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Service and Maintenance Manual

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1. 1 5 1 4 Cylinder Specifications 1 5 1 5 Major Component Weights 1 9 1 6 Critical Stability Weights 1 9 2 1 Cylinder Component Specifications 2 11 2 2 Holding Valve Torque Specifications 2 11 2 3 JLG SMART System Flash Fault Codes 2 22 2 4 Preventive Maintenance and Inspection Schedule 2 29 3 1 JLG SMART System Flash Fault Codes 3 2 3 2 JLG SMART System Troubleshooting 3 3 3 3 Hydraulic System Troubleshooting 3 5 ii JLG Sizzor JLG Sizzor SECTION 1 SPECIFICATIONS JLG Sizzor EE AA AA AA AAA AA a tt 1532E 1932E 3 7 gallons 14 0 liters at full mark on tank 3 2 gallons 12 1 liters at add mark on tank 2033E 2046E 2646E 2658E 5 4 gallons 20 4 liters at full mark on tank 1532E 1932E Approximately 4 4 gallons 16 8 liters 2033E 2046E 2646E 2658E Approximately 6 5 gallons 24 6 liters 24 Volts DC motor 2 section gear pump 3 1 gpm 11 7 Ipm output each section Single Voltage 110 Volts AC 60 Hz input 24 Volts DC 25 Amp output w auto timer Dual Voltage 240 Volts 120 Volts AC
2. 2 10 2 12 Rod Assembly Installation 2 10 2 13 Brake Cylinder Assembly 2 14 2 14 Steer Cylinder Assembly 2 16 2 15 Tilt Switch Leveling Manual Adjustment 2 18 2 16 Tilt Switch Leveling Voltmeter Adjustment 2 18 2 17 Pressure Setting Adjusiments 2 20 2 18 Pothole Protection System Limit Switch Adjustment Power Lift Down 2 21 2 19 Pothole Protection System Limit Switch Adjustment Gravity Lift Down 2 21 2 20 JLG SMART System Controller 2 23 2 21 Drive Motor Assembly Eaton 2 24 2 22 Electrical Schematic Power Lift Down Machines 2 30 2 23 Electrical Schematic Gravity Lift Down Machines 2 32 2 24 Hydraulic Diagram Standard Power Lift Down Machines 2 34 2 25 Hydraulic Diagram Standard Gravity Lift Down Machines 2 35 3 1 JLG SMART System Controller 3 2 LIST OF TABLES TABLE NO TITLE PAGE NO 1 1 Torque Requirements 1 3 1 2 Ree 1 3 1 3 Lubrication Specifications
3. 6 Il DL Aa Lo Mondion EE E EE sl AM E Lto LimitSwitch amp E47 1 TUT 11 Placards and Decas 12 Po o e 12 Wheel and Tire Assemblies 1 f sg LO 8 DriveMotors 8 31388 1 ll DT PATTERN Io RENE ee GC TA 15 SteerOvlinder 1 T 8815 4 TU 16 Steer Components 1 8 1 46 8 T n 47 Wheel Bearings 00 OU Ts TU TY TUT d 18 Sizzor Arms Lu x lc xc JM AS c c a 20 WearPadss A 21 PivotPinsBots 8 07 7 da gt Tra TTTAN o 11 722 Switches GromdConrd m LD 9 ControlTags a 24 Placards and Decals peace dc dcum 25 Hose and Cable 1 48 Inspection and Maintenance Code 10 to be performed every two years 1200 hours JLG Sizzor 2 29 JLG Sizzor SECTION 2 PROCEDURES JLG Sizzor UNE CONTACTOR HORN OPTION BEACON OPTION QA YOLOWINGD Sa YO Wu ANNOYS s MWULOd uj d T H 3NYOIH a E iul i 58 E SE S a a qawwa 1231353030 E 598 maz 110 mn ut E 596 MTONYO NL 3230 C1 818 El 6C aya NWOQ Lan l O aaa arian Di S03 ma ISYA ANO CUWMYOW IAO Ven O 3ONYYO PLATFORM CONTROL CABLE BLU RED ORN RED HA 2 z SE a E us e or e aa SLTA F2 NMOH9 eK NOIVHTI39OY MENO EX xm yva JEX moe Ni JONVHO o Hoy H3318 ES M
4. 2 1 CONTA Re O O RO 2 2 Servicing and Maintenance Guidelines 2 3 Lubrication Information 2 4 Cylinders Theory of Operation 2 5 Valves Theory of Operation 2 6 Component Functional Description 2 7 Weg A II A 2 8 Cylinder Checking Procedures 2 9 Lift Cylinder Removal and Installation 2 10 Lift Cylinder Repair Machines manufactured before August 1996 2 11 Lift Cylinder Repair Machines manufactured August 1996 to present 2 12 Brake Cylinder Repair 2 13 Steer Cylinder Repair 2 14 Tilt Switch Adjustment 2 15 Limit Switch Adjustment 2 16 Pressure Setting Procedures 2 17 Pothole Protection System Limit Switch Adjustment 2 18 JLG SMART System 2 19 Drive Motor Repair Eaton e 9 h s E 8 B E 8 6 0 DD GU NO WE ENEE NET WEEN 9 79 w 9 9 4 9 SS 98 9 9 9 4 O A 9 E 9 9 AE K Re REES Wer x 9 4 6 x gt a 9 9 6 8 8 8 6 0 NN 4 3 9 9 9 9 HS 29 9 8 9 W 9 9 8 mw s 9 E 9 9 amp V 9 9 RR E RES 4 9 4 9 9 Re e 2 20 Preventive Maintenance and Inspection Schedule SECTI
5. Steer Cylinder All Models Parking Brake Cylinder All Models Power Lift Down Parking Brake Cylinder All Models Gravity Lift Down JLG Sizzor 8 9 39 75 2 00 101 0 5 1 4 00 39 75 2 50 10 2 101 0 6 4 4 00 39 75 2 50 10 2 101 0 6 4 1 50 6 25 0 75 3 8 15 9 1 9 1 75 1 75 1 125 4 4 4 4 2 9 2 00 1 75 1 00 5 1 4 4 2 5 1 5 JLG Sizzor SECTION 1 SPECIFICATIONS JLG Sizzor INDEX NO TVPE INTERVAL NUMBER COMPONENT LUBE POINTS LUBE METHOD HOURS COMMENTS 1 Hydraulic Oil Fill Cap Drain Plug HO Check HO Level 10 1200 Check oil every 10 hrs HO Change HO Change oil every 1200 hrs 2 Hydraulic Filter Element N A N A 50 300 Change filter after first 50 hours of operation then every 300 hours thereafter 3 Kingpin Housing 2 Grease Fittings MPG Pressure Gun 600 N A 1 each housing 4 Wheel Bearings 2 Rear Wheels MPG Repack 1200 N A Key To Lubricants MPG Multi Purpose Grease HO Hydraulic Oil Mobilfluid 424 or Kendall Hyken 052 TO AVOID PERSONAL INJURY USE SAFETY PROP FOR ALL MAINTENANCE REQUIRING PLATFORM TO BE ELEVATED Notes 1 Be sure to lubricate like items on each side of machine 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 Lubrica
6. fixture Clean all parts thoroughly in an approved cleaning solvent Inspectthe cylinder rod for scoring tapering ovality or other damage If necessary dress rod with Scotch Brite or equivalent Replace rod if necessary 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 piston surface for damage and scor ing and for distortion Dress piston surface or replace piston as necessary 6 Inspect seal and o ring grooves in piston for burrs and sharp edges Dress applicable surfaces as necessary 7 Inspect cylinder guide inside diameter for scoring or other damage and for ovality and tapering Replace as necessary 8 Inspect seal and o ring grooves in guide for burrs and sharp edges Dress applicable surfaces as necessary 9 Inspect cylinder guide outside diameter for scoring or other damage and ovality and tapering Replace as necessary JLG Sizzor JLG Sizzor 10 inspect the oil ports for blockage or the pres ence of dirt or other foreign material Repair as necessary Notes Prior to cylinder assembly ensure that the proper cylin der seal kit is used Refer to Section 11 of this manual Apply a light film of hydraulic oll to all components prior to assembly 1 Using suitable protection cl
7. Figure 2 8 Wiper Seal Installation Place a new o ring and back up seal in the applicable outside diameter groove of the cylinder head as shown in the following illus tration Cylinder o Ring p Head Back Up Ring 4 JLG Sizzor Figure 2 9 Head Seal Kit Installation Install a washer ring onto the rod then care fully install the head gland on the rod ensur ing that the wiper and rod seals are not damaged or dislodged Push the head along the rod to the rod end as applicable Carefully slide the piston spacer onto the rod If applicable correctly place a new o ring and back up rings in the inner piston diame ter groove Using suitable protection clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible Carefully thread the piston on the cylinder rod hand tight ensuring that the o ring and back up rings are not damaged or dis lodged Thread the piston onto the rod until it abuts the spacer end and install the tapered bush ing 2 9 JLG Sizzor Guide Lock Ring Piston Figure 2 10 Piston Seal Kit Installation Note When installing the tapered bushing the piston and mat ing end of the rod must be free of oil A WARNING WHEN REBUILDING THE LIFT CYLINDER APPLY LOCTITE 242 TO TAPERED BUSHING BOLTS THEN TIGHTEN BOLTS SECURELY REFER TO TA BLE 8 1 FOR PROPER BOLT TORQUE VALUES 10 Install the bol
8. JELI Service and Maintenance Manual Model 1532E 1932E 2033E 2046E 2646E 2658E 3120725 March 1 1998 ANSI JLG Sizzor 1 This section contains the general safetv pre cautions which must be observed during maintenance of the aerial platform lt is of utmost importance that maintenance person nel pay strict attention to these warnings and precautions to avoid possible injury to them selves or others or damage to the equipment A maintenance program must be established by a qualified person and must be followed to ensure that the machine is safe to operate A WARNING MODIFICATION OF THE MACHINE WITHOUT CERTIFI CATION BV A RESPONSIBLE AUTHORITV THAT THE MACHINE IS AT LEAST AS SAFE AS ORIGINALLV MANUFACTURED IS A SAFETY VIOLATION 2 The specific precautions to be observed dur ing machine maintenance are inserted at the appropriate point in the manual These pre cautions are for the most part those that apply when servicing hydraulic and larger machine component parts 3 Your safety and that of others is the first consideration when engaging in the mainte nance 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 pro vided SINCE THE MACHINE MANUFACTURER HAS NO DI RECT CONTRO
9. PONENTS JLG INDUSTRIES INC RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI 52 BAR AT A MINI MUM DISTANCE OF 12 INCHES 30 5 CM AWAY FROM THESE COMPONENTS IF ELECTRICAL ELECTRONIC COMPONENTS ARE SPRAYED SPRAYING MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION JLG Sizzor JLG Sizzor SOIS SSI eneen TROUBLE SECTION 3 TROUBLESHOOTING BLESH PROBABLE CAUSE Emergency Stop switch not activated Joystick not in neutral position flash code 2 7 Joystick potentiometer not centered Idle time out flash code 1 1 Mux stream not being updated flash code 9 3 No power to the multiplexer card in the platform Platform cable not connected to platform box or SMART System at base J2 Faulty multiplexer card Battery voltage out of range flash code 4 4 If battery charger is plugged in voltage of batteries may be above 31 Volts Battery voltage too low Line contactor open circuit flash code 3 1 Loose wiring connections on line contactor or at harness connection J1 Open coil on line contactor Faultv wiring at J1 JLG Sizzor aasam aaa JLG Sizzor Se OS NATOK RD EDITI Te eee ee NS coos DSO REMEDY Activate Emergency Stop switch and wait for flash of LED s Release joystick then select function Use analyzer to verify potenti
10. This section contains troubleshooting information to be used for locating and correcting most of the operating problems which mav develop in the aerial platform if a problem should develop which is not presented in this section or which is not corrected bv listed corrective actions technicallv qualified guidance should be obtained before proceeding with anv maintenance The troubleshooting procedures applicable to the aerial platform are listed and defined in Table 3 2 JLG SMART System Troubleshooting and Table 3 3 Hydraulic System Troubleshooting Each malfunction within an individual group or sys tem is followed by a listing of probable causes which will enable determination of the applicable remedial action The probable causes and the re medial action should where possible be checked in the order listed in the tables It should be noted that there is no substitute for a thorough knowledge of the equipment and related systems it should be recognized that the majority of the problems arising in the machine will be centered in the hydraulic and electrical systems For this rea son every effort has been made to ensure that all likely problems in these areas are given the fullest possible treatment In the remaining machine groups only those problems which are sympto matic of greater problems which have more than one probable cause and remedy are included This means that problems for which the probable cause and
11. Adjust the chine pressure switch as necessary 6 From the platform control station activate Drive by pressing the DRIVE switch and ac Kee Ee tivating the controller to the full forward po 1 With the pothole protection system in the sition fully down position mount the limit switch as shown in Figure 2 19 7 While monitoring the pressure gauge at M2 adjust P2 to 3200 psi 50 0 psi 220 bar 2 Adjust the switch to provide for 1 1 6 inch 3 4 0 bar maximum clearance between the roller and the cam 8 Remove the plugs from the drive hose and l port 8 then reconnect the drive hose to port 3 Tighten the switch mounting hardware 4 Repeat the adjustment procedure for the limit switch on the opposite side of the ma chine 2 17 Pothole Protection System Limit Switch Agiusment To identify power Lift Down and gravity Lift Down ma chines refer to the effectivity page for serial number identification See Figure 218 4 With the pothole protection teni in the down position as shown and the limit switch installed loosen the switch arm adjusting bolt to permit the arm to move freelv 2 Rotate the arm until it contacts the pivot bar then slide the arm in the adjusting slot until a 2 1 2 inch radius is obtained as shown in Adjustment Power Lift Down Figure 2 18 Figure 2 19 Pothole Protection Svstem Limit Switch 3 Tighten the bolt to lock the arm in this posi tion Updated
