JLG 500RTS Service Manual

Service & Maintenance Manual

Models

400RTS 500RTS

3120829

November 12, 2007

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

SECTION A. INTRODUCTION - MAINTENANCE SAFETY

PRECAUTIONS

A.A GENERAL

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

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 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.

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

• USE ONLY APPROVED, NONFLAMMABLE CLEANING SOLVENTS.

3120829 – JLG Sizzor – a

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

REVISION LOG

June 1, 1993 - Original Issue

May 28, 1999 - Revised

February 29, 2000 - Revised

September 12, 2001 - Revised

August 4, 2004 - Revised

August 31, 2006 - Revised

November 12, 2007 - Revised

b – JLG Sizzor – 3120829

TABLE OF CONTENTS

SUBJECT - SECTION, PARAGRAPH PAGE NO.

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

A.A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-a

A.B Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-a

A.C Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-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 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.6 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1.7 Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.8 Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

1.9 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

1.10 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

1.11 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

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 Coupling Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

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

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

2.11 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

2.12 Tilt Alarm Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

2.13 Pressure Setting Procedures - (400RTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

2.14 Pressure Setting Procedures - (500RTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

2.15 Drive Pump Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

2.16 Throttle Checks and Adjustments - Ford Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2.17 Throttle Checks and Adjustments - Deutz F3L1011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

2.18 Hydraulic Component Start-Up Procedures and Recommendations . . . . . . . . . . . . . . . . . . . . . .2-14

2.19 Oscillating Axle Lockout Cylinder Bleeding Procedure - (If Equipped) . . . . . . . . . . . . . . . . . . . . .2-16

2.20 Lockout Cylinder Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16

2.21 Piston Drive Motor - 2WD & 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2.22 Drive Torque Hub - 2WD/4WD Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18

2.23 Drive Torque Hub/Brake - 4WD Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23

2.24 Drive Brake - 2WD/4WD Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28

2.25 Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30

2.26 Dual Fuel/LPG System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30

2.27 Freewheeling Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

2.28 Limit Switch Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31

2.29 Preventive Maintenance and Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

SECTION 3 - TROUBLESHOOTING

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

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

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

3120829 – JLG Sizzor – i

TABLE OF CONTENTS

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

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

1-2. Serial Number Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

1-3. Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

2-1. Poly-Pak Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

2-2. Pressure Adjustment Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2-3. Throttle Checks and Adjustments - Ford VSG 413. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

2-4. Precision Governor Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2-5. Throttle Adjustments, Deutz F3L1011. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2-6. Piston Drive Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17

2-7. Drive Torque Hub - (2WD/4WD rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

2-8. Torque Hub Carrier Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

2-9. Drive Torque Hub/Brake - 4WD Front. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

2-10. Torque Hub Cover Pipe Plug Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

2-11. Drive Brake - (2WD/4WD Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

2-12. Drive Hub Engaged. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31

2-13. Drive Hub Disengaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

2-14. Drive Cut-out Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31

2-15. Drive Speed Cutout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31

3-1. Hydraulic Schematic (Sheet 1 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3-2. Hydraulic Schematic (Sheet 2 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

3-3. Hydraulic Schematic (Sheet 3 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3-4. Hydraulic Schematic (Sheet 4 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

3-5. Hydraulic Schematic (Sheet 5 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

3-6. Hydraulic Schematic (Sheet 6 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

3-7. Electrical Schematic - 400 RTS - Ford LRG (Sheet 1 of 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18

3-8. Electrical Schematic - 400 RTS - Ford LRG (Sheet 2 of 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19

3-9. Electrical Schematic - 400 RTS - Ford LRG (Sheet 3 of 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20

3-10. Electrical Schematic - 400 RTS - Ford LRG (Sheet 4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

3-11. Electrical Schematic - 400RTS - Ford LRG (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

3-12. Electrical Schematic - 400RTS - Ford LRG (Sheet 2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

3-13. Electrical Schematic - 400RTS - Ford LRG (Sheet 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

3-14. Electrical Schematic - 400 RTS - Ford VSG (Sheet 1 of 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

3-15. Electrical Schematic - 400 RTS - Ford VSG (Sheet 2 of 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

3-16. Electrical Schematic - 400 RTS - Ford VSG (Sheet 3 of 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28

