JLG 40RTS Service Manual

SERVICE & MAINTENANCE

Model

25RTS
33RTS
40RTS

AUSTRALIAN OFFICE

JLG INDUSTRIES, INC.
P.O. Box 5119
11 Bolwarra Road
Port Macquarie, Australia
Telephone: [phone]
Fax: [phone]

3120826

March 12, 2004

EUROPEAN OFFICE

JLG INDUSTRIES (EUROPE)
Kilmartin Place,
Tannochs i d e Park
Uddingston, Scotland, G71 5PH
Telephone: [phone]
Main Fax: [phone]
Parts Fax: [phone]

CORPORATE OFFICE

JLG INDUSTRIES, INC.
1 JLG Drive
McConnellsburg, PA.
17233-9533
USA
Telephone: [phone]
Fax: [phone]

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.

A.B HYDRAULIC SYSTEM SAFETY

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.

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, 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 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 BOOM UNTIL
BOOM HAS BEEN SAFELY RESTRAINED FROM ANY
MOVEMENT BY BL OCKING OR OV ERHEAD SL ING,
OR BOOM SAFETY PROP HAS BEEN ENGAGED.

• BEFORE MAKING ADJUSTMENTS, LUBRICATING OR
PERFORMING ANY OTHER MAINTENANCE, SHUT OFF
ALL POWER CONTROLS.

• BATTER Y SHOULD ALWAYS BE DISCONNECTED DUR­ING REPLACEMENT OF ELECTRICAL COMPONENTS.

• KEEP ALL SUPPOR T EQUIPMENT AND ATTACHMENTS
STOWED IN THEIR PROPER PLACE.

• USE ONLY APPROVED, NONFLAMMABLE CLEANING
SOLVENTS.

3120826 – JLG Sizzor – a

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 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a

A.B Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a

A.C Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a

SECTION 1 - SPECIFICATIONS

1.1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 Component Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.3 Performance Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.4 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.5 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1.6 Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

1.7 Limit Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

1.8 Cylinder Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

1.9 Major Component Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1.10 Critical Stability Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

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 Sliding Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.8 Pump and Coupling Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.9 Cylinder Checking Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.10 Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2.11 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2.12 Tilt Alarm Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2.13 Limit Switch Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2.14 Drive Pump Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2.15 Throttle Checks and Adjustments - Ford . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

2.16 Throttle Checks and Adjustments - Deutz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17

2.17 Automatic Choke Adjustment - Ford Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

2.18 Hydraulic Component Start-Up Procedures and Recommendations . . . . . . . . . . . . . . . . . . . . . . 2-18

2.19 Pressure Setting Procedures - (2 W/S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

2.20 Pressure Setting Procedures - (4 W/S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

2.21 Oscillating Axle Lockout Cylinder Bleeding Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

2.22 Lockout Cylinder Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

2.23 Piston Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

2.24 Drive Torque Hub - 2WD/4WD Rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

2.25 Drive Torque Hub/Brake - 4WD Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

2.26 Drive Brake - 2WD/2WS Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41

2.27 Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44

2.28 Dual Fuel/LPG System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44

2.29 Freewheeling Feature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45

2.30 Preventive Maintenance and Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46

SECTION 3 - TROUBLESHOOTING

3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 Troubleshooting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.3 Hydraulic Circuit Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3120826 – JLG Sizzor – i

TABLE OF CONTENTS

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

1-1. Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-2. Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1-3. Serial Number Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

2-1. Pump and Coupling Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

2-2. Top Lift Cylinder Pin Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

2-3. Bottom Lift Cylinder Pin Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2-4. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2-5. Arms and Platform Positioning and Support, Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

2-6. Holding Valve and Fitting Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

2-7. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

2-8. Steer Cylinder Snap Ring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

2-9. Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

2-10. WIper Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

2-11. Poly-Pak Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

2-12. Wear Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

2-13. Piston O-Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

2-14. Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2-15. Tilt Alarm Switch - Manual Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2-16. Tilt Alarm Switch - Voltmeter Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2-17. Limit Switch Cut-Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2-18. Throttle Checks and Adjustments - Ford . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15

2-19. Precision Governor Adjustments (1600269 Controller) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

2-20. Precision Governor Adjustments (1600325 Controller) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2-21. Pressure Adjustment Locations (2 W/S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20

2-22. Oscillating Axle Cam Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21

2-23. Drive Hub Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21

2-24. Pressure Adjustment Locations (4 W/S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22

2-25. Drive Hub Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23

2-26. Piston Drive Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26

2-27. Drive Torque Hub - 2WD/4WD Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-36

2-28. Drive Torque Hub/Brake - 4WD Front. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-40

2-29. Drive Brake - 2WD/2WS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43

2-30. Drive Hub Disengaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45

2-31. Drive Hub Engaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-45

3-1. Hydraulic Schematic - Sheet 1 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

3-2. Hydraulic Schematic - Sheet 2 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

3-3. Hydraulic Schematic - Sheet 3 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

3-4. Electrical Schematic (Ford) - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

3-5. Electrical Schematic (Ford) - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15

3-6. Electrical Schematic (Deutz) - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

3-7. Electrical Schematic (Deutz) - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

ii – JLG Sizzor – 3120826

TABLE OF CONTENTS

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

1-1 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-2 Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-3 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-4 Cylinder Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

1-5 Major Component Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1-6 Critcal Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

2-1 Cylinder Piston Nut Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

2-2 Holding Valve Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2-3 Preventive Maintenance and Safety Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47

3-1 Platform Assembly - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2 Chassis Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3-3 Chassis Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3-4 Hydraulic System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3-5 Electrical System Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

3120826 – JLG Sizzor – iii

TABLE OF CONTENTS

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iv – JLG Sizzor – 3120826

SECTION 1 - SPECIFICATIONS

SECTION 1. SPECIFICATIONS

1.1 CAPACITIES

Hydraulic Oil Tank

Approximately 64.4 liters (17 U.S. gallons) w/15% air
space

Hydraulic System (Including Tank)

Approximately 75.7 liters (20 U.S. gallons)

Fuel Tank

Approximately 56.8 liters (15 U.S. gallons)

Engine Crankcase

Gasoline Engine

3.2 liters (3.4 quarts) w/filter

2.7 liters (2.9 quarts) w/o filter

Diesel Engine

6.5 liters (6.9 quarts) w/filter

6.0 liters (6.3 quarts) w/o filter

Coolant Capacity (Gasoline Engine)

13.2 liters (3.5 U.S. gallons)

Diesel Engine

Manufacturer - Deutz

Low RPM - 2000

High RPM - 3000

Battery - 85 Amphour, 550 Cold Cranking Amps

Fuel Consumption

Low RPM - 4.9 lph (1.3 gph)

High RPM - 6.0 lph (1.6 gph)

Horsepower - 27 @ 2800 RPM

Drive/Steer System

Toe-In - Adjust to 6.4 mm (1/4 in.) overall

Drive Motor - 6.3 cm[3] (2.48 in.[3]) displacement

Drive Hub (2WD 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 - 11
bar (160 psi) initial, 13 bar (190 psi) full.

Drive Brake (2WD/4WD Rear) - Spring applied, hydraulic
release, release pressure - 10 bar (150 psi) initial, 12 bar
(170 psi) full.

1.2 COMPONENT DATA

Gasoline Engine

Manufacturer - Ford

Displacement - 1.3 liter

Low RPM - 2200

High RPM - 3000

Alternator - 55 Amp external

Battery - 85 Amphour, 550 Cold Cranking Amps

Fuel Consumption

Low RPM - 6.7 lph (1.8 gph)

High RPM - 11.4 lph (3.0 gph)

Horsepower - 40 @ 3000 RPM

Hydraulic Filter - Inline

Return - Bypass Type

25 Microns Nominal

Tires

Standard - 31 - 15.5 x 15 NHS, 8 ply, pneumatic, inflate to
4 bar (60 psi).

Optional - 12 - 16.5 NHS, 6 ply, foam filled

Optional - 12 - 16.5 NHS, 6 ply, pneumatic, inflate to 4 bar
(60 psi).

NOTE: All wheel lugs must be torqued at 90 ft lbs. every 50

hours.

3120826 – JLG Sizzor – 1-1

SECTION 1 - SPECIFICATIONS

1.3 PERFORMANCE DATA

Travel Speed

Gasoline 2 W/D - 8-10 seconds per 15 m (50 ft.)

Gasoline 4 W/D - 12-14 seconds per 15 m (50 ft.)

Diesel 2 W/D - 9-11 seconds per 15 m (50 ft.)

Diesel 4 W/D - 14-16 seconds per 15 m (50 ft.)

Gradeability

2 Wheel Drive - 25% (14°)

4 Wheel Drive - 45% (24°)

Turning Radius (Outside)

2 Wheel Steer - 5.51 m (18 ft.1 in.)

4 Wheel Steer - 3.43 m (11 ft. 3 in.)

Lift Speed

Lift up - 25RTS - 50-55 seconds

33RTS - 53-58 seconds

40RTS - 58-63 seconds

Machine Weight

25RTS - Approx. 3,445 kg (7,600 lb.)

33RTS - Approx. 3,720 kg (8,200 lb.)

40RTS - Approx. 4,175 kg (9,200 lb.)

Machine Height (Platform Lowered)

25RTS - 2.6 m (103.5 in.)

33RTS - 2.8 m (111.5 in.)

40RTS - 3.0 m (119.5 in.)

Machine Length

3.78 m (12 ft. 5 in.)

Machine Width

All Models - Standard Tires - 2.29 m (7 ft. 6 in.)

All Models - Optional Tires - 2.31 m (7 ft. 7 in.)

1.4 LUBRICATION

Ta b l e 1- 1 . Hy d r au l i c O i l

Lift down - All models - 30-40 seconds

Platform Capacity - Fixed Platform

25RTS - 910 kg (2,000 lb.)

33RTS - 680 kg (1,500 lb.)

40RTS - 455 kg (1,000 lb.)

Platform Capacity - Mechanical Platform Extension with Deck Extended

25RTS - Main Deck - 570 kg (1,250 lb)

Extension -230 kg (500 lb)

33RTS - Main Deck - 340 kg (750 lb)

Extension - 230 kg (500 lb)

40RTS - Main Deck - 115 kg (250 lb)

Extension - 230 kg (500 lb)

Platform Capacity - Mechanical Platform Extension with Deck Retracted

25RTS - 795 kg (1,750 lb)

33RTS - 570 kg (1,250 lb)

40RTS - 340 kg (750 lb)

HYDRAULIC SYSTEM OPERATING

TEMPERATURE RANGE

0 to +23 degrees F

(-18 to -5 degrees C )

0 to +210 degrees F

(-18 to +100 degrees C)

+50 to +210 degrees F

(+10 to +100 degrees C)

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.

NOTE: When temperatures remain consistently below -7° C

( 20° F ), JLG Industries recommends the use of
Mobil DTE11.