12. 5 98 JLG Sizzor 2 21 JLG Sizzor 2 18 JLG SMART SYSTEM Se Vatt NUI a a a a aa KUCK ECC tate KC ere ON The JLG SMART System uses a 24 Volt multiplex motor control unit working in conjunction with a joystick controller and several switches to operate all machine functions The SMART System has a built in LED to indicate any faults which occur during operation of the ma chine The system also stores the last ten trouble faults for use in troubleshooting the machine Each fault is indicated by a first sequence of flashes then a short pause followed by a second sequence then a long pause before everything repeats When a fault occurs in normal operation the flash fault repeats while the fault is present as far as possible normal operation continues If there is more than one fault present the most important two will be indicated alternately Faults are grouped according to the first digit the second digit provides an extra diagnostic indication Refer to Table 2 3 for flash fault codes In addition the control unit may be programmed for any future options that are added to the machine The SMART System may be adjusted using a custom designed calibrator or special system soft ware installed on a personal computer PC prefer ably a laptop operating under DOS or Windows Both the analyzer JLG kit no 2901443 and the computer software JLG kit no 2900874 are avail able from JLG and inclu
13. 50 Hz input 24 Volts DC 20 Amp output w auto timer Japanese Specification 120 Volts AC 50 60 Hz input 1532E 1932E 6 Volt 235 Amp Hour 2033E 2046E 2646E 2658E 6 Volt 245 Amp Hour Tires 1532E 1932E Standard 4 50 x 14 00 Solid Rib Optional 4 50 x 14 00 Solid Non Marking Rib Tires 2033E 2046E 2646E 2658E Standard 5 00 x 16 00 Solid Rib Optional 5 00 x 16 00 Solid Non Marking Rib Optional 2046E 2646E 2658E 7 50 x 16 00 Solid Floatation Tread Parking Brake All models Single cylinder spring applied hydraulically released Drive Motors 1532E 1932E 12 5 in 205 cm displace ment 2033E 14 2 in 233 cm displacement 2046E 2646E 2658E 15 9 in 261 cm dis placement Return Bypass Type 10 Microns Nominal 1532E 1932E 30 in x 64 in 0 8 m x 1 6 m 2033E 30 in x 94 in 0 8 m x 2 4 m 2046E 2646E 42 in x 94 in 1 1 m x 2 4 m 2658E 54 in x 94 in 1 4 m x 2 4 m PERFORMANCE DATA AE 1532E 1932E Low Speed 1 3 mph 2 1 kmh Elevated Speed 0 7 mph 1 1 kmh Maximum Speed 2 4 mph 3 9 kmh 2033E Low Speed 1 3 mph 2 1 kmh Elevated Speed 0 7 mph 1 1 kmh Maximum Speed 2 75 mph 4 4 kmh 2046E Low Speed 1 3 mph 2 1 kmh Elevated Speed 0 7 mph 1 1 kmh Maximum Speed 2 25 mph 3 6 kmh 2646E 2658E Low Speed 1 2 mph 1 9 kmh Elevated Speed 0 7 mph 1 1 kmh
14. 9 3 Mux stream not being updated 9 6 Point A short circuit 9 7 Point A open circuit 9 8 Motor open circuit 9 9 power circuit failure driver short circuit bat cap lt 15V AA IMPORTANT IT IS A GOOD PRACTICE TO AVOID PRESSURE WASH ING ELECTRICAL ELECTRONIC COMPONENTS SHOULD PRESSURE WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRICAL ELECTRONIC COM PONENTS JLG INDUSTRIES INC RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI 52 BAR AT A MINI MUM DISTANCE OF 12 INCHES 30 5 CM AWAY FROM THESE COMPONENTS IF ELECTRICAL ELECTRONIC COMPONENTS ARE SPRAYED SPRAYING MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION 2 22 JLG Sizzor JLG Sizzor SECTION 2 PROCEDURES JLG Sizzor Torque Batterv Cable Post Nuts to 60 in Ib 7 Nm DO NOI OVERTIGHTEN Figure 2 20 JLG SMART System Controller JLG Sizzor 2 23 JLG Sizzor SECTION 2 PROCEDURES JLG Sizzor Housing Seal Pressure Washer Backup Washer Ring Retaining Ring Retaining Bearing Bail Ring Retaining Key Plug O ring Cap Screw Internal ead End Cap ex n Shaft Output Figure 2 21 Drive Motor Assembly Cap Screw 2 19 D EEE A UAE 1 Cleanliness is extremelv important when re pairing hvdraulic motors Work in a clean area Before disconnecting the hydraulic motor thoroughly clean the exterior Re move motor from the machine before disas sembly drain the oil from
15. Maximum Speed 2 25 mph 3 6 kmh Change 1 JLG Sizzor 1 1 JLG Sizzor SECTION 1 SPECIFICATIONS JLG Sizzor A ic All Models 25 1532E 600 Ib 272 kg 1932E 500 lb 227 kg 2033E 2646E Standard 750 Ib 340 kg 2033E 2646E Optional 1 000 Ib 454 kg 2046E 2658E 1 000 Ib 454 kg If machine is equipped with optional pipe racks 1532E 1932E 2033E 87 degrees maximum load on pipe racks is 100 Ib 45 kg Maximum total capacity of pipe racks and plat 2046E 2646E 2658E 80 degrees occur e E 2033E 2646E 650 Ib 295 kg Not 2046E 2658E 900 Ib 408 kg E Scissor scissor lifts are equipped with either Power Lift Down or Gravity Lift Down To identify Power Lift Down or Gravity Lift Down machines refer to the effec tivity page for serial number identification All Models 250 Ib 113 kg 1 person Power Down Machines 1532E Up 20 25 seconds Down 18 28 seconds 4 Foot 1 2 m Extension 1939E 750 Ib 340 kg 2 persons Up 20 25 seconds 6 Foot 1 8 m Extension Down 18 28 seconds 350 Ib 159 kg 1 person 2033E 2046E Up 28 33 seconds FOR MODELS 2033E 2046E 2646E AND 2658E Down 29 35 seconds EQUIPPED WITH EITHER THE 4 FT 1 2 M OR 6 FT 2646E 2658E 1 8 M POWERED DECK EXTENSION THE MAXI Up 40 45 seconds MUM TOTAL PLATFORM CAPACITV WITH THE EX TENSION EXTENDED OR RETRACTED IS 750 LB Down 34 40 seconds 340 KG 2 PE
16. Powered Deck Extension Relief If Equipped 3000 psi 207 bar Updated 6 98 Change 1 1 8 JLG Sizzor Tilt Alarm optional 5 degrees Illuminates a light on the platform and sounds an alarm when the machine is 5 degrees out of level in any direction High Drive Cut Out High drive speed is cut out when the platform is raised above the stowed position 1 000 Pound Capacity Cut Out Optional on Models 2033E and 2646E When Models 2033E and 2646E are equipped for the optional 1 000 pounds 454 kg platform capacity this limit switch cuts out drive at the following plat form heights 2033E 17 feet 5 2 m 2646E 19 feet 5 8 m Drive Cut Out Models 2033E 2046E 2646E and 2658E with Powered Deck Extension On these machines the Drive function is cut out when the powered deck extension is extended with the platform raised above the stowed posi tion Temperature Switch equipped on machines after and including serial number 0200037715 This switch prevents the high drive function from engaging when the oil temperature is very cold The machine will remain in low drive until the oil has warmed and will then auotmatically move up to high drive Overload Protection Japanese Specification Only When the platform is loaded to 120 of its rated capacity the LIFT UP and DRIVE func tions are cut out and the platform alarm if equipped is sounded for two seconds on two seconds off while the operator t
17. Sizzor 3 1 JLG Sizzor Table 3 1 JLG SMART Svstem M Flash Fault Codes 1 1 2 1 2 2 2 3 2 4 2 5 3 1 3 3 4 2 4 4 9 1 9 2 9 3 9 6 9 7 9 8 9 9 Change 1 3 2 SECTION 3 TROUBLESHOOTING Idle time out EMS inputs both together or neither Platform digital inputs includes high drive for gt 10 seconds Ground digital inputs Steering digital inputs Cut out input not a fault but an indication Accelerator analog input Arm guard or platform descent delay system European CE Specification Machines Only Line contactor open circuit or welded Line contactor or other driver short circuit or tripped Temperature cut back Battery supply voltage out of range Watchdog reset EEprom Fault Mux stream not being updated Point A short circuit Point A open circuit Motor open circuit Power circuit failure driver short circuit bat cap lt 15V JLG Sizzor Torque Battery Cable Post Nuts to 60 in Ib 7 Nm DO NOT OVERTIGHTEN Figure 3 1 JLG SMART System Controller IMPORTANT WHEN INSTALLING A NEW SMART SYSTEM CONTROL LER ON THE MACHINE ELECTRICAL SILICONE GREASE JLG PART NUMBER 0100076 OR 7016397 MUST BE APPLIED TO THE BACK OF THE CONTROLLER IMPORTANT IT IS A GOOD PRACTICE TO AVOID PRESSURE WASH ING ELECTRICAL ELECTRONIC COMPONENTS SHOULD PRESSURE WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRICAL ELECTRONIC COM
18. displacement to keep the difference JLG Sizzor SECTION 2 PROCEDURES JLG Sizzor constant This differential pressure is applied across the valve s meter in spool with the effect that pump flow is determined by the degree of spool opening independent of load pressure Return lines are connected together simplifying routing of return flow and to help reduce cavita tion Load sensing lines connect through shuttle valves to feed the highest load signal back to the sequence valve Integral actuator port relief valves anti cavitation check valves and load check valves are standard 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 sys tem control The relief valve provides an alter nate 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 pres sure 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 w
19. gt HorveswTcH MEMBRANE GREENSS3 7 pecksetecTswrcH SWITCH do sa gt 6 gt urrsetectswrch PAD a VELAED 22 B gt 24 VOLTS SWITCHES ORANGE 553 gt 10 gt POSI TRAC SWITCH ORANGE 52 gt gt 17 gt DRIVE SELECT SWITCH ORANGE 556 gt 12 gt DRIVE SELECT UGHT REO 1 1 I ahah JLG Sizzor 3 E aa E es 3 E SZ q E T g 2 5 A GE 5 EZS ea iis Me a SERE 10758 0 KA JA A WA E S l l E E BRS AANA Is i J10 218 RRR Qi mm A8 ig is Elie B BB AA POLIREDIBR EIE PE Lj iw i 3 a o Wille EE KETTEL Figure 2 23 JLG Sizzor 1282773 B Electrical Schematic Gravity Lift Down Machines Sheet 2 of 2 Change 1 2 33 JLG Sizzor SECTION 2 PROCEDURES JLG Sizzor mn 4 Ca DRIVE MOTOR DRIVE MOTOR LEFT RIGHT FRONT 20 26 REAR 4 18 2033 amp 15 1932 ONLY 110 IL BRAKE CVLINDER 15 201 90 ONIV FOR 20 26 Figure 2 24 Hvdraulic Diagram Standard Power Lift Down Machines 2 34 JLG Sizzor JLG Sizzor SECTION 2 PROCEDURES JLG Sizzor FRONT FRONT DRIVE MOTOR DRIVE MOTOR LEFT RIGHT 20 26 REAR LEFT STEER CYL RIGHT EE ES ry E 2 ST Bi STEER RT v P gili DECK EXT DECK BRAKE CYLINDER 90 ONLY FOR 20 26 as 1282726 E Figure 2 25 Hydraulic Diagram Gravity Lift Down Machines JLG Sizzor 2 35 2 36 Blank Updated 10 98 JLG Sizzor GENERAL
20. leak develop between the cylinder and its related control valve VALVES THEORY OF OPERATION Control valves used are four way three position solenoid valves of the sliding spool design When a circuit is activated and the control valve sole noid energizes the spool is shifted and the cor responding 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 cen ter 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 ma chine fitted in the bore of the valve body Lands on the spool divide the bore into various cham bers 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 spring loaded to center position therefore when the control is released the spool automatically re turns to neutral prohibiting any flow through the circuit The proportional control valves provide a power output matching that required by the load A small line connected to a load sensing port feeds load pressure back to a sequence valve The sequence valve senses the difference between the load and pump outlet pressure and varies the pump
21. place shaft on a clean smooth hard surface output end of shaft up Position housing over shaft and carefully lower housing over bullet and shaft Drive Bearing and Retaining Ring into Housing Bearing Ball Ring Retaining 10 Remove bullet from shaft end and place retaining ring and bearing on shaft along with bearing driver tool Press these parts into housing SECTION 2 PROCEDURES JLG Sizzor NOTE WHEN HANDLING MOTOR ASSEMBLY WITHOUT BEARING INSTALLED EXTRA CARE SHOULD BE TAKEN TO MAKE SURE THAT THE BACK END OF THE OUTPUT SHAFT ALWAYS STAYS FLUSH WITH THE BACK END OF HOUSING SURFACE IF OUTPUT SHAFT MOVES IN EITHER DIRECTION MORE THAN 0 79MM 1 32 IN OUTPUT SHAFT SHOULD BE REMOVED FROM THE HOUSING SO THAT THE SEAL MAY BE INSPECTED FOR CUTS IF NECESSARY REPLACE SEAL PER STEPS 7 AND 8 AND THEN REINSTALL OUTPUT SHAFT PER STEP 9 Ring Retaining 11 Install retaining ring making sure retaining ring is fully engaged in ring groove in hous ing 12 Reposition housing shaft end down The illustrations have been created from the master parts drawing and are for part refer ance only 2 26 JLG Sizzor JLG Sizzor NOTE IF THE SHAFT IS NOT FLUSH OR SLIGHTLV BELOW GEROLER MOUNTING SURFACE PLACE DRIVE IN OPEN END OF THE SHAFT AND THROUGH SPLINE STRIKE DRIVE WITH A SOFT HAMMER SHAFT END SHOULD BE IN A HOLE ON A BENCH SO IT IS FREE TO MOVE FORWARD THE HOUSING ONLY SHOULD BE SUPPORTED