3-17. Electrical Schematic - 400 RTS - Ford VSG (Sheet 4 of 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29

3-18. Electrical Schematic - 400RTS - Deutz (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30

3-19. Electrical Schematic - 400RTS - Deutz (Sheet 2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31

3-20. Electrical Schematic - 400RTS - Deutz (Sheet 3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32

3-21. Electrical Schematic - 400RTS - Deutz (Sheet 4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33

3-22. Electrical Schematic - 400RTS - Deutz (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34

3-23. Electrical Schematic - 400RTS - Deutz (Sheet 2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35

3-24. Electrical Schematic - 400RTS - Deutz (Sheet 3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36

3-25. Electrical Schematic - 400RTS - Deutz (Sheet 4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37

3-26. Electrical Schematic - 500 RTS Ford LRG (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

3-27. Electrical Schematic - 500 RTS Ford LRG (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

3-28. Electrical Schematic - 500 RTS Ford LSG (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-40

3-29. Electrical Schematic - 500 RTS Ford LSG (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41

3-30. Electrical Schematic - 500 RTS Ford VSG (Sheet 1 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-42

3-31. Electrical Schematic - 500 RTS Ford VSG (Sheet 2 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43

3-32. Electrical Schematic - 500RTS Deutz (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-44

3-33. Electrical Schematic - 500RTS Deutz (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-45

3-34. Electrical Schematic - 500RTS Duetz (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-46

3-35. Electrical Schematic - 500RTS Duetz (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-47

ii – JLG Sizzor – 3120829

TABLE OF CONTENTS

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

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

1-2 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-3 Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1-4 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-5 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

1-6 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

2-1 Cylinder Piston Nut Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

2-2 Holding Valve Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

2-3 Drive Cutout Heights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

2-4 Preventive Maintenance and Safety Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

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

3120829 – JLG Sizzor – iii

TABLE OF CONTENTS

This page intentionally left blank.

iv – JLG Sizzor – 3120829

SECTION 1 - SPECIFICATIONS

SECTION 1. SPECIFICATIONS

1.1 CAPACITIES

Hydraulic Oil Tank

Approximately 138.17 liters (36.5 U.S. gallons) w/10% air space.

Hydraulic System (Including Tank)

Approximately 166.56 liters (44 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

6.0 liters (6.34 quarts) w/filter

5.5 liters (5.8 quarts) w/o filter

Coolant Capacity (Gasoline Engine)

13.2 liters (3.5 U.S. gallons)

Diesel Engine

Manufacturer/Model - Deutz F3L-1011

Oil Capacity

6.0 liters (6.34 quarts) w/filter

5.5 liters (5.8 quarts) w/o filter

Mid RPM - 2000

High RPM - 3000

Alternator - 60 Amphour

Battery - 60 Amphour, 1000 Cold Cranking Amps

Fuel Consumption

Low RPM - 7.19 lph (1.9 gph)

High RPM - 9.46 lph (2.5 gph)

Horsepower - 42 @ 3000 RPM

Drive/Steer System

Tires 400RTS

Standard - 31 - 15.5 x 15 NHS, 8 ply, pneumatic, inflate to

2.4 bar (35 PSI)

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

1.2 COMPONENT DATA

Gasoline Engine

Displacement - 4.5 liter

Manufacturer/Model - Ford LRG-425

Oil Capacity

4.3 liters (4.5 quarts) w/ filter

3.8 liters (4.0 quarts) w/o filter

Low RPM - 750

Mid 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 - 70 @ 2800 RPM

Coolant Capacity - 13.2 liters (3.5 U.S. gallons)

Tires 500RTS

Standard - 12 x 16.5 NHS, 8 ply, pneumatic, inflate to 3.1 bar (45 PSI)

Optional - 31 - 15.5 x 15 NHS, 8 ply, pneumatic, inflate to

2.4 bar (35 PSI)

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

Steer System

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

Drive Motors/Hubs/Brakes

Drive Motor - 6.3 cm

Drive Hub (2WD Gasoline and Diesel Engine - 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

(2.48 in.3) displacement

3120829 – JLG Sizzor – 1-1

SECTION 1 - SPECIFICATIONS

NOTE: Wheel lugs should be torqued to 109 Nm (80 ft lb) at

50 hour intervals.

