JLG 3969 Service Manual
Service and Maintenance Manual
Models
3369electric
3969electric
3120768
March 10, 2004
ANSI
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.
MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION 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 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.
SINCE THE MACHINE MANUFACTURER HAS NO
DIRECT CONTROL OVER THE FIELD INSPECTION
AND MAINTENANCE, SAFETY IN THIS AREA RESPONSIBILITY OF THE OWNER/OPERATOR.
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
FAILURE TO COMPLY WITH SAFETY PRECAUTIONS
LISTED IN THIS SECTION MAY RESULT IN MACHINE
DAMAGE, PERSONNEL INJURY OR DEATH AND IS A
SAFETY VIOLATION.
• NO SMOKING IS MANDATORY. NEVER REFUEL DURING ELECTRICAL STORMS. ENSURE THAT FUEL CAP
IS CLOSED AND SECURE AT ALL OTHER TIMES.
• REMOVE ALL RINGS, WA TCHES AND JE WELRY 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 CAUTIONS ON MACHINE AND IN SERVICE MANUAL.
• KEEP OIL, GREASE, WATER, ETC. WIPED FROM
STANDING SURFACES AND HAND HOLDS.
• USE CAUTION WHEN CHECKING A HOT, PRESSURIZED COOLANT SYSTEM.
• NEVER WORK UNDER AN ELEVATED SIZZOR UNTIL
PLATFORM 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 AL WA YS BE DISCONNECTED DURING REPLACEMENT OF ELECTRICAL COMPONENTS.
A.B HYDRAULIC SYSTEM SAFETY
• KEEP ALL SUPPOR T EQUIPMENT AND ATTACHMENTS
It should be noted that the machines hydraulic systems operate at extremely high potentially dangerous pressures. Every effort should be made to
relieve any system pressure prior to disconnecting
or removing any portion of the system.
3120768 – JLG Sizzor – a
STOWED IN THEIR PROPER PLACE.
• USE ONLY AP PROVED, NONFLAMMABLE CLEANING
SOLVENTS.
INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
REVISON LOG
March 25, 1999 - Original Issue (This manual was part of complete manual 3120597)
Updated November 24, 1999 - page 1-2
Updated November 24, 1999 - page 2-11
Updated March 10, 2004 - page 2-11
b – JLG Sizzor – 3120768
TABLE OF CONTENTS
TABLE OF CONTENTS
SUBJECT - SECTION, PARAGRAPH PAGE NO.
SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A.A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a-a
A.B Hydraulic System Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a-a
A.C Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a-a
SECTION 1 - SPECIFICATIONS
1.1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Component Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.3 Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.4 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.5 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.6 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.7 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.8 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.9 critical stability weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.10 Relays/Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.11 Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
SECTION 2 - PROCEDURES
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.2 Servicing and Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.3 Lubrication Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2.4 Cylinders - Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
2.5 Valves - Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
2.6 Component Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
2.7 Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
2.8 Motor Controller - Modes of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
2.9 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
2.10 CYlinder Checking Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
2.11 Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
2.12 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
2.13 Tilt Switch Indicator Leveling Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11
2.14 Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11
2.15 Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11
2.16 Drive Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
2.17 Drive Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14
2.18 Free Wheeling Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15
2.19 Preventive Maintenance and Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16
SECTION 3 - TROUBLESHOOTING
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.2 Troubleshooting Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.3 Hydraulic Circuit Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3120768 – JLG Sizzor – i
TABLE OF CONTENTS (Continued)
LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.
1-1. Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-2. Serial Number Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1-3. Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
2-1. Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
2-2. Capscrew Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-3. Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
2-4. Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
2-5. Oil-lite Bearing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
2-6. Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
2-7. Wiper Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2-8. Installation of Head Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
2-9. Piston Seal Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
2-10. Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
2-11. Poly-Pak Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
2-12. Rod Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
2-13. Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
2-14. Drive Torque Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13
2-15. Drive Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15
3-1. Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
3-2. Platform Wiring Diagram (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
3-2. Platform wiring Diagram (Sheet 2 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
3-3. Ground Control Wiring Diagram (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
3-3. Ground Control Wiring Diagram (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
LIST OF TABLES
TABLE NO. TITLE PAGE NO.
