Service & Maintenance Manual

Models
400RTS
500RTS
3120696
November 12, 2007
 INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

SECTION A. INTRODUCTION - MAINTENANCE SAFETY

PRECAUTIONS

Relieve system pressure by cycling the applicable

A.A GENERAL
control several times with the engine stopped and
This section contains the general safety precautions ignition on, to direct any line pressure back into the
which must be observed during maintenance of the reservoir. Pressure feed lines to system components
aerial platform. It is of utmost importance that main- can then be disconnected with minimal fluid loss.
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.C MAINTENANCE
A maintenance program must be followed to ensure
that the machine is safe to operate.
FAILURE TO COMPLY WITH SAFETY PRECAUTIONS
LISTED IN THIS SECTION MAY RESULT IN MACHINE
DAMAGE, PERSONNEL INJURY OR DEATH AND IS A
MODIFICATION OF THE MACHINE WITHOUT CERTIFI- SAFETY VIOLATION.
CATION BY A RESPONSIBLE AUTHORITY THAT THE
MACHINE IS AT LEAST AS SAFE AS ORIGINALLY • NO SMOKING IS MANDATORY. NEVER REFUEL DUR-
MANUFACTURED, IS A SAFETY VIOLATION. ING ELECTRICAL STORMS. ENSURE THAT FUEL CAP
IS CLOSED AND SECURE AT ALL OTHER TIMES.
The specific precautions to be observed during • REMOVE ALL RINGS, WATCHES AND JEWELRY WHEN
maintenance are inserted at the appropriate point in PERFORMING ANY MAINTENANCE.
the manual. These precautions are, for the most
part, those that apply when servicing hydraulic and • DO NOT WEAR LONG HAIR UNRESTRAINED, OR
LOOSE-FITTING CLOTHING AND NECKTIES WHICH
larger machine component parts.
ARE APT TO BECOME CAUGHT ON OR ENTANGLED
IN EQUIPMENT.
Your safety, and that of others, is the first consider-
• OBSERVE AND OBEY ALL WARNINGS AND CAU-
ation when engaging in the maintenance of equip-
TIONS ON MACHINE AND IN SERVICE MANUAL.
ment. Always be conscious of weight. Never attempt
to move heavy parts without the aid of a mechanical • KEEP OIL, GREASE, WATER, ETC. WIPED FROM
device. Do not allow heavy objects to rest in an STANDING SURFACES AND HAND HOLDS.
unstable position. When raising a portion of the
• USE CAUTION WHEN CHECKING A HOT, PRESSUR-
equipment, ensure that adequate support is pro- IZED COOLANT SYSTEM.
vided.
• 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.
SINCE THE MACHINE MANUFACTURER HAS NO
DIRECT CONTROL OVER THE FIELD INSPECTION • BEFORE MAKING ADJUSTMENTS, LUBRICATING OR
AND MAINTENANCE, SAFETY IN THIS AREA RESPON- PERFORMING ANY OTHER MAINTENANCE, SHUT OFF
SIBILITY OF THE OWNER/OPERATOR. ALL POWER CONTROLS.

• BATTERY SHOULD ALWAYS BE DISCONNECTED DUR-

ING REPLACEMENT OF ELECTRICAL COMPONENTS.
A.B HYDRAULIC SYSTEM SAFETY
• KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS
It should be noted that the machines hydraulic sys- STOWED IN THEIR PROPER PLACE.
tems operate at extremely high potentially danger- • USE ONLY APPROVED, NONFLAMMABLE CLEANING
ous pressures. Every effort should be made to SOLVENTS.
relieve any system pressure prior to disconnecting
or removing any portion of the system.

3120696 – JLG Sizzor – a

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

REVISION LOG

Original Issue - June 1993

Revised - May 19, 1999

Revised - September 26, 2003

Revised - August 31, 2006

Revised - November 12, 2007

b – JLG Sizzor – 3120696

 TABLE OF CONTENTS

TABLE OF CONTENTS
SUBJECT - SECTION, PARAGRAPH PAGE NO.
SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A.A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-a
A.B Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-a
A.C Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-a
SECTION 1 - SPECIFICATIONS
1.1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.2 Component Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.3 Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.4 Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.5 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.6 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.7 Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.8 Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1.9 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1.10 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
1.11 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
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 Sliding Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
2.8 Pump Coupling Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
2.9 Cylinder Checking Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
2.10 Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
2.11 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
2.12 Tilt Alarm Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
2.13 Pressure Setting Procedures - (400RTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
2.14 Pressure Setting Procedures - (500RTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
2.15 Drive Pump Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
2.16 Throttle Checks and Adjustments - Ford Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11
2.17 Throttle Checks and Adjustments - Deutz F3L1011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11
2.18 Oscillating Axle Lockout Cylinder Bleeding Procedure - (If Equipped) . . . . . . . . . . . . . . . . . . . . .2-14
2.19 Lockout Cylinder Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14
2.20 Piston Drive Motor - 2WD & 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14
2.21 Drive Torque Hub - 2WD/4WD Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16
2.22 Drive Torque Hub/Brake - 4WD Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21
2.23 Drive Brake - 2WD/4WD Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26
2.24 Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28
2.25 Dual Fuel/LPG System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28
2.26 Freewheeling Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28
2.27 Limit Switch Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29
2.28 Preventive Maintenance and Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30
SECTION 3 - TROUBLESHOOTING
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.2 Troubleshooting Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.3 Hydraulic Circuit Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3120696 – JLG Sizzor – i