22. 13 Install seal in seal groove housing 14 Place drive in shaft engage spline Mark drive using mark on shaft as a referance point Timing procedure is shown below 15 Place Geroler over drive seal groove up star point or star valley aligned with mark on drive per your rotation preferance 16 Align bolt holes on Geroler with housing holes and install seal in seal groove of Geroler 17 Place end cap on Geroler insert seven cap screws and pretorque in a criss cross pat tern to a 28 34 Nm 250 300 in Ib Final torque in a criss cross pattern to a 51 62 Nm 450 550 in Ib 18 Install new o ring on case drain plug This plug would be present only when case drain option is not being used Torque plug to7 9 Nm 64 84 inlb Timing Geroler Star Valley Reverse Timing Star Point Std Timing Parallel 7 Geroler Marked Drive for Reference SECTION 2 PROCEDURES JLG Sizzor 2 20 PREVENTIVE MAINTENANCE AND The preventive maintenance and inspection checks are listed and defined in the following table This table is divided into two basic parts the AREA to be inspected and the INTERVAL at Which the inspection is to take place Under the AREA portion of the table the various svstems along with the components that make up that svs tem are listed The INTERVAL portion of the table is divided into five columns representing the vari ous inspection time periods The numbers listed wi
23. 4 hvdraulic oil which has an SAE viscosity of 10W 30 and a viscosity index of 152 or as an alternate Kendall Hyken 052 hydraulic oil which has an SAE viscosity of 10W 20 and a viscosity index of 152 Mobilfluid 424 and Kendall Hyken 052 are fully compatible and can be mixed as necessary When temperatures remain consistently below 20 F 7 C an amount of no 2 diesel fuel not to exceed 20 of system capacity may be added to the hydraulic oil res ervoir This diesel fuel will thin the hydraulic oil for easier cold weather operation and will almost com pletely dissipate from the hydraulic system over a sev eral month period of time When cold weather is past it may be necessary to drain and refill the hydraulic sys tem to rid the system of any remaining diesel fuel 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 or Kendall Hyken 052 is desired contact JLG Indus tries for proper recommendations Table 1 3 Lubrication Specifications DD DROP ND O RRM Multipurpose Gr dripping point of 350 F Excellent water resistance and adhesive qualities and being of extreme pressure type Timken OK 40 pounds minimum SECTION 1 SPECIFICATIONS JLG Sizzor 1 6 SERIAL NUMBER LOCATIONS For machine ident
24. 532E 1650 psi 114 bar High Drive Cartridge Coil Attach Nut 8 10 ft Ib 11 14 Nm 1932E 2050 psi 141 bar Counterbalance Valve Cartridges 35 40 ft Ib 47 54 Nm 2046E 2050 psi 141 bar Posi Trac Valve Cartridge 4 6 ft Ib 5 8 Nm 2946E so psi ace bar Posi Trac Valve Cartridge Coil Attach Nut 10 12 ft Ib 14 16 Nm 7 pel aj Socket Head Cap Screws 60 in Ib 7 Nm Only machines prior to but not including serial number 0200037715 are equipped with thehigh drive pres sure switch Figure 2 17 Pressure Setting Adjustments Updated 6 98 2 20 JLG Sizzor JLG Sizzor SECTION 2 PROCEDURES JLG Sizzor A 1 Install a a pressure gauge at gauge SEN M2 located at the bottom front of the valve body The port is identified by a stamping on the valve body 2 Disconnect the drive hose from port 8 on the valve body then plug the hose and the valve port 3 Remove the wires from the high drive pres sure switch and perform a continuity check using a voltmeter 4 Activate drive by pressing the DRIVE switch Figure 2 17 Pressure Setting Adjustments and activating the controller to the full for 1532E 1932E 2033E 2046E 2646E 2658E ward position Figure 2 18 Pothole Protection System Limit Switch 5 Monitor the voltmeter to ensure the pressure e Repeat the adjustment procedure for the switch is activated when the hydraulic pres Lia switch on the opposite side of the ma sure reaches 1100 psi 76 bar
25. L OVER THE FIELD INSPECTION AND MAINTENANCE SAFETY IN THIS AREA IS THE RE SPONSIBILITY OF THE OWNER OPERATOR chines hydraulic systems operate at ex tremely high and potentially dangerous pres sures Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of the system INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS JLG Sizzor 2 Relieve system pressure by cycling the appli cable control several times with the engine stopped and ignition on to direct any line pressure back into the return line to the res ervoir Pressure feed lines to system compo nents can then be disconnected with minimal fluid loss A WARNING FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION MAY RESULT IN MACHINE DAMAGE PERSONNEL INJURY OR DEATH AND IS A SAFETY VIOLATION e REMOVE ALL RINGS WATCHES AND JEWELRY WHEN PERFORMING ANY MAIN TENANCE e DO NOT WEAR LONG HAIR UNRE STRAINED OR LOOSE FITTING CLOTHING AND NECKTIES WHICH ARE APT TO BE COME CAUGHT ON OR ENTANGLED IN EQUIPMENT e 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 NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL SAFETY PROPS HAVE BEEN ENGAGED OR PLATFORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING es BEFORE MAKING ADJUSTMENTS LUBRI CATING OR PERFORMING AN
26. NT EXTREME CARE SHOULD BE TAKEN WHEN INSTALL ING THE CYLINDER ROD HEAD AND PISTON AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BAR REL SURFACES 12 With barrel clamped securely and while adequately supporting the rod insert the pis ton end of the rod into the cylinder barrel Ensure that the piston seals are not dam aged or dislodged 13 Continue pushing the rod into the barrel until the cylinder head can be inserted into the cylinder barrel 14 Slide the head into the barrel and engage the threads Turn the head counterclockwise until the first thread just passes the engage ment point the head will move noticeably then turn the head clockwise until it is hand SECTION 2 PROCEDURES JLG Sizzor tight or fully seated Insert a spanner wrench into the holes provided and tighten 1 8 to 1 4 tum past fully seated 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 removed install the cartridge tvpe holding valve and fittings in the port block using new o rings as applicable Torque the holding valve cartridge to 50 55 ft Ib 68 75 Nm 2 12 BRAKE CYLINDER REPAIR A IMPORTANT DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA 1 Tag and disconnect the hoses from the cyl inder ports
27. ON 3 TROUBLESHOOTING 3 1 eo AL D 3 2 Troubleshooting Information 3 3 Hydraulic Circuit Checks 3 4 JLG SMART System AA 9 9 8 9 9 0 8 4 9 6 5 nn B 5 6 5 4 v 9 9 5 9 8 9 B eene s e JLG Sizzor JLG Sizzor PAGE NO ooo OO noO 2 11 2 13 2 15 2 17 2 19 2 19 2 21 2 22 2 24 2 27 3 1 3 1 3 2 JLG Sizzor TABLE OF CONTENTS JLG Sizzor LIST OF ILLUSTRATIONS FIGURE NO FIGURE TITLE PAGE NO 1 1 TORQUE UA ose si ate Sake a phn bebe B conde teams th 1 4 1 2 Lubrication Chart 1532E 1932E 2033E 2046E 2646E 2658E 1 6 1 3 Serial Number Locations 1532E 1932E 2033E 2046E 2646E 2658E 1 7 2 1 Dele by TETTE A DATA PARE 2 7 2 2 Cylinder Head Retainer Cap Screw Removal 2 7 2 3 SEET GEES 2 7 2 4 Tapered Bushing Removal 2 7 2 5 Gar Max Bearing Installation 2 8 2 6 Rod Seal Installation NN 2 9 2 7 Poly Pak Seal Installation 2 9 2 8 Wiper Seal Installation 2 9 2 9 Head Seal Kit Installation 2 9 2 10 Piston Seal Kit Installation 2 10 2 11 Tapered Bushing Installation
28. OTA ek Lume 03948 EK ANT 197735 ano aya EK anions un au XK amni omg ek an 107139930 mame iI VA NUN INI AMA T ER amou sono gt O A 038 lt Maison EMERGENCY STOP Figure 2 22 Electrical Schematic Power Lift Down Machines Sheet 1 of 2 JLG Sizzor 2 30 JLG Sizzor SECTION 2 PROCEDURES JLG Sizzor on 8 SA E ae m A DIRECTION Ji avos NID E so SWITCHES DIR A SO plus So SS LEFT 7X 9 ree 24 VOLTS Se y 4 v ROCKER N RIGHT e SWITCHES a RED P 2 424 VOLTS LED S BLURED gt gt 4 gt DECK SELECT LIGHT VELRED gt 3 gt LIFT SELECT LIGHT REDRLU gt 5 gt orveswrch MEMBRANE BLKAED 7 gt veckseectswrch SWITCH YELALK 6 urTseectswrce PAD RED 1 04 VOLTS SWITCHES BRNBLK POSL TRAC SWITCH ORANGE gt gt 41 gt DRIVE SELECT SWITCH BLUE gt gt 42 gt DRIVE SELECT LIGHT REO 12 HI up PROTECTION ARMGUARD E MHI AN 21 SWITCH i 22 a 5 TILT PROTECTION SENSOR TCH a S Uer bos WR 22 OPTION tp CCT E SES a lt 2 t 3 a ul p x ji 3 I d 6 g es ES 5288565 E SEE d E add Ca rom RE ye c r S 5 5 i ji 3 Jo Jo B aaa p INPUT 24 VOLTS INPUT 4 VOLTS 84 VOLTS 24 VOLTS B M 5 Jd J 1282507 G Figure 2 22 El
29. REIGN SUBSTANCES FROM CYLINDER OPENINGS PARTICULARY AT THE HEAD 1 Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting A WARNING DO NOT FULLY EXTEND CYLINDER TO END OF STROKE RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE SECTION 2 PROCEDURES JLG Sizzor 2 Operate the hydraulic power source and ex tend the cylinder Shut down and disconnect the power source Adequately support the cylinder rod if applicable 3 Remove the cartridge type holding vaive and fittings from the cylinder port block Dis card o rings 4 Place the cylinder barrel into a suitable hold ing fixture A IMPORTANT EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD HEAD AND PISTON AVOID PULL ING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES 5 Using a suitable spanner wrench inserted in the holes provided turn the cylinder head counter clockwise to remove it from the cyl inder barrel If the head is difficult to turn or moves erratically tap the tube adjacent to the head with a brass or plastic mallet while turning it 6 Attach a suitable pulling device to the cylin der rod end 7 With the barrel clamped securely apply pressure to the rod pulling device and care fully withdraw the complete rod assembly from the cylinder barrel 8 Using suitable protection clamp the cylinder rod in a vise or similar holding fixture
30. RSONS Gravity Down Machines o 1532E Up 18 23 seconds 1532E approx 2400 Ib 1089 kg Down 22 27 seconds 1932E approx 2520 Ib 1143 kg 1932E 2033E approx 3870 Ib 1756 kg Up 18 23 seconds 2046E approx 3620 Ib 1642 kg Down 23 28 seconds 2646E approx 4100 Ib 1860 kg 2033E 2046E 2658E approx 4230 Ib 1919 kg Up 28 33 seconds a Down 26 31 seconds 2646E 2658E 1532E 1932E 50 0 in 1 3 m Up 40 45 seconds 2033E 2046E 2646E 2658E 73 0 in 1 9 m Down 37 42 seconds 1 2 JLG Sizzor JLG Sizzor SECTION 1 SPECIFICATIONS JLG Sizzor ta kulma SS 1532E 15 feet 4 6 m 1932E 19 feet 5 8 m 2033E 2046E 20 feet 6 1 m 2646E 2658E 26 feet 7 9 m 1532E 75 75 in 1 9 m 1932E 79 75 in 2 0 m 2033E 2046E 79 0 in 2 0 m 2646E 2658E 84 25 in 2 1 m Standard Handrails All Models 39 5 in 1 0 m Fold Down Handrails 1532E 1932E 2033E 39 5 in 1 0 m 2046E 2646E 2658E 43 5 in 1 1 m 1532E 1932E 68 0 in 1 7 m 2033E 2046E 2646E 2658E 96 0 in 2 4 m 1532E 1932E w standard tires 32 5 in 0 8 m 2033E w standard tires 33 0 in 0 8 m 2046E 2646E w standard tires 46 0 in 1 2 m 2658E w standard tires 58 0 in 1 5 m 2046E 2646E 2658E w optional floatation tires 60 0 in 1 5 m With Platform Lowered All Models 2 13 in 5 4 cm With Platform Elevated Potho
31. TABLE OF CONTENTS SUBJECT SECTION PARAGRAPH INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS EFFECTIVITY PAGE 4 E 9 9 8 E 94 p 9 5 9 o 4 99 92 52 u ao E 9 v9 5 9 9 9 b 9 S 9 4 b 4 9 0 5 3 B 3 9 B e v eo s Doro 9 9 s 8 a 9 E 0 9 B8 B 8 b O 8 BG DE B O A3 9 3 59 0 5 v9 b 3 8 ac 9 o 9 9 u 8 9 9 k E 4 9 a b a 5 9 9 9 WG B 8 8 9 DB 3 8 B v 3 3 9 3 v 9 9 namo 9 5 4 a 9 9 9 Aa 9 8 9 9 9 8 8 9 9 9 t 4 93 8 9 9 s VW 9 9 9 a 3 4 s 9 ua SECTION 1 SPECIFICATIONS RS gg 9 9 85 9 9 9 9 9 3 9 V 9 9 8 B 9 d B 9 8 G6 V b 8 9 9 9 9 9 V 9 8 B 8 9 V G6 9 G HU vw VW 5 ash ee eee sesch esch wesch A OON ROAOM L 0 2 299 5 a 0 V 9 9 9 geng 9 9 O 9 GF 9 e 5 B BG DB OG s 9 BO 9 9 V ao s Torque Requirements Lubrication mo voa 9 5 9 3 9 6 0 amp seg 9 8 e o o 9 a e eo eneen xw Cylinder specifications Pressure Settings She mL Major Component Weights Critical Stability Weights SECTION 2 PROCEDURES 0 9 8 9 0 5 5 Aa 3 5 6 98 0 5 0 V 9 9 5 4 0 BN v e 3 5 e een A O 0 0000000092 00 000000 m0 010000m 000080081 00 1 U