1-1 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-2 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-3 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-4 Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-5 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-6 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-7 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
2-1 Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
2-2 Cylinder Piston Nut Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
2-3 Holding Valve Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
2-4 Preventive Maintenance and Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17
3-1 Platform Assembly Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3-2 Chassis Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3-3 Hydraulic System Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
3-4 Electrical System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
3-5 Flash Code Troubleshooting Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
ii – JLG Sizzor – 3120768
SECTION 1 - SPECIFICATIONS
SECTION 1. SPECIFICATIONS
1.1 CAPACITIES
Hydraulic Oil Tank
11.0 gallons (41.6 liters)
Hydraulic System
Approximately 13.2 gallons (50.0 liters)
Tor q u e H u b s ( 2 )
17 ounces (0.5 liters)
1.2 COMPONENT DATA
Battery Charger
Input, 110 VAC,60 HZ
Output, 48 VDC (23 Amp)
Batteries (8)
6 Volt, 245 AmpHour
Drive System
Drive Motor - 36 VDC, 4.1 H.P. @ 1880 rpm. continuous,
rotation - reversible
Drive Brake- 24 VDC, spring-applied, electrically released
Steer System
Tires - ST205 75R15, Load Range C, 6 Ply Rating, Poly
Filled
1.3 PERFORMANCE DATA
Travel Speed
3369/3969 electric - 3.0 mph (4.8 kmh)
High Drive for/rev (sec/50 ft) - 11-13 sec
Creep Drive for/rev (sec/50 ft) - 50-60 sec
Gradeability
25%
Turning Radius (Inside)
3369 electric - 60 in (1.52 m)
3969 electric - 60 in (1.52 m)
Turni ng Rad ius (O u tsid e )
3369 electric - 149 in (3.81 m)
3969 electric - 149 in (3.81 m)
Platform Lift Speed
3369 electric - Lift Up - 75 - 80 seconds
3369 electric - Lift Down - 50 - 60 seconds
3969 electric - Lift Up - 75 - 80 seconds
3969 electric - Lift Down - 50 - 60 seconds
Platform Capacity
3369 electric - 1000 lbs (454 kg)
3969 electric - 750 lbs (340 kg)
Platform Extension Capacity
3369 electric - 500 lbs (227 kg)
Toe-In - Adjust to 1/4 inch (6.4 mm) overall
Hydraulic Filter
Return, 25 Micron
Hydraulic Pump/Electric Motor Assembly
Motor - 48 VDC, 5.5 H.P. @ 2500 rpm
Pump - 0.098 in.[3]/rev. (1.6 cm[3]/rev.)
Pump Output - 1.09 gpm (4.13 lpm) @ 2000 psi (137.9
Bar)
3969 electric - 500 lbs (227 kg)
Machine Weight
3369 electric - 8,000 lbs (3629 kg)
3969 electric - 8,800 lbs (3992 kg)
Machine Height (w/rails folded down)
3369 electric - 73 in (1.85 m)
3969 electric - 79 in (2.01 m)
Machine Length (stowed)
3369 electric - 109 in (2.77 m)
3969 electric - 109 in (2.77 m)
3120768 – JLG Sizzor – 1-1
SECTION 1 - SPECIFICATIONS
Machine Width
3369 electric - 69 in (1.80 m)
3969 electric - 69 in. (1.80 m)
Wheelbase
3369 electric - 77 in (1.98 m)
3969 electric - 77 in (1.98 m)
Ground Clearance
3369 electric - 7 in (17.8 cm)
3969 electric - 7 in (17.8 cm)
Maximum Tire Load
3369 electric - 3060 lb (1388 kg)
3969 electric - 3145 lb (1427 kg)
Maximum Bearing Pressure
3369 electric - 56 psi (3.9 bar)
3969 electric - 58 psi (3.9 bar)
NOTE: Hydraulic oils must have anti-wear qualities at least
to API Service Classification GL-3, and sufficient
chemical stability for mobile hydraulic system service. JLG Industries recommends Mobilfluid 424
hydraulic oil, which has an SAE viscosity index of
152.
When temperatures remain consistently below 2° F
(-7 ° C), JLG recommends the use of Mobil DTE 11.
NOTE: Aside from JLG recommendations, it is not advisable
to mix oils of different brands or types, as they may
not contain the same required additives or be of
comparable viscosities.
Lubrication Specifications
Table 1-3. Lubrication Specifications
KEY SPECIFICATIONS
EPGL Extreme Pressure Gear Lub e (oil) meeting API service
classification GL- 5 or MIL-Spec MIL-L-2105
HO Hydraulic Oil. API service classification Gl-3, BP Energo l
SHS46.
LL Synthetic Lithium Lub ricant, Gredag 741 Grease.
1.4 TORQUE SPECIFICATIONS
Ta b l e 1 - 1 . To r qu e S pe ci f i c a t i o n s
DESCRIPTION
Torque Hub 75 ft. lbs.
