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SECTION 2 - PROCEDURES

3120768

– JLG Sizzor –

2-11

2.13 TILT SWITCH INDICATOR LEVELING 

PROCEDURE

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

Manual Adjustment

1.

Park the machine on a flat level surface. Be sure it is
as level as possible, with tires filled to rated pres-
sure.

NOTE:

Ensure switch mounting is level and securely
attached.

2.

Tighten the three flange nuts with a socket wrench.
Each nut should be tightened approximately one-
quarter of its spring’s travel.

3.

Using bubble level on top of indicator, Tighten or
loosen the three flange nuts until indicator is level.

4.

Individually push down on one corner at a time.
There should be enough travel to cause the indica-
tor to trip. If the indicator does not trip in all three
tests, the flange nuts have been tightened too far.

2.14 LIMIT SWITCHES

Drive Cut-Out Limit Switch (3969electric)

This switch is located on the front of the machine frame.
Adjust cam to trip limit switch when platform is elevated to
32 ft (9.75 m).

High Speed Drive Cut-Out 

High drive speed is cut out when platform is raised above
stowed (fully lowered) position.

NOTE:

There is no adjustment to be made to the Platform
Ext. limit switch which bolts on the bottom of the plat-
form (If Equipped).

2.15 PRESSURE SETTING PROCEDURES

Main Relief at Pump

1.

Install pressure gauge at port “G” on 4640915 valve.

2.

Activate and bottom out Lift Up. Adjust Main Relief to
2500 psi (172.37 bar).

Lift UP Relief

1.

With pressure gauge at “G” port on 4640915 valve,
activate and bottom out Lift Up.

2.

Adjust Lift Relief to 2500 psi (172 bar).on the 3369ES
and 2700 psi (186 bar) on the 3969ES

Lift Down Relief

1.

With pressure gauge at “G” port on 4640915 valve,
activate and bottom out Lift Down.

2.

Adjust Lift Relief to 900 psi (62.06 bar).

Steer Relief

1.

With pressure gauge at “G” port on 4640915 valve,
activate and bottom out Steer Left or Right.

2.

Adjust Steer Relief to 1200 (82.7 bar).

3.

Shut down hydraulic system and remove pressure
gauge.

Updated 11/24/99

Summary of Contents for 3369electric

Page 1: ...Service and Maintenance Manual ANSI Models 3369electric 3969electric 3120768 March 10 2004...

Page 2: ......

Page 3: ...ould 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 remov...

Page 4: ...ETY PRECAUTIONS b JLG Sizzor 3120768 REVISON LOG March 25 1999 Original Issue This man ual was part of complete manual 3120597 Updated November 24 1999 page 1 2 Updated November 24 1999 page 2 11 Upda...

Page 5: ...2 1 General 2 1 2 2 Servicing and Maintenance Guidelines 2 1 2 3 Lubrication Information 2 2 2 4 Cylinders Theory of Operation 2 3 2 5 Valves Theory of Operation 2 3 2 6 Component Functional Descript...

Page 6: ...bly 2 15 3 1 Hydraulic Schematic 3 9 3 2 Platform Wiring Diagram Sheet 1 of 2 3 10 3 2 Platform wiring Diagram Sheet 2 of 2 3 11 3 3 Ground Control Wiring Diagram Sheet 1 of 2 3 12 3 3 Ground Control...

Page 7: ...gpm 4 13 lpm 2000 psi 137 9 Bar 1 3 PERFORMANCE DATA Travel Speed 3369 3969 electric 3 0 mph 4 8 kmh High Drive for rev sec 50 ft 11 13 sec Creep Drive for rev sec 50 ft 50 60 sec Gradeability 25 Tur...

Page 8: ...rom 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 Lubrication Specifications MPG...

Page 9: ...requencies must be increased accordingly Table 1 4 Lubrication Chart INDEX NUMBER COMPONENT NO TYPE LUBE POINTS LUBE METHOD INTERVAL HOURS COMMENTS 1 HydraulicOil FillCap DrainPlug HO KendallHyken052...

Page 10: ...nt of the frame If the serial number plate is dam aged or missing the machine serial number is stamped on the right front of the machine frame Table 1 5 Cylinder Specifications DESCRIPTION BORE STROKE...

Page 11: ...SECTION 1 SPECIFICATIONS 3120768 JLG Sizzor 1 5 Figure 1 2 Serial Number Location...

Page 12: ...SECTION 1 SPECIFICATIONS 1 6 JLG Sizzor 3120768 Figure 1 3 Torque Chart...

Page 13: ...s in order to func tion properly 2 At any time when hydraulic oil lines are discon nected clear adjacent areas as well as the openings and fittings themselves As soon as a line or compo nent is discon...

Page 14: ...interval When recommended lubricants are not available consult your local supplier for an equivalent that meets or exceeds the specifications listed Batteries Clean batteries using a non metallic bru...

Page 15: ...OF OPERATION 1 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...

Page 16: ...e operational Pump Motor Drive Pump motor drive will start only if the following conditions are satisfied 1 FWD and REV switch off 2 Traction mode off brake applied 3 TEB operate The function is selec...

Page 17: ...activate cylinder through one complete cycle and check for leaks If leakage continues at a rate of 6 8 drops per minute or more cylinder repairs must be made Cylinders With Single Counterbalance Valv...

Page 18: ...es in the lift cylinder and the lower arm assembly Secure in place with bolt locknut and keeper shaft 3 Remove cylinder port plugs and hydraulic line caps and correctly attach lines to cylinder ports...