32. WARNING DO NOT FULLY EXTEND CYLINDER TO END OF STROKE RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE 2 Place the cylinder barrel 1 into a suitable holding fixture 3 Using a suitable pair of snap ring pliers carefully remove the retaining ring 12 from the cylinder barrel 4 Attach a suitable pulling device to the cylin der rod end 4 IMPORTANT EXTREME CARE SHOULD BE TAKEN WHEN RE MOVING THE CYLINDER ROD GUIDE AND PIS TON AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES 5 With the barrel clamped securely apply pressure to the rod pulling device and care fully withdraw the complete rod assembly from the cylinder barrel 6 Using suitable protection clamp the cylinder rod 13 in a vise or similar holding fixture JLG Sizzor 2 13 JLG Sizzor 2 14 Cylinder Barrel Piston Locknut Piston O Ring O Ring Piston Ring O Ring SECTION 2 PROCEDURES JLG Sizzor Back Up Ring Seal Guide Wiper Ring Retainer Ring Rod Figure 2 13 Brake Cylinder Assembly Carefully remove the piston locknut 2 and piston 3 from the cylinder rod Remove and discard the piston ring 6 and o rings 4 and 5 Carefully remove the guide 10 from the cylinder rod Remove and discard the o ring 7 back up ring 8 rod seal 9 and wiper ring 11 Remove the cylinder rod from the holding
33. Y OTHER MAINTENANCE SHUT OFF ALL POWER CONTROLS BATTERY SHOULD ALWAYS BE DISCON NECTED DURING REPLACEMENT OF ELECTRICAL COMPONENTS e KEEP ALL SUPPORT EQUIPMENT AND AT TACHMENTS STOWED IN THEIR PROPER PLACE e USE ONLY APPROVED NONFLAMMABLE CLEANING SOLVENTS JLG Sizzor a JLG Sizzor EFFECTIVITY PAGE NOTE This manual is split from the combined Operators and Safety Service and Maintenance and Illustrated Parts Manual 3123000 Original Issue July 1996 Revised September 1996 Service and Maintenance Manual 3120725 Original Issue April 1997 A IMPORTANT NOTE Machines through serial number 34920 are equipped with power LIFT DOWN Machines begin ning with serial number 34921 are equipped with gravitv LIFT DOWN Machines with the following serial numbers are also equipped with gravitv LIFT DOWN 33685 33687 33691 33693 33697 33699 33701 33707 34044 34049 34141 34143 34172 34174 Where differences in machine operation exist appli cable serial numbers will be referenced Refer to the listing above for exceptions to the power lift down serial number block Change 1 June 1997 pages b 1 1 1 8 2 22 2 28 2 29 3 2 3 3 3 4 Change 2 August 1997 pages b 2 15 2 16 2 17 Change 3 March 1998 pages 2 24 2 25 2 26 2 27 2 28 2 29 2 30 2 31 2 32 2 33 2 34 2 35 2 36 Table of contents Change 2 b JLG Sizzor JLG Sizzor JLG Sizzor TABLE OF CONTENTS
34. amp the cylinder rod in a vise or similar holding fixture 2 Place a new wiper ring 11 rod seal 9 o ring 7 and back up ring 8 into the appli cable cylinder guide 10 grooves 3 Carefully install the guide on the rod ensur ing that the wiper ring and rod seal are not damaged or dislodged Push the guide onto the rod 4 Place a new piston ring 6 and o rings 4 and 5 on the piston 5 Carefully place the piston on the threaded end of the cylinder rod ensuring that the o ring is not damaged or dislodged Push the piston onto the rod as far as it will go 6 Install the piston locknut 2 on the threaded end of the cylinder rod and torque to 100 120 ft Ib 136 163 Nm 7 Remove the cylinder rod from the holding fixture 8 Position the cylinder barrel in a suitable holding fixture A DANGER EXTREME CARE SHOULD BE TAKEN WHEN IN STALLING THE CYLINDER ROD GUIDE AND PIS TON AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES 9 With the barrel clamped securely and while adequately supporting the cylinder rod in sert the piston end of the rod into the cylin der barrel Ensure that the piston ring and o ring are not damaged or dislodged 10 Continue pushing the rod into the barrel until the cylinder guide can be inserted into the cylinder barrel 11 Using all applicable safety precautions se cure the cylinder rod assembly with a new reta
35. art be ing lifted 2 Should it be necessary to remove a compo nent on an angle keep in mind that the capacity of an eyebolt or similar bracket lessens as the angle between the support ing structure and the component becomes less than 90 degrees 3 If a part resists removal check to see whether all nuts bolts cables brackets wir ing etc have been removed and that no adjacent parts are interfering When disassembling or reassembling a compo nent complete the procedural steps in se quence Do not partially disassemble or assem ble one part then start on another Always re check your work to assure that nothing has been overlooked Do not make any adjustments other than those recommended without obtaining proper approval JLG Sizzor 2 1 JLG Sizzor SECTION 2 PROCEDURES JLG Sizzor When assembling pressure fit parts use an anti seize or molybdenum disulfide base com pound to lubricate the mating surface 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 a 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 bear ings until they are ready to install 4 Lubric
36. as close to the piston and head as possible 9 Remove the lock nut which attaches the pis ton to the rod and remove the piston 10 Slide the head off the rod from the piston end 11 Remove and discard the sealing o ring wiper u cup seal static o ring static back up ring and wear ring 12 Remove the piston guidelock ring 13 Remove and discard the piston o ring and seals then remove the piston spacer 14 Remove the rod from the holding fixture Remove the cylinder head gland and re tainer if applicable Discard the o rings back up rings rod seals and wiper seals JLG Sizzor 2 11 JLG Sizzor 2 12 1 Clean all parts thoroughiv in an approved cleaning solvent Inspect the cylinder rod for scratches or pits deep enough to catch the fingernail Pits that go to the base metal are unacceptable Scratches that catch the fingernail but are not to the base metal less than 0 5 inch 12 7 mm long and primarily in the circum ferential direction are acceptable provided they cannot cut the rod seal Chrome should be present over the entire surface of the rod the lack of chrome on the rod surface is unacceptable If an unacceptable condition exists repair or replace the rod Inspect the threaded portion of the rod for excessive damage Dress the threads as necessary Inspect inner surface of cylinder barrel tube for scratches and pits There should be no scratches or pits deep enough
37. ate 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 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 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 en gage and hold the part properly When re placing 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 recom mended shop practices See Figure 1 1 Clearly mark or tag hydraulic lines and electrical wiring as well as their receptacles when discon necting or removing them from the unit This will assure that they are correctly reinstalled 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 C
38. cessary Inspect the oil ports for blockage or the pres ence of dirt or other foreign material Repair as necessary If applicable inspect piston rings for cracks or other damage Replace as necessary JLG Sizzor Notes Prior to cvlinder assembiv ensure that the proper cvlin der seal kit is used Refer to Section 11 of this manual Apply a light film of hydraulic oil to all components prior to assembly 1 Using a special tool pictured in the following illustration install a new rod seal into the applicable cylinder head gland groove Re fer to the following illustration for the proper tool size Seal Tool 1 45015K21 1 1 2 45015K22 2 45015K23 Rod Seal Cylinder Head Figure 2 6 Rod Seal Installation A IMPORTANT WHEN INSTALLING NEW POLY PAK TYPE PISTON SEALS ENSURE SEALS ARE INSTALLED PROPERLY REFER TO FIGURE 2 7 FOR CORRECT SEAL ORIENTA TION IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION PISTON REF Figure 2 7 Poly Pak Seal Installation 2 Using a soft mallet tap a new wiper seal into the applicable cylinder head gland groove Install a new wear ring into the applicable head gland groove as shown below SECTION 2 PROCEDURES JLG Sizzor Wiper Seal Cylinder Mallet Head Note When installing wiper seal ensure seal are installed properly Install seal so that the flat part of seal is facing into head 3
39. cylinder rod section two ensuring that the o ring is not damaged or dislodged Push the piston onto the rod as far as it will go 6 Attach cylinder rod section one to the threaded end of cylinder rod section two and assemble 7 Remove the cylinder rod assembly from the holding fixture 8 Position the cylinder barrel in a suitable holding fixture A IMPORTANT EXTREME CARE SHOULD BE TAKEN WHEN IN STALLING THE CYLINDER ROD CYLINDER ROD GUIDE AND PISTON AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES 9 With the barrel clamped securely and while adequately supporting the cylinder rod as sembly insert the piston end of the rod as sembly into the cylinder barrel Ensure that the piston ring and o ring are not damaged or dislodged 10 Continue pushing the rod into the barrel until the cylinder rod guide can be inserted into the end of the cylinder barrel SECTION 2 PROCEDURES JLG Sizzor 11 Coat the threads of the cylinder rod guide with Loctite 242 then secure the cylinder rod guide to the cylinder barrel using a suit able spanner wrench 12 On the remaining cylinder rod guide 2 place a new wiper ring 1 rod seal 3 o ring 5 and back up ring 4 into the cylin der rod guide grooves 13 Carefully install the cylinder rod guide onto rod section two and slide the guide into the end of the cylinder barrel 14 Coat the threads of the cy
40. d run cylinder through one complete cycle to check for leaks LIFT CYLINDER REMOVAL AND INSTALLATION Place the machine on a flat and level sur face Start the motor and raise the platform Shut down the engine and attach a suitable lifting device to the platform Remove the bolt and locknut 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 Retract the lift cylinder rod completely Tag and disconnect the hydraulic lines then cap the lift cylinder hydraulic lines and ports Remove the bolt and locknut securing the barrel end attach pin to the lower arm as sembly Using a suitable brass drift drive out the barrel end attach pin from the arm assembly Carefully remove the cylinder from the scis sor lift and place in a suitable work area SECTION 2 PROCEDURES JLG Sizzor 1 install lift cylinder in place using suitable slings aligning barrel end attach pin mount ing 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 bolt and locknut 3 Remove cylinder port plugs and hydraulic line caps and correctly attach lines to cylin der ports 4 Extend the cylinder rod until the attach pin hole aligns with those in the upper arm as sembly Using a s
41. de a connecting cable and SMART System adjustment procedures Refer to Section 3 for SMART System troubleshooting procedures A IMPORTANT WHEN INSTALLING A NEW SMART SYSTEM CONTROL LER ON THE MACHINE IT WILL BE NECESSARY TO PROGRAM THE CONTROLLER FOR THE PROPER MA CHINE CONFIGURATION INCLUDING OPTIONS REFER TO ANALYZER KIT NO 2901443 OR COMPUTER SOFT WARE KIT NO 2900874 FOR PROGRAMMING INSTRUC TIONS MACHINES EQUIPPED WITH GRAVITY LIFT DOWN SEE EFFECTIVITY PAGE MUST BE PRO GRAMMED FOR GRAVITY LIFT DOWN AT CONTROL LER REPLACEMENT A IMPORTANT WHEN INSTALLING A NEW SMART SYSTEM CONTROL LER ON THE MACHINE ELECTRICAL SILICONE GREASE JLG PART NUMBER 0100076 OR 7016397 MUST BE APPLIED TO THE BACK OF THE CONTROL LER Change 1 SECTION 2 PROCEDURES JLG Sizzor Table 2 3 JLG SMART System Flash Fault Codes 1 1 Idle time out 2 1 EMS inputs both together or neither 2 2 Platform digital inputs includes high drive for gt 10 seconds 2 3 Ground digital inputs 2 4 Steering digital inputs 2 5 Cut out input not a fault but an indication 2 7 Accelerator analog input 2 8 Arm guard or platform descent delay system cut out European CE Specification Machines Only 3 1 Line contactor open circuit or welded 3 3 Line contactor or other driver short circuit or tripped 4 2 Temperature cut back 4 4 Battery supply voltage out of range 9 1 Watchdog reset 9 2 EEprom Fault