Some machines may be specially equipped with Mobil
EAL224H biodegradable and non-toxic hydraulic oil. This
oil is vegetable oil based and possesses the same anti­wear and rust protection characteristics as mineral oils,
but will not adversely affect ground water or the environ­ment when spilled or leaked in small amounts. Mobil

EAL224H has a viscosity of 34 cST at 40° C and a viscosity
index of 213. The operating range of this oil is -18° C to
+83° C

SAE VISCOSITY GRADE

10W

10W-20,10W-30

20W-20

1-2 – JLG Sizzor – 3120826

SECTION 1 - SPECIFICATIONS

Figure 1-1. Torque Chart

3120826 – JLG Sizzor – 1-3

SECTION 1 - SPECIFICATIONS

Figure 1-2. Lubrication Diagram

1-4 – JLG Sizzor – 3120826

Table 1-2. Lubrication Chart

SECTION 1 - SPECIFICATIONS

INDEX

NO

1 Oscillating Axle Pivot Point (Optional) 1 Grease Fitting MPG - Pressure Gun 100

2 Lockout Cylinders ( Optional) 2 Grease Fitting s (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)

5 Tow Bar Hitch (Optional) 1 Grease Fitting MPG - Pressu re Gun 100

6 Wheel Bearings (2-W/D) N/A MPG - Repack 2000

7 *Whee l Drive Hub (4-W/D) (Optional) Fill Plug EPGL (SAE 90) 500

8 Engine Crankcase Fill Cap/Drain Plu g Check Engine Oi l Level 10/100

9 Lift Cylinder 2 Grease Fittings MPG - Pressure Gun 100

10 *Wheel Drive Hub Fill Plug EPGL (SAE 90) 500

11 Rear Steering Spind les (4-W/S)

12 Rail Slides N/A MPG - Brush 100

13 Hydraulic Oil Reser voir Fill Cap/Drain Plu g HO - Check HO Level (See note 4)/

14 ** Hydraulic Filter Element N/A Initial Change - 40 Ho urs 250

COMPONENT NUMBER/TYPE LUBE POINTS LUBE METHOD

2 Grease Fittings MPG - Pressure Gun 100

(Optional)

2 Grease Fittings MPG - Pressure Gun 100

(Optional)

HO - Change HO

INTERVAL

HOURS

10/500

*Torque Hubs should be 1/2 full of lubricant

** JLG Industries recommends replacing the hydraulic
filter after the first 40 hours of operation and every 250
hours thereafter.

KEY TO LUBRICANTS:

MPG - Multi-purpose Grease

EPGL - Extreme Pressure Gear Lube

HO - Hydraulic Oil (Mobil 424)

TO AVOID PERSONAL INJURY, USE SAFETY PROP FOR ALL
MAINTENANCE REQUIRING PLATFORM TO BE ELEVATED.

NOTE: When temperatures remain consistently below -7°

C ( 20° F ), JLG Industries recommends the use of
Mobil DTE11.

NOTE: 1. Be sure to lubricate like items on each side

2. 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,
lubrication frequencies must be increased accord­ingly.

3. Operate hydraulic functions through one com­plete cycle before checking hydraulic oil level in
tank. Oil should be visible in ADD sight window on
hydraulic 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.

3120826 – JLG Sizzor – 1-5

SECTION 1 - SPECIFICATIONS

NOTE: Aside from JLG recommendations, it is not adv is abl e

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

Table 1-3. Lubrication Specifications

KEY SPECIFICATIONS

MPG Multipurpose Gre ase having a minimum dripping

point of 350 degress F. Excellent water resistanc e

and adhesive qualiti es, and being of extreme pres-

sure type. (Timken OK 40 pounds minimum.)

EPGL Extreme Pressure Gear Lube (oil ) meeting API ser-

vice classifica tion 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. A PI service classification GL- 3, e.g.

Mobil 424.

1.5 PRESSURE SETTINGS

2-W/S

2 Stack Racine Valve

Main Relief - 172 bar (2500 psi)

Steer Relief - 103 bar (1500 psi)

Lift Overload Relief Pressure

25RTS - 90 bar (1300 psi)

33RTS - 107 bar (1550 psi)

40RTS - 138 bar (2000 psi)

4-W/S

3 Stack Racine Valve (If Equipped)

Main Relief - 172 bar (2500 psi)

Steer Relief - 103 bar (1500 psi)

Lift Overload Relief Pressure

25RTS - 90 bar (1300 psi)

33RTS - 107 bar (1550 psi)

40RTS - 138 bar (2000 psi)

Leveling Jacks Valve (If Equipped) - 90 bar (1300 psi)

1-6 – JLG Sizzor – 3120826

SECTION 1 - SPECIFICATIONS

Figure 1-3. Serial Number Location

1.6 SERIAL NUMBER LOCATIONS

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 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.

Tilt Alarm - 3° - A horn is sounded and a warning light is
illuminated when the machine is operated on a slope that
exceeds 3° with the platform raised. If the machine is oper­ated on a 3° slope with the platform completely lowered,
only the warning light is illuminated.

1.8 CYLINDER SPECIFICATIONS

NOTE: All dimensions are given in inches (in), with the met-

ric equivalent, centimeters (cm), in parentheses.

Table 1-4. Cylinder Specifications

Description Bore Stroke Rod Dia

Lift Cylinder

(25RTS/33RTS)

Lift Cylinder

(40RTS)

Lockout Cylind er
(Oscillating Axle)

Leveling Jack

Cylinder

Steer Cylinder 2.5

5.0

(12.7)

5.0

(12.7)

3.0

(7.6)

2.0

(5.1)

(6.4)

66.6

(169.2)

65.6

(166.4)

3.75
(9.5)

14.0

(35.6)

7.1

(18.1)

3.0

(7.6)

3.5

(8.9)

1.25
(3.2)

1.25
(3.2)

1.25
(3.2)

3120826 – JLG Sizzor – 1-7

SECTION 1 - SPECIFICATIONS

1.9 MAJOR COMPONENT WEIGHTS 1.10 CRITICAL STABILITY WEIGHTS

Table 1-5. Major Component Weights

Component Lb Kg

Fixed Platform 660 300

Platform Extension 300 136

Arm Assembly- 25 RTS (Incl udes
Lift Cylinder)

2403 1090

DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS
OF DIFFERENT WEIGHT OR SPECIFICATION (FOR EXAMPLE:
FILLED TIRES, ENGINE) DO NOT MODIFY UNIT IN ANY WAY TO
AFFECT STABILITY.

Table 1-6. Critcal Stability Weights

Component Lb Kg

Arm Assembly- 33 RTS (Incl udes
Lift Cylinder)

Arm Assembly- 40 RTS (Incl udes
Lift Cylinder)

Chassis with Pneumatic Tires 3398 1541

Chassis with Foam Fil led Tires 4102 1860

3130 1418

3860 1750

Tires (Balasted Only) 295 134

Engine (Ford) 525 238

Engine (Deutz) 342 155

1-8 – JLG Sizzor – 3120826

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.

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 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.

Cleanliness

2. At any time when air, fuel, or 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.

Components 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°.

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.

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 air, fuel, and 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.

3120826 – 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 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. 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.

Lubrication

Service applicable components with the amount, type,
and grade of lubricant recommended in 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.

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., 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 (suc­tion) lines.

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. Keep the system clean. If evidence of metal or rub­ber particles is 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.

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 as necessary, at the speci­fied intervals required in Section 1. Always examine
filters for evidence of metal particles.

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.

2-2 – JLG Sizzor – 3120826

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. 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 , 100V A C heater to a m inimum t emperature of

-26° C (-15° F).

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 -29°
C (-20 ° F). However, use of this oil will give poor per­formance at temperatures above 49° C (120° F). Sys-
tems using DTE 11 oil should not be operated at
temperatures above 94° C (200° F). under any con­dition.

Changing Hydraulic Oil

1. 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 50 hours of operation and
every 300 hours thereafter. If it is necessary to
change the oil, use only those oils meeting or
exceeding the specifications appearing in this man­ual. If unable to obtain the same type of oil supplied
with the machine, consult local supplier for assis­tance in selecting the proper equivalent. Avoid mix­ing petroleum and synthetic base oils. JLG
Industries recommends changing the hydraulic oil
annually.

2. Use every precaution to keep the hydraulic oil clean.
If the oil must be poured from the original container
into another, be sure to clean all possible contami­nants from the service container. Always clean the
mesh element of the filter and replace the cartridge
any time the system oil is changed.

3. While the unit is shut down, a good preventive main­tenance 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 a variety of single purpose grease requirements.
Should any question arise regarding the use of greases in
maintenance stock, consult your local supplier for evalua­tion. Refer to Section 1 for an explanation of the lubricant
key designations appearing in the Lubrication Chart.

2.4 CYLINDERS - THEORY OF OPERATION

Cylinders are of the double acting type. The Lift and Steer
systems incorporate double acting cylinders. A double
acting cylinder is one that requires oil flow to operate the
cylinder rod in both directions. Directing oil (by actuating
the corresponding control valve to the piston side of the
cylinder) forces the piston to travel toward the rod end of
the barrel, extending the cylinder rod (piston attached to
rod). When the oil flow is stopped, movement of the rod
will stop. By directing oil to the rod side of the cylinder, the
piston will be forced in the opposite direction and the cyl­inder rod will retract.

NOTE: The lift cylinder is a single acting cylinder which

takes hydraulic pressure to extend and gravity to
retract.

A holding valve is used in the Lift 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 design. When a circuit is acti­vated and the control valve solenoid energizes, the spool
is shifted and the corresponding work port opens to per­mit oil flow to the component in the selected circuit, with
the opposite work port opening to reservoir. Once the cir­cuit 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 spring­loaded to center position, therefore when the control is
released, the spool automatically returns to neutral, pro­hibiting any flow through the circuit.

3120826 – JLG Sizzor – 2-3

SECTION 2 - PROCEDURES

Relief Valves

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. Complete
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.

Crossover Relief Valves

Crossover relief valves are used in circuits where the actu­ator requires an operating pressure lower than that sup­plied to the system. When the circuit is activated and the
required pressure at the actuator is developed, the cross­over relief diverts excess pump flow to the reservoir. Indi­vidual, integral relief’s are provided for each side of the
circuit.

2.7 SLIDING WEAR PADS

The original thickness of the sliding pads is 50.8 mm (2.0
in.). Replace sliding pads when worn to 47.5 mm (1.87in.).

2.8 PUMP AND 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 disassem­bled or replaced. Lubricate the splines with Texaco Code
1912 Pump Coupling Grease ONLY. No other lubricant is
recommended.

2.6 COMPONENT FUNCTIONAL DESCRIPTION

Piston Hydraulic Pump

The Sundstrand piston hydraulic pump is attached to and
driven by the engine. The pump is a 45.9 cm[3] (2.8 in.[3])
displacement piston pump that powers the drive motors.

Gear Hydraulic Pump

The John Barnes gear pump is “piggy-backed” to the pis-
ton pump, and operates all machine functions except
drive. The gear pump has a displacement of 10.5 cm[3]
(0.6 in. [3]).

Manual Descent Valve

The manual descent valve is located on top of the holding
valve on the lift cylinder. The holding valve is 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.

Figure 2-1. Pump and Coupling Lubrication

2.9 CYLINDER CHECKING PROCEDURES

NOTE: Cylinder checks must be performed any time a cylin-

der component is repl ac ed or wh en im pro per system
operation is suspected.

Cylinder w/o Counterbalance Valves - Steer 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.

2-4 – JLG Sizzor – 3120826

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. 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.

port is leaking, the counterbalance valve is defective
and must be replaced.

5. If no repairs are necessary or when repairs have
been made, carefully reconnect hydraulic hoses to
the appropriate ports.