Wheel Bolts 90 ft. lbs.
NOTE: When maintenance becomes necessary or a fas-
tener has loosened, refer to the Torque Chart to
determine proper torque value.
TORQUE VALUE
(DRY)
102 (NM)
(122 NM)
INTERVAL HOURS
500
50
1.5 LUBRICATION
Ta b l e 1 - 2 . Hy dr au li c O i l
Hydraulic System Operating Temper-
ature Ra nge
0° F to 23° F (-18°C to -5°C) 10W
SAE Viscosit y Grade
*MPG may be substituted for these lubricants, if necessary, but service intervals will be reduced.
NOTE: Refer to Lubrication Chart for specific lubrication pro-
cedures.
1.6 PRESSURE SETTINGS
Lift Up Relief - 3369ES - 2500 psi (172 bar)
3969ES - 2700 psi (186 bar)
Lift Down Relief - 1000 psi (69 bar)
Steer Relief - 1200 psi (82.74 bar)
NOTE: Main Relief at Pump - 2700 psi (186.2 bar)
0° F to 210° F (-18°C to +99°C) 10W-20, 10W- 0
50° F to 210° F (+10°C to +99°C) 20W-20
Updated 11/24/99
1-2 – JLG Sizzor – 3120768
SECTION 1 - SPECIFICATIONS
Figure 1-1. Lubrication Chart
Table 1-4. Lubrication Chart
INDEX
NUMBER
1 Hydraulic Oil Fill Cap/Drain P lug HO-Kendall Hyken 05 2 8/800 Check oil every 8 hours of operation.
2 Torque Hub Fill Plug/Half Full EPGL-SAE 90 2000 Check oil level at side plug on hub.
3 Wheel Bearings N/A MPG - Repac k 800 2 years
4 Sliding P ads Wear Pads (8) MPG - Brush 50 N/A
5 (not s hown) Hydraulic Filter Element N/A Replaceab le Element 40/250 Replace fil ter element after first 40 hours of
KEY TO LUBRICANTS:
HO - Hydraulic Oil -Kendall Hyken 052
EPGL - Extreme Pressure Gear Lube
COMPONENT
NO/TYPE LUBE
POINTS
LUBE/METHOD
NOTE: Be sure to lubricate like items on each side of the
INTERVAL
HOURS
Change oil every 800 hours of operation.
operation then ever y 250 hours thereafter.
machine.
Recommended lubricating intervals are based on
machine operations under normal conditions. For
machines used in multi-shift operations and/or
exposed to hostile environments or conditions, lubricating frequencies must be increased accordingly
COMMENTS
3120768 – JLG Sizzor – 1-3
SECTION 1 - SPECIFICATIONS
1.7 CYLINDER SPECIFICATIONS
NOTE: All dimensions are given in inches (in.), with the met-
ric equivalent, centimeters (cm), given in parentheses. .
Table 1-5. Cylinder Specifications
DESCRIPTION BORE STROKE ROD DIA.
Lift Cylinder 4.00
(10.16)
Steer Cylinder
(Double Rod)
NOTE: All dimensions are given in inches (in.), with the met-
ric equivalent, centimeters (cm), given in parentheses.
2.00
(5.08)
14.68
(37.29)
3.00
(7.62)
each direction
2.50
(6.35)
1.25
(3.18)
each rod
1.8 MAJOR COMPONENT WEIGHTS
Table 1-6. Major Component Weights
COMPONENT 3369 ELECTRIC 3969 ELECTRIC
LBS. KG. LBS. KG.
Platform 761 345 761 345
Platform Extension 320 145 320 145
Arm Assembly (Inc ludes Lift
Cylinders)
Chassis (Includes Batt ery
Box and Foam filled Tires)
Machine Complete (G VW) 8000 3629 8800 3992
3393 1539 3903 1770
3662 1661 3662 1661
1.9 CRITICAL STABILITY WEIGHTS
Table 1-7. Critical Stability Weights
COMPONENT 3369/3969 ELECTRIC
LBS. KG.
Platform 761 345
Platform Extension 320 145
Foam Filled Tires 150 68
Battery (Each) 77 35
1.10 RELAYS/CIRCUIT BREAKERS
Console Box
Relay - Potter & Brumfield P/N K10P-11D15-48 48VDC.
Circuit Breaker - Wood Electric Corp. P/N W58 x BIA4 A-5.