42. distortion Dress piston surface or replace piston as necessary Inspect seal and o ring grooves in piston for burrs and sharp edges Dress applicable surfaces as necessary Inspect cylinder guide inside diameter for scoring or other damage and for ovality and tapering Replace as necessary Inspect seal and o ring grooves in guide for burrs and sharp edges Dress applicable surfaces as necessary Inspect cylinder guide outside diameter for scoring or other damage and ovality and tapering Replace as necessary Inspect the oil ports for blockage or the pres ence of dirt or other foreign material Repair as necessary JLG Sizzor Notes Prior to cylinder assembly ensure that the proper cylin der seal kit is used Refer to the illustrated Parts Manual Apply a light film of hydraulic oll to all components prior to assembly 1 Using suitable protection clamp the cylinder rod section one 7 in a vise or similar hold ing fixture 2 Place a new wiper ring 1 rod seal 3 o ring 5 and back up ring 4 into the cylin der rod guide 2 grooves 3 Carefully install the cylinder rod guide on rod section one ensuring that the wiper ring and rod seal are not damaged or dislodged Push the guide onto the rod section 4 Place a new piston ring 8 on the piston 10 and a new o ring 9 on the threaded end of cylinder rod section two 7a 5 Carefully place the piston on the threaded end of
43. e machine Each fault is indicated by a first sequence of flashes thena short pause followed by a second sequence then a long pause before everything repeats When a fault occurs in normal operation the flash fault repeats while the fault is present as far as possible normal operation continues If there is more than one fault present the most important two will be indicated alternately Faults are grouped according to the first digit the second digit provides an extra diagnostic indication Refer to Table 9 1 for flash fault codes In addition the control unit may be programmed for any future options that are added to the machine The SMART System may be adjusted using a custom designed analyzer or special system soft ware installed on a personal computer PC or a laptop computer operating under DOS or Win dows Both the analyzer JLG kit no 2901443 and the computer software JLG kit no 2900874 are available from JLG and include a connecting cable and SMART System adjustment procedures A IMPORTANT WHEN INSTALLING A NEW SMART SYSTEM CONTROL LER ON THE MACHINE IT WILL BE NECESSARY TO PROGRAM THE CONTROLLER FOR THE PROPER MA CHINE CONFIGURATION INCLUDING OPTIONS REFER TO ANALYZER KIT NO 2901443 OR COMPUTER SOFT WARE KIT NO 2900874 FOR PROGRAMMING INSTRUC TIONS MACHINES EQUIPPED WITH GRAVITY LIFT DOWN SEE EFFECTIVITY PAGE MUST BE PRO GRAMMED FOR GRAVITY LIFT DOWN AT CONTROLLER REPLACEMENT JLG
44. ectrical Schematic Power Lift Down Machines Sheet 2 of 2 JLG Sizzor 2 31 JLG Sizzor SECTION 2 PROCEDURES JLG Sizzor PLATFORM WORKLIGHTS OPTION i 26 038 40 gt i Let QIWNHO SGD gt D 1 LI D t 1 i MULTIPLEXER BOARD J4 X e ul a BATTERY DISCHARGE INDICATOR x E E i EL CL E SE i EMERGENCY STOP PLATFORM CONTROL R o CABLE HOUR METER LINE CONTACTOR HORN OPTION LT BLU ORN 52 3 D ob ab ob up ED 2 ep ob ISNUHA W134 gt O Ss T m FR Wo e ta Fou V 9rag 32 E5355 365 2 gt 38 amp E sg NM PSEE SE E 38 F UOLOVINOO INN NUYTY ONNOUS SvVULISOS INCH 133135 4930 Afta HIATT HIS NEID HIS Woo 137 T nian gt 3SU3A3MU SAO QUWMHOJ TAO SITOA Fa YALI a 0390198 n dmniomas ANA LK amuonasin Ven PK amni ama GK at 1931391930 mame waa Gk Mason EX Ina OLSIIQA b Tani Figure 2 23 Electrical Schematic Gravity Lift Down Machines Sheet 1 of 2 Change 1 JLG Sizzor 2 32 JLG Sizzor SECTION 2 PROCEDURES DIRECTION SWITCHES ROCKER a SWITCHES IL BLIYORN 52 2 TILT LIGHT YELRED 22 2 gt e4VOLTS ED S GREEN S5 7 gt 4 gt DECK SELECT LIGHT TANSS6 gt 3 gt UFTSELECT UGHT ORANGE 654 gt 5
45. em and replace with recommended oil Refer to Table 1 1 Hydraulic Oil Oil viscosity too high Drain system and replace with recommended oil Refer to Table 1 1 Hydraulic Oil Main relief valve set too high Adjust relief valve to proper pressure Hydraulic system oil low Replenish oil as necessary Defective pump on motor Repair or replace motor Main relief valve set too low Reset valve as required Hydraulic pump not functioning properly Repair or replace pump Leak in component line or fitting Repair or replace component line or fitting Scored valve spool scored cylinder Replace valve replace cylinder Sticking or binding valve cartridge piston rod etc Clean repair or replace components as necessary Hydraulic oil not at operating temperature Allow oil sufficient time to warm up JLG Sizzor 3 5 3 6 Blank Corporate Office JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 USA Phone 717 485 5161 Fax 717 485 6417 JLG Worldwide Locations JLG Industries Australia P O Box 5119 11 Bolwarra Road Port Macquarie N S W 2444 Australia Phone 61 2 65 811111 Fax 61 2 65 810122 JLG Latino Americana Ltda Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil Phone 55 19 3295 0407 Fax 55 19 3295 1025 JLG Industries Europe Kilmartin Place Tannochside Park Uddingston G71 5PH Scot
46. enter punch Using an allen wrench loosen the eight 8 cvlinder head retainer cap screws and remove cap screws from cvlinder barrel Cap Screws Washer Figure 2 2 Cvlinder Head Retainer Cap Screw Removal 6 If applicable using a suitable spanner wrench loosen the spanner nut retainer and remove the spanner nut from the cylinder barrel 7 Attach a suitable pulling device to the cylin der rod port block or cylinder rod end as applicable A IMPORTANT EXTREME CARE SHOULD BE TAKEN WHEN RE MOVING THE CYLINDER 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 care fully withdraw the complete rod assembly from the cylinder barrel EH Jul A 3 i 8 PROTECTED 1 ROD CLAMP E C Ka SUPPORT kell TABLE Figure 2 3 Rod Support 9 Using suitable protection clamp the cvlinder rod in a vise or similar holding fixture as close to the piston as possible 10 If applicable loosen and remove the nut which attaches the piston to the rod then remove the piston from the rod 11 If applicable loosen and remove the cap screw s securing the tapered bushing to the piston 12 Insert the capscrew s in the threaded holes in the outer piece of the tapered bushing Progressively tighten the cap screw s until the bushing is loose on the pis
47. form Control Console illuminates the tilt alarm sounds Slowly back off the nut counting the number of turns until the circuit is closed again BLACK YELLOW SECTION 2 PROCEDURES JLG Sizzor Divide the number of turns determined in step 4 in half Tighten the nut this many turns The line determined by this nut and the X nut is now parallel to the ground Repeat steps 3 through 5 for the remaining Y nut The switch is now level Individually push down on one corner at a time there should be enough travel to cause the switch to trip If the switch does not trip in all three tests the flange nuts have been tightened too far Loosen the X nut and repeat steps 3 through 7 Park the machine on a flat level surface and ensure the machine is level If the motor is not running turn the ignition switch to ON Connect the black lead of the voltmeter to ground and the red lead to the yellow wire protruding from the pot on the bottom of the sensor Figure 2 16 Tilt Switch Leveling Voltmeter Adjustment JLG Sizzor JLG Sizzor 5 Check the voltage at the trip point in all four directions If the voltage reading is not sym metrical repeat step 4 above 15 EN e en ADIUSIMEKE The get limit switch is located on the left side of the frame of the machine When acti vated the switch cuts out the High Drive func tion Adjust the switch to activate when t
48. he plat form is raised above the stowed position PRESSURE SETTING PROCEDURES Ga SS RENE E AN ES NR PRUDENS DE REND IN ANI Notes Make all pressure adjustments with motor operating and hydraulic oil at normal operating temperature In addition all functions must be operated from the plat form control station in order to achieve full pump speed It may be necessary to use an assistant to adjust the pressure settings while operating the functions from the platform control station Steer and Lift functions are governed by M1 Drive is governed by M2 E SERIES SCISSOR LIFTS ARE EQUIPPED WITH EITHER POWER LIFT DOWN WHICH REQUIRES A LIFT DOWN RELIEF ADJUSTMENT OR GRAVITY LIFT DOWN WHICH DOES NOT TO IDENTIFY POWER LIFT DOWN AND GRAVITY LIFT DOWN MACHINES REFER TO THE EFFECTIVITY PAGE FOR MACHINE SERIAL NUMBER IDENTIFICATION 1 Install a pressure gauge at gauge DH M1 located at the bottom rear of the valve body The port is identified by a stamping on the valve body 2 Disconnect the hose from valve port 3 then plug the hose and the valve port 3 From the platform control station activate the Lift Up function bv pressing the LIFT switch and activating the controller to the full forward position SECTION 2 PROCEDURES JLG Sizzor 4 While monitoring the pressure gauge at M1 adjust the Lift Up Relief as follows Power Lift Down Machines All 2100 psi 100 psi 145 bar 7 bar Grav
49. hen operating pressure of the component is reached Crossover relief vaives 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 Indi vidual integral reliefs are provided for each side of the circuit COMPONENT FUNCTIONAL DESCRIPTION The main hydraulic pump is an integral part of the electric motor pump assembly located at the rear of the battery and ground control tray on the frame of the machine The pump is a two section pump that provides an output of 3 13 gpm 11 8 lpm from each pump section JLG Sizzor The lift cvlinder counterbalance manual descent valve is located on top of the lift cvlinder The counterbalance valve is used to hold the platform in place when raised A cable is connected to the valve which when pulled manually opens the LIFT DOWN port and allows the platform to be lowered in the event hydraulic power is lost The positive traction solenoid valve is located on the main control valve and is activated by a switch on the platform control box When acti vated it equally divides the flow of hydraulic oil in the drive circuit to send an equal amount of oil to each drive motor WEAR PADS The original thickness of the sliding pads is 2 0 inches 51 mm Replace sliding pads when w
50. ification a serial number plate is affixed to the machine On all machines with Power Lift down the plate is located one of two places depending on the date of manufacture on the rear center of the machine frame just below the top step of the ladder or on the rear platform kickplate Check your machine for the specific location On all ma chines with Power Lift Down the serial number plate is located on the left rear side of the machine frame just above the left rear tire and wheel assembly In addition if the serial number plate is damaged or missing the machine serial number is stamped on the right front of the frame 1 7 Note All dimensions are given in inches in with the metric equivalent centimeters cm given in parentheses Table 1 4 Cylinder Specifications 2 00 1532E 1932E 5 1 Power Lift Down Lift Cylinder 1532E 1932E Gravitv Lift Down Lift Cvlinder 2033E 2046E Power Lift Down 300 30 625 7 6 77 8 3 00 30 38 2 00 7 6 77 2 5 1 3 50 39 75 2 00 8 9 101 0 5 1 EPGL Extreme Pressure Gear Lube oil meeting PG O Refer to Figure 1 2 for specific lubrication procedures API service classification GL 5 or MIL Spec MIL L 2105 Hvdraulic Qil API service classification GL 3 g Mobilfluid 424 or Kendall Hvken 052 Lift Cvlinder 2033E 2046E Gravitv Lift Down Lift Cvlinder 2646E 2658E Power Lift Down Note Lift Cylinder 2646E 2658E Gravity Lift Down
51. index of 152 Mobilfluid 424 and Kendall Hyken 052 are fully compatible and can be mixed as necessary Note Start up of hydraulic system with oll temperatures below 15 degrees F 26 degrees C is not recommended If it is necessary to start the system in a sub zero environ ment it will be necessary to heat the oil with a low density 100VAC heater to a minimum temperature of 15 degrees F 26 degrees C 3 The only exception to the above is to drain and fill the system with Mobil DTE 11 oil or its equivalent This will allow start up at tem peratures down to 20 degrees F 29 de JLG Sizzor or hydraulic oils increases JLG s recom mended oil change interval to 1200 hours However filter elements must be changed after the first 50 hours of operation and every 300 hours thereafter When changing the oil use only those oils meeting or ex ceeding the specifications appearing in this manual If you are unable to obtain the same type of oil supplied with the machine consult your local supplier for assistance in selecting the proper equivalent Avoid mixing petro leum and synthetic base oils 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 While the unit i
