JLG 25RTS Service & Maintenance Download Page 31

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SECTION 2 - PROCEDURES

3120826

– JLG Sizzor –

2-15

Figure 2-18. Throttle Checks and Adjustments - Ford

E-301

GAIN

SPEED

(HI ENGINE)

SPEED

(LOW ENGINE)

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

Summary of Contents for 25RTS

Page 1: ...CE JLG INDUSTRIES EUROPE Kilmartin Place Tannochside Park Uddingston Scotland G71 5PH Telephone 01698 811005 Main Fax 01698 811055 Parts Fax 01698 811455 CORPORATE OFFICE JLG INDUSTRIES INC 1 JLG Driv...

Page 2: ......

Page 3: ...should be noted that the machines hydraulic sys tems operate at extremely high potentially danger ous pressures Every effort should be made to relieve any system pressure prior to disconnecting or re...

Page 4: ...LG Sizzor 3120826 REVISON LOG Original Issue June 1993 Revised August 24 1999 Revised September 30 1999 Revised February 29 2000 Revised March 14 2001 Revised September 18 2001 Revised April 15 2002 R...

Page 5: ...cking Procedures 2 4 2 10 Cylinder Removal and Installation 2 5 2 11 Cylinder Repair 2 6 2 12 Tilt Alarm Switch 2 12 2 13 Limit Switch Adjustment Procedure 2 13 2 14 Drive Pump Start up Procedure 2 13...

Page 6: ...rm Switch Voltmeter Adjustment 2 13 2 17 Limit Switch Cut Out 2 13 2 18 Throttle Checks and Adjustments Ford 2 15 2 19 Precision Governor Adjustments 1600269 Controller 2 15 2 20 Precision Governor Ad...

Page 7: ...ajor Component Weights 1 8 1 6 Critcal Stability Weights 1 8 2 1 Cylinder Piston Nut Torque Specifications 2 10 2 2 Holding Valve Torque Specifications 2 10 2 3 Preventive Maintenance and Safety Inspe...

Page 8: ...TABLE OF CONTENTS iv JLG Sizzor 3120826 This page intentionally left blank...

Page 9: ...ph 3 0 gph Horsepower 40 3000 RPM Diesel Engine Manufacturer Deutz Low RPM 2000 High RPM 3000 Battery 85 Amphour 550 Cold Cranking Amps Fuel Consumption Low RPM 4 9 lph 1 3 gph High RPM 6 0 lph 1 6 gp...

Page 10: ...200 lb Machine Height Platform Lowered 25RTS 2 6 m 103 5 in 33RTS 2 8 m 111 5 in 40RTS 3 0 m 119 5 in Machine Length 3 78 m 12 ft 5 in Machine Width All Models Standard Tires 2 29 m 7 ft 6 in All Mode...

Page 11: ...SECTION 1 SPECIFICATIONS 3120826 JLG Sizzor 1 3 Figure 1 1 Torque Chart...

Page 12: ...SECTION 1 SPECIFICATIONS 1 4 JLG Sizzor 3120826 Figure 1 2 Lubrication Diagram...

Page 13: ...Change 40Hours 250 Torque Hubs should be 1 2 full of lubricant JLG Industries recommends replacing the hydraulic filter after the first 40 hours of operation and every 250 hours thereafter KEY TO LUBR...

Page 14: ...550 psi 40RTS 138 bar 2000 psi 4 W S 3 Stack Racine Valve If Equipped Main Relief 172 bar 2500 psi Steer Relief 103 bar 1500 psi Lift Overload Relief Pressure 25RTS 90 bar 1300 psi 33RTS 107 bar 1550...

Page 15: ...si tion Tilt Alarm 3 A horn is sounded and a warning light is illuminated when the machine is operated on a slope that exceeds 3 with the platform raised If the machine is oper ated on a 3 slope with...

Page 16: ...O AFFECT STABILITY Table 1 5 Major Component Weights Component Lb Kg FixedPlatform 660 300 PlatformExtension 300 136 Arm Assembly 25RTS Includes LiftCylinder 2403 1090 Arm Assembly 33RTS Includes Lift...

Page 17: ...uled basis in order to function properly 2 At any time when air fuel or oil lines are discon nected clear adjacent areas as well as the openings and fittings themselves As soon as a line or compo nent...

Page 18: ...y Lubrication Service applicable components with the amount type and grade of lubricant recommended in this manual at the specified intervals When recommended lubricants are not available consult your...

Page 19: ...ays the best choice however multi purpose greases usually have the qualities which meet a variety of single purpose grease requirements Should any question arise regarding the use of greases in mainte...

