JLG 40RTS Service Manual

SERVICE & MAINTENANCE

Model

25RTS

33RTS

40RTS

3120826

March 12, 2004

AUSTRALIAN OFFICE	EUROPEAN OFFICE		CORPORATE OFFICE
JLG INDUSTRIES, INC.	JLG INDUSTRIES (EUROPE)		JLG INDUSTRIES, INC.
P.O. Box 5119	Kilmartin Place,		1 JLG Drive
11 Bolwarra Road	Tannochside Park		McConnellsburg, PA.
Port Macquarie, Australia	Uddingston, Scotland, G71 5PH		17233-9533
Telephone: [phone]	Telephone: [phone]		USA
Fax: [phone]	Main Fax:	01698 811055	Telephone:	[phone]
	Parts Fax:	01698 811455	Fax: (717)	485-6417

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

SECTION A. INTRODUCTION - MAINTENANCE SAFETY

PRECAUTIONS

A.A GENERAL

This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others, or damage to the equipment. A maintenance program must be followed to ensure that the machine is safe to operate.

MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST AS SAFE AS ORIGINALLY MANUFACTURED, IS A SAFETY VIOLATION.

The specific precautions to be observed during maintenance are inserted at the appropriate point in the manual. These precautions are, for the most part, those that apply when servicing hydraulic and larger machine component parts.

Your safety, and that of others, is the first consideration when engaging in the maintenance of equipment. Always be conscious of weight. Never attempt to move heavy parts without the aid of a mechanical device. Do not allow heavy objects to rest in an unstable position. When raising a portion of the equipment, ensure that adequate support is provided.

SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE FIELD INSPECTION AND MAINTENANCE, SAFETY IN THIS AREA RESPONSIBILITY OF THE OWNER/OPERATOR.

Relieve system pressure by cycling the applicable control several times with the engine stopped and ignition on, to direct any line pressure back into the reservoir. Pressure feed lines to system components can then be disconnected with minimal fluid loss.

A.C MAINTENANCE

FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION MAY RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A SAFETY VIOLATION.

•NO SMOKING IS MANDATORY. NEVER REFUEL DURING ELECTRICAL STORMS. ENSURE THAT FUEL CAP IS CLOSED AND SECURE AT ALL OTHER TIMES.

•REMOVE ALL RINGS, 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 BLOCKING OR OVERHEAD SLING, OR BOOM SAFETY PROP HAS BEEN ENGAGED.

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

•BATTERY SHOULD ALWAYS BE DISCONNECTED DURING REPLACEMENT OF ELECTRICAL COMPONENTS.

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.

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

•USE ONLY APPROVED, NONFLAMMABLE CLEANING SOLVENTS.

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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

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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

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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

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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

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SECTION 1. SPECIFICATIONS

1.1CAPACITIES

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)

13.2liters (3.5 U.S. gallons)

1.2COMPONENT 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

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.

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.

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1.3PERFORMANCE 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

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)

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.)

1.4LUBRICATION

Table 1-1. Hydraulic Oil

HYDRAULIC SYSTEM OPERATING	SAE VISCOSITY GRADE
TEMPERATURE RANGE
0 to +23 degrees F	10W
(-18 to -5 degrees C)
0 to +210 degrees F	10W-20,10W-30
(-18 to +100 degrees C)
+50 to +210 degrees F	20W-20
(+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

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Figure 1-1. Torque Chart

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Figure 1-2. Lubrication Diagram

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Table 1-2. Lubrication Chart

	INDEX	COMPONENT	NUMBER/TYPE LUBE POINTS	LUBE METHOD	INTERVAL
	NO				HOURS
	1	Oscillating Axle Pivot Point (Optional)	1 Grease Fitting	MPG - Pressure Gun	100
	2	Lockout Cylinders (Optional)	2 Grease Fittings (1 each cylinder)	MPG - Pressure Gun	100
	3	Front Steering Spindles (2-W/D)	2 Grease Fittings	MPG - Pressure Gun	100
	4	Front Steering Spindles (4-W/D)	2 Grease Fittings	MPG - Pressure Gun	100
		(Optional)
	5	Tow Bar Hitch (Optional)	1 Grease Fitting	MPG - Pressure Gun	100
	6	Wheel Bearings (2-W/D)	N/A	MPG - Repack	2000
	7	*Wheel Drive Hub (4-W/D) (Optional)	Fill Plug	EPGL (SAE 90)	500
	8	Engine Crankcase	Fill Cap/Drain Plug	Check Engine Oil 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 Spindles (4-W/S)	2 Grease Fittings	MPG - Pressure Gun	100
		(Optional)
	12	Rail Slides	N/A	MPG - Brush	100
	13	Hydraulic Oil Reservoir	Fill Cap/Drain Plug	HO - Check HO Level (See note 4)/	10/500
				HO - Change HO
	14	** Hydraulic Filter Element	N/A	Initial Change - 40 Hours	250

*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.