6. Remove lifting device from platform, activate hydrau­lic 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 bolts, lock washers, and flat washers
securing the cylinder rod attach pin #1 to the upper
inner arm assembly. Using a suitable brass drift,
drive out the rod end attach pin from the arm assem­bly.

Cylinders w/Single Counterbalance Valves ­Lift Cylinder

OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION
ONLY.

1. Using all applicable safety precautions, activate
hydraulic system.

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 2.5 cm (1
in.) below the platform.

3. Shut down hydraulic system and allow machine to
sit for 10-15 minutes. Carefully remove hydraulic
hoses from cylinder port block.

4. 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

Figure 2-2. Top Lift Cylinder Pin Location

3. Retract the lift cylinder rod completely.

4. Tag and disconnect, then cap the lift cylinder
hydraulic lines and ports.

5. Remove the bolts, lock washers, and flat washers
securing the barrel end attach pin to the lower arm
assembly. Using a suitable brass drift, drive out the
barrel end attach pin #2 from the arm assembly.

3120826 – JLG Sizzor – 2-5

SECTION 2 - PROCEDURES

Figure 2-3. Bottom Lift Cylinder Pin Location

6. Carefully remove the cylinder from the Sizzor lift and
place in a suitable work area.

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.

Lift Cylinder Installation

1. Install lift cylinder in place using suitable slings or
supports, aligning barrel end attach pin #2 mount­ing holes on lower arm assembly.

2. Using a suitable drift, drive the barrel end attach pin
#2 through the mounting holes in the lift cylinder
and the lower arm assembly. Secure in place with
the bolts, flat washers, and lock washers.

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 #1 hole
aligns with those in the upper arm assembly. Using a
suitable drift, drive the cylinder rod attach pin #1
through the aligned holes. Secure the pin in place
with the bolts, lock washers, and flat washers.

5. Remove support from platform and position the
safety props to the stowed position.

6. Lower platform to stowed position and shut down
motor/engine. Check hydraulic fluid level and adjust
accordingly.

Figure 2-4. Cylinder Barrel Support

2. Connect a suitable auxiliary hydraulic power source
to the cylinder port block fitting.

DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE.
RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES­SURE.

3. Operate the hydraulic power source and extend the
cylinder. Shut down and disconnect the power
source. Adequately support the cylinder rod, if appli­cable.

CYLINDERS WITH DOUBLE HOLDING VALVES. BEFORE REMOV­ING HOLDING VALVES CRACK BLEEDER TO RELEASE PRES­SURE.

2-6 – JLG Sizzor – 3120826

SECTION 2 - PROCEDURES

Figure 2-5. Arms and Platform Positioning and Support, Cylinder Repair

3120826 – JLG Sizzor – 2-7

SECTION 2 - PROCEDURES

Figure 2-6. Holding Valve and Fitting Removal

4. If applicable, remove the cartridge-type holding
valve and fittings from the cylinder port block. Dis­card o-rings.

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. Attach a suitable pulling device to the cylinder rod
port block end or cylinder rod end, as applicable.

EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL­INDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFF­CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND
CYLINDER BARREL SURFACES.

8. With the barrel clamped securely, apply pressure to
the rod pulling device and carefully withdraw the
complete rod assembly from the cylinder barrel.

9. Using suitable protection, clamp the cylinder rod in
a vise or similar holding fixture as close to the piston
as possible.

10. Remove the set screw(s), if applicable, and nut
which attach the piston to the rod, and remove the
piston. Discard set screws.

NOTE: Steer Cylinder has two retainers at each e nd of cyli n-

der.

11. This step only applies to the steer cylinder, remove
snap rings from rod which attach the piston to the
rod.

Figure 2-8. Steer Cylinder Snap Ring Removal

12. Remove and discard the piston o-rings, seal rings,
and wear rings.

13. Remove piston spacer, and head, from the rod. Dis­card the o-rings, back-up rings, rod seals, and wiper
seals.

14. Remove the cylinder head gland. Remove the rod
from the holding fixture.

2-8 – JLG Sizzor – 3120826

SECTION 2 - PROCEDURES

Cleaning and Inspection

1. Clean all parts thoroughly in an approved cleaning
solvent.

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.

3. Inspect threaded portion of rod for excessive dam­age. Dress threads as necessary.

4. Inspect inner surface of cylinder barrel tube for scor­ing or other damage. Check inside diameter for
tapering or ovality. Replace if necessary.

5. Inspect threaded portion of barrel for damage. Dress
threads as necessary.

6. Inspect piston surface for damage and scoring and
for distortion. Dress piston surface or replace piston
as necessary.

7. Inspect seal and o-ring grooves in piston for burrs
and sharp edges. Dress applicable surfaces as nec­essary.

8. Inspect cylinder head inside diameter for scoring or
other damage and for ovality and tapering. Replace
as necessary.

9. Inspect seal and o-ring grooves in head for burrs
and sharp edges. Dress applicable surfaces as nec­essary.

Assembly

NOTE: Prior to cylinder assembly, ensure that the proper

cylinder seal kit is used.
Apply a light film of hydraulic oil to all components

prior to assembly.

1. Place a new wiper seal and rod seal into the applica­ble cylinder head gland grooves.

Figure 2-9. Rod Seal Installation

Use a soft mallet to tap a new wiper seal into the applica­ble cylinder head gland groove.

10. If applicable, inspect cylinder head retainer or end
cap for surface or thread damage. Repair or replace
as necessary.

11. Inspect cylinder head outside diameter for scoring
or other damage and ovality and tapering. Replace
as necessary.

12. If applicable, inspect thread ring for scoring or other
damage. Dress threads or applicable surfaces as
necessary.

13. If applicable, inspect rod and barrel bushings for
signs of correct lubrication and excessive wear.
Replace as necessary.

14. Inspect travel limiting collar or spacer for burrs and
sharp edges. If necessary, dress inside diameter
surface with Scotch Brite or equivalent.

15. If applicable, inspect port block fittings and holding
valve. Replace as necessary.

16. Inspect the oil ports for blockage or the presence of
dirt or other foreign material. Repair as necessary.

17. If applicable, inspect piston rings for cracks or other
damage. Replace as necessary.

Figure 2-10. WIper Seal Installation

WHEN INSTALLING NEW “POLY-PAK” TYPE PISTON SEALS
(AXLE LOCKOUT CYLINDER), ENSURE SEALS ARE INSTALLED
PROPERLY. REFER TO FIGURE 2-11 FOR CORRECT SEAL ORIEN­TATION. IMPROPER SEAL INSTALLATION COULD RESULT IN
CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION.

3120826 – JLG Sizzor – 2-9

SECTION 2 - PROCEDURES

Figure 2-11. Poly-Pak Seal Installation

Figure 2-12. Wear Seal Installation

Figure 2-13. Piston O-Ring Installation

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. Cylinder Piston Nut Torque Specifications

1. Place a new wear ring into the inner head diameter
groove and a new o-ring on the outer diameter
groove.

2. Carefully install the head gland on the rod, ensuring
that the wiper and rod seals are not damaged or dis­lodged. Push the head along the rod to the rod end,
as applicable.

3. Place a new o-ring into the inner piston diameter
groove and a new o-ring and wear ring on the outer
diameter groove

.

Description

Nut Torque

Value

Lift Cylinder 400 ft lb

(542 Nm)

Setscrew

torque Value

100 in lb
(12 Nm)

Lockout Cylinde r N/A N/A

Level Cylinder 5 0 ft lb

(68 Nm)

100 in lb
(12 Nm)

Steer Cylinder N/A N/A

Table 2-2. Holding Valve Torque Specifications

Description Torque Value

Sun - 7/8 hex M20 x 1.5 thds 30 - 35 ft lb 41 - 48 Nm

Sun - 1-1/8 hex 1 - 1 4 UNS thds 45 - 50 ft lb 61 - 68 Nm

Sun - 1-1/4 hex M36 x 2 thds 150 - 153 ft lb 204 - 207 Nm

Racine - 1-1/8 hex 1-1/16 - 12 thds 50 - 55 ft lb 68 - 75 Nm

Racine - 1-3/8 hex 1-3/16 - 12 thds 75 - 80 ft lb 102 - 109 Nm

Racine - 1-7/8 hex 1-5/8 - 12 thds 100 - 110 ft lb 136 - 149 Nm

9. Push the piston onto the rod until it abuts the spacer
end and install the attaching nut.

WHEN REBUILDING THE CYLINDERS, APPLY LOCTITE #242 TO
PISTON NUT AND SETSCREW, THEN TORQUE PISTON NUT.
REFER TO TABLE 2-1, CYLINDER PISTON NUT TORQUE SPECIFI­CATIONS

NOTE: The Steer Cylinder uses snap rings to secure piston.

10. Prior to setscrew installation spot drill rod before
installing the setscrew(s) which secure the piston
attaching nut to the diameter groove.

2-10 – JLG Sizzor – 3120826

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.

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.

13. 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.

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.

16. 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.

17. If applicable, install the cartridge-type holding valve
and fittings in the port block using new o-rings as
applicable. Refer to Table 2-2, Holding Valve Torque
Specifications.

3120826 – JLG Sizzor – 2-11

SECTION 2 - PROCEDURES

Figure 2-15. Tilt Alarm Switch - Manual Adjustment

2.12 TILT ALARM SWITCH

NOTE: The machine is equipped with a tilt alarm switch fac-

tory set to activate at 3° and will sound an alarm and
illuminate a warning light on th e platfor m co ntrol co n­sole. 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.

PERFORM TILT ALARM SWITCH LEVELING PROCEDURE A MINI­MUM OF EVERY SIX MONTHS TO ENSURE PROPER OPERATION
AND ADJUSTMENT OF SWITCH.

Manual Adjustment

1. Park the machine on a flat, level surface and ensure
machine is level.

NOTE: Ensure switch mountin g br acke t is level and secu rel y

attached.

2. Level the base of the indicator by tightening the
three flange nuts. Tighten each nut through approxi­mately one half of it’s spring’s travel. DO NOT
ADJUST THE “X” NUT DURING THE REMAINDER
OF THE PROCEDURE.

3. With the electrical connections complete, slowly
tighten one of the “Y” nuts until the circuit is closed
and the light on the Platform Control Console illumi­nates.

4. Slowly back off the nut, counting the number of
turns, until the circuit is again closed and the light
again illuminates.

5. Divide the number of turns determined in step (4) in
half. Tighten the nut this many turns. The line deter­mined by this nut and the “X” nut is now parallel to
the ground.

6. Repeat steps (3) through (5) for the remaining “Y”
nut. The switch is now level.

7. 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
“X” nut and repeat steps (3) through (7).

Voltmeter Adjustment

1. Park machine on a flat, level surface and ensure
machine is level.

2. If motor is not running, turn ignition switch to ON.

3. Connect black lead of voltmeter to ground and red
lead to yellow wire protruding from pot on bottom of
sensor.

4. Adjust leveling nuts to obtain the highest possible
voltage reading.

5. Check voltage at trip point in all four directions. If
voltage reading is not symmetrical, repeat step (4)
above.

2-12 – JLG Sizzor – 3120826

Figure 2-16. Tilt Alarm Switch - Voltmeter Adjustment

SECTION 2 - PROCEDURES

2.13 LIMIT SWITCH ADJUSTMENT 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.

2. The high drive speed switch should be set to cut out
high drive at this point

Figure 2-17. Limit Switch Cut-Out

2.14 DRIVE PUMP START-UP PROCEDURE

THE FOLLOWING PROCEDURE SHOULD ALWAYS BE PER­FORMED WHEN STARTING A NEW PUMP OR WHEN RESTARTING
AN INSTALLATION IN WHICH EITHER THE PUMP OR MOTOR
HAVE BEEN REMOVED FROM THE SYSTEM.