Page 19: ...he piston from the cylinder rod 14 Remove and discard the piston o rings back up rings guidelock rings and hydrolock seals 15 If applicable remove the piston spacer from the rod 16 Remove the rod from...

Page 20: ...alve Replace as necessary 16 Inspect the oil ports for blockage or the presence of dirt or other foreign material Repair as necessary 17 If applicable inspect piston rings for cracks or other damage R...

Page 21: ...ng end of the rod must be free of oil WHEN REBUILDING THE LIFT CYLINDER APPLY LOCTITE 242 TO TAPERED BUSHING BOLTS THEN TIGHTEN BOLTS SECURELY REFER TO TABLE 2 2 CYLINDER PISTON NUT TORQUE SPECIFICATI...

Page 22: ...loading o ring and seal ring are not damaged or dislodged 23 Continue pushing the rod into the barrel until the cyl inder head gland can be inserted into the barrel cyl inder or if applicable until th...

Page 23: ...tric This switch is located on the front of the machine frame Adjust cam to trip limit switch when platform is elevated to 32 ft 9 75 m High Speed Drive Cut Out High drive speed is cut out when platfo...

Page 24: ...scard 8 Remove thrust washer from the output shaft 9 The output shaft may now be pressed out of the housing 10 The bearing cups will remain in hub as will the inner bearing cone The outer bearing cone...

Page 25: ...uilding or repairing the unit the retaining ring 9 o rings 22 and seal 2 should always be replaced Assembly 1 With the hub shaft sub assembly resting on the shaft install internal gear The spline of t...

Page 26: ...ore holes in housing marked in step 3 and install four shoulder bolts A tap with a hammer may be necessary to align shoul der bolt with hub counterbore 13 Install bolts into remaining holes 14 Pipe pl...

Page 27: ...nt to a suitable maintenance area 1 Chock all wheels securely 2 Engage the mechanical release on both brakes by loosening completely reversing towards drive motor and tightening the three nuts on each...

Page 28: ...Machine Inspection Report form Forms are supplied with each new machine and are also available from JLG Customer Service Forms must be completed and returned to JLG Industries JLG INDUSTRIES REQUIRES...

Page 29: ...aulicPump Motor 1 5 4 Valves 1 5 5 HydraulicFilter 5 14 14 6 HydraulicHosesandTubing 1 5 7 HydraulicOilTank 3 5 4 8 Breather HydraulicTank 6 14 9 LiftCylinder 1 5 6 13 4 10 LimitSwitch 1 7 11 Placards...

Page 30: ...SECTION 2 PROCEDURES 2 18 JLG Sizzor 3120768 This page intentionally left blank...

Page 31: ...lems arising in the machine will be centered in the hydraulic and electrical systems For this reason every effort has been made to ensure that all likely problems in these areas are given the fullest...

Page 32: ...ionnotactivatedwithin3secondsafter enableswitchwasdepressed Reactivateenableswitch Enableswitchnotfunctioningproperly Replaceenableswitchcircuitcard Loadcapacityexceeded Personneland or equipmentonpla...

Page 33: ...Restrictedorbrokenhydrauliclineorfitting Clean repairorreplaceasnecessary Controlvalvenotfunctioningproperly Repairorreplacevalve Wornsealsinliftcylinder Replaceseals Cylindernotfunctioningproperly Re...

Page 34: ...n Machinewillnottravelforward Enableswitchnotactivated Activateenableswitch Functionnotactivatedwithin3secondsafter enableswitchwasdepressed Reactivateenableswitch Enableswitchnotfunctioningproperly R...

Page 35: ...entsteeringlinkage Repairorreplacesteeringlinkageasrequired Hydraulicpumpnotfunctioningproperly Repairorreplacehydraulicpump Steercylindernotfunctioningproperly Repairorreplacesteercylinder Steeringin...

Page 36: ...ionline Repairorreplacesuctionline Systemoverheating Oilviscositytoohigh Drainhydraulicsystemandreplacewithrecom mendedoil Hydraulicoillowinreservoir Replenishoiltoproperlevel Extendeddrivingperiods D...

Page 37: ...eriesasnecessary Novoltagesuppliedtodrivemotors Checkmotorcontrollerandcontactorsfor properfunctioning Repairorreplaceasneces sary Defectivefunctionswitch Replaceswitch Defectivecircuitbreaker Replace...

Page 38: ...g Replacecontroller Rectify replace Adjustasnecessaryorreplace 7Flashes Checkbatteryvoltagewithvoltmeter Checkpowerconnections fuses etc Checkforbatteryleakagetoframe Replacecontroller Change chargeba...

Page 39: ...SECTION 3 TROUBLESHOOTING 3120768 JLGSizzor 3 9 Figure 3 1 Hydraulic Schematic...

Page 40: ...SECTION 3 TROUBLESHOOTING 3 10 JLG Sizzor 3120768 Figure 3 2 Platform Wiring Diagram Sheet 1 of 2...

Page 41: ...SECTION 3 TROUBLESHOOTING 3120768 JLGSizzor 3 11 Figure 3 2 Platform wiring Diagram Sheet 2 of 2...

Page 42: ...SECTION 3 TROUBLESHOOTING 3 12 JLG Sizzor 3120768 Figure 3 3 Ground Control Wiring Diagram Sheet 1 of 2...

Page 43: ...SECTION 3 TROUBLESHOOTING 3120768 JLGSizzor 3 13 Figure 3 3 Ground Control Wiring Diagram Sheet 2 of 2...

Page 44: ...SECTION 3 TROUBLESHOOTING 3 14 JLG Sizzor 3120768 This page intentionally left blank...

Page 45: ......

Page 46: ...nson 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 31 23 557 2493 JLG I...

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