52. ing is closest to the threads In stall a new sealing o ring into the groove between the threads and the flange lip In stall a new wear ring into the inside applica ble head groove If possible the head seal assembly should sit for at least one hour to allow the seals to elastically restore 3 Carefully slide the head assembly onto the cylinder rod ensuring that the wiper seal o ring and wear ring are not damaged or dislodged JLG Sizzor JLG Sizzor 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 appli cable 5 Place a new o ring in the inner piston diame ter groove 6 Carefully place the piston on the cylinder rod ensuring that the o ring is not damaged or dislodged 7 Using suitable protection clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible 8 Push the piston onto the rod until it abuts the spacer end and install the attaching nut A WARNING APPLY LOCQUIC PRIMER T AND LOCTITE 242 TO PISTON NUT THREADS THEN TIGHTEN NUT TO TORQUE SHOWN IN TABLE 2 1 8 Torque the piston nut to the proper torque as outlined in Table 2 1 9 Remove the cylinder rod from the holding fixture 10 Install new seals and a new guidelock ring in the applicable outside diameter grooves of the piston 11 Position the cylinder barrel in a suitable holding fixture A IMPORTA
53. ining ring 12 SECTION 2 PROCEDURES JLG Sizzor 12 Reconnect the hydraulic hoses to the appli cable cylinder ports 2 13 STEER CYLINDER REPAIR S igure 2 14 A IMPORTANT DISASSEMBLV OF THE CVLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA 1 Tag and disconnect the hoses from the cyl inder ports A WARNING DO NOT FULLY EXTEND CYLINDER TO END OF STROKE RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE 2 Place the cylinder barrel 6 into a suitable holding fixture 3 Using a suitable hammer tap around the outside of the cylinder barrel and guide 2 to shatter the Loctite 4 Using a suitable spanner wrench carefully remove the guide from the rod clevis end of the cylinder barrel 5 Attach a suitable pulling device to the clevis end of cylinder rod section one 7 44 IMPORTANT EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD GUIDE AND PISTON AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BAR REL SURFACES 6 With the barrel clamped securely apply pressure to the rod pulling device and care fully withdraw the complete rod assembly from the cylinder barrel 7 Using a suitable hammer tap around the outside of the cylinder barrel and guide 2 to shatter the Loctite 8 Using a suitable spanner wrench carefully remove the remaining guide 2 from the cylinder barrel Remove and discard the wiper
54. install the cartridge type hold ing valve and fittings in the port block using new o rings as applicable Refer to Table 2 2 for proper holding valve torque specifica tions 2 10 JLG Sizzor JLG Sizzor Table 2 1 Cvlinder Component Torque Specifications Tapered Bushing Retaining Screws 80 ft Ib Lift Cylinder 108 Nm Head Retaing Screws 9 ft ib Lift Cylinder 12 Nm Piston Nut Lift Cylinder 1532E 1932E 375 450 ft Ib Machines built August 1996 to present 508 610 Nm Piston Nut Lift Cylinder 2033E 2046E Machines built August 1996 to present Piston Nut Lift Cylinder 2646E 2658bE Machines built August 1996 to present 800 1000 ft Ib 1085 1356 Nm 1125 1375 ft ib 1525 1864 Nm Sun 7 8 hex M20 x 1 5 thds 30 35 ft Ib 41 48 Nm Sun 1 1 8 hex 1 14 UNS thds 45 50 ft Ib 61 68 Nm Sun 1 1 4 hex M36 x 2 thds 150 160 ft Ib 204 207 Nm 50 55 ft Ib 68 75 Nm 75 80 ft Ib 102 109 Nm 100 110 ft Ib 136 149 Nm Racine 1 1 8 hex 1 1 16 12 thds Racine 1 3 8 hex 1 3 16 12 thds Racine 1 7 8 hex 1 5 8 12 thds 2 11 LIFT CYLINDER REPAIR Machines sent This procedure mav be used for lift cvlinders on both power down and gravitv down machines Refer to the effectivitv page for serial number identification IMPORTANT DISASSEMBLV OF THE CVLINDER SHOULD BE PER FORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA BE SURE TO CLEAN ALL DIRT OR OTHER FO
55. ity Lift Down Machines 1532E 1650 psi 114 bar 1932E 2050 psi 141 bar 2033E 1700 psi 117 bar 2046E 2050 psi 141 bar 2646E 2000 psi 138 bar 2658E 2300 psi 159 bar Note Steps 5 through 7 apply only to those machines equipped with Power Lift Down Machines equipped with Gravity Lift Down have no adjustment 5 Remove the plugs from valve port 3 and the applicable hose then reconnect the hose to vaive port 3 6 From the platform control station activate the Lift Down function by pressing the LIFT switch and activating the controller to the full rearward position bottoming out the LIFT DOWN function 7 Adjust the Lift Down relief to 800 psi 55 bar 8 If adjusting the steer pressure proceed to Steer Adjustment if not remove the pres sure gauge from gauge port M1 1 If necessary connect a pressure gauge to gauge port M1 then open the Steer Tow valve 2 Activate drive by pressing the DRIVE switch and activating the controller to the full for ward position While holding the controller activate Steer Right and check Steer Right pressure If necessary adjust Steer Right pressure to 1700 psi 117 bar 3 Activate drive by pressing the DRIVE switch and activating the controller to the full for ward position While holding the controller activate Steer Left and check Steer Left pressure If necessary adjust Steer Left pressure to 1700 psi 117 bar 4 Close the Steer Tow val
56. keep hy draulic oil clean including reserve oil in stor age Hydraulic system filters should be grees C However use of this oil will give poor performance at temperatures above 120 degrees F 49 degrees C Systems using DTE 11 oil should not be operated at temperatures above 200 degrees F 94 de grees C under any condition checked cleaned and or replaced as nec 1 Use of any of the recommended crankcase essary at the specified intervals required in Section 1 Always examine filters for evi dence of metal particles 3 Cloudy oils indicate a high moisture content which permits organic growth resulting in oxidation or corrosion If this condition oc curs the system must be drained flushed and refilled with clean oil 4 It is not advisable to mix oils of different brands or types except as recommended 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 3 1 Refer to Table 1 1 for recommendations for viscosity ranges 2 JLG recommends Mobilfluid 424 which has an SAE viscosity of 10W 30 and a viscosity index of 152 or as an alternate Kendall Hyken 052 hydraulic oil which has an SAE viscosity of 10W 20 and a viscosity
57. land Phone 44 1 698 811005 Fax 44 1 698 811055 JLG Industries UK Unit 12 Southside Bredbury Park Industrial Estate Bredbury Stockport SK6 2sP England Phone 44 870 200 7700 Fax 44 870 200 7711 JLG Europe B V Jupiterstraat 234 2132 HJ Foofddorp The Netherlands Phone 31 23 565 5665 Fax 31 23 557 2493 JLG Industries Pty Ltd Unit 1 24 Industrial Complex Herman Street Meadowdale Germiston South Africa Phone 27 11 453 1334 Fax 27 11 453 1342 JLG Deutschland GmbH Max Planck Strasse 21 D 27721 Ritterhude Ihipohl Bei Bremen Germany Phone 49 421 693 500 Fax 49 421 693 5035 JLG Industries Norge AS Sofeimyrveien 12 N 1412 Sofienyr Norway Phone 47 6682 2000 Fax 47 6682 2001 Plataformas Elevadoras JLG Iberica S L Trapadella 2 PI Castellbisbal Sur 08755Castellbisbal Spain Phone 34 93 77 24700 Fax 34 93 77 11762 JLG Industries Italia Via Po 22 20010 Pregnana Milanese MI Italy Phone 39 02 9359 5210 Fax 39 02 9359 5845 JLG Polska UI Krolewska 00 060 Warsawa Poland Phone 48 91 4320 245 Fax 48 91 4358 200 JLG Industries Sweden Enkopingsvagen 150 Box 704 SE 175 27 Jarfalla Sweden Phone 46 8 506 59500 Fax 46 8 506 59534
58. ld be checked for out of roundnesss If out of roundness exceeds 0 007 inch 0 178 mm this is unacceptable Check for the condition of the dynamic seals looking par ticularly for metallic particles embedded in the seal surface It is normal to cut the static seal on the retaining ring groove upon disas sembly Remove the rod seal static o ring backup ring and rod wiper Damage to the seal grooves particularly on the sealing sur faces is unacceptable If an unacceptable condition exists replace the head 9 Inspect the port block fittings and holding valve Replace as necessary 10 Inspect the oil ports for blockage or the pres ence of dirt or other foreign material Repair Notes Prior to cylinder assembly ensure that the proper cylin der seal kit is used Refer to the Illustrated Parts Manual Apply a light film of hydraulic oil to all components prior to assembly A IMPORTANT WHEN INSTALLING NEW POLY PAK TYPE PISTON SEALS ENSURE SEALS ARE INSTALLED PROPERLY REFER TO FIGURE 2 7 FOR CORRECT SEAL ORIENTA TION IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION 1 Using round nose pliers or special installa tion tools twist the loaded u cup seal into a C shape and allow it to snap into the groove Use a similar technique for installing the wiper 2 Install a new static o ring and back up o ring into the static seal groove verifying that the back up o r
59. le Protection System Deployed All Models 0 75 in 1 9 cm 1532E 1 055 Ib 479 kg 66 psi 4 6 bar 1932E 1 085 Ib 492 kg 68 psi 4 7 bar 2033E 1 460 Ib 662 kg 81 psi 5 6 bar 2046E 1 530 Ib 694 kg 85 psi 5 9 bar 2646E 1 645 Ib 746 kg 91 psi 6 3 bar 2658E 1 755 Ib 796 kg 92 psi 6 3 bar A Wheel Lugs 90 ft Ib 122 Nm B Wheel Hub To 125 150 ft Ib Drive Motor 169 203 Nm C Lifting Bar Attach 900 in Ib Bolts 2033E with 102 Nm Power Lift Down w Loctite D Motor Controller 60 in Ib At Controller Battery Terminal Nuts 7 Nm Replacement Only Torque nut to 125 150 ft Ibs dry then add extra torque to line up the slot with the hole in the shaft to install the cotter pin Note When maintenance becomes necessary or a fastener has loosened refer to the Torque Chart Figure 1 1 to determine proper torque value 1 5 LUBRICATION Table 1 2 Hydraulic Oil 0 F to 210 F 10W 20 10W 30 18 C to 99 C 0 F to 23 F 10W 18 C to 5 C 50 F to 210 F 20W 20 10 C to 210 C JLG Sizzor 1 3 JLG Sizzor UNPLATED GAP SCREWS UNBRAKO 1960 SERIES SOCKET HEAD CAP SCREW WITH LOC WEL PATCH VALUES FOR ZING PLATED BOLTS ONLY SAE GRADE 5 BOLTS 8 GRADE 2 NUTS SAE GRADE 8 BOLTS amp GRADE 8 NUTS ir SECTION 1 SPECIFICATIONS JLG Sizzor N olo pali N RIN Oo eo
60. lean all metal parts with non flammable cleaning solvent Lubricate com ponents as required to aid assembly Service applicable components with the amount type and grade of lubricant recommended in this manual at the specified intervals When recom mended lubricants are not available consult your local supplier for an equivalent that meets or exceeds the specifications listed Clean batteries using a non metallic brush and a solution of baking soda and water Rinse with clean water After cleaning thoroughly dry bat teries and coat terminals with an anti corrosion compound Components and assemblies requiring lubrica tion and servicing are shown in Section 1 LUBRICATION INFORMATION 1 The primary enemy of a hydraulic system is contamination Contaminants enter the sys tem by various means e g using inade quate 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 JLG Sizzor JLG Sizzor SECTION 2 PROCEDURES JLG Sizzor 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
61. linder rod guide with Loctite 242 then secure the cylinder rod guide to the cylinder barrel using a suit able spanner wrench 15 Reconnect the hydraulic hoses to the appli cable cylinder ports 2 14 TILT SWITCH ADJUSTMENT SORTS SSS SESS The machine may be equipped with a tilt switch sensor factory set to activate when the machine is out of level in any direction at 5 degrees and will cut out 2 speed drive Consult factory for tiit sensor adjustment The only field adjustment necessary is leveling the switch on the spring loaded studs There are two methods of adjust ment a manual adjustment and an adjustment using a voltmeter A CAUTION PERFORM TILT ALARM SWITCH LEVELING PRO CEDURE A MINIMUM OF EVERY SIX MONTHS TO ENSURE PROPER OPERATION AND ADJUSTMENT OF SWITCH LIL IA ROI a a aa a EE KA 1 Park the machine on a flat level surface and ensure the machine is level Note Ensure switch mounting bracket is level and securelv attached 2 Level the base of the indicator bv tightening the three flange nuts Tighten each nut through approximatelv one half of its spring travel DO NOT ADJUST THE X NUT DURING THE REMAINDER OF THE PRO CEDURE Updated 9 97 JLG Sizzor 2 17 JLG Sizzor Figure 2 15 Tilt Switch Leveling Manual Adjustment 2 18 3 With the electrical connections complete slowly tighten one of the Y nuts until the circuit is closed the light on the Plat