THE FOLLOWING PROCEDURE SHOULD ALWAYS BE PER­FORMED WHEN STARTING A NEW PUMP OR WHEN RESTARTING
AN INSTALLATION IN WHICH EITHER THE PUMP OR MOTOR
HAVE BEEN REMOVED FROM THE SYSTEM.
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 PRECAU­TIONS BEFORE MOVING THE MACHINE.

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.

Fill reservoir with recommended hydraulic fluid, which
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 components,
which may result in unexpected machine movement.

3120826 – JLG Sizzor – 2-13

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.

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.

“Jog” or slowly rotate prime mover until charge pressure
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 pressure lines through
high pressure gauge ports.

DO NOT START PRIME MOVER UNLESS PUMP IS IN NEUTRAL
POSITION (0 DEGREES SWASHPLATE ANGLE). TAKE PRECAU­TIONS TO PREVENT MACHINE MOVEMENT IN CASE PUMP IS
ACTUATED DURING INITIAL START-UP.

Once charge pressure has been established, increase
speed to normal operating RPM. Charge pressure should
be approximately 15.5 bar (220 psi) minimum. If charge
pressure is incorrect, shut down and determine cause for
improper pressure.

2.15 THROTTLE CHECKS AND ADJUSTMENTS - FORD

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.

Throttle Adjustments - In Sequence

NOTE: Step s (1) and (2) are pr eliminary settings.

1. 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 tun­ing.

2. Turn ‘droop’ CCW as far as it will go. Then turn
screw slot CW until vertical. ‘Droop’ should not need
further adjustment.

3. Turn idle adjusting screw on carburetor CCW until
there is a gap between the screw and stop plate.

4. Start engine and allow it to come up to operating
temperature.

5. Remove wire from no. 7 connector on controller,
which will switch engine speed to HIGH. On the E­301 controller adjust ‘high speed’ screw until engine
runs at 2800 rpm. On the E-401H controller adjust
‘main speed’ screw until engine runs at 2800 rpm.

NOTE: If engine surges, turn ‘gain’ screw one or two

INADEQUATE CHARGE PRESSURE WILL AFFECT THE OPERA­TOR’S ABILITY TO CONTROL THE MACHINE.

Shut down prime mover and connect external control
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.

Charge pressure should remain at 15.5 bar -16.9 bar (220
psi - 240 psi) minimum during forward or reverse opera­tion. Continue to cycle slowly between forward and
reverse for at least five minutes.

Shut down prime mover, remove gauges, and plug ports.
Check reservoir level and add fluid if necessary.

degrees CCW until surging stops, no more.

6. Replace wire no. 7 connector on controller, which
will return engine to LOW speed. On the E-301 con­troller adjust ‘low speed’ until engine runs at 2200
rpm. On the E-401H controller adjust ‘mid speed’
until engine runs at 2200 rpm.

7. Recheck speeds. When satisfied, apply a drop of fin­gernail polish to all trimpot screws. Replace cover.

2-14 – JLG Sizzor – 3120826

SECTION 2 - PROCEDURES

SPEED

(HI ENGINE)

SPEED

E-301

Figure 2-18. Throttle Checks and Adjustments - Ford

GAIN

(LOW ENGINE)

Figure 2-19. Precision Governor Adjustments (1600269 Controller)

3120826 – JLG Sizzor – 2-15

SECTION 2 - PROCEDURES

E - 401H

Figure 2-20. Precision Governor Adjustments (1600325 Controller)

GAIN

2-16 – JLG Sizzor – 3120826

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.)

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 2200 rpm. Shut down engine. Reattach
actuator cable to throttle lever, making sure that low
engine setting remains the same. Restart engine and
check settings. If necessary, adjust slide pin to contact low
engine limit switch at 2200 rpm. Shut down engine.

With the aid of an assistant, start engine from platform and
allow it to come up to operating temperature. 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
2800 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.

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. (If actual temperature is 80°F,
set at 1/32" and rotate two (2) marks CCW [lean]
direction).

d. Tighten the three cover plate screws and check

for free rotation (no sticking or binding) of the
choke shaft.

2.17 AUTOMATIC CHOKE ADJUSTMENT ­FORD ENGINE

1. At 21° C (70°F) the choke plate should be open .8
mm (1/32 in.) (not touching the choke bore).

2. If the ambient temperature is not 21° C (70°F), an
addtional adjustment is required. As follows:

a. Loosen the three cover plate screws.

b. Adjust the cover to open the choke plate.8 mm

(1/32 in.)..

3120826 – JLG Sizzor – 2-17

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.

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 NECES­SARY 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 system com­ponents (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 move­ment.

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.

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 loca­tions, 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 be en purged , and t he fittin g
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 the housing con­tains 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, (esp ec ial ly mo tor), l oc atio n m ay be
such that access to the case drain port after installa­tion is not realistic.

NOTE: Make certain that the oil b ei ng us ed to fill the comp o-

nent housing is as clean as possible, and store the
fill container in such a way as to prevent it from
becoming contamin ate d.

Install a 60 bar (or 1000 psi) pressure gauge in the charge
pressure gauge port in order to monitor the charge pres­sure 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.

DO NOT START THE ENGINE UNLESS PUMP IS IN THE NEUTRAL
POSITION (0 DEGREES SWASHPLATE ANGLE). TAKE PRECAU­TIONS 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 possi­ble RPM until charge pressure has been established.
Excess air should be bled from the system lines as close
to the motors as possible.

2-18 – JLG Sizzor – 3120826

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 eng ine at low i dle and tigh ten the sy stem
lines as soon as oil is observed to leak from them.
When oil is observe d to " lea k" at th e mo tor th e li ne i s
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 pres­sure is inadequate, shut down and determine the cause
for improper pressure.

INADEQUATE CHARGE PRESSURE WILL AFFECT THE OPERA­TOR’ 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 cer­tain the pump remains in neutral. With the engine at nor­mal 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 for­ward 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.

7. Bottom out Lift Up functions and adjust Lift Up Relief
Pressure to:

25RTS - 90 bar (1300 psi)

33RTS - 106 bar (1550 psi)

40RTS - 138 bar (2000 psi)

8. De-energize Lift function, shut down motor, and dis­connect pressure gauge.

Lift Down Speed Adjustment

1. Activate engine and allow hydraulic system to come
up to operating temperature.

2. Adjust color flow valve lift down speed at 30-40 sec­onds.

Leveling Jacks Valve (If Equipped)

1. Activate engine and allow hydraulic system to come
up to operating temperature.

2. Install pressure gauge at quick connect on Racine
Two Stack Va l v e .

3. Energize and bottom out any jack function. Adjust
relief cartridge as follows:

25RTS - 90 bar (1300 psi)

33RTS - 106 bar (1550 psi)

40RTS - 138 bar (2000 psi)

4. De-energize jack function and shut down engine.
Remove pressure gauge.

2.19 PRESSURE SETTING PROCEDURES - (2 W/S)

Racine Two Stack Valve

1. Install pressure gauge at quick connect on Racine
Two Stack Va l v e .

2. Adjust both Steer Section Crossover Relief’s all the
way in.

3. 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 172
bar (2500 psi).

6. Bottom out Steer Right and Steer Left functions and
adjust each Steer Crossover Relief to 103 bar (1500
psi).

3120826 – JLG Sizzor – 2-19

SECTION 2 - PROCEDURES

Figure 2-21. Pressure Adjustment Locations (2 W/S)

2-20 – JLG Sizzor – 3120826

SECTION 2 - PROCEDURES

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 Va l v e .

2. Adjust both Steer Section Crossover Relief’s all the
way in.

3. 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 172
bar (2500 psi).

6. Bottom out Front Steer Right and Steer Left func­tions and adjust each Steer Crossover Relief to 103
bar (1500 psi).

7. Bottom out Rear Steer Right and Steer Left functions
and adjust each Steer Crossover Relief to 103 bar
(1500 psi).

8. Bottom out Lift Overload functions and adjust Lift
Up Relief Pressure as follows:

4. De-energize jack function and shut down engine.
Remove pressure gauge.

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.

25RTS - 90 bar (1300 psi)

33RTS - 106 bar (1550 psi)

40RTS - 138 bar (2000 psi)

9. De-energize Lift function, shut down motor, and dis­connect pressure gauge.

Lift Down Speed Adjustment

1. Activate engine and allow hydraulic system to come
up to operating temperature.

2. Adjust color flow valve lift down speed at 25-30 sec­onds.

Leveling Jacks Valve (If Equipped)

1. Activate engine and allow hydraulic system to come
up to operating temperature.

2. Install pressure gauge at quick connect on Racine
Two Stack Va l v e .

3. Energize and bottom out any jack function. Adjust
relief cartridge as follows:

25RTS - 90 bar (1300 psi)

Figure 2-22. Oscillating Axle Cam Valve

1. Making sure that machine is on a level surface and
rear wheels are blocked, disengage drive hubs.

NOTE: All drive hubs must be unlocked on machines

equipped with 4WD.

.

Figure 2-23. Drive Hub Disconnect

33RTS - 106 bar (1550 psi)

40RTS - 138 bar (2000 psi)

3120826 – JLG Sizzor – 2-21

SECTION 2 - PROCEDURES

Figure 2-24. Pressure Adjustment Locations (4 W/S)

2-22 – JLG Sizzor – 3120826

SECTION 2 - PROCEDURES

2. Activate machine hydraulic system from platform
control station.

3. Start the Engine and place Engine Speed and Drive
Speed control switches to their respective “LOW”
positions.

4. Depress the Enable switch and activate Drive con­troller to “FORWARD” position.

5. Using a suitable lifting equipment lift front of
machine up and place a 20 cm (8 in.) high block
under left front wheel.

6. 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).

7. Using a suitable lifting deviece lift front of machine
and remove the block.

8. Transfer the block to right front wheel and repeat
steps 1 through 6, substituting the word “right” for
“left” in steps 5.

NOTE: After lockout cylinders are bled be sure to engage

drive hubs before removing stop block from rear
wheels.

3. 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.

5. Raise machine platform approximately 0.6 meters (2
ft.); ensure lockout cylinder cam valve is free of siz­zor arm trip bar.

6. Place drive controller to “REVERSE” position and
carefully drive machine off block and ramp.

7. Have an assistant check to see that left front wheel
remains locked in position off the ground.

8. Lower machine platform; lockout cylinder should
then release the wheel and allow it to rest on the
ground.

9. Transfer the block to front of right front wheel and
repeat steps 1 through 8, substituting 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.

Figure 2-25. Drive Hub Connect

9. To check lockout cylinder after bleeding, refer to
Section 2.22, Lockout Cylinder Check.

2.22 LOCKOUT CYLINDER CHECK

NOTE: Ensure platform is completely low e red pri or t o b egi n-

ning lockout cylinder check.

1. Place a 20 cm (8 in.) high block with ramp in front of
left front wheel.

2.23 PISTON DRIVE MOTOR

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 back plate.