When maintenance becomes necessary or a fastener has loosened, refer to Figure 1-3., Torque Chart, to determine proper torque value.

Hydraulic Filter - Inline

Return - Bypass Type

25 Micron Nominal

1.3 PERFORMANCE DATA

Travel Speed

2 Wheel Drive - 5.6 kmh (3.5 mph)

4 Wheel Drive - 4.5 kmh (2.8 mph)

Gradeability

2 Wheel Drive - 25% (14°)

4 Wheel Drive - 45% (24°)

Turning Radius (Outside)

2 Wheel Steer - 4.0 m (13 ft 2 in)

4 Wheel Steer - 2.0 m (6 ft 6 in)

With Deck Retracted

400RTS - 680 kg (1,500 lb)

500RTS - 900 kg (2,000 lb)

Platform Capacity - Dual Extensions

400RTS - 680 kg (1,500 lb)

500RTS - 900 kg (1,984 lb)

Platform Capacity - Wide Deck, Dual Extensions (500RTS Only)

500RTS - 680 kg (1,500 lb)

Machine Weight

400RTS - Approx. 6,797kg (14,985 lb)

500RTS - Approx. 6,940 kg (15,300 lb)

Machine Height (Platform Lowered)

400RTS - 2.9 m (116 in)

500RTS - 3.15 m (126 in)

Machine Length

4.72 m (15 ft 5 in)

Lift Speed - 400RTS

Up - 42 - 50 seconds

Down - 60 - 70 seconds

Lift Speed - 500RTS

Up - 65 - 80 seconds

Down - 70 - 80 seconds

Platform Capacity - Fixed Platform

400RTS - 905 kg (2,000 lb)

500RTS - 1135 kg (2,500 lb)

Platform Capacity - Traversing Platform Extension (If Equipped)

400RTS (With Deck Extended)

Machine Capacity - 680 kg (1,500 lb)

Extension - 265 kg (500 lb)

500RTS (With Deck Extended)

Machine Capacity - 905 kg (2000 lb)

Extension - 265 kg (500 lb)

Machine Width

Standard Tires - 2.3 m (7 ft 6 in)

Foam Filled Tires - 2.3 m (7 ft 7 in)

1.4 LUBRICATION

Table 1-1. Hydraulic Oil

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 sufficienthemical stability for mobile hydraulic system service. JLG Industries recommends Mobil 424 hydraulic oil, which has an SAE viscosity of 10W-20 and viscosity index of 152.

SAE VISCOSITY GRADE

10W

10W-20,10W-30

20W-20

1-2 – JLG Sizzor – 3120829

SECTION 1 - SPECIFICATIONS

NOTE: Aside from JLG recommendations, it is not advisable

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

1.5 LUBRICATION SPECIFICATIONS

Table 1-2. Lubrication Specifications

KEY SPECIFICATIONS

MPG Multipurpose Grease having a minimum dripping

point of 350 degrees 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 c lass, MIL-L-2104B/

MIL-L-2104C.

HO Hydraulic Oil. API service classification GL-3, e.g.

Mobil 424.

NOTE: Refer to Figure 1-1., Lubrication Diagram for specific

lubrication procedures.

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.

Lift Cut-Out (If Equipped)

Lift is cut out at 6.8 m (22 ft) when leveling jacks are in the stowed position.

Drive Cut-Out (If Equipped)

Drive is cut out when platform is at 6.8 m (22 ft) above stow position, or when leveling jacks are in the set position.400RTS Tilt Alarm - 5° (If Equipped)

A horn is sounded and a warning light is illuminated when the machine is operated on a slope that exceeds 5° with the platform raised. If the machine is operated on a 5° slope with the platform completely lowered, only the warning light is illuminated.

500RTS - 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.

