JLG 26MRT Installations- und Benutzerhandbuch

SERVICE & MAINTENANCE

Model

26MRT

3120791

December 1, 2000

AUSTRALIAN OFFICE

JLG INDUSTRIES, INC.

P.O. Box 5119

11 Bolwarra Road

Port Macquarie, Australia

Telephone: 065 811111

Fax: 065 810122

EUROPEAN OFFICE

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 Drive

McConnellsburg, PA.

17233-9533

USA

Telephone: (717) 485-

5161

Fax: (717) 485-6417

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

3120791 – JLG Sizzor – a

SECTION A. INTRODUCTION - MAINTENANCE SAFETY

PRECAUTIONS

A.A GENERAL

This section contains the general safety precautions

which must be observed during maintenance of the

aerial platform. It is of utmost importance that main-

tenance personnel pay strict attention to these warn-

ings and precautions to avoid possible injury to

themselves or others, or damage to the equipment.

A maintenance program must be followed to ensure

that the machine is safe to operate.

MODIFICATION OF THE MACHINE WITHOUT CERTIFI-

CATION BY A RESPONSIBLE AUTHORITY THAT THE

MACHINE IS AT LEAST AS SAFE AS ORIGINALLY

MANUFACTURED, IS A SAFETY VIOLATION.

The specific precautions to be observed during

maintenance are inserted at the appropriate point in

the manual. These precautions are, for the most

part, those that apply when servicing hydraulic and

larger machine component parts.

Your safety, and that of others, is the first consider-

ation when engaging in the maintenance of equip-

ment. 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

DIRECT CONTROL OVER THE FIELD INSPECTION

AND MAINTENANCE, SAFETY IN THIS AREA RESPON-

SIBILITY OF THE OWNER/OPERATOR.

A.B HYDRAULIC SYSTEM SAFETY

It 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 removing any portion of the system.

Relieve system pressure by cycling the applicable

control several times with the engine stopped and

ignition on, to direct any line pressure back into the

reservoir. Pressure feed lines to system components

can then be disconnected with minimal fluid loss.

A.C MAINTENANCE

FAILURE TO COMPLY WITH SAFETY PRECAUTIONS

LISTED IN THIS SECTION MAY RESULT IN MACHINE

DAMAGE, PERSONNEL INJURY OR DEATH AND IS A

SAFETY VIOLATION.

• NO SMOKING IS MANDATORY. NEVER REFUEL DUR-

ING ELECTRICAL STORMS. ENSURE THAT FUEL CAP

IS CLOSED AND SECURE AT ALL OTHER TIMES.

• REMOVE ALL RINGS, WATCHES AND JEWELRY

WHEN PERFORMING ANY MAINTENANCE.

• DO NOT WEAR LONG HAIR UNRESTRAINED, OR

LOOSE-FITTING CLOTHING AND NECKTIES WHICH

ARE APT TO BECOME CAUGHT ON OR ENTANGLED

IN EQUIPMENT.

• OBSERVE AND OBEY ALL WARNINGS AND CAU-

TIONS ON MACHINE AND IN SERVICE MANUAL.

• KEEP OIL, GREASE, WATER, ETC. WIPED FROM

STANDING SURFACES AND HAND HOLDS.

• USE CAUTION WHEN CHECKING A HOT, PRESSUR-

IZED COOLANT SYSTEM.

• NEVER WORK UNDER AN ELEVATED BOOM UNTIL

BOOM HAS BEEN SAFELY RESTRAINED FROM ANY

MOVEMENT BY BLOCKING OR OVERHEAD SLING,

OR BOOM SAFETY PROP HAS BEEN ENGAGED.

• BEFORE MAKING ADJUSTMENTS, LUBRICATING OR

PERFORMING ANY OTHER MAINTENANCE, SHUT

OFF ALL POWER CONTROLS.

• BATTERY SHOULD ALWAYS BE DISCONNECTED

DURING REPLACEMENT OF ELECTRICAL COMPO-

NENTS.

• KEEP ALL SUPPORT EQUIPMENT AND ATTACH-

MENTS STOWED IN THEIR PROPER PLACE.

• USE ONLY APPROVED, NONFLAMMABLE CLEANING

SOLVENTS.