4. Use a plastic mallet and tap the back plate to loosen
it.

5. Remove o-ring from back plate.

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 disassem­bled unless pins or spring are damaged.

2. Activate machine hydraulic system from platform
control station.

3120826 – JLG Sizzor – 2-23

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:

2 ea. 3/8 I.D. x 1-1/8 O.D. flat washers

1 ea. 3/8 x 3-1/4 N.C. cap screw

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.

7. Inspect thrust race; surface should show no signs of
scoring or grooves.

8. Inspect flat surface on back plate; it should be free
of excessive scoring or metal build-up. Do not lap
back plate.

9. 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.

1 ea. 3/8 N.C. nut

a. Place one of the flat washers over the 3/8 x 3-1/4

cap screw and place this through the center of
the piston block.

b. Place the other washer over the cap screw and

let it rest on the three pins.

c. Screw nut on cap screw and compress the

spring inside the piston block.

d. Using a pair of snap ring pliers, remove internal

snap ring.

e. Remove bolt, nut, and two washers.

f. Remove two washers, spring, three pins, and

pin keeper.

10. Remove thrust race, shaft seal, washer, and drive
shaft from housing.

11. Remove two snap rings, thrust washers, and thrust
bearing from drive shaft.

Inspection

1. Wash all parts thoroughly in a suitable solvent.

2. Examine needle bearings in housing and back plate.
If needles are free of excessive play and remain in
bearing cage, there is no need to replace bearing.

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 I.D. of new shaft seal and press into position.
Retain with snap ring.

3. Inspect thrust washers and thrust bearing. All sur­faces should be free of any signs of wear or fretting.

4. Inspect spider and pivot. Conical surfaces should be
free of wear and score marks.

5. Inspect pistons. The O.D. surface should be smooth
and free of scoring. Shoes should be snug fit to pis­ton. Face of shoes should be flat and free of scoring
and flaking. Do not lap piston shoes.

3. Compress pin keeper and install in spline area of
piston block.

2-24 – JLG Sizzor – 3120826

SECTION 2 - PROCEDURES

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 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.

6. Install pivot, spider, and piston assemblies in piston
block assembly.

7. Lubricate thrust race and install in housing assem­bly.

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 back plate if necessary.

10. Install new o-ring on back plate.

11. Install back plate on housing.

12. Install six cap screws and torque to 20-24 Nm (15-18
ft lbs).

.

3120826 – JLG Sizzor – 2-25

SECTION 2 - PROCEDURES

Figure 2-26. Piston Drive Motor

2-26 – JLG Sizzor – 3120826

SECTION 2 - PROCEDURES

2.24 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 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

1. Turn hub over on to its side. Remove coupling from
wide end of spindle.

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.

3. Remove sixteen flat washers from cover assembly.

4. Lift cover assembly off of ring gear, and set cover on
table, interior side facing up.

BEWARE OF SHARP EDGES IN COUNTER BORE WHEN REMOV­ING O-RING.

5. Remove o-ring from counter bore around edge of
cover. Discard o-ring.

NOTE: If o-ring is not in cover counter bore, it is in ring gear

counter bore. Remov e o-rin g from hub a nd dis card i t.

6. If necessary, disassemble cover as follows:

7. Remove thrust washer from counter bore in top of
carrier assembly.

8. Remove input gear from middle of carrier assembly .

9. Lift ring gear off of hub.

10. Lift carrier assembly out of hub.

11. If necessary, disassemble carrier assembly as fol­lows:

NOTE: When removing needle rollers from cluster gears,

discard old needle rollers and use new ones during
re-assembly.

a. Using a punch and hammer, drive roll pin into

planet shaft.

NOTE: If ro ll pin i sn ’t driven all the way into the planet shaft,

carrier could be damaged when planet shaft is
removed from carrier.

b. Using a punch and hammer, drive planet shaft

from carrier housing; one thrust washer, one
cluster gear, and one more thrust washer will
come off planet shaft and come to rest inside
carrier. Remove these parts from inside carrier.

c. Remove sixteen needle rollers from inside one

end of cluster gear. Discard needle rollers.

d. Repeat steps (a) through (c) to remove and dis-

assemble two remaining cluster gears.

12. Remove thrust spacer from input shaft assembly in
middle of spindle.

13. Lift input shaft assembly out of middle of spindle,
and stand input shaft on its splined end.

a. Remove two bolts holding disconnect cap to

cover .

b. Remove disconnect cap from on top of cover

cap and cover.

c. Remove two bolts securing cover cap to cover.

Remove cover cap.

d. Remove disconnect rod from cover cap.

e. Pry o-ring from groove inside cover cap. Discard

o-ring.

f. Remove o-ring from flange of cover cap. Discard

o-ring.

g. Remove pipe plug from cover.

WEAR SAFETY GLASSES WHEN PERFORMING STEP (14). BE
AWARE THAT SPRING AND SPACERS COMPRESSED BY RETAIN­ING RING MAY POP SUDDENLY OFF SHAFT WHEN RETAINING
RING IS REMOVED.

14. Using retaining ring pliers, remove retaining ring
from groove on input shaft.

15. Remove one spacer, one spring, and other spacer
from input shaft.

16. Remove thrust washer from around spindle.

17. Lift internal gear out of hub.

3120826 – JLG Sizzor – 2-27

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.

WEAR SAFETY GLASSES WHILE PERFORMING STEP (A).

a. Remove retaining ring from around spindle in

hub.

b. Remove spacer from around spindle in hub.

c. Set hub, small end/spindle facing down, up on

something that will support hub’s 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. 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.

e. Bearing cone should be lying loose in wide end

of hub. Remove bearing cone from inside hub.

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. 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 COUNTER BORE WHEN INSTALL­ING O-RING.

Assemble hub-spindle assembly as follows:

NOTE: Make sure cup sits square with counter bore before

pressing.

1. Set hub onto its large end. Press bearing cup into
counter bore in small end of hub.

NOTE: If hammer and punch are used to remove bearing

cups, make sure counter bore is not struck with
punch when removing bearing cup.

f. Remove bearing cup from counter bore in small

end of hub.

g. Turn hub over and lift it out of flange-support.

Remove bearing cup from wide end of hub.

h. Press nine studs out of stud holes in hub.

2. Press nine studs into stud holes in hub.

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. Do not be concerned if
gears seem to roll hard as long as they roll with consis­tency.

2-28 – JLG Sizzor – 3120826

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.

NOTE: Make su re cup sits squar e 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.

6. Press seal into small end of hub.

7. Oil spindle, then lower hub, small end down, onto
spindle.

5. Set hub onto its large end. Place bearing cone into
bearing cup.

8. Press bearing cone onto spindle in hub.

9. Place spacer onto spindle in hub.

3120826 – JLG Sizzor – 2-29

SECTION 2 - PROCEDURES

NOTE: Make sure retaining ring is securel y seate d in groov e

in spindle.

10. Place retaining ring over spacer onto spindle in hub.

11. Grease o-ring and place it into counter bore in hub.

14. Place thrust washer around spindle so that it rests
on bottom of internal gear.

15. Stand input shaft on its splined end. Place one
spacer onto smooth end of input shaft.

NOTE: O-ring may be stretched or pinched togeth er to m ake

it fit counter bore exactly.

12. Oil all exposed surfaces inside hub.

13. Place internal gear into hub so that its internal
splines mesh with external splines of spindle. Oil
internal gear.

16. Place one spring onto smooth end of input shaft.

2-30 – JLG Sizzor – 3120826

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.

18. Using retaining ring pliers, insert retaining ring into
groove on input shaft by compressing spring and
spacers together.

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.

19. With large, splined end down, place input shaft
assembly into spindle.

22. Place thrust spacer on top of input gear.

3120826 – JLG Sizzor – 2-31

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.

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.

4. Set carrier housing on table, sideways. Insert a
planet shaft, roll pin hole last, into one of the planet
shaft holes from roll-pin-holed side of carrier hous­ing.

6. Following the thrust washer, place cluster gear, large
end toward roll pin hole in carrier housing, onto
planet shaft.

7. Following the cluster gear, place one more thrust
washer onto planet shaft, fitting the tang of thrust
washer into the slot on the inside edge of the planet
shaft hole. Now insert shaft through the opposite
planet shaft hole in carrier housing.

8. Use an alignment punch or similar tool to align the
roll pin holes in carrier housing and planet shaft.

9. Drive roll pin down into the aligned roll pin holes in

5. Place one thrust washer onto the end of planet shaft
inside carrier. Fit tang of thrust washer into the slot
on the inside edge of the planet shaft hole.

carrier housing and planet shaft.

2-32 – JLG Sizzor – 3120826

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.

12. With “X-marked side facing up, place ring gear
around cluster gears.

NOTE: This will hold punch marks in position while installing

carrier into hub.

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. Place thrust
washer into counter bore in top of carrier assembly .

Assemble cover as follows:

1. Using disconnect rod, push o-ring into groove inside
cover cap.

2. Place o-ring onto cover cap so it rests against flange
of cover cap.

13. 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
outside of ring gear and hub.

3120826 – JLG Sizzor – 2-33

SECTION 2 - PROCEDURES

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.

8. Place two remaining bolts into bolt holes in discon­nect cap, and tighten bolts.

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. Set cover assembly on table, interior side up.
Grease o-ring and place it into counter bore around
edge of cover.

5. Place two cover cap bolts into any two bolt holes
180 degrees apart on cover cap, then tighten bolts.

6. Torque both bolts to 4 - 5 Nm (36 - 49 in. lbs.).

7. With large end down, place disconnect cap onto
cover cap, aligning pipe plug hole in disconnect cap
over pipe plug hole in cover cap.

NOTE: O-ring may be stretched or pinc hed tog ether t o make

it fit counter bore exactly.

2-34 – JLG Sizzor – 3120826

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.

13. Place four flat washers on top of bolt holes in cover
assembly.

14. Place shoulder bolts into four shoulder bolt holes in
cover and tighten by hand.

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. Ratio is last two digits of model number on
unit’s ID tag. For example, if model number is
W1BFF0335, then roll unit 35 times in each direc­tion.

20. Leak test unit in accordance with paragraph c at a
pressure of 0.4 bar (5 psi) for 2-3 minutes.

2.25 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 UNIT’S GEARS AND SEALANTS ARE
WORKING PROPERLY.

Disassembly

15. Place remaining twelve flat washers onto remaining
bolt holes in cover.

16. Place twelve bolts into remaining bolt holes in cover
and tighten.

17. Torque shoulder bolts to 25 - 34 Nm (18 - 25 ft. lbs.).
Torque bolts to 25 - 34 Nm (18 - 25 ft. lbs.).

1. Remove pipe plug from cover and drain oil from unit.

2. 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.

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 10-11
bar (140 - 160 psi).

f. Roll test brake in both clockwise and counter-

clockwise directions. Perform same number of
turns in each direction as ratio of unit. This num­ber is the same as the last two digits of the
model number found on the unit’s ID tag. For
example, if unit’s model number is W1BJ4U318,
then it should be rolled 18 times in both direc­tions.

g. Set hand pump to “RELEASE” and check to see

if brake has reset itself. If brake has reset roll
checker should not be able to turn.

