JLG 3369electric Installations- und Benutzerhandbuch

Service and Maintenance Manual

ANSI

Models

3369electric

3969electric

3120768

March 10, 2004

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

3120768 –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 SIZZOR UNTIL

PLATFORM 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 DUR-

ING REPLACEMENT OF ELECTRICAL COMPONENTS.

• KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS

STOWED IN THEIR PROPER PLACE.

• USE ONLY APPROVED, NONFLAMMABLE CLEANING

SOLVENTS.

INTRODUCTION - MAINTENANCE SAFETY 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

Updated March 10, 2004 - page 2-11

3120768 – JLG Sizzor – i

TABLE OF CONTENTS

SUBJECT - SECTION, PARAGRAPH PAGE NO.

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

A.A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a-a

A.B Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a-a

A.C Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a-a

SECTION 1 - SPECIFICATIONS

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

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

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

1.4 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

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

1.6 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.7 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1.8 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1.9 critical stability weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1.10 Relays/Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1.11 Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

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 Motor Controller - Modes of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

2.9 Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

2.10 CYlinder Checking Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

2.11 Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2.12 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2.13 Tilt Switch Indicator Leveling Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

2.14 Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

2.15 Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

2.16 Drive Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

2.17 Drive Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

2.18 Free Wheeling Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15

2.19 Preventive Maintenance and Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16

SECTION 3 - TROUBLESHOOTING

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

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

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

ii – JLG Sizzor – 3120768

TABLE OF CONTENTS (Continued)

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

1-1. Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-2. Serial Number Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

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

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

2-2. Capscrew Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2-3. Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

2-4. Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

2-5. Oil-lite Bearing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

2-6. Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

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

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

2-9. Piston Seal Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

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

2-11. Poly-Pak Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

2-12. Rod Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

2-13. Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2-14. Drive Torque Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13

2-15. Drive Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Wiring Diagram (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

1-1 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

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

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

1-4 Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-5 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1-6 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1-7 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

2-1 Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

2-2 Cylinder Piston Nut Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

2-3 Holding Valve Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

2-4 Preventive Maintenance and Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17

3-1 Platform Assembly Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

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

3-3 Hydraulic System Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

3-4 Electrical System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

3-5 Flash Code Troubleshooting Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

SECTION 1 - SPECIFICATIONS

3120768 – JLG Sizzor – 1-1

SECTION 1. SPECIFICATIONS

1.1 CAPACITIES

Hydraulic Oil Tank

11.0 gallons (41.6 liters)

Hydraulic System

Approximately 13.2 gallons (50.0 liters)

To r q u e H u b s ( 2 )

17 ounces (0.5 liters)

1.2 COMPONENT DATA

Battery Charger

Input, 110 VAC,60 HZ

Output, 48 VDC (23 Amp)

Batteries (8)

6 Volt, 245 AmpHour

Drive System

Drive Motor - 36 VDC, 4.1 H.P. @ 1880 rpm. continuous,

rotation - reversible

Drive Brake- 24 VDC, spring-applied, electrically released

Steer System

Tires - ST205 75R15, Load Range C, 6 Ply Rating, Poly

Filled

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

Hydraulic Filter

Return, 25 Micron

Hydraulic Pump/Electric Motor Assembly

Motor - 48 VDC, 5.5 H.P. @ 2500 rpm

Pump - 0.098 in.[3]/rev. (1.6 cm[3]/rev.)

Pump Output - 1.09 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%

Turning Radius (Inside)

3369 electric - 60 in (1.52 m)

3969 electric - 60 in (1.52 m)

Turning Radius (Outside)

3369 electric - 149 in (3.81 m)

3969 electric - 149 in (3.81 m)

Platform Lift Speed

3369 electric - Lift Up - 75 - 80 seconds

3369 electric - Lift Down - 50 - 60 seconds

3969 electric - Lift Up - 75 - 80 seconds

3969 electric - Lift Down - 50 - 60 seconds

Platform Capacity

3369 electric - 1000 lbs (454 kg)

3969 electric - 750 lbs (340 kg)

Platform Extension Capacity

3369 electric - 500 lbs (227 kg)

3969 electric - 500 lbs (227 kg)

Machine Weight

3369 electric - 8,000 lbs (3629 kg)

3969 electric - 8,800 lbs (3992 kg)

Machine Height (w/rails folded down)

3369 electric - 73 in (1.85 m)

3969 electric - 79 in (2.01 m)

Machine Length (stowed)

3369 electric - 109 in (2.77 m)

3969 electric - 109 in (2.77 m)

SECTION 1 - SPECIFICATIONS

1-2 – JLG Sizzor – 3120768

Machine Width

3369 electric - 69 in (1.80 m)

3969 electric - 69 in. (1.80 m)

Wheelbase

3369 electric - 77 in (1.98 m)

3969 electric - 77 in (1.98 m)

Ground Clearance

3369 electric - 7 in (17.8 cm)

3969 electric - 7 in (17.8 cm)

Maximum Tire Load

3369 electric - 3060 lb (1388 kg)

3969 electric - 3145 lb (1427 kg)

Maximum Bearing Pressure

3369 electric - 56 psi (3.9 bar)

3969 electric - 58 psi (3.9 bar)

1.4 TORQUE SPECIFICATIONS

NOTE: When maintenance becomes necessary or a fas-

tener has loosened, refer to the Torque Chart to

determine proper torque value.