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

b– JLG Sizzor – 3120791

REVISON LOG

Original Issue - June 1993

Revised - May 19, 1999

Revised - December 6, 1999

3120791 – JLG Sizzor – i

TABLE OF CONTENTS

SUBJECT - SECTION, PARAGRAPH PAGE NO.

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

A.A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .aa

A.B Hydraulic System Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .aa

A.C Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .aa

SECTION 1 - SPECIFICATIONS

1.1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.2 Component Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.3 Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.4 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.5 Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.6 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1.7 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1.8 Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1.9 Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1.10 Major Component Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1.11 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

SECTION 2 - PROCEDURES

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 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

2.7 Wear Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

2.8 Cylinder Checking Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

2.9 Lift Cylinder Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

2.10 Lift Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

2.11 Steer Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

2.12 Tilt Alarm Switch Adjustment (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

2.13 Limit Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13

2.14 Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13

2.15 Drive Axle Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

2.16 Brake Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23

2.17 Throttle Checks and Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26

2.18 Control Card Setup and Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26

2.19 Valve Driver Card Setup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29

2.20 Preventive Maintenance and Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31

SECTION 3 - TROUBLESHOOTING

3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.2 Troubleshooting Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.3 Hydraulic Circuit Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

ii – JLG Sizzor – 3120791

TABLE OF CONTENTS

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

1-1. Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1-2. Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1-3. Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

2-1. Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2-2. Cap Screw Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2-3. Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2-4. Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2-5. Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

2-6. Poly-Pak Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

2-7. Wiper Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

2-8. Head Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

2-9. Piston Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

2-10. Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

2-11. Rod Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

2-12. Steer Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

2-13. Tilt Switch Leveling - Manual Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

2-14. Tilt Switch Leveling - Voltmeter Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13

2-15. Valve Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

2-16. Drive Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16

2-17. Carrier Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21

2-18. Ring Gear and Pinion Tooth Contact Pattern. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22

2-19. Ring Gear Pattern Interpretation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23

2-20. Brake Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25

2-21. ADDCO Adjustments (Gasoline/Dual Fuel Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27

2-22. ADDCO Adjustments (Diesel Engine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28

2-23. Valve Driver Card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29

3-1. Electrical Schematic - Yanmar (Sheet of 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

3-2. Electrical Schematic - Yanmar (Sheet of 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

3-3. Electrical Schematic - Daihatsu (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

3-4. Electrical Schematic - Daihatsu (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

3-5. Hydraulic Schematic (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

3-6. Hydraulic Schematic (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

1-1 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1-2 Lubrication Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-3 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-4 Major Component Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-5 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-6 Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

2-1 Cylinder Component Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

2-2 Holding Valve Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

2-3 Preventive Maintenance and Safety Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32

3-1 Elevation System Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

3-2 Chassis Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

3-3 Hydraulic System Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

3-4 Electrical System Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .3-8

SECTION 1 - SPECIFICATIONS

3120791 – JLG Sizzor – 1-1

SECTION 1. SPECIFICATIONS

1.1 CAPACITIES

Hydraulic Oil Tank

15.0 gallons (56.8 liters)

Hydraulic System (Including Tank)

Approximately 18.0 gallons (68.1 liters)

Fuel Tank

7.8 gallons (29.5 liters)

Drive Axle

3 pints (6.4 liters)

1.2 COMPONENT DATA

Engine

Daihatsu Gasoline/LP

3 cylinder, liquid-cooled

21 horsepower @ 3,000 rpm

Idle - 1,500 rpm

Mid Engine - 2,000 rpm

High Engine - 3,000 rpm

Alternator - 14 Amp

Cooling System Capacity

Engine - 1.9 quarts (1.8 liters)

Crankcase Capacity - 3.2 quarts (3.0 liters)

Yanmar Diesel

3 cylinder, liquid-cooled

22 horsepower @ 3,000 rpm

Idle - 1,200 rpm

Mid Engine - 2,000 rpm

High Engine - 3,000 rpm

Alternator - 40 Amp

Cooling System Capacity

1.0 quarts (0.9 liters) - engine

Crankcase Capacity - 2.5 quarts (2.4 liters)

Drive Pump

Closed loop piston type

Output - 15 gpm (56.8 lpm) @ 3,000 rpm

Displacement - 1.16 in.3/rev. (19.0 cm3/rev.)

Lift/Steer Pump

Gear type

Output - 3.1 gpm (11.7 lpm) @ 3,000 rpm.