3120826 – JLG Sizzor – 2-35

SECTION 2 - PROCEDURES

Figure 2-27. Drive Torque Hub - 2WD/4WD Rear

2-36 – JLG Sizzor – 3120826

SECTION 2 - PROCEDURES

h. Remove roll checker from spindle/brake.

i. Remove hydraulic line from its brake port.

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.

4. Remove the twelve grade 8 bolts and four shoulder
bolts from cover.

5. Remove flat washers from cover.

6. Remove cover from hub.

7. 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 counter bore in cover. Dis­card o-ring.

c. Turn cover over. Remove two bolts that hold dis-

connect cap in place.

d. Remove disconnect cap from cover.

e. Remove two remaining bolts that hold cover cap

in place.

f. Remove cover cap from cover.

g. Remove disconnect rod from cover cap.

h. Remove o-ring from groove inside cover cap.

Discard o-ring.

i. Remove o-ring from outside of cover cap. Dis-

card o-ring.

8. Remove thrust washer from carrier assembly.

9. Remove thrust spacer from input shaft assembly).

10. Remove ring gear from mesh with carrier assembly.

13. Remove input gear from input shaft assembly.

14. Remove thrust spacer from input shaft assembly.

15. Remove input shaft assembly from spindle/brake.

16. If necessary, disassemble input shaft as follows:

a. Remove retaining ring from input shaft. Discard

retaining ring.

b. Slide spacer, spring, and other spacer off of

input shaft.

17. Remove thrust washer from bottom of internal gear.

18. Remove internal gear from hub.

19. Remove o-ring from counter bore in hub. Discard o­ring.

20. Using a screwdriver or chisel and hammer,
straighten out tang on lock washer which has been
bent into notch in locknut.

21. Using an N-13 locknut wrench (tool no. T-141863),
loosen locknut. Remove locknut from spindle/brake
and discard.

22. Remove lock washer from spindle/brake and dis­card.

23. Remove tongued washer from spindle/brake.

24. Lift bearing cone out of hub.

25. Lift hub off of spindle/brake.

26. Using a slide hammer, remove seal from small end
of hub. Discard seal.

27. Lift bearing cone off of spindle/brake.

11. Remove carrier assembly from hub.

12. If necessary, disassemble carrier assembly as fol­lows:

a. Locate roll pin in carrier housing. Drive roll pin

down into planet shaft until it bottoms against
carrier housing. 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 orig­inally went into.

c. Remove planet shaft from carrier housing. Two

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.

28. Using a soft punch and hammer, remove bearing
cup from deep end of hub.

NOTE: When using punch, be very careful not to strike

counter bore of hub where cup is located.

29. Using a soft punch and hammer, remove bearing
cup from shallow end of hub.

NOTE: This cup can be reached by putting punch into small

access hole in bottom of hub’s deep end.

30. Remove two pipe plugs from pipe plug holes in side
of hub.

31. Remove two magnetic pipe plugs from pipe plug
holes in flange of hub.

32. Hammer out nine studs.

3120826 – JLG Sizzor – 2-37

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. 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. 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

1. Grease o-ring.

2. Place o-ring into counter bore in hub.

BEWARE OF SHARP EDGES AND BURRS IN COUNTER BORE
WHEN INSTALLING O-RING.

NOTE: O-rings may be stretched to fit counter bore. If an o-

ring has been st retched too m uch, sim ply squee ze o­ring together bit by bit while placing it around co unter
bore. It can be made to fit exactly.

3. Oil exposed surfaces inside hub.

4. Mark four shoulder bolt holes on hub so for align­ment with shoulder bolt holes in ring gear and cover.

5. Place internal gear into hub so its internal splines
mesh with external splines of spindle/brake.

6. Oil internal gear.

7. Place thrust washer onto spindle/brake so it rests on
bottom of internal gear.

SAFETY GLASSES SHOULD BE WORN DURING FOLLOWING
PROCEDURE.

b. Place retaining ring onto input shaft. Using

retaining ring pliers, insert retaining ring into
groove on input shaft by compressing spring
and spacers together.

9. With large, splined end down, place input shaft
assembly into spindle/brake.

10. Place thrust spacer onto input shaft.

11. With internal splines facing up, place input gear into
mesh with input shaft assembly.

12. Assemble carrier as follows:

a. Apply grease to inside of one cluster gear.

b. Line one half of cluster gear with 16 needle roll-

ers.

c. Place one spacer inside cluster gear so it rests

on 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 hous­ing 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).

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.

k. Repeat steps (a) through (j) to install two remain-

ing cluster gears.

8. Assemble input shaft as follows:

a. Place one spacer, spring, and other spacer, IN

THAT ORDER, onto smooth end of shaft.

2-38 – JLG Sizzor – 3120826

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.

14. With squared shoulder side down, place internal
gear into mesh with cluster gears in carrier. If ring
gear is on correctly, the “X” marking a shoulder bolt
hole should face up.

NOTE: Make sure punch marks on cluster gears remain in

their correct positions when installing ring gear.

15. Place carrier assembly and ring 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.

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. If an o-

ring has been str etched too m uch, sim ply squ eeze o­ring together bit by bit while pl acing it around co unter
bore. It can be made to fit exactly.

l. 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. Make sure shoulder bolt
holes in cover and ring gear are aligned.

NOTE: 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.

16. Oil all exposed surfaces inside hub.

17. Place thrust spacer onto input shaft assembly.

18. Place thrust washer into counter bore in carrier

19. 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 degrees apart on cover cap and tighten.

f. Using a torque wrench, apply 4- 5 Nm (36 to 49

in. lbs) 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.

21. Place sixteen flat washers 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 25 - 35 Nm (18 - 25 ft. lbs.) of torque to all
bolts.

25. Leak test unit at a pressure of 0.4 bar (5 psi) for 2-3
minutes.

3120826 – JLG Sizzor – 2-39

SECTION 2 - PROCEDURES

Figure 2-28. Drive Torque Hub/Brake - 4WD Front

2-40 – JLG Sizzor – 3120826

SECTION 2 - PROCEDURES

2.26 DRIVE BRAKE - 2WD/2WS REAR

Disassembly

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. MIN. (1361 KG MINI­MUM), COVER CAN BE HELD IN POSITION WHILE REMOVING
WASHER HEAD CAP 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 discs, return
plate, and friction discs from housing.

7. Remove dowel pins, springs (5 & 6), and spring
retainer 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 .

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.

4. Insert shaft assembly and retaining ring in housing.

5. Insert dowel pins, spring retainer, and springs (5 &

6) in housing

3120826 – JLG Sizzor – 2-41

SECTION 2 - PROCEDURES

NOTE: Be sure to use the same number of springs and

same spring pattern as recorded during disassem­bly.

6. Position new large diameter return plate in housing
with tabs guided by dowel pins until disc rests on
springs.

8. Add additional new discs and new friction discs as
required to complete assembly.

9. Insert separators in holes of return plate.

NOTE: Discs and friction discs should remain dry during

installation. No oil residue should be allowed to con­taminate di sc surfaces.

7. Place a new friction disc on shaft until it contacts
return plate.

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. Insert piston into end cover,
being careful not to shear o-rings or back-up rings.

2-42 – JLG Sizzor – 3120826

SECTION 2 - PROCEDURES

Figure 2-29. Drive Brake - 2WD/2WS

3120826 – JLG Sizzor – 2-43

SECTION 2 - PROCEDURES

11. Install case seal in housing, then install bleeder
screw in end cover.

12. Position end cover on housing, aligning dowel pins
with holes 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.

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, with­out 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 fuel regu­lator.

13. Install washer head cap screws and tighten evenly
to draw end cover to housing. Torque washer head
cap screws to 75 Nm (55 ft. lbs.).

NOTE: If ava il abl e, a hy d rau li c p r es s wil l si mpl if y ins t alla t i on

of end cover on housing. Clamp cover in position
while tightening washer head cap screws.

14. If hydrostatic bench testing is done on brake assem­bly, release pressure should not exceed 2000 psi
(138 bar) unless two additional bolts are used for
supplemental clamping.

2.27 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.

Changing From LP Gas to Gasoline

1. With engine operating on LP under a no-load condi­tion, 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 posi­tion.

3. Close hand valve on LP gas supply by turning clock­wise.

Using Liquid Petroleum (LP) Gas

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.

1. If machine is to be left overnight or longer, it must be
parked outside or the LPG tank removed and stored
outside.

2-44 – JLG Sizzor – 3120826

SECTION 2 - PROCEDURES

2. LPG is extremely flammable. No smoking.

3. Only trained and authorized personnel are permitted
to operate filling equipment.

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. 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 & 505.

DO NOT USE AN LPG TANK THAT IS DAMAGED. A DAMAGED
TANK MUST BE REMOVED FROM SERVICE. FROST ON THE SUR­FACE OF A TANK, VALVES, OR FITTINGS INDICATES LEAKAGE.
A STRONG ODOR OF LPG FUEL CAN INDICATE A LEAK.

2.29 FREEWHEELING FEATURE

RUNAWAY VEHICLE/MACHINE HAZARD. MACHINE HAS NO TOW­ING BRAKES. TOWING VEHICLE MUST BE ABLE TO CONTROL
MACHINE AT ALL TIMES. ON-HIGHWAY TOWING NOT PERMIT­TED. FAILURE TO FOLLOW INSTRUCTIONS COULD CAUSE SERI­OUS INJURY OR DEATH.

To D is en ga ge To r q u e H u b s ( F r e e w h e e l )

1. Chock wheels securely.

Figure 2-30. Drive Hub Disengaged

2. Disengage (reverse) disconnect caps on drive
torque hubs by removing two attaching cap screws,
turning cap around, then reinstalling and tightening
cap screws.

3. If desired, remove chocks and using suitable equip­ment for assistance, move machine to an appropri­ate maintenance area. Again chock wheels securely.

To Engage Torque Hubs

Engage (reverse) disconnect cap on both drive torque
hubs by removing two attaching cap screws, turning cap
around, then reinstalling and tightening cap screws.

Figure 2-31. Drive Hub Engaged

3120826 – JLG Sizzor – 2-45

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. The “INTERVAL” portion of the table is
divided into five columns representing the various inspec­tion time periods. The numbers listed within the interval
column represent the applicable inspection code for
which that component is to be checked.

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 (stamp)
inspection dates. Notify dealer if inspection is over­due.

The inspection and maintenance code numbers are as fol­lows:

1. Check for proper and secure installation.

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
Industries.

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.

5. Check for leakage.

6. Check for presence of excessive dirt or foreign
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 inspection
stamp.

2-46 – JLG Sizzor – 3120826

SECTION 2 - PROCEDURES

Table 2-3. Preventive Maintenance and Safety Inspection

AREA INTERVAL

10Hours

(Daily)

P LA TF O RM

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

C HA S S IS

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. Hydraulic Pump 1 5

7. Valves 1 5

8. Hydraulic Filter ( See Lubrication Chart) 5,14 14

9. Hydraulic Hoses and Tubing 1 5

10. Hydraulic Oil Ta nk* 3 5 4

11. Hydraulic Tank Breather 6,14

12. Fuel Tank 3,5 4

13. Lift Cylinder 1,12 5,6,13 4

14. Limit Switch 1,7

15. Tilt Alarm Switch 1,7

16. Placards and Decal s 1,2

17. Wheel and Tire Asse mblies 1 8,9

18. Drive Motors 1,5,6

19. Drive Brakes 1,6 8

20. Drive Torque Hubs 1,3,5,6

21. Steer Cylinder 1 5,6,13 4

22. Steer Components 1 4,6 8

23. Wheel Bearings (2 W heel Drive) 8 12

24. Sizzor Arms 1,4

25. Safety Props 1,4

26. Sliding Wear Pads 8

27. Pivot Pins/Bolts 1,4 7,8

28. Switches, Ground C ontrol 1,11

29. Control Tags 1,2

50 Hours
(Weekly)

200 Hours

(Monthly)

500 Hours

(3 Month)

1000 Hours

(6 Month)

*Inspection and Maintenance Code 10 to be performed annually

3120826 – JLG Sizzor – 2-47

SECTION 2 - PROCEDURES

This page left blank intentionally.