1.5 LUBRICATION

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 index of

152.

When temperatures remain consistently below 2° F

(-7 ° C), JLG recommends the use of Mobil DTE 11.

NOTE: 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.

Lubrication Specifications

*MPG may be substituted for these lubricants, if neces-

sary, but service intervals will be reduced.

NOTE: Refer to Lubrication Chart for specific lubrication pro-

cedures.

1.6 PRESSURE SETTINGS

Lift Up Relief - 3369ES - 2500 psi (172 bar)

3969ES - 2700 psi (186 bar)

Lift Down Relief - 1000 psi (69 bar)

Steer Relief - 1200 psi (82.74 bar)

NOTE: Main Relief at Pump - 2700 psi (186.2 bar)

Ta b l e 1 - 1 . To r q u e S p e c i f i c a t i o n s

DESCRIPTION TORQUE VALUE

(DRY) INTERVAL HOURS

Torque Hub 75 ft. lbs.

102 (NM)

500

Wheel Bolts 90 ft. lbs.

(122 NM)

Ta b l e 1 - 2 . H y d r a u l i c O i l

Hydraulic System Operating Temper-

ature Range

SAE Viscosity Grade

0° F to 23° F (-18°C to -5°C) 10W

0° F to 210° F (-18°C to +99°C) 10W-20, 10W- 0

50° F to 210° F (+10°C to +99°C) 20W-20

Table 1-3. Lubrication Specifications

KEY SPECIFICATIONS

EPGL Extreme Pressure Gear Lube (oil) meeting API service

classification GL-5 or MIL-Spec MIL-L-2105

HO Hydraulic Oil. API service classification Gl-3, BP Energol

SHS46.

LL Synthetic Lithium Lubricant, Gredag 741 Grease.

Updated 11/24/99

SECTION 1 - SPECIFICATIONS

3120768 – JLG Sizzor – 1-3

KEY TO LUBRICANTS:

HO - Hydraulic Oil -Kendall Hyken 052

EPGL - Extreme Pressure Gear Lube

NOTE: Be sure to lubricate like items on each side of the

machine.

Recommended lubricating intervals are based on

machine operations under normal conditions. For

machines used in multi-shift operations and/or

exposed to hostile environments or conditions, lubri-

cating frequencies must be increased accordingly

Table 1-4. Lubrication Chart

INDEX

NUMBER COMPONENT NO/TYPE LUBE

POINTS LUBE/METHOD INTERVAL

HOURS COMMENTS

1 Hydraulic Oil Fill Cap/Drain Plug HO-Kendall Hyken 052 8/800 Check oil every 8 hours of operation.

Change oil every 800 hours of operation.

2 Torque Hub Fill Plug/Half Full EPGL-SAE 90 2000 Check oil level at side plug on hub.

3 Wheel Bearings N/A MPG - Repack 800 2 years

4 Sliding Pads Wear Pads (8) MPG - Brush 50 N/A

5 (not s hown) Hydraulic Filter Element N/A Replaceable Element 40/250 Replacefilter element after first 40hoursof

operation then every 250 hours thereafter.

Figure 1-1. Lubrication Chart

SECTION 1 - SPECIFICATIONS

1-4 – JLG Sizzor – 3120768

1.7 CYLINDER SPECIFICATIONS

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

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

ses. .

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

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

ses.

1.8 MAJOR COMPONENT WEIGHTS

1.9 CRITICAL STABILITY WEIGHTS

1.10 RELAYS/CIRCUIT BREAKERS

Console Box

Relay - Potter & Brumfield P/N K10P-11D15-48 48VDC.

Circuit Breaker - Wood Electric Corp. P/N W58 x BIA4 A-5.

1.11 SERIAL NUMBER LOCATIONS

For machine identification, a serial number plate is affixed

to the front 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 ROD DIA.

Lift Cylinder 4.00

(10.16)

14.68

(37.29)

2.50

(6.35)

Steer Cylinder

(Double Rod)

2.00

(5.08)

3.00

(7.62)

each direction

1.25

(3.18)

each rod

Table 1-6. Major Component Weights

COMPONENT 3369 ELECTRIC 3969 ELECTRIC

LBS. KG. LBS. KG.

Platform 761 345 761 345

Platform Extension 320 145 320 145

Arm Assembly (Includes Lift

Cylinders)

3393 1539 3903 1770

Chassis (Includes Battery

Box and Foamfilled Tires)

3662 1661 3662 1661

Machine Complete (GVW) 8000 3629 8800 3992

Table 1-7. Critical Stability Weights

COMPONENT 3369/3969 ELECTRIC

LBS. KG.

Platform 761 345

Platform Extension 320 145

Foam Filled Tires 150 68

Battery (Each) 77 35

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