62. o co co NIN LIN 1380 85600 2000 96900 1750 1 2200 107300 1880 2625 115500 2320 1575 9475 140500 3040 2530 2165 3000 131500 2440 1440 1080 1155 1525 104000 2380 1780 1907 1750 118100 2720 2040 3160 2360 2025 126500 840 1009 1175 87200 1820 1360 920 1118 1300 96600 2000 1500 4 660 802 925 77000 1460 1100 1322 1680 1260 1506 1940 1460 1755 e Q Q N O O St 00 OO O eio CN L09 NM qy y e looo o 1440 47500 880 0 9690 53800 1120 1 0730 59600 1240 1 5800 87700 2200 1640 1974 2300 142200 3560 2660 2844 3925 158000 3270 1 1550 64100 1 8150 73000 0 3730 0 4620 0 5090 0 6060 0 6630 0 7630 0 8560 1 4050 78000 These torque values do not apply to cadium plated fasteners 7 1 1250 1 2500 18 LA 18 10 16 EUM 14 8 12 RES 12 7 112 HEH 1 500 ale 1800 11 12 1 500 Note Figure 1 1 Torque Chart JLG Sizzor SAE GRADE 8 SAE GRADE 5 JLG Sizzor Notes Hvdraulic oils must have anti wear qualities at least to API Service Classification GL 3 and sufficient chemical stability for mobile hydraulic system service JLG Indus tries recommends Mobilfluid 42
63. ometer is centered Accel should be 0 Replace joystick JLG part no 1600257 thru June 1997 or 1600266 after June 1997 if not 0 Select function again Use voltmeter to verify power on J4 of the multiplexer board Re connect cable to platform box or J2 Replace multiplexer card JLG part no 0610123 Check voltage with VOM Unplug battery charger Check voltage with VOM Plug in battery charger Check wire terminations on line contactor and harness connection at JI Tighten connections as necessary Clean corrosion from line contactor Replace line contactor JLG part no 3740117 Repair or replace wiring as necessary Change 1 3 3 JLG Sizzor SECTION 3 TROUBLESHOOTING JLG Sizzor TROUBLESHOOTING CHAR TROUBLE PROBABLE CAUSE REMEDV d Ce Ce NN 5995 a NNN RAUS 25050906 RN KO RRS DO OOO RAD 525 POLOS OPTAR RI Line contactor welded Replace line contactor flash code 3 1 JLG part no 3740117 Line contactor or other driver short Disconnect valve harness at J1 Using circuit or tripped flash code 3 3 an ohm meter measure resistance between B and each pin of the connector except pin 10 Each reading should be 1 12 megaohms If any reading is less replace controller JLG part no 1600258 Point A short circuit flash code 9 6 e Motor lead connections loose Check motor lead connections Tighten connections as necessary Faulty controller Replace controller JLG
64. or warped surfaces Check for leakage Check for presence of excessive dirt or for eign material Check for proper operation and freedom of movement Check for excessive wear or damage Check for proper tightness and adjustment 10 Drain clean and refill Check for proper operation while pump mo tor is running Check for proper lubrication Check for evidence of scratches nicks or rust and for straightness of rod Check for condition of element replace as necessary Check for proper inflation Check Inspection Decal for current inspec tion stamp JLG Sizzor SECTION 2 PROCEDURES JLG Sizzor JLG Sizzor SECTION 2 PROCEDURES JLG Sizzor Table 2 4 Preventive Mai em AAA NVA NY EX PLATFORM DAILY WEEKLY MONTHLY 3 MONTH 6M AR 1 Controller if Equipped HINGE AA MGE WEE ee WAA EENG 2 Switches a UY 3 Placards and Decas o o 12 ia qo c je c NESARA DEENS _5 Hoseand Cabe 1 T o 48 ENTE DE DON DE A SEC NN EN a SERA E chassis 1 1 PEINE AS ERES ERE L2 BateyChage 8 14 O 3 Hydraulic Pump Motor J 1 5 EGET a 5 Hydraulic Filter See Lubrication Chart 5 m L6 HydraulicHosesandTubing 1 s L7 Hydraulic OilTank 1 1 3 s 4 o 8 Hydraulic Tank Breather
65. orn to 1 875 inches 48 mm CLINDER CHECKING EAOLEDURES Note Cylinder checks must be performed any time a cylinder component is replaced or when improper system opera tion is suspected 44 IMPORTANT OPERATE FUNCTIONS FROM GROUND CONTROL STATION ONLY A WARNING DO NOT FULLY EXTEND CYLINDER TO END OF STROKE RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE 1 Using ali applicable safety precautions acti vate motor and fully extend cylinder to be checked Shut down motor SECTION 2 PROCEDURES JLG Sizzor 2 Carefully disconnect hydraulic hose from re tract port of cylinder There will be initial weeping of hydraulic fluid which can be caught in a suitable container After the in itial discharge there should be no further leakage from the retract port 3 Activate motor 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 mo tor 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 e
66. part no 1600258 Point A open circuit flash code 9 7 Faulty controller Replace controller JLG part no 1600258 e Motor stalled Determine cause Repair or replace motor JLG part no 3600266 as necessary Motor open circuit flash code 9 8 e Faulty motor Replace motor JLG part no 3600266 Cutout input flash code 2 5 Use analyzer to verify limit switch inputs Drive cutout and Elevation cutout should be HI Adjust or repair malfunctioning limit switch e Malfunctioning limit switch Cutout input flash code 2 5 Malfunctioning limit switch Use analvzer to verifv limit switch inputs Pothole should be HI Adjust or repair malfunctioning limit switch Lower platform below drive cutout height Platform above drive cutout height settee teeta tentata Cutout input flash code 2 5 Use analyzer to verify limit switch inputs Extension limit should be HI Retract deck extension Deck extension extended Change 1 3 4 JLG Sizzor JLG Sizzor SECTION 3 TROUBLESHOOTING JLG Sizzor TROUBLESHOOTING CHART PROBABLE CAUSE TROUBLE REMEDV Air bubbles in oil Reservoir too low Replenish oil as necessarv Qil filter dirtv Clean and or replace filter as necessarv Oil in reservoir low Replenish oil as necessary Restricted reservoir air vent Clean vent Oil viscosity too high Drain syst
67. remedy may be immediately obvious are not listed in this section The first rule for troubleshooting any circuit that is hydraulically operated and electrically controlled is to determine if the circuit is lacking hydraulic oil and electrical control power This can be ascertained by overriding the bypass valve mechanically or elec trically so that oil is available to the function valve then overriding the function valve mechanically If the function performs satisfactorily the problem ex ists with the control circuit SECTION 3 TROUBLESHOOTING JLG Sizzor 3 3 The first reference for improper function of a hy draulic system where the cause is not immediately apparent should be the Troubleshooting Chart The best place to begin the problem analysis is at the power source pump Once it is determined that the pump is serviceable then a systematic check of the circuit components beginning with the control would follow For aid in troubleshooting refer to the Illustrated Parts Manual for hydraulic diagrams of the various circuits 3 4 JLG SMART SYSTEM The JLG SMART System uses a 24 Volt multiplex motor control unit working in conjunction with a joystick controller and several switches to operate all machine functions The SMART System has a built in LED to indicate any faults which occur during operation of the ma chine The system also stores the last ten trouble faults for use in troubleshooting th
68. ries to activate either LIFT UP or DRIVE Remove weight from the platform to restore LIFT UP and DRIVE func tions operation and to silence the alarm if equipped JLG Sizzor 2 1 This section provides information necessarv to per form maintenance on the scissor lift Descriptions techniques and specific procedures are designed to provide the safest and most efficient maintenance for use bv personnel responsible for ensuring the correct installation and operation of machine com ponents and svstems Note Maintenance procedures provided in this section applv to all six scissor lift models covered in this manual Procedures that apply to a specific model will be so noted A CAUTION WHEN AN ABNORMAL CONDITION IS NOTED AND PROCEDURES CONTAINED HEREIN DO NOT SPE CIFICALLY RELATE TO THE NOTED IRREGULAR ITY WORK SHOULD BE STOPPED AND TECHNI CALLY 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 SERVICING AND MAINTENANCE GUIDELINES The following information is provided to assist you in the use and application of servicing and maintenance procedures contained in this chap ter Your safety and that of others is the first con sideration when engaging in the main
69. ring 1 rod seal 3 back up ring 4 and o ring 5 9 Using suitable protection clamp cylinder rod section two 7a in a vise or similar holding fixture Change 2 JLG Sizzor 2 15 JLG Sizzor 10 11 12 Change 2 2 16 Wiper Ring Guide Rod Seal Back Up Ring O Ring Cylinder Barrel SECTION 2 PROCEDURES JLG Sizzor 7 Rod Section One 7a Rod Section Two 8 Piston Seal 9 O Ring 10 Piston Figure 2 14 Steer Cylinder Assembly Carefully remove cylinder rod section one 7 from cylinder rod section two 7a and carefully remove the piston 10 from the cylinder rod Remove and discard the piston seal 8 and o ring 9 Carefully remove the guide 2 from cylinder rod section one Remove and discard the o ring 5 back up ring 4 rod seal 3 and wiper ring 1 Remove the cylinder rod from the holding fixture Clean all parts thoroughly in an approved cleaning solvent Inspect the cylinder rod for scoring tapering ovality or other damage If necessary dress rod with Scotch Brite or equivalent Replace rod if necessary Inspect threaded portion of rod for excessive damage Dress threads as necessary 4 10 JLG Sizzor Inspect inner surface of cylinder barrel tube for scoring or other damage Check inside diameter for tapering or ovality Replace if necessary Inspect piston surface for damage and scor ing and for
70. s shut down a good preven tive maintenance measure is to make a thor ough inspection of all hydraulic components lines fittings etc as well as a functional check of each system before placing the machine back in service 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 ques tion arise regarding the use of greases in main tenance stock consult your local supplier for evaluation Refer to Table 1 2 for an explanation ofthe lubricant key designations appearing in the Lubrication Chart 2 3 JLG Sizzor 2 4 2 5 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 Direct ing 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 oi 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 A holding valve is used in the Lift circuit to prevent retraction of the cylinder rod should a hydraulic line rupture or a
71. scoring or other damage and for ovality and tapering Replace as necessary Inspect threaded portion of head for dam age Dress threads as necessary Inspect seal and o ring grooves in head for burrs and sharp edges Dress applicable surfaces as necessary Inspect cylinder head outside diameter for scoring or other damage and ovality and tapering Replace as necessary SECTION 2 PROCEDURES 13 JLG Sizzor If applicable inspect rod and barrel bearings for signs of correct lubrication and excessive wear If necessary replace bearings as fol lows a Thoroughly clean steel bushing hole of burrs dirt etc to facilitate bearing installa tion b Inspect steel bushing for wear or other damage If steel bushing is worn or dam aged rod or barrel as applicable must be replaced c Lubricate inside of steel bushing with WD 40 prior to bearing installation d Using arbor of the correct size carefully press the bearing into the steel bushing Note Install the cylinder pin into the Gar Max bearing dry Lubrication is not required with chrome pins and bear Steel Bushing Gar Max Bearing Figure 2 5 Gar Max Bearing Installation 14 15 16 17 JLG Sizzor Inspect travel limiting collar or spacer for burrs and sharp edges If necessary dress inside diameter surface with Scotch Brite or equivalent If applicable inspect port block fittings and holding valve Replace as ne