Page 20: ...a 45 9 cm 3 2 8 in 3 displacement piston pump that powers the drive motors Gear Hydraulic Pump The John Barnes gear pump is piggy backed to the pis ton pump and operates all machine functions except...

Page 21: ...ice or prop approximately 2 5 cm 1 in below the platform 3 Shut down hydraulic system and allow machine to sit for 10 15 minutes Carefully remove hydraulic hoses from cylinder port block 4 There will...

Page 22: ...from platform and position the safety props to the stowed position 6 Lower platform to stowed position and shut down motor engine Check hydraulic fluid level and adjust accordingly 2 11 CYLINDER REPAI...

Page 23: ...SECTION 2 PROCEDURES 3120826 JLG Sizzor 2 7 Figure 2 5 Arms and Platform Positioning and Support Cylinder Repair...

Page 24: ...apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel 9 Using suitable protection clamp the cylinder rod in a vise or similar holding fixtu...

Page 25: ...eter for scoring or other damage and ovality and tapering Replace as necessary 12 If applicable inspect thread ring for scoring or other damage Dress threads or applicable surfaces as necessary 13 If...

Page 26: ...install the attaching nut WHEN REBUILDING THE CYLINDERS APPLY LOCTITE 242 TO PISTON NUT AND SETSCREW THEN TORQUE PISTON NUT REFER TO TABLE 2 1 CYLINDER PISTON NUT TORQUE SPECIFI CATIONS NOTE The Stee...

Page 27: ...cylinder Ensure that the piston loading o ring and seal ring are not damaged or dislodged 14 Continue pushing the rod into the barrel until the cyl inder head gland can be inserted into the barrel cy...

Page 28: ...tighten one of the Y nuts until the circuit is closed and the light on the Platform Control Console illumi nates 4 Slowly back off the nut counting the number of turns until the circuit is again close...

Page 29: ...E PUMP OR MOTOR HAVE BEEN REMOVED FROM THE SYSTEM THE FOLLOWING PROCEDURE MAY REQUIRE THE MACHINE TO BE DISABLED WHEELS RAISED OFF THE GROUND DRIVE FUNCTION DISCONNECTED ETC WHILE PERFORMING THE PROCE...

Page 30: ...erse machine operation Charge pressure should remain at 15 5 bar 16 9 bar 220 psi 240 psi minimum during forward or reverse opera tion Continue to cycle slowly between forward and reverse for at least...

Page 31: ...SECTION 2 PROCEDURES 3120826 JLG Sizzor 2 15 Figure 2 18 Throttle Checks and Adjustments Ford E 301 GAIN SPEED HI ENGINE SPEED LOW ENGINE Figure 2 19 Precision Governor Adjustments 1600269 Controller...

Page 32: ...SECTION 2 PROCEDURES 2 16 JLG Sizzor 3120826 E 401H GAIN Figure 2 20 Precision Governor Adjustments 1600325 Controller...

Page 33: ...NGINE switch Activate and Drive Controller and hold it in full drive posi tion Adjust slide pin to contact high engine limit switch at 2800 rpm Shut off all switches and controllers Reconnect modular...

Page 34: ...However due to hose routing or low reservoir loca tions there may be air trapped within this line It is important to assure that the air is bled from this line This can be accomplished by loosening th...

Page 35: ...auges and plug ports Check reservoir level and add filtered fluid if needed The machine is now ready for operation 2 19 PRESSURE SETTING PROCEDURES 2 W S Racine Two Stack Valve 1 Install pressure gaug...

Page 36: ...SECTION 2 PROCEDURES 2 20 JLG Sizzor 3120826 Figure 2 21 Pressure Adjustment Locations 2 W S...

Page 37: ...nction shut down motor and dis connect pressure gauge Lift Down Speed Adjustment 1 Activate engine and allow hydraulic system to come up to operating temperature 2 Adjust color flow valve lift down sp...

Page 38: ...SECTION 2 PROCEDURES 2 22 JLG Sizzor 3120826 Figure 2 24 Pressure Adjustment Locations 4 W S...

Page 39: ...Engine Speed and Drive Speed control switches to their respective LOW positions 4 Place Drive controller to FORWARD position and carefully drive machine up ascension ramp until left front wheel is on...

Page 40: ...ng 3 Inspect thrust washers and thrust bearing All sur faces should be free of any signs of wear or fretting 4 Inspect spider and pivot Conical surfaces should be free of wear and score marks 5 Inspec...