1.6 PRESSURE SETTINGS

400RTS

Rexroth/Hydraforce Valve

Main Relief - 156 bar (2250 psi)

Steer Relief - 103 bar (1500 psi)

Steer Relief 4-W/S (If Equipped) - 103 bar (1500 psi)

Platform Extension (If Equipped) - 34 bar (500 psi)

500RTS

Rexroth/Hydraforce Valve

Main Relief - 193 bar (2800 psi)

Steer Relief - 103 bar (1500 psi)

Steer Relief 4-W/S (If Equipped) - 103 bar(1500 psi)

Platform Extension (If Equipped) -83 bar (1200 psi)

3120829 – JLG Sizzor – 1-3

SECTION 1 - SPECIFICATIONS

Figure 1-1. Lubrication Diagram

1-4 – JLG Sizzor – 3120829

Table 1-3. Lubrication Chart

SECTION 1 - SPECIFICATIONS

INDEX

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)

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

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

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

8 Hydraulic Oil Reservoir Fill Cap/Drain Plug HO - Check HO Level (See note 4)/

9 ** Hydraulic Filter Element N/A Initial Change - 40 Hours 250

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

11 Rear Steering Spindles (4-W/S)

12 400 RTS Sizzor Arm Pivot Pins

13 Rail Slides N/A MPG - Brush 100

14 Platform Extensi on Slides (Optional) N/A MPG - Brush 100

15 Lift Cylinder 4 Grease Fittings MPG - Pressur e Gun 100

16 Engine Crankcase Fill Cap/Drain Plug Check Engine Oil Level 10/100

COMPONENT NUMBER/TYPE LUBE POINTS LUBE METHOD

2 Grease Fittings MPG - Pressure Gun 100

(Optional)

2 Grease Fittings MPG - Pressure Gun 100

(Optional)

500 RTS Sizzor Arm Pivot Pins

3 0 G r e a s e F i t t i n g s ( 4 0 0 R T S ) 38 Grease Fittings (500RTS)

MPG - Pressure Gun MPG - Pressure Gun

HO - Change HO

INTERVAL

HOURS

10/500

100

KEY TO LUBRICANTS:

MPG - Multi-purpose Grease

EPGL - Extreme Pressure Gear Lube

HO - Hydraulic Oil (Mobil 424)

*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.

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

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. (gasoline or diesel engine only).

3120829 – JLG Sizzor – 1-5

SECTION 1 - SPECIFICATIONS

Figure 1-2. Serial Number Location

1.8 SERIAL NUMBER LOCATIONS

For machine identification, a serial number plate is affixed to the machine. On gasoline or diesel powered machines, the plate is located on the right front side of the frame rail. In addition, should the serial number plate be damaged or missing, the machine serial number is stamped on the top of frame between the front wheels.

1.9 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

(400RTS/500RTS)

Steer Cylinder 3.0

Lockout Cylinder

(Oscillating Axle)

Leveling Jack

Cylinder

Traversing Platform Cylinder 1.5

5.0

(12.7)

(7.6)

3.0

(7.6)

3.0

(7.6)

(3.8)

78.5

(199)

7.5

(19.05)

3.75

(9.5)

18.75

(47.6)

4 8

(121)

3.5

(8.9)

1.5

(3.8)

1.25 (3.2)

2.0

(5.0)

1.00 (2.5)

1-6 – JLG Sizzor – 3120829

SECTION 1 - SPECIFICATIONS

1.10 MAJOR COMPONENT WEIGHTS 1.11 CRITICAL STABILITY WEIGHTS

Table 1-5. Major Component Weights

Component Lb Kg

Fixed Platform (180 cm x 426 cm). 1235 560

Platform Extension. 275 125

Arm Assembly - 400RTS - Includes

Lift Cylinder.

Arm Assembly - 500RTS - Includes

Lift Cylinder.

400RTS

Chassis - Includes Pneumatic Tires. 5450 2472

Chassis - Includes Foam-Filled Tires. 6154 2791

500RTS

7750 3515

8699 3946

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. Critical Stability Weights

Component Lb Kg

Tires (Balasted Only)12X16.5 295 134

Engine (Ford) 525 238

Engine (Deutz) 600 272

Chassis - Includes Outriggers,

and Pneumatic Tires.

Chassis - Includes Outriggers,

and Foam-Filled Tires.

6052 2745

6756 3065

3120829 – JLG Sizzor – 1-7

SECTION 1 - SPECIFICATIONS

UNPLATED CAP SCREWS

VALUES FOR ZINC PLATED BOLTS ONLY

SAE GRADE 8

SAE GRADE 5

Figure 1-3. Torque Chart

Note: These torque values do not apply to cadium plated fasteners.

1-8 – JLG Sizzor – 3120829

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

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.