Displacement - 0.24 in.3/rev. (4.0 cm3/rev.).

Steer/Drive System

Steer (Front) Tires - Dico Multi-Trac C/S 26 x 12.00 - 12

NHS; 6 ply; inflate to 40 psi (2.8 bar).

Toe-In - Adjust to 1/4 inch (6.4 mm) overall.

Drive (Rear) Tires - Dico Tru-Power TL 26 x 12.00 - 12

NHS; 6 ply; inflate to 40 psi (2.8 bar).

Drive Brake - Mico hydraulic multi-disc.

Drive Motor - Eaton 2000 Series; 8.0 in.3/rev. (131 cm3/

rev.).

Drive Axle - Dana Model 44 rigid semi-float, no spin axle

assembly; 5.89 ratio; oil capacity - 3 pints (1.4 liters).

Hydraulic Filter - Inline

Return - Bypass Type

10 Microns Nominal

Platform Size

Standard - 54 in. x 88 in. (1.4 m x 2.2 m)

1.3 PERFORMANCE DATA

Travel Speed

Maximum Speed - 4.5 mph (7.2 kmh)

Elevated Speed - 0.7 mph (1.1 kmh)

Gradeability

35%

Turning Radius

Inside - 8 ft. 1 in. (2.5 m)

Outside - 15 ft. 4 in. (4.7 m)

SECTION 1 - SPECIFICATIONS

1-2 – JLG Sizzor – 3120791

Lift

Up - 34-42 seconds

Down - 31-39 seconds

Platform Capacity

Standard - 1,000 lb. (455 kg).

Manual Platform Extension Capacity

250 lb. (115 kg)

Machine Weight

Approximately 5,200 lb. (2359 kg)

Wheelbase

78.0 in. (2.0 m)

Machine Height (Platform Fully Elevated)

26 ft. (7.9 m)

Machine Height (Platform Lowered)

89.0 in. (2.3 m)

Platform Railing Height

39.5 in. (1.0 m)

Machine Length

105.0 in. (2.7 m)

Machine Width

69.0 in. (1.8 m)

Ground Clearance

5.5 in. (14.0 cm)

Maximum Tire Load

2,030 lb. (921 kg) @ 19 psi (1.3 bar)

1.4 TORQUE REQUIREMENTS

All wheel lug nuts should be torqued to 90 ft lb (122 Nm)

every 150 hours.

NOTE: When maintenance becomes necessary or a fas-

tener has loosened, refer to the Torque Chart Figure

7-1 to determine proper torque value.

1.5 LUBRICATION

Hydraulic Oil

NOTE: Hydraulic oils must have anti-wear qualities at least

to API Service Classification GL-3, and sufficient

chemical stability for mobile hydraulic system ser-

vice. JLG Industries recommends Mobilfluid 424

hydraulic oil, which has an SAE viscosity of 10W-30

and a viscosity index of 152.

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 reservoir. This diesel fuel will “thin”

the hydraulic oil for easier cold weather operation,

and will almost completely dissipate from the hydrau-

lic system over a several month period of time. When

cold weather is past, it may be necessary to drain

and refill the hydraulic system 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 is desired, contact JLG Indus-

tries for proper recommendations.

Table 1-1. Hydraulic Oil

HYDRAULICSYSTEMOPERATING

TEMPERATURERANGE SAEVISCOSITYGRADE

0to+23degreesF

(-18to-5degreesC) 10W

0to+210degreesF

(-18to+100degreesC) 10W-20,10W-30

+50to+210degreesF

(+10to+100degreesC) 20W-20

SECTION 1 - SPECIFICATIONS

3120791 – JLG Sizzor – 1-3

Lubrication Specifications

1.6 CYLINDER SPECIFICATIONS

NOTE: All dimensions are given in inches (in), with the met-

ric equivalent, centimeters (cm), given in parenthe-

ses.

1.7 PRESSURE SETTINGS

Main Relief - 2100 psi (145 bar)

Steer Relief - 1500 psi (103 bar)

Lift Up Relief - 2100 psi (145 bar)

Lift Down Relief - 900 psi (62 bar)

1.8 SERIAL NUMBER LOCATIONS

For machine identification, a serial number plate is affixed

to the machine. The plate is located on the rear center of

the machine frame, just below the middle step of the lad-

der. In addition, if the serial number plate is damaged or

missing, the machine serial number is stamped on the

right front frame rail, adjacent to the sizzor arms.