Page 41: ...8 N C nut 3 8 x 3 1 4 cap screw and two washers 6 Install pivot spider and piston assemblies in piston block assembly 7 Lubricate thrust race and install in housing assem bly 8 Install piston block a...

Page 42: ...SECTION 2 PROCEDURES 2 26 JLG Sizzor 3120826 Figure 2 26 Piston Drive Motor...

Page 43: ...ard o ring g Remove pipe plug from cover 7 Remove thrust washer from counter bore in top of carrier assembly 8 Remove input gear from middle of carrier assembly 9 Lift ring gear off of hub 10 Lift car...

Page 44: ...support Remove bearing cup from wide end of hub h Press nine studs out of stud holes in hub Roll Test The purpose of a roll test is to determine if the unit s gears are rotating freely and properly G...

Page 45: ...sits square with counter bore before pressing 4 Turn hub over onto its small end Press bearing cup down into counter bore in deep end of hub 5 Set hub onto its large end Place bearing cone into beari...

Page 46: ...stretched or pinched together to make it fit counter bore exactly 12 Oil all exposed surfaces inside hub 13 Place internal gear into hub so that its internal splines mesh with external splines of spi...

Page 47: ...ING IS RELEASED BEFORE IT IS PROPERLY IN PLACE 18 Using retaining ring pliers insert retaining ring into groove on input shaft by compressing spring and spacers together 19 With large splined end down...

Page 48: ...ne thrust washer onto the end of planet shaft inside carrier Fit tang of thrust washer into the slot on the inside edge of the planet shaft hole 6 Following the thrust washer place cluster gear large...

Page 49: ...13 Place carrier assembly and ring gear together into mesh with internal gear aligning X marked shoul der bolt in ring gear over one of the shoulder bolt holes in hub Mark location of shoulder bolt h...

Page 50: ...e disconnect cap onto cover cap aligning pipe plug hole in disconnect cap over pipe plug hole in cover cap 8 Place two remaining bolts into bolt holes in discon nect cap and tighten bolts 9 Torque bot...

Page 51: ...ORQUE HUB BRAKE 4WD FRONT TORQUE HUB UNITS SHOULD ALWAYS BE ROLL AND LEAK TESTED BEFORE DISASSEMBLY AND AFTER ASSEMBLY TO MAKE SURE THAT THE UNIT S GEARS AND SEALANTS ARE WORKING PROPERLY Disassembly...

Page 52: ...SECTION 2 PROCEDURES 2 36 JLG Sizzor 3120826 Figure 2 27 Drive Torque Hub 2WD 4WD Rear...

Page 53: ...y went into c Remove planet shaft from carrier housing Two thrust washers and cluster gear will slide off d Remove needle rollers and spacer from inside cluster gear e Repeat steps a through d to remo...

Page 54: ...r 7 Place thrust washer onto spindle brake so it rests on bottom of internal gear 8 Assemble input shaft as follows a Place one spacer spring and other spacer IN THAT ORDER onto smooth end of shaft SA...

Page 55: ...pipe plug hole in cover cap over pipe plug hole in cover e Place two cover cap bolts into any two bolt holes 180 degrees apart on cover cap and tighten f Using a torque wrench apply 4 5 Nm 36 to 49 i...

Page 56: ...SECTION 2 PROCEDURES 2 40 JLG Sizzor 3120826 Figure 2 28 Drive Torque Hub Brake 4WD Front...

Page 57: ...ck assembly consisting of discs return plate and friction discs from housing 7 Remove dowel pins springs 5 6 and spring retainer from housing NOTE Not all models use the same number of springs or spri...

Page 58: ...ld remain dry during installation No oil residue should be allowed to con taminate disc surfaces 7 Place a new friction disc on shaft until it contacts return plate 8 Add additional new discs and new...

Page 59: ...SECTION 2 PROCEDURES 3120826 JLG Sizzor 2 43 Figure 2 29 Drive Brake 2WD 2WS...

Page 60: ...BE FOLLOWED Changing From Gasoline to LP Gas 1 Start engine from ground control station 2 Open hand valve on LP gas supply tank by turning valve counterclockwise BE SURE ALL GASOLINE IS EXHAUSTED BEF...

Page 61: ...ALVES OR FITTINGS INDICATES LEAKAGE A STRONG ODOR OF LPG FUEL CAN INDICATE A LEAK 2 29 FREEWHEELING FEATURE RUNAWAY VEHICLE MACHINE HAZARD MACHINE HAS NO TOW ING BRAKES TOWING VEHICLE MUST BE ABLE TO...