 TABLE OF CONTENTS

LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.
1-1. Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-2. Serial Number Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1-3. Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
2-1. Poly-Pak Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
2-2. Pressure Adjustment Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
2-3. Throttle Checks and Adjustments - Ford VSG 413. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
2-4. Precision Governor Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
2-5. Throttle Adjustments, Deutz F3L1011. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13
2-6. Piston Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15
2-7. Drive Torque Hub - (2WD/4WD rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17
2-8. Torque Hub Carrier Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20
2-9. Drive Torque Hub/Brake - 4WD Front. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22
2-10. Torque Hub Cover Pipe Plug Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25
2-11. Drive Brake - (2WD/4WD Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27
2-12. Drive Hub Engaged. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29
2-13. Drive Hub Disengaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29
2-14. Drive Cut-out Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29
2-15. Drive Speed Cutout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29
3-1. Hydraulic Schematic (Sheet 1 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
3-2. Hydraulic Schematic (Sheet 2 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
3-3. Hydraulic Schematic (Sheet 3 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
3-4. Hydraulic Schematic (Sheet 4 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
3-5. Hydraulic Schematic (Sheet 5 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
3-6. Hydraulic Schematic (Sheet 6 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
3-7. Electrical Schematic - 400 RTS - Ford LRG (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18
3-8. Electrical Schematic - 400 RTS - Ford LRG (Sheet 2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19
3-9. Electrical Schematic - 400 RTS - Ford LRG (Sheet 3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
3-10. Electrical Schematic - 400 RTS - Ford LRG (Sheet 4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
3-11. Electrical Schematic - 400RTS - Ford LRG (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22
3-12. Electrical Schematic - 400RTS - Ford LRG (Sheet 2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23
3-13. Electrical Schematic - 400RTS - Ford LRG (Sheet 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24
3-14. Electrical Schematic - 400 RTS - Ford VSG (Sheet 1 of 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26
3-15. Electrical Schematic - 400 RTS - Ford VSG (Sheet 2 of 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27
3-16. Electrical Schematic - 400 RTS - Ford VSG (Sheet 3 of 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28
3-17. Electrical Schematic - 400 RTS - Ford VSG (Sheet 4 of 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29
3-18. Electrical Schematic - 400RTS - Deutz (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30
3-19. Electrical Schematic - 400RTS - Deutz (Sheet 2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31
3-20. Electrical Schematic - 400RTS - Deutz (Sheet 3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32
3-21. Electrical Schematic - 400RTS - Deutz (Sheet 4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33
3-22. Electrical Schematic - 400RTS - Deutz (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34
3-23. Electrical Schematic - 400RTS - Deutz (Sheet 2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35
3-24. Electrical Schematic - 400RTS - Deutz (Sheet 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36
3-25. Electrical Schematic - 500 RTS Ford LRG (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38
3-26. Electrical Schematic - 500 RTS Ford LRG (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39
3-27. Electrical Schematic - 500 RTS Ford LSG (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-40
3-28. Electrical Schematic - 500 RTS Ford LSG (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41
3-29. Electrical Schematic - 500 RTS Ford VSG (Sheet 1 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-42
3-30. Electrical Schematic - 500 RTS Ford VSG (Sheet 2 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43
3-31. Electrical Schematic - 500RTS Duetz (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-44
3-32. Electrical Schematic - 500RTS Duetz (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-45
3-33. Electrical Schematic - 500RTS Duetz (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-46
3-34. Electrical Schematic - 500RTS Duetz (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-47

ii – JLG Sizzor – 3120696

 TABLE OF CONTENTS

LIST OF TABLES
TABLE NO. TITLE PAGE NO.
1-1 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-2 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-3 Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1-4 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1-5 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
1-6 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
2-1 Cylinder Piston Nut Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
2-2 Holding Valve Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
2-3 Drive Cutout Heights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29
2-4 Preventive Maintenance and Safety Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31
3-1 Platform Assembly - Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3-2 Chassis Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3-3 Chassis Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
3-4 Hydraulic System Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
3-5 Electrical System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