2-48 – JLG Sizzor – 3120826

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.

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 prob­able 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 thor­ough 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 proba­ble cause and remedy may be immediately obvious are
not listed in this section.

The first rule for troubleshooting any circuit that is hydrau­lically operated and electrically controlled is to determine
if the circuit is lacking hydraulic oil and electrical 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 mechani­cally. 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 sys­tem, where the cause is not immediately apparent, should
be the troubleshooting chart. The best place to begin the
problem analysis is at the power source (pump) Once it is
determined that the pump is serviceable, then a system­atic 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.

3120826 – JLG Sizzor – 3-1

SECTION 3 - TROUBLESHOOTING

Table 3-1. Platform Assembly - Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

No response to control s witch

Enable switch not ac tivated Activate enable switch

Function not activated within the 3 seconds after
enable switch was d epressed

Enable switch not fu nctioning properly Replace e nable switch circuit card

Lift control swi tch inoperative Repair or replace lift c ontrol switch

Hydraulic system oil low Replenish oil as neces sary

No power supply See wiring diagram

Restricted or brok en supply line on valve bank or
hydraulic pump

Control valve no t functioning properly Repair or replace val ve

Defective dump va lve on cylinder Repair or replace dump valve

Lift cylinder not f unctioning properly Repa ir or replace lift cylinder

Hydraulic pump not func tioning properly Repair or r eplace hydraulic pump

Platform will not raise

Enable switch not ac tivated Activate enable switch

Function not activated within the 3 seconds after
enable switch was d epressed

Enable switch not fu nctioning properly Replace e nable switch circuit card

Load capacity exceeded. ( Personnel and/or equip­ment.)

Hydraulic system oil low Replenish oil as ne cessary

Broken or binding pi vot pin Repair or replace piv ot pin

Restricted or broken hydrau lic line or fitting Clean, repair or replace line or fittin g

Control valve no t functioning properly Repair or replace contr ol valve

Lift cylinder not f unctioning properly Repa ir or replace lift cylinder

Pump does not res pond when lift control switch is
moved to the up position

No electrical signal being sent to lift up control valve
cartridge

Platform will not lower

Enable switch not ac tivated Activate enable switch

Function not activated within the 3 seconds after
enable switch was d epressed

Enable switch not fu nctioning properly Replace e nable switch circuit card

Pump does not res pond when lift control switch is
moved to the down position

No electrical si gnal being sent to lift down cont rol
valve cartridge

Lift down control valve cartridge not functioning
properly

Lift cylinder not f unctioning properly Repa ir or replace lift cylinder

Reactivate enable switc h

Clean, repair or replace line

Reactivate enable switc h

Reduce load. (Refer to capacity placard.)

Refer to electrical troubleshooting table

Refer to electrical troubleshooting table

Reactivate enable switc h

Refer to electrical troubleshooting table

Refer to electrical troubleshooting table

Repair or replace li ft down control valve cartridge

3-2 – JLG Sizzor – 3120826

TROUBLE PROBABLE CAUSE REMEDY

Platform raises and lowers erratically

Platform drifts down

High drive does not op erate below set height

SECTION 3 - TROUBLESHOOTING

Table 3-1. Platform Assembly - Troubleshooting

Hydraulic system low Replenish hydraulic o il as required

Restricted or broken hydrau lic line or fitting Clean, repair or replace line or fi tting

Lack of lubricant o n lift cylinder attach pins Lubricate as required (Refer to lubrica tion chart)

Counterbalance valv e on lift cylinder improperly
adjusted or not functi oning properly

Control valve n ot functioning properly Repair or replace v alve

Sizzor arm pins no t properly lubricated Lubricate as necessary

Worn seals in lift cy linder Replace seals

Cylinder not functioni ng properly Repair or replace lift cylinder

Manual lowering val ve not functioning properly Repair or repl ace valve

Worn seals in lift cy linder Replace seals

Holding valve o n lift cylinder not functioning pro p­erly

Damaged wiring on l imit switch Repair or replace wir ing

Damage limit switc h Replace limit s witch

Flow control valve not functioning properly Repair or replace flow control valve

Flow control valve not properly set Reset flow control va lve

Replace valve

Repair or replace h olding valve

3120826 – JLG Sizzor – 3-3

SECTION 3 - TROUBLESHOOTING

TROUBLE PROBABLE CAUSE REMEDY

No response to control

Enable switch not activated Activate enable switch

Function not activated within the 3 secon ds after
enable switch was depressed

Enable switch not functioning properly Replace enable swi tch circuit card

Hydraulic syste m oil low Replenish oi l as necessary

Drive hubs diseng aged Engage h ubs

Controller not prop erly adjusted Correc tly adjust controller

Hydraulic pump not functioning properly Repair or replace pum p

Restricted or b roken pump supply line Clean, repair or replace li ne

Restricted or b roken line on valve bank Clean, repair or r eplace line

Drive motor(s) not functioning properly Repair or replace motor(s)

Damaged wiring on c ontroller Repair or replace wiring

Controller not func tioning properly Repair or replace c ontroller

Drive brake not releasing Determine cause and repair or replace brake

Machine drives err atically

Microswitch on contr oller improperly adjusted Adjust microswitch on controller for proper opera -

Machine will not travel forw ard

Enable switch not activated Activate enable switch

Function not activated within the 3 secon ds after
enable switch was depressed

Enable switch not functioning properly Replace enable swi tch circuit card

Hydraulic syste m oil low Replenish oi l as necessary

Restricted or b roken hydraulic line or fitting Clean, repair or replace line or fitting

Controller not adj usted properly Cor rectly adjust controller

Control valve not f unctioning properly Repair or repl ace valve

Drive motor(s) not functioning properly Repair or replace motor(s)

Defective controll er Repair or replace c ontroller

Machine will not travel in reverse

See: Machine will not travel forward

High speed function does not operate

Loose or damaged wirin g between controller and
high speed switch

Defective high spee d control switch R eplace switch

Loose or damaged w ire in control box wire har ­ness

Table 3-2. Chassis Troubleshooting

DRIVE SYSTEM

Reactivate enable switch

tion

Reactivate enable switch

Ensure proper connec tion of wires. Using suitable
test meter, perform continuity tes t on wiring
between controller and switches. Repair or
replace wires as ne cessary.

Ensure proper con nection of wire at the control
switch. Using suitable test meter, perform continu­ity test on wire. re pair or replace harness as neces ­sary.

3-4 – JLG Sizzor – 3120826

TROUBLE PROBABLE CAUSE REMEDY

No response to control

Machine hard to s teer or steering is erratic

Steering inoperative

SECTION 3 - TROUBLESHOOTING

Table 3-2. Chassis Troubleshooting

Loose or damaged wire b etween platform and
high speed solen oid

High speed solenoi d not functioning properly Replace e sol enoid

Loose or damaged wir es between high sped relay
and high speed limi t switch

High speed limit switch not functioning properly Repair or replace limit switch

Loose or damaged wir e in valve wiring harness Ensur e proper connection of wires a t the terminal

STEERING SYSTEM

Enable swit ch not activated Activate enable switch

Function not activated within the 3 secon ds after
enable switch was depressed

Enable switch not functioning properly Replace enable s witch circuit card

Hydraulic syste m oil low Replenish oi l as necessary

Damaged wiring o n control switch or solenoid
valve

Controller not func tioning properly Replace controller

Restricted or b roken hydraulic line on valv e bank
or hydraulic pump

Control valve not f unctioning properly Repair or replace valve

Steer cylinde r not functioning properly R epair or replace steer cylinder

Hydraulic syste m oil low Replenish oi l as necessary

Restricted hydr aulic line or fitting Clean, r epair or replace line or fitt ing

Lack of lubricati on Lubricate as required (refer to lu brication chart)

Restricted cro ssover relief valve (press ure low) Clean or replace valve

Steer system pressu re low Adjust pressu re

Bent steering lin kage Repair or replace linkage as requir ed

Hydraulic pump not functioning properly Repair or replace pum p

Steer cylinde r not functioning properly R epair or replace cylinder

Tire pressure low Correct tire pres sure

Bent or seized sp indle Replace s pindle

Damaged wiring o n controller or solenoid valve See proper wiring diagram

Solenoid valve no t functioning properly Repair or replace valv e

Controller not func tioning properly Replace controller

Relief valve improp erly set or not functioning prop­erly

Steer cylinde r not functioning properly R epair or replace steer cylinder

Ensure proper con nection of wire at the platform
and at the high s peed solenoid. Using suitable tes t
meter, perform continuity t est on wire. repair or
replace harness as necessary.

Ensure proper con nection of wires between high
speed relay and high speed limit switc h. Using
suitable test meter, perform contin uity test on wire.
repair or replac e harness as necessary.

strip. Using sui table test meter, perform continuity
test on wire. repair or replace har ness as neces­sary.

Reactivate enable switch

See proper wiring diagr am

Clean repair or repl ace line

Reset, repair or r eplace valves as required

3120826 – JLG Sizzor – 3-5

SECTION 3 - TROUBLESHOOTING

TROUBLE PROBABLE CAUSE REMEDY

Machine will not steer le ft or right

Enable switch not activated Activate enable switch

Function not activated within the 3 secon ds after
enable switch was depressed

Enable switch not functioning properly Replace enable swi tch circuit card

Wiring on control ler is damaged R epair or replace wiring

Wiring on solenoid valve is damaged Repai r or replace wiring

Coil in solenoid is damaged Replace coil

Bent cylinder ro d Repair or replace c ylinder

Damaged steer li nkage Repair or replace s teer linkage

Crossover rel ief valve stuck Repair or repl ace crossover relief valve

Pressure setti ng incorrect R eset pressure setting

Machine wanders; s teering not firm

Crossover reli ef valve set too low or not function ing
properly

Steer linkages l oose Tighten linkage

Steer wheel toe- in not set properly Adjust toe-in f or 1/4 inch overall

Spindle bushings badly worn Replace bushings

Spindle bushings to tight Replace bu shings

Axle will no t oscillate

Defective lockout cylinder Repair or replace cylinder

Lockout valve s ticking Repair or replace valve

Lack of lubricati on on axle pin Lubricate pin

Lockout valve d efective Repair or replace valve

Axle will n ot lock

Air in lockout system Bleed loc kout system

Defective lockout valve R epair or replace valve

Defective pressure r educing valve feeding lockout
system

Table 3-2. Chassis Troubleshooting

Reactivate enable switch

Reset, repair or r eplace valve as required

OSCILLATING AXLE (IF EQUIPPED)

Repair or replace valve

3-6 – JLG Sizzor – 3120826

TROUBLE PROBABLE CAUSE REMEDY

Engine will not st art

Engine will not start (Ignition O.K.)

