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SECTION 3 - TROUBLESHOOTING

3120826

– JLG Sizzor –

3-7

Table 3-3. Chassis Troubleshooting

TROUBLE

PROBABLE CAUSE

REMEDY

ENGINE

Engine will not start

Station power selector switch is not in required
position

Actuate switch as required

Circuit breaker open

Determine and correct cause. Reset circuit breaker

Start lockout solenoid not working

Replace solenoid

Start switch defective

Replace start switch

Defective anti-dieseling solenoid on carburetor

Replace solenoid or carburetor

Damaged wiring in ignition circuit (broken wire on
starter

repair or replace wiring

Ignition switch not functioning properly

Replace switch

Defective ignition module

Replace ignition module

Ignition circuit shorted to ground

Repair circuit card as required

Battery cable(s) not making contact

Clean and tighten cables

Engine will not start (Ignition O.K.)

No fuel

Replenish fuel as necessary

Restricted or broken fuel line

Clean or replace line

Battery defective or requires charging

Charge or replace battery as required

Engine will not accelerate above low speed

Damaged wiring on speed control switch on gover-
nor solenoid

Repair or replace wiring

Speed control switch not functioning properly

Replace switch

Defective precision governor (Ford)

Repair or replace governor

Defective Adeco throttle actuator (Deutz)

Repair or replace actuator

Governor not functioning properly

Repair or replace governor

Defective electronic governor

Replace governor

Engine will not decelerate below high speed

See engine will not accelerate above low speed

Содержание 25RTS

Страница 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...

Страница 2: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 64: ...SECTION 2 PROCEDURES 2 48 JLG Sizzor 3120826 This page left blank intentionally...

Страница 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...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 83: ......

Страница 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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