1.11 SERIAL NUMBER LOCATIONS
For machine identification, a serial number plate is affixed
to the front of the frame. If the serial number plate is damaged or missing, the machine serial number is stamped
on the right front of the machine frame.
1-4 – JLG Sizzor – 3120768
SECTION 1 - SPECIFICATIONS
Figure 1-2. Serial Number Location
3120768 – JLG Sizzor – 1-5
SECTION 1 - SPECIFICATIONS
Figure 1-3. Torque Chart
1-6 – JLG Sizzor – 3120768
SECTION 2. PROCEDURES
SECTION 2 - PROCEDURES
2.1 GENERAL
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.
WHEN AN ABNORMAL CONDITION IS NOTED AND PROCEDURES
CONTAINED HEREIN DO NOT SPECIFICALLY RELATE TO THE
NOTED IRREGULARITY, WORK SHOULD BE STOPPED AND
TECHNICALLY QUALIFIED GUIDANCE OBTAINED BEFORE WORK
IS RESUMED.
2. The maintenance procedures included consist of
servicing and component removal and installation,
disassembly, and assembly, inspection, lubrication
and cleaning. Information on any special tools or
test equipment is also provided where applicable.
2.2 SERVICING AND MAINTENANCE
GUIDELINES
General
The following information is provided to assist you in the
use and application of servicing and maintenance procedures 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.
2. At any time when hydraulic oil lines are disconnected, clear adjacent areas as well as the openings
and fittings themselves. As soon as a line or component is disconnected, cap or cover all openings to
prevent entry of foreign matter.
3. Clean and inspect all parts during servicing or maintenance, 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 containers until they are ready to be used.
Component Removal and Installation
1. 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.
2. Should it be necessary to remove a component on
an angle, keep in mind that the capacity of an eyebolt or similar bracket lessens, as the angle between
the supporting structure and the component
becomes less than 90 degrees.
3. If a part resists removal, check to see whether all
nuts, bolts, cables, brackets, wiring, etc. have been
removed and that no adjacent parts are interfering.
Component Disassembly and Reassembly
When disassembling or reassembling a component, complete 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.
Cleanliness
1. The most important single item in preserving the
long service life of a machine is to keep dirt and foreign materials out of the vital components. Precautions have been taken to safeguard against this.
Shields, covers, seals and filters are provided to
keep oil supplies clean; however, these items must
be maintained on a scheduled basis in order to function properly.
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.
3120768 – JLG Sizzor – 2-1
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 be installed.
4. Lubricate new or used serviceable bearings before
installation. When pressing a bearing into a retainer
or bore, apply pressure to the outer race. If the 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. Be sure to cut holes in the right location as
blank gaskets can cause serious system damage.
Bolt Usage and Torque Application
1. Use bolts of proper length. A bolt which is too long
will bottom before the head is tight against its related
part. If a bolt is too short, there will not be enough
thread area to engage and hold the part properly.
When replacing bolts, use only those having the
same specifications of the original, or one which is
equivalent.
2. Unless specific torque requirements are given within
the text, standard torque values should be used on
heat treated bolts, studs and steel nuts, in accordance with recommended shop practices.
Hydraulic Lines and Electrical Wiring
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 contamination. Contaminants enter the system by various
means, e.g.; 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.
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 operation. Every precaution must be taken to keep
hydraulic oil clean, including reserve oil in storage.
Hydraulic system filters should be checked,
cleaned, and/or replaced at the specified intervals
required in Section 1. Always examine filters for evidence of metal particles.
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. Keep the system clean. If evidence of metal or rubber particles are found in the hydraulic system, drain
and flush the entire system.
2. Disassemble and reassemble parts on clean work
surface. Clean all metal parts with non-flammable
cleaning solvent. Lubricate components, as
required, to aid assembly.
3. Cloudy oils indicate a high moisture content which
permits organic growth, resulting in oxidation or corrosion. 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 operating, are recommended for use.
NOTE: Metal particles may appear in the oil or filters of new
machines due to the wear-in of meshing components.
Hydraulic Oil
Lubrication
Service applicable components with the amount, type,
and grade of lubricant recommended in this manual, at
the specified interval. When recommended lubricants are
not available, consult your local supplier for an equivalent
that meets or exceeds the specifications listed.
2-2 – JLG Sizzor– 3120768
1. Refer to Lubrication Specification Table for recommendations for viscosity ranges.
2. JLG recommends Kendall Hyken 052 Hydraulic Oil,
which has an SAE viscosity of 10W-20 and a viscosity index of 152.
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