Engine will not ac celerate above low speed

Engine will not decelerate below high speed

SECTION 3 - TROUBLESHOOTING

Table 3-3. Chassis Troubleshooting

ENGINE

Station power sele ctor switch is not in requir ed
position

Circuit breaker o pen Determin e and correct cause. Reset circui t breaker

Start lockout so lenoid not working Replace solenoid

Start switch defective Replace start switc h

Defective anti-di eseling solenoid on carbure tor Replace solenoid or carb uretor

Damaged wiring in igni tion circuit (broken wire on
starter

Ignition switch not fu nctioning properly Rep lace switch

Defective ignition module Replace ignition module

Ignition circuit shor ted to ground Repair circuit card as required

Battery cable(s) not making contact Clean and tighten cables

No fuel Replenish fuel as nec essary

Restricted or broken f uel line Clean or replace line

Battery defective or r equires charging Charge or replace ba ttery as required

Damaged wiring on sp eed control switch on gover­nor solenoid

Speed control sw itch not functioning properly Rep lace switch

Defective preci sion governor (Ford) Repair or rep lace governor

Defective Adeco t hrottle actuator (Deutz) Repair or replace actuator

Governor not functioni ng properly Repair o r replace governor

Defective electronic gov ernor Replace govern or

See engine will not ac celerate above low speed

Actuate switch as requir ed

repair or replace wiri ng

Repair or replace wiring

3120826 – JLG Sizzor – 3-7

SECTION 3 - TROUBLESHOOTING

Table 3-4. Hydraulic System Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

Hydraulic pump noi sy

Air entering system through broken line or fitting Repair or replace line or fitting

Air bubbles in oil Replenish oil as required

Faulty pump couple r Replace coupler

Defective pump beari ng Repair or replace pump

Oil filter(s) dir ty Clean and/or replace filter(s) as necessary

Pump cavitating (Vacuum in pump due to oil star­vation

Restricted suc tion line Clean, repair, or replace l ine

OIl in reserve lo w Replenish oil to pro per level

Restricted rese rvoir air vent Clean vent

Oil viscosity t o high Drain system and replace w ith recommended oil

Leak in suction line or manifold Repair or replace line or manifold as necessary

System overheating

Oil viscosity t oo high Drain system and replace wit h recommended oil

Restricted or b locked hydraulic line Repair or replace line

Machine overloaded C heck weight in platform

Main relief va lve set too high Reset val ve as required

Hydraulic system o il low Replenish oil as necessar y

Pump not delivering o il

Restricted suc tion line Clean repair or r eplace line

Air entering system through broken line or fittin g
(suction side)

Oil level too low Replenish oi l to proper level

Plugged strainer in tank Clean strainer

Pump coupling defect ive Replace pump cou pling

Broken pump drive s haft Repair or replace pu mp

System pressure too l ow

Main relief va lve set too low Reset valve as required

Main reli ef valve s tuck in open position Clean, r epair or replace valve (Check system oil for

Hydraulic pump not func tioning properly R epair or replace pump

Leak in component, li ne or fitting Repair or replace component, line or fi tting

Scored valve spo ol; Scored cylinder Replace valve; Replace cylinder

System(s) operate erra tically

Sticking or bind ing valve spools, piston rod, et c Clean, repair or replace c omponents as required

Hydraulic oil not a t optimum operating tempera­ture

Pump drive slippi ng Repair or repl ace drive

(Refer to hydraulic oi ls)

(Refer to hydraulic oi ls)

Replace or repair l ine or fitting

contamination)

Allow oil sufficient time to warm up

3-8 – JLG Sizzor – 3120826

TROUBLE PROBABLE CAUSE REMEDY

Regardless of whi ch way handle is moved, only
one function occurs

Valve will not function when handl e is moved in
either direction

No response to a function control switc h

SECTION 3 - TROUBLESHOOTING

Table 3-5. Electrical System Troubleshooting

HAND CONTROLLER

Improper or loose wi ring to the solenoid(s) Check all wiring for prop er connections

Directional valve stuck in one direction Repair or replace valve

Enable switch not activated Act ivate enable switch

Function not activated within the 3 seconds after
enable switch was depressed

Enable switch not func tioning properly Replace enable switch circuit card

No electrical power to handle Check elec trical input to hand controller ( 12V)

No electrical power to valve Check electrical output of printed circuit board and

Improper ground Check for proper grounding of handle

Defective controller Repair or re place controller

Microswitches on controlle r bad or need adjust­ment

CONTROL SWITCHES

Emergency stop switch not positi oned properly Place emergency stop switch to on

Platform/Ground select switch not positioned
properly

Circuit breaker open Determine and correct cau se. Reset circuit

No voltage present at em ergency stop switch Check battery ca ble from battery to emergency

Emergency stop switch not functi oning properly Replace switch

No voltage suppli ed to start relay from emer gency
stop switch

No voltage input at terminal stri p Check wi re from battery to terminal strip for pr oper

No voltage pres ent at circuit breaker Check wire from ter minal strip to battery for proper

Defective circuit breaker Replace circuit bre aker

No voltage present at P latform/Ground select
switch

Reactivate enable swit ch

electrical signal at the valve

Adjust or replac e switches

Place switch to pl atform or ground, as necessary

breaker

stop switch for proper conne ction or damage.
Repair or replace cable as necessary

Check battery cable from sw itch to relay for proper
connection or dama ge. Repair or replace cable as
necessary

connection or dama ge. Repair or replace cable as
necessary

connection or dama ge. Repair or replace cable as
necessary

Unplug ground control box harness from platform
receptacle. check wi re from applicable pin in plug
to control box po wer switch for proper connection.
Using suitable test me ter, perform continuity test
on wire. Repair or replace harness as necessary

3120826 – 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 present at fun ction control switch Check wiring from power switch to function control

Defective function control switch Replace function control switch

No voltage present at ap plicable control valve coil Check applicable wire for proper connection at

No voltage supplied to motor from start relay Check battery cable from relay to motor for proper

Defective motor/pump assembly Replace motor/pump assembly

Engine will not crank

Discharged battery or l oose battery terminals Check and char ge battery or replace battery as

Starter relay faulty or faulty relay connections U sing a test meter, check relay coil termina ls for

Malfunctioning starter s olenoid or motor Replace solenoid or motor in accord ance with

Defective start lockout solenoid Replace start lockout so lenoid

Malfunctioning ignition switch Using a test meter, check igniti on switch for cor-

Faulty ignition and/or starter circuit wiring Check wiring continu ity. refer to wiring diagram

Defective ring gear o r flywheel Replace ri ng gear

Ammeter inoperativ e

Damaged wiring in circuits Repair or replace wiring

Ammeter not functio ning properly Replace ammeter

Alternator not charging Repair or replace alternator

Travel warning horn inopera tive

Circuit breaker open Determine and correct cau se

Damaged wiring in horn circuit Replace horn

Hourmeter inoperativ e

Damaged wiring in hourmeter cir cuit Repair or replace wiri ng

Inoperative hourmeter Replace hourm eter

switch for proper connection or damage. Repai r or
replace wiring as ne cessary

terminal strip, valve har ness plug pin, valve har­ness receptacle pin and valve coil. Using suit able
test meter, perform continuity test on wire. Repair
or replace harness as necessary

connection or damage. R epair or replace cable as
necessary

ENGINE STARTER SYSTEM

necessary. Clean and secure battery terminals

presence of electrical power and for energization
of relay coil. Also check relay terminals for correct
switching of con tacts. Replace relay as necessary

applicable manufactu rer’s manual

rect switching of contacts. replace switch as nec­essary

INSTRUMENTS AND IN DICATORS

3-10 – JLG Sizzor – 3120826

SECTION 3 - TROUBLESHOOTING

2792368 A

Figure 3-1. Hydraulic Schematic - Sheet 1 of 3

3120826 – JLG Sizzor – 3-11

SECTION 3 - TROUBLESHOOTING

2792368 A

Figure 3-2. Hydraulic Schematic - Sheet 2 of 3

3-12 – JLG Sizzor – 3120826

SECTION 3 - TROUBLESHOOTING

2792368 A

Figure 3-3. Hydraulic Schematic - Sheet 3 of 3

3120826 – JLG Sizzor – 3-13

SECTION 3 - TROUBLESHOOTING

Figure 3-4. Electrical Schematic (Ford) - Sheet 1 of 2

3-14 – JLG Sizzor – 3120826

SECTION 3 - TROUBLESHOOTING

Figure 3-5. Electrical Schematic (Ford) - Sheet 2 of 2

3120826 – JLG Sizzor – 3-15

SECTION 3 - TROUBLESHOOTING

Figure 3-6. Electrical Schematic (Deutz) - Sheet 1 of 2

3-16 – JLG Sizzor – 3120826

SECTION 3 - TROUBLESHOOTING

Figure 3-7. Electrical Schematic (Deutz) - Sheet 2 of 2

3120826 – JLG Sizzor – 3-17

SECTION 3 - TROUBLESHOOTING

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3-18 – JLG Sizzor – 3120826

McConnellsburg PA. 17233-9533

Customer Support Toll Free: [phone]

JLG Worldwide Locations

Corporate Office

JLG Industries, Inc.

1 JLG Drive

USA

Phone: [phone]

Fax: [phone]

JLG Industries (Australia)
P.O. Box 5119
11 Bolwarra Road
Port Macquarie
N.S.W. 2444
Australia
Phone: [phone]
Fax: [phone]

JLG Latino Americana Ltda.
Rua Eng. Carlos Stevenson,
80-Suite 71
13092-310 Campinas-SP
Brazil
Phone: [phone]
Fax: [phone]

JLG Industries (Europe)
Kilmartin Place,
Tannochside Park
Uddingston G71 5PH
Scotland
Phone: [phone]
Fax: [phone]

JLG Industries (UK)
Unit 12, Southside
Bredbury Park Industrial Estate
Bredbury
Stockport
SK6 2sP
England
Phone: [phone]
Fax: [phone]

JLG Europe B.V.
Jupiterstraat 234
2132 HJ Foofddorp
The Netherlands
Phone: [phone]
Fax: [phone]

JLG Industries (Pty) Ltd.
Unit 1, 24 Industrial Complex
Herman Street
Meadowdale
Germiston
South Africa
Phone: [phone]
Fax: [phone]

JLG Deutschland GmbH
Max Planck Strasse 21
D-27721 Ritterhude/lhlpohl
Bei Bremen
Germany
Phone: [phone]
Fax: [phone]

JLG Industries (Norge AS)
Sofeimyrveien 12
N-1412 Sofienyr
Norway
Phone: [phone]
Fax: [phone]

Plataformas Elevadoras
JLG Iberica, S.L.
Trapadella, 2
P.I. Castellbisbal Sur
08755Castellbisbal
Spain
Phone: [phone]
Fax: [phone]

JLG Industries (Italia)
Via Po. 22
20010 Pregnana Milanese - MI
Italy
Phone: [phone]
Fax: [phone]

JLG Polska
UI. Krolewska
00-060 Warsawa
Pol and
Phone: [phone]
Fax: [phone]

JLG Industries (Sweden)
Enkopingsvagen 150
Box 704
SE - 175 27 Jarfalla
Sweden
Phone: [phone]
Fax: [phone]