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NOTE: Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities. If use of hydraulic oil other than Mobilfluid 424 is desired, contact JLG Industries for proper recommendations.

Lubrication Specifications

Table 1-3. Lubrication Specifications

KEY	SPECIFICATIONS
MPG	Multipurpose Grease having a minimum dripping
	point of 350 degress F. Excellent water resistance
	and adhesive qualities, and being of extreme pres-
	sure type. (Timken OK 40 pounds minimum.)
EPGL	Extreme Pressure Gear Lube (oil) meeting API ser-
	vice classification GL-5 or MIL-Spec MIL-L-2105.
EO	Engine (crankcase) Oil. Gas - API SF/SG class, MIL-
	L-2104. Diesel - API CC/CD class, MIL-L-2104B/
	MIL-L-2104C.
HO	Hydraulic Oil. API service classification GL-3, e.g.
	Mobil 424.

1.5PRESSURE 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)

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Figure 1-3. Serial Number Location

1.6SERIAL 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.

1.7LIMIT 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.

1.8CYLINDER SPECIFICATIONS

NOTE: All dimensions are given in inches (in), with the metric equivalent, centimeters (cm), in parentheses.

Table 1-4. Cylinder Specifications

Description	Bore	Stroke	Rod Dia
Lift Cylinder	5.0	66.6	3.0
(25RTS/33RTS)	(12.7)	(169.2)	(7.6)
Lift Cylinder	5.0	65.6	3.5
(40RTS)	(12.7)	(166.4)	(8.9)
Lockout Cylinder	3.0	3.75	1.25
(Oscillating Axle)	(7.6)	(9.5)	(3.2)
Leveling Jack	2.0	14.0	1.25
Cylinder	(5.1)	(35.6)	(3.2)
Steer Cylinder	2.5	7.1	1.25
	(6.4)	(18.1)	(3.2)

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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 Assembly25 RTS (Includes	2403	1090
Lift Cylinder)
Arm Assembly33 RTS (Includes	3130	1418
Lift Cylinder)
Arm Assembly40 RTS (Includes	3860	1750
Lift Cylinder)
Chassis with Pneumatic Tires	3398	1541
Chassis with Foam Filled Tires	4102	1860

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
Tires (Balasted Only)	295	134
Engine (Ford)	525	238
Engine (Deutz)	342	155

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SECTION 2. PROCEDURES

2.1GENERAL

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.

2.2SERVICING 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

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.

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.

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.

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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.

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.

Bolt Usage and Torque Application

1.Use bolts of proper length. A bolt which is too long will bottom before the head is tight against its related part. If a bolt is too short, there will not be enough thread area to engage and hold the part properly. When replacing bolts, use only those having the same specifications of the original, or one which is equivalent.

2.Unless specific torque requirements are given within the text, standard torque values should be used on heat-treated bolts, studs, and steel nuts, in accordance with recommended shop practices.

Hydraulic Lines and Electrical Wiring

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.

2.3 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.

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.

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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, 100VAC heater to a minimum temperature 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). Systems 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.

2.4CYLINDERS - 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.

2.5VALVES - 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.

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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.

2.6COMPONENT 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.

2.7SLIDING 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.).

2.8PUMP 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.

Figure 2-1. Pump and Coupling Lubrication

Gear Hydraulic Pump

The John Barnes gear pump is “piggy-backed” to the piston pump, and operates all machine functions except drive. The gear pump has a displacement of 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.

2.9CYLINDER CHECKING PROCEDURES

NOTE: Cylinder checks must be performed any time a cylinder component is replaced or when improper 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.

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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.

2.10CYLINDER 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.

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Figure 2-3. Bottom Lift Cylinder Pin Location

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

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.

2.11 CYLINDER REPAIR

NOTE: The following are general procedures that apply to all of the cylinders on this machine. Procedures that apply to a specific cylinder will be so noted.

Disassembly

DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.

1.Place the cylinder barrel into a suitable holding fixture.

Figure 2-4. 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 PRES-

SURE.

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

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

Figure 2-6. Holding Valve and Fitting Removal	Figure 2-7. Cylinder Rod Support

5.Tap around outside of cylinder head retainer with a suitable hammer to shatter loctite.

6.Using a suitable chain wrench, loosen the cylinder head retainer, if applicable, and/or cylinder head gland, and remove from cylinder barrel.

7.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 CYL-

INDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFF-

CENTER, 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 end of cylinder.

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.

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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.

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.

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.

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 ORIEN-

TATION. IMPROPER SEAL INSTALLATION COULD RESULT IN

CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION.

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Figure 2-11. Poly-Pak Seal Installation

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

Figure 2-12. Wear Seal Installation

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

.

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

	Description		Nut Torque					Setscrew
				Value				torque Value
	Lift Cylinder			400 ft lb					100 in lb
				(542 Nm)					(12 Nm)
	Lockout Cylinder				N/A				N/A
	Level Cylinder			50 ft lb					100 in lb
				(68 Nm)					(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 - 14 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 SPECIFI-

CATIONS

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.

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