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

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.

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.

3120829 – JLG Sizzor – 2-1

SECTION 2 - PROCEDURES

4. Lubricate new or used serviceable bearings before installation. When pressing a bearing into a retainer or bore, apply pressure to the outer race. If the bearing is to be installed on a shaft, apply pressure to the inner race.

Gaskets

Check that holes in gaskets align with openings in the mating parts. If it becomes necessary to hand-fabricate a gasket, use gasket material or stock of equivalent material and thickness. Be sure to cut holes in the right location, as blank gaskets can cause serious system damage.

Bolt Usage and Torque Application

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

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

Hydraulic Lines and Electrical Wiring

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. 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. Disassemble and reassemble parts on clean work surface. Clean all metal parts with non-flammable cleaning solvent. Lubricate components, as required, to aid assembly.

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.

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. 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.

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 Mobil 424 hydraulic oil, which has an SAE viscosity of 10W-20 and a viscosity index of

152.

2-2 – JLG Sizzor – 3120829

SECTION 2 - PROCEDURES

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 40 hours of operation and every 250 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 Steer, Leveling Jack, and Deck Extension 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 take

hydraulic pressure to extend and gravity to retract.

A holding valve is used in the Lift, and Leveling Jack 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.

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

3120829 – JLG Sizzor – 2-3

SECTION 2 - PROCEDURES

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 reliefs are provided for each side of the circuit.

2.6 COMPONENT FUNCTIONAL DESCRIPTION

Piston Hydraulic Pump

The Sundstrand piston hydraulic pump is attached to and driven by the gasoline or diesel engine. The pump is a

45.9 cm the drive motors.

(2.8 in3 ) displacement piston pump that powers

Gear Hydraulic Pump

1912 Pump Coupling Grease ONLY. No other lubricant is recommended.

2.9 CYLINDER CHECKING PROCEDURES

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

der component is replaced or when improper system operation is suspected.

Cylinder w/o Counterbalance Valves - Steer Cylinder, Platform Ext. 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. 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.

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 of10.5 cm

(0.6 in3).

Manual Descent Valve (If Equipped)

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.

2.7 SLIDING WEAR PADS

The original thickness of the sliding pads is 15.2 cm (6.0 in). Replace sliding pads when worn to 14.5 cm (5.7 in).

2.8 PUMP 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

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.

Cylinders w/Single Counterbalance Valves Lift Cylinder, Leveling Jacks (If Equipped)

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

2-4 – JLG Sizzor – 3120829

WHEN WORKING ON THE LIFT CYLINDER, RAISE THE PLATFORM COMPLETELY AND SUPPORT THE PLATFORM USING A SUITABLE OVERHEAD LIFTING DEVICE.

SECTION 2 - PROCEDURES

assembly. Using a suitable brass drift, drive out the barrel end attach pin from the arm assembly.

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

2. Raise platform completely and place a suitable overhead lifting device or prop approximately 2.5 cm (1 in) below the platform.

NOTE: Step (3) applies to the leveling jacks only.

3. Fully extend leveling jacks to check.

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

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

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

7. 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 Installation

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

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

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 hole aligns with those in the upper arm assembly. Using a suitable drift, drive the cylinder rod attach pin through the aligned holes. Secure the pin in place with the bolts, lockwashers, and flatwashers.

5. 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

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 locknut, bolts, flatwashers and keeper shaft securing the cylinder rod attach pin to the upper inner arm assembly. Using a suitable brass drift, drive out the rod end attach pin from the arm assembly.

3. Retract the lift cylinder rod completely.

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

5. Remove the bolts, lockwashers, and flatwashers securing the barrel end attach pin to the lower arm

3120829 – JLG Sizzor – 2-5

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

1. 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.

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

SECTION 2 - PROCEDURES

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

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

4. Place the cylinder barrel into a suitable holding fixture. Tap around outside of cylinder head retainer with a suitable hammer to shatter loctite.

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

NOTE: Steer Cylinder has two head retainers at each end of

cylinder.

Platform Ext. Cylinder has a snap ring in barrel end of cylinder. Remove snap ring before withdraw of the rod.

6. 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.

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

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

NOTE: On the Steer Cylinder, the rod and piston are all one

unit.