Page 62: ...ne 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 JLG INDUSTRIES REQUIRES THAT A...

Page 63: ...mp 1 5 7 Valves 1 5 8 HydraulicFilter SeeLubricationChart 5 14 14 9 HydraulicHosesandTubing 1 5 10 HydraulicOilTank 3 5 4 11 HydraulicTankBreather 6 14 12 FuelTank 3 5 4 13 LiftCylinder 1 12 5 6 13 4...

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Page 65: ...hor ough 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 th...

Page 66: ...operly Replaceenableswitchcircuitcard Loadcapacityexceeded Personneland orequip ment Reduceload Refertocapacityplacard Hydraulicsystemoillow Replenishoilasnecessary Brokenorbindingpivotpin Repairorrep...

Page 67: ...tproperlylubricated Lubricateasnecessary Wornsealsinliftcylinder Replaceseals Cylindernotfunctioningproperly Repairorreplaceliftcylinder Platformdriftsdown Manualloweringvalvenotfunctioningproperly Re...

Page 68: ...sted Adjustmicroswitchoncontrollerforproperopera tion Machinewillnottravelforward Enableswitchnotactivated Activateenableswitch Functionnotactivatedwithinthe3secondsafter enableswitchwasdepressed Reac...

Page 69: ...ringoncontrolswitchorsolenoid valve Seeproperwiringdiagram Controllernotfunctioningproperly Replacecontroller Restrictedorbrokenhydrauliclineonvalvebank orhydraulicpump Cleanrepairorreplaceline Contro...

Page 70: ...gincorrect Resetpressuresetting Machinewanders steeringnotfirm Crossoverreliefvalvesettoolowornotfunctioning properly Reset repairorreplacevalveasrequired Steerlinkagesloose Tightenlinkage Steerwheelt...

Page 71: ...module Replaceignitionmodule Ignitioncircuitshortedtoground Repaircircuitcardasrequired Batterycable s notmakingcontact Cleanandtightencables Enginewillnotstart IgnitionO K Nofuel Replenishfuelasneces...

Page 72: ...epairorreplaceline Machineoverloaded Checkweightinplatform Mainreliefvalvesettoohigh Resetvalveasrequired Hydraulicsystemoillow Replenishoilasnecessary Pumpnotdeliveringoil Restrictedsuctionline Clean...

Page 73: ...lswitch Emergencystopswitchnotpositionedproperly Placeemergencystopswitchtoon Platform Groundselectswitchnotpositioned properly Placeswitchtoplatformorground asnecessary Circuitbreakeropen Determinean...

Page 74: ...minals Starterrelayfaultyorfaultyrelayconnections Usingatestmeter checkrelaycoilterminalsfor presenceofelectricalpowerandforenergization ofrelaycoil Alsocheckrelayterminalsforcorrect switchingofcontac...

Page 75: ...SECTION 3 TROUBLESHOOTING 3120826 JLG Sizzor 3 11 Figure 3 1 Hydraulic Schematic Sheet 1 of 3 2792368 A...

Page 76: ...SECTION 3 TROUBLESHOOTING 3 12 JLG Sizzor 3120826 Figure 3 2 Hydraulic Schematic Sheet 2 of 3 2792368 A...

Page 77: ...SECTION 3 TROUBLESHOOTING 3120826 JLG Sizzor 3 13 Figure 3 3 Hydraulic Schematic Sheet 3 of 3 2792368 A...

Page 78: ...SECTION 3 TROUBLESHOOTING 3 14 JLG Sizzor 3120826 Figure 3 4 Electrical Schematic Ford Sheet 1 of 2...

Page 79: ...SECTION 3 TROUBLESHOOTING 3120826 JLG Sizzor 3 15 Figure 3 5 Electrical Schematic Ford Sheet 2 of 2...

Page 80: ...SECTION 3 TROUBLESHOOTING 3 16 JLG Sizzor 3120826 Figure 3 6 Electrical Schematic Deutz Sheet 1 of 2...

Page 81: ...SECTION 3 TROUBLESHOOTING 3120826 JLG Sizzor 3 17 Figure 3 7 Electrical Schematic Deutz Sheet 2 of 2...

Page 82: ...SECTION 3 TROUBLESHOOTING 3 18 JLG Sizzor 3120826 This page intentionally left blank...

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Page 84: ...Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil Phone 55 19 3295 0407 Fax 55 19 3295 1025 JLG Europe B V Jupiterstraat 234 2132 HJ Foofddorp The Netherlands Phone 31 23 565 5665 Fax...

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