72. tenance 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 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 SECTION 2 PROCEDURES JLG Sizzor 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 properiv 2 At anv 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 discon nected 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 pas sages 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 1 Use adjustable lifting devices whenever possible if mechanical assistance is re quired All slings chains cables etc should be parallel to each other and as near perpendicular as possible to top of p
73. the motor 2 Remove the 7 cap screws and disassemble the motor as shown 2 24 JLG Sizzor JLG Sizzor SECTION 2 PROCEDURES JLG Sizzor Press Seal into Housing Housing Ring Retaining Shaft Seal Housing 3 Remove retaining ring from front of housing 7 Place housing on a smooth clean surface lu bricate pressure seal with petroleum jelly and insert in the housing seal lip in the down position Use a socket as a seal driver 4 Remove bearing and retaining ring with spe cial tool insert tool cone end first and drive these two parts out from back side of hous ing Seal will be damaged when tool is in serted and must be replaced upon reas sembly Ring Retaining 5 Remove retaining ring washer backup washer and pressure seal from housing l Washer Thick 6 Check all mating surfaces To reduce the chance of leakage replace any parts that have scratches or burrs Wash all metal parts in clean solvent Blow them dry with pressurized air Do not wipe parts dry with paper towels or cloth Lint in a hydraulic system will cause damage Washer Backup Thin Pressure Seal in Place Housing 8 Place backup washer washer and retaining ring on top of the pressure seal Make sure the retaining ring is fully engaged in groove in housing JLG Sizzor 2 25 JLG Sizzor his 9 Place seal bullet over shaft With bullet and shaft seal lubricated with petroleum jelly
74. thin the interval column represent the applicable inspection code for which that component is to be checked The checks and services listed in this schedule are not intended to replace anv local or regional regu lations that mav pertain to this tvpe of equipment nor should the lists be considered as all inclusive Variances in interval times may occur due to cli mate and or conditions and depending on the lo cation and use of the machine JLG Industries requires that a complete annual inspection be performed in accordance with the Annual Machine Inspection Report form Forms are supplied with each new machine and are also available from JLG Customer Service Form must be completed and returned to JLG Industries IMPORTANT JLG INDUSTRIES REQUIRES THAT A COMPLETE ANNUAL INSPECTION BE PERFORMED IN AC CORDANCE WITH THE ANNUAL MACHINE IN SPECTION REPORT FORM Note This machine requires periodic safety and maintenance inspections be a JLG Dealer A decal located on the frame affords a place to record stamp inspection dates Notify dealer if inspection is overdue JLG Sizzor 2 27 JLG Sizzor The inspection and maintenance code numbers are as follows 2 28 1 2 3 4 oO 11 12 13 14 15 16 Check for proper and secure installation Check for visible damage and legibility Check for proper fluid level Check for any structural damage cracked or broken welds bent
75. ting intervals are calculated on 10 hours of machine operation per week Figure 1 2 Lubrication Chart 1532E 1932E 2033E 2046E 2646E 2658E 1 6 JLG Sizzor JLG Sizzor SECTION 1 SPECIFICATIONS JLG Sizzor SERIAL NUMBER SERIAL NUMBERED PLAT STAMPED may be at either location MACHINES WITH POWER LIFT DOWN SERIAL NUMBER STAMPED right front SERIAL NUMBER PLATE MACHINES WITH GRAVITY LIFT DOWN Figure 1 3 Serial Number Locations 1532E 1932E 2033E 2046E 2646E 2658E JLG Sizzor 1 7 JLG Sizzor SECTION 1 SPECIFICATIONS JLG Sizzor 1 8 PRESSURE SETTINGS 1 9 LIMIT SWITCHES Note The machines are equipped with the following limit E Scissor scissor lifts are equipped with either Power switches Lift Down or Gravity Lift Down To identify Power Lift Down or Gravity Lift Down machines refer to the effec tivity page for serial number identification Steer Relief 1700 psi 117 bar Lift Up Relief 2100 psi 100 psi 145 bar 7 bar Lift Down Relief 800 psi 55 bar High Drive Pressure Switch 1100 psi 76 bar Powered Deck Extension Relief If Equipped 3000 psi 207 bar Main Relief 3200 psi 3 4 0 bar Steer Relief 1700 psi 117 bar Lift Up Relief 1532E 1650 psi 114 bar 1932E 2050 psi 141 bar 2033E 1700 psi 117 bar 2046E 2050 psi 141 bar 2646E 2000 psi 138 bar 2658E 2300 psi 159 bar O bar
76. to catch the fingernail Scratches that catch the fingernail but are less than 0 5 inch 12 7 mm long and primarily in the circumferential direction are acceptable provided they cannot cut the piston seal The roughness of the bore should be between 10 and 20 pinches RMS Significant variations greater than 8 pinches difference are unacceptable If an unacceptable condition exists repair or re place the cylinder barrel tube Inspect the threaded portion of the barrel tube for damage Dress the threads as nec essary Inspect piston outside surface for scratches or polishing Deep scratches are unaccept able Polishing indicates uneven loading and when this occurs the diameter should be checked for out of roundness If out of roundness exceeds 0 007 inch 0 178 mm this is unacceptable Check the condition of the seal and o ring looking particularly for metallic particles embedded in the seal and o ring surfaces Remove the seal and o ring Damage to the seal grooves particularly on the sealing surfaces is unacceptable If an unacceptable condition exists replace the piston Inspect the piston spacer for burrs and sharp edges If necessary dress inside diameter surface with Scotch Brite or equivalent SECTION 2 PROCEDURES JLG Sizzor 8 Inspect the cylinder head inside bore for scratches or polishing Deep scratches are unacceptable Polishing indicates uneven loading and when this occurs the bore shou
77. ton then re move the bushing from the piston Piston Tapered A Bushing Figure 2 4 Tapered Bushing Removal 13 Screw the piston counter clockwise by hand and remove the piston from the cylin der rod 14 Remove and discard the piston o rings back up rings guidelock rings and hydrolock seals JLG Sizzor 2 7 JLG Sizzor 15 16 10 11 12 If applicable remove the piston spacer from the rod Remove the rod from the holding fixture Remove the cylinder head and retainer plate from the rod Clean all parts thoroughly in an approved cleaning solvent Inspectthe cylinder rod for scoring tapering ovality or other damage If necessary dress rod with Scotch Brite or equivalent Replace rod if necessary Inspect threaded portion of rod for damage Dress threads as necessary Inspect inner surface of cylinder barrel tube for scoring or other damage Check inside diameter for tapering or ovality Replace if necessary Inspect threaded portion of barrel for dam age Dress threads as necessary Inspect piston surface for damage and scor ing and for distortion Dress piston surface or replace piston as necessary Inspect threaded portion of piston for dam age dress threads as necessary Inspect seal and o ring grooves in piston for burrs and sharp edges Dress applicable surfaces as necessary Inspect cylinder head inside diameter for
78. ts into the bushing using Loc tite 242 Refer to Table 2 1 for proper bolt torque values Tapered Bushing EN Cap ER Screws a Sedi Figure 2 11 Tapered Bushing Installation 11 Remove the cylinder rod from the holding fixture 12 Place new guidelocks and hydrolock seals in the applicable outside diameter grooves of both the piston and the cylinder head Refer to Figure 2 10 13 Position the cylinder barrel in a suitable holding fixture SECTION 2 PROCEDURES JLG Sizzor A IMPORTANT EXTREME CARE SHOULD BE TAKEN WHEN IN STALLING THE CVLINDER ROD HEAD AND PIS TON AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CVLINDER BARREL SURFACES 14 With the barrel clamped securely and while adequately supporting the rod insert the pis ton end into the cylinder barrel Ensure that the piston loading o ring and seal ring are not damaged or dislodged 15 Continue pushing the rod into the barrel until the cylinder head gland can be inserted into the cylinder barrel 16 Secure the cylinder head gland using the washer ring and socket head bolts Refer to Table 2 1 for proper bolt torque specifica tions Spacer Head Cylinder ae Barrel Piston Figure 2 12 Rod Assembly Installation 17 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 18 If applicable
79. uitable drift drive the cylin der rod attach pin through the aligned holes taking care to align the pin retaining hole with the hole in arm assembly Secure the pin in place with the boit and locknut 5 Lower platform to stowed position and shut down motor Check hydraulic fluid level and adjust accordingly 2 10 LIFT CYLINDER REPAIR Machines Note The following procedures apply to the lift cylinder Re pair procedures for the brake and steer cylinders are found in paragraphs 2 12 and 2 13 A IMPORTANT DISASSEMBLV OF THE CVLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA BE SURE TO CLEAN ALL DIRT OR OTHER FOREIGN SUBSTANCES FROM CYLINDER OPENINGS PARTICULARY AT THE HEAD 1 Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting A WARNING DO NOT FULLY EXTEND CYLINDER TO END OF STROKE RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE 2 Operate the hydraulic power source and ex tend the cylinder Shut down and disconnect the power source Adequately support the cylinder rod if necessary JLG Sizzor JLG Sizzor SECTION 2 PROCEDURES JLG Sizzor 3 If applicable remove the cartridge tvpe holding valve and fittings from the cylinder port block Discard o rings Figure 2 1 Barrel Support 4 Place the cvlinder barrel into a suitable hold ing fixture 5 To aid in realignment mark cvlinder head and barrel with a c
80. ve Updated 5 98 JLG Sizzor 2 19 JLG Sizzor SECTION 2 PROCEDURES JLG Sizzor Posi Trac Valve High Drive Ed Pressure Switch Flow Divider Counterbalance Valves Tow Valve High Drive Valve SA Brake Valve Lift Up Relief See Note 2 WA Lift Down Relief See Note 1 Sy A Aajust to 800 psi 55 bar e Cae High Drive Check Valve A 172 NG NH e Steer Right Relief A Steer Left Relief Fa Adjust to 1700 psi 117 bar Main Relief components Shuttle Valve Power Lift Down Adjust to 3000 psi 207 bar Gravity Lift Down Adjust to 3200 psi 220 bar Shuttle Valve Cartridge 25 30 ft Ib 34 41 Nm Tow Valve Cartridge 25 30 ft Ib 34 41 Nm When valve components are removed and or replaced the following torque values apply when re installing the Brake Valve Cartridge 35 40 ft Ib 47 54 Nm ied l E eelere applies onl 10 mose Lift Up Relief Cartridge 25 30 ft Ib 34 41 Nm Machines equipped with Gravity Lift Down have Lift Down Relief Cartridge 25 30 ft Ib 34 41 Nm no Lift Down adjustment Refer to Effectivity Power Lift Down Machines Only Page for serial number identification High Drive Check Valve 25 30 ft Ib 34 41 Nm NOTE 2 Adjust Lift Up Relief as foll Steer Relief Cartridges 25 30 ft Ib 34 41 Nm Sa a A ENS Main Relief Cartridge 25 30 ft Ib 34 41 Nm dab Be a dah Ai 2100 pense bal High Drive Cartridge 4 6 ft Ib 5 8 Nm 1
81. xtend port leakage is less than 6 8 drops per minute carefully recon nect hose to extend port then activate cylin der through one complete cycle and check for leaks A IMPORTANT OPERATE ALL FUNCTIONS FROM GROUND CON TROL STATION ONLY 1 Using all applicable safety precautions acti vate hydraulic system 44 WARNING WHEN WORKING ON THE LIFT CYLINDER RAISE THE PLATFORM COMPLETELY AND SUPPORT THE PLATFORM USING A SUITABLE OVERHEAD LIFTING DEVICE DO NOT FULLY EXTEND LIFT CYLINDER TO END OF STROKE RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE 2 Raise platform completely then retract cylin der slightly to avoid trapping pressure Place a suitable overhead lifting device approxi mately 1 inch 2 5 cm below the platform JLG Sizzor 2 5 JLG Sizzor Shut down hydraulic system and allow ma chine to sit for 10 15 minutes Carefully re move hydraulic hoses from cylinder port block There will be initial weeping of hydraulic fluid which can be caught in a suitable con tainer 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 the counterbal ance valve is defective and must be re placed If no repairs are necessary or when repairs have been made carefully reconnect hy draulic hoses to the appropriate ports Remove lifting device from platform activate hydraulic system an

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