9. Remove the setscrew(s), if applicable, and nut which attach the piston to the rod, and remove the piston. Discard nylon point set screws.

10. Remove the piston rings.

11. Remove and discard the piston o-rings, seal rings, and backup rings.

12. Remove the set screw, if applicable, piston spacer, and wear ring, if applicable, from the rod.

13. Remove the rod from the holding fixture. Remove the cylinder head gland and retainer, if applicable. Discard the o-rings, back-up rings, rod seals, and wiper seals.

Cleaning and Inspection

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.

2-6 – JLG Sizzor – 3120829

SECTION 2 - PROCEDURES

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. Refer to the Illustrated Parts manual.

Apply a light film of hydraulic oil to all components prior to assembly.

WHEN INSTALLING NEW POLY-PAK TYPE PISTON SEALS (AXLE LOCKOUT CYLINDER), ENSURE SEALS ARE INSTALLED PROPERLY. REFER TO FIGURE 2-1 FOR CORRECT SEAL ORIENTATION. IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION.

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

Lift Cylinder 400 ft lb

Lockout Cylinder N/A N/A

Level Cylinder 400 ft lb

Platform Ext. Cylinder N/A N/A

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

Nut Torque

Value

(542 Nm)

Setscrew

torque Value

100 in lb (12 Nm)

Figure 2-1. Poly-Pak Seal Installation

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

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. 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.

4. If applicable, correctly place a new o-ring and backup rings in the inner piston diameter groove.

5. Carefully place the piston on the cylinder rod, ensuring that the o-ring and back-up rings are not damaged or dislodged.

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

7. Push the piston onto the rod until it abuts the spacer end, apply locktite # 242 and install the attaching nut. Refer to Table 2-1, Cylinder Piston Nut Torque Specifications.

NOTE: On the Steer Cylinder, the rod and piston are all one

unit.

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

9. Remove the cylinder rod from the holding fixture.

10. Place new o-rings and seals in the applicable outside diameter grooves of both the piston and the cylinder head.

3120829 – JLG Sizzor – 2-7

SECTION 2 - PROCEDURES

11. 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.

12. With barrel clamped securely, and while adequately supporting the rod, insert the piston end into the barrel cylinder. Ensure that the piston loading o-ring and seal ring are not damaged or dislodged.

13. Continue pushing the rod into the barrel until the cylinder head gland can be inserted into the barrel cylinder.

14. If applicable, secure the cylinder head retainer using a suitable spanner type wrench.

15. 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.

16. 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.

2.12 TILT ALARM SWITCH

NOTE: The machine may be equipped with a tilt alarm

switch (sensor), optional on 400RTS, which is factory set to activate at 5° on the 400RTS and 3° on the 500RTS that will sound an alarm and illuminate a warning light on the platform control console. Consult factory for tilt sensor adjustment. The only field adjustment necessary is leveling the switch on the spring loaded studs.

3. 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 nuts and repeat steps (2) and (3).

2.13 PRESSURE SETTING PROCEDURES (400RTS)

Rexroth/Hydraforce Valve

1. Install pressure gauge at port G on Rexroth/ Hydraforce Valve.

2. Adjust both steer section crossover reliefs 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 156 bar (2250 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 platform ext. extended functions and adjust each ext. crossover relief to 83 bar (1200 psi).

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

2.14 PRESSURE SETTING PROCEDURES (500RTS)

Rexroth/Hydraforce Valve

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 mounting bracket is level and securely

attached.

2. Level the base of the indicator by tightening the three flange nuts. Tighten each nut until bubble in the indicator is in the center of indicator.

2-8 – JLG Sizzor – 3120829

1. Install pressure gauge at port G on Rexroth/ Hydraforce Valve.

2. Adjust both steer section crossover reliefs 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 193 bar (2800 psi).

6. Bottom out front steer right and steer left functions and adjust each steer crossover relief to 103 bar (1500 psi ).

SECTION 2 - PROCEDURES

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

8. Bottom out Platform Ext. Extended functions and adjust each Ext. Crossover Relief to 83 bar (1200 psi).

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

2.15 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 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.

1. 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.

2. 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.

7. 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.

