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Service and Maintenance Manual

ANSI

Models

3369electric
3969electric

3120768

March 10, 2004

Содержание 3369electric

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

Страница 2: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 45: ......

Страница 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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