3 - TROUBLESHOOTING Figure 3-30.
SECTION 3 - TROUBLESHOOTING Figure 3-31.
SECTION 3 - TROUBLESHOOTING Figure 3-32.
SECTION 3 - TROUBLESHOOTING Figure 3-33.
SECTION 3 - TROUBLESHOOTING 1283064 F Figure 3-34.
SECTION 3 - TROUBLESHOOTING NOTES: 3-48 – JLG Sizzor – 3120696
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.
Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia +61 2 65 811111 JLG Latino Americana Ltda. Rua Eng. Carlos Stevenson, 80-Suite 71 13092-310 Campinas-SP Brazil +55 19 3295 0407 +55 19 3295 1025 +61 2 65 810122 JLG Deutschland GmbH Max-Planck-Str.