8. Once charge pressure has been established, increase speed to normal operating RPM. Charge pressure should be approximately 15.5 bar (22 psi) minimum. If charge pressure is incorrect, shut down and determine cause for improper pressure.

INADEQUATE CHARGE PRESSURE WILL AFFECT THE OPERATORS ABILITY TO CONTROL THE MACHINE.

9. 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.

10. Charge pressure should remain at 15.5 bar - 16.9 bar (22 psi - 24 psi) minimum during forward or reverse operation. Continue to cycle slowly between forward and reverse for at least five minutes.

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

3. 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.

4. 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.

5. Install a 0 to 50 psi (0 to 35 bar) pressure gauge in the charge pressure gauge port to monitor charge pressure during start-up.

6. 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.

3120829 – JLG Sizzor – 2-9

SECTION 2 - PROCEDURES

ADJUST MAIN RELIEF TO 156 BAR

(2250 PSI) ON 400RTS AND 193 BAR

(2800 PSI) ON 500RTS

ADJUST DECK EXT TO

83 BAR (1200PSI)

PRESSURE PORT

ADJUST FRONT STEER

TO 90 BAR (1300 PSI)

NOTE: Pressure on deck ext./retract, leveling jacks, lift up, and overload all work off of system pressure

ADJUST LIFT DOWN SPEED

ADJUST REAR STEER TO

90 BAR (1300 PSI)

Figure 2-2. Pressure Adjustment Locations

TO 70-60 SECONDS. ON 400RTS

AND 80-70 SECONDS ON 500RTS

2-10 – JLG Sizzor – 3120829

SECTION 2 - PROCEDURES

2.16 THROTTLE CHECKS AND ADJUSTMENTS - FORD ENGINE

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: Steps (1) and (2) are preliminary 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 all the way out CCW until there is a gap between the screw and stop plate.

2.17 THROTTLE CHECKS AND ADJUSTMENTS - DEUTZ F3L1011

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).

1. 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 2000 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 2000 rpm. Shut down engine.

2. 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 3000 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.

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. Adjust speed screw until engine runs at 3000 rpm.

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

CCW until surging stops, no more.

6. Replace wire no. 7 connector on controller, which will return engine to LOW speed. Adjust remote until engine runs at 2200 rpm.

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

NOTE: Start with large end of hub facing up, large end of

spindle facing down

WEAR SAFETY GLASSES WHEN PERFORMING THE FOLLOWINGSTEP . BE AWARE THAT SPRING AND SPACERS COMPRESSED BY RETAINING RING MAY POP SUDDENLY OFF SHAFT WHEN RETAINING RING IS REMOVED.USING RETAINING RING PLIERS, REMOVE RETAINING RING FROM GROOVE ON INPUT SHAFT.

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

2. Remove thrust washer from around spindle.

3. Lift internal gear out of hub.

BEWARE OF SHARP EDGES IN COUNTERBORE WHEN REMOVING O-RING.

4. Remove o-ring from counterbore in hub. Discard oring.

5. If necessary, disassemble hub-spindle assembly as follows:

3120829 – JLG Sizzor – 2-11

SECTION 2 - PROCEDURES

Figure 2-3. Throttle Checks and Adjustments - Ford VSG 413

STARTER LOCKOUT SPEED ADJUST

MAIN SPEED ADJUST

FACTORY ADJUST

GAIN ADJUST

OVERSPEED ADJUST

MID SPEED ADJUST

Figure 2-4. Precision Governor Adjustments

2-12 – JLG Sizzor – 3120829

SECTION 2 - PROCEDURES

Figure 2-5. Throttle Adjustments, Deutz F3L1011

3120829 – JLG Sizzor – 2-13

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.

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, (especially motor), location may be such that access to the case drain port after installation is not realistic.

NOTE: Make certain that the oil being used to fill the compo-

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

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.

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 been purged, and the fitting can be retightened to its specified torque. If the tank needs to be pressurized in order to start the flow of

"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.

NOTE: With the engine on low idle, "crack", (loosen-don't

remove), the system lines at the motor(s). Continue to run the engine at low idle and tighten the system lines as soon as oil is observed to leak from them. When oil is observed to "leak" at the motor the line is full, the air has been purged, and the system hoses should be retightened to their specified torque.

2-14 – JLG Sizzor – 3120829

+ 70 hidden pages