1.9 LIMIT SWITCHES

The machine is equipped with the following limit switches:

Tilt Alarm (Optional) - 5° - Illuminates a light on the plat-

form and sounds an alarm when the machine is 5° 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.

1.10 MAJOR COMPONENT WEIGHTS

1.11 CRITICAL STABILITY WEIGHTS

DO NOT REPLACE ITEMS CRITICAL TO STABILITY, SUCH AS

ENGINES, AXLES OR TIRES, WITH ITEMS OF DIFFERENT

WEIGHT OR SPECIFICATION. DO NOT MODIFY UNIT IN ANY WAY

TO AFFECT STABILITY.

Table 1-2. Lubrication Specifications

KEY SPECIFICATIONS

MPG MultipurposeGreasehavingaminimumdripping

pointof350degressF.Excellentwaterresistance

andadhesivequalities,andbeingofextremepres-

suretype.(TimkenOK40poundsminimum.)

EPGL ExtremePressureGearLube(oil)meetingAPIser-

viceclassificationGL-5orMIL-SpecMIL-L-2105.

EO Engine(crankcase)Oil.Gas-APISF/SGclass,MIL-

L-2104.Diesel-APICC/CDclass,MIL-L-2104B/

MIL-L-2104C.

HO HydraulicOil.APIserviceclassificationGL-3,e.g.

Mobil424.

Table 1-3. Cylinder Specifications

Description Bore Stroke Rod Dia.

Lift Cylinder 4.00

(10.2) 39.75

(101.0) 2.50

(6.4)

SteerCylinder

(DoubleRrod) 2.00

(5.1) 2.69

(6.83) 1.25

(3.18)

Table 1-4. Major Component Weights

Component lb kg

Platform 382 173

ManualPlatformExtension 221 100

ArmAssembly(IncludesLiftCylinder) 1618 734

Chassis-w/StandardTires 2979 1351

Table 1-5. Critical Stability Weights

Component lb kg

TireandWheelAssembly-Std (each) 50 23

DaihatsuGasoline/LPEngine 132 60

YanmarDieselEngine 183 81

DanaDriveAxle 130 59

SECTION 1 - SPECIFICATIONS

1-4 – JLG Sizzor – 3120791

Figure 1-1. Lubrication Diagram

Table 1-6. Lubrication Chart

INDEX

NO COMPONENT NUMBER/TYPE LUBE POINTS LUBE METHODS INTERVAL

HOURS

1 WheelBearings 2- FrontWheels MPG-repack 1200

2 HydraulicOil FillCap/DrainPlug HO-CheckHOLevel

HO-ChangeHO Daily/1200

3 HydraulicReturnFilter N/A N/A 50/300

4 ChargePumpFilter N/A N/A 50/300

5 Crankcase-VanguardGasoline/LP

Engine FillCap/DrainPlug EO-CheckEOLevel

EO-ChangeEO Daily/50/300

6 Crankcase-YanmarDieselEngine FillCap/DrainPlug EO-CheckEOLevel

EO-ChangeEO Daily/50/300

7 RearAxle FillCap/DrainPlug EPGL-Check EPGLLevel

EPGL-Change EPGL 150/1200

KEY TO LUBRICANTS:

EO - Engine Oil

EPGL - Extreme Pressure Gear Lubricant

HO - Hydraulic Oil - Mobilfluid 424

MPG - Multi-purpose Grease

TO AVOID PERSONAL INJURY, USE SAFETY PROP FOR ALL

MAINTENANCE REQUIREING PLATFORM TO BE ELEVATED.

NOTE: 1. Be sure to lubricate like items on each side.

2. Recommended lubricating intervals are based

on maching operations under normal conditions.

For machines used in multi-shift operations and/or

exposed to hostile environments or conditions,

lubrication frequencies must be increased accord-

ingly.

3. Operate hydraulic functions through one com-

plete cycle before checking hydraulic oil level in

tank. Oil should be visible in ADD sight window on

hydraulic tank. If oil is not visible, add oil until oil is

visible in both ADD and FULL sight windows on

tank. Do not overfill tank.

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