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iv – JLG Sizzor – 3120696

 SECTION 1 - SPECIFICATIONS

SECTION 1. SPECIFICATIONS

Diesel Engine
1.1 CAPACITIES
Manufacturer/Model - Deutz F3L-1011
Hydraulic Oil Tank
Oil Capacity
Approximately 36.5 U.S. gallons (138.17 liters) w/10% air
space. 6.34 quarts (6.0 liters) w/filter
5.8 quarts (5.5 liters) w/o filter
Hydraulic System (Including Tank)
Mid RPM - 2000
Approximately 44 U.S. gallons (166.56 liters).
High RPM - 3000
Fuel Tank
Alternator - 60 Amphour
Approximately 15 U.S. gallons (56.8 liters)
Battery - 60 Amphour, 1000 Cold Cranking Amps
Engine Crankcase Fuel Consumption
Gasoline Engine
Low RPM - 1.9 gph (7.19 lph)
3.4 quarts (3.2 liters) w/filter
High RPM - 2.5 gph (9.46 lph)
2.9 quarts (2.7 liters) w/o filter
Horsepower - 42 @ 3000 RPM
Diesel Engine
Drive/Steer System
6.34 quarts (6.0 liters) w/filter
Tires 400RTS
5.8 quarts (5.5 liters) w/o filter
Standard - 31 - 15.5 x 15 NHS, 8 ply, pneumatic, inflate to
Coolant Capacity (Gasoline Engine) 60 PSI (4.1bar)
3.5 U.S. gallons (13.2 liters) Optional - 12 - 16.5 NHS, 6 ply, foam filled
Tires 500RTS
1.2 COMPONENT DATA Standard - 12 x 16.5 NHS, 8 ply, pneumatic, inflate to 45
PSI (3.1 bar)
Gasoline Engine
Optional - 31 - 15.5 x 15 NHS, 8 ply, pneumatic, inflate to
Displacement - 4.5 liter
60 PSI (4.1 bar)
Manufacturer/Model - Ford LRG-425
Optional - 12 - 16.5 NHS, 6 ply, foam filled
Oil Capacity
Steer System
4.5 quarts (4.3 liters) w/ filter
Toe-In - Adjust to 1/4 inch (6.4 mm) overall
4.0 quarts (3.8 liters) w/o filter
Drive Motors/Hubs/Brakes
Low RPM - 750
Drive Motor - 2.48 in.3 (6.3 cm3) displacement
Mid RPM - 2200
Drive Hub (2WD Gasoline and Diesel Engine - Rear) - Hub
High RPM - 3000
ratio 35:1
Alternator - 55 Amp external
Drive Hub (4WD Rear) - Hub ratio 24:1
Battery - 85 Amphour, 550 Cold Cranking Amps
Drive Hub/Brake (4WD Front) - Hub ratio 24:1; brake -
Fuel Consumption spring applied, hydraulic release, release pressure - 160
psi (11 bar) initial, 190 psi (13 bar) full
Low RPM - 1.8 gph (6.7 lph)
Drive Brake (2WD/4WD Rear) - Spring applied, hydraulic
High RPM - 3.0 gph (11.4 lph)
release, release pressure - 150 psi (10 bar) initial, 170 psi
Horsepower - 70 @ 2800 RPM (12 bar) full
Coolant Capacity - 3.5 U.S. gallons (13.2 liters)

3120696 – JLG Sizzor – 1-1

 SECTION 1 - SPECIFICATIONS

NOTE: Wheel lugs should be torqued to 80 ft lb (112 Nm) at With Deck Retracted
50 hour intervals.
400RTS - 1,500 lb (680 kg)
When maintenance becomes necessary or a fas- 500RTS - 2,000 lb (907 kg)
tener has loosened, refer to the Torque Chart, Figure
1-1, to determine proper torque value. Platform Capacity - Wide Deck, Dual
Extensions (500RTS Only)
Hydraulic Filter - Inline
500RTS - 1500 lb (680 kg)
Return - Bypass Type
25 Micron Nominal Machine Weight
400RTS - Approx. 14,985 lb (6,797kg)
1.3 PERFORMANCE DATA 500RTS - Approx. 15,300 lb (6,940 kg)

Travel Speed Machine Height (Platform Lowered)

2 Wheel Drive - 3.5 mph (5.6 kmh) 400RTS - 116.625 in (2.9 m)
4 Wheel Drive - 2.8 mph (4.5 kmh) 500RTS - 126.3125 in (3.15 m)

Gradeability Machine Length

2 Wheel Drive - 25% (14°) 15 ft 5 in (4.72 meters)
4 Wheel Drive - 45% (24°)
Machine Width
Turning Radius (Outside) Standard Tires - 7 ft 6 in (2.3 meters)
2 Wheel Steer - 13 ft 2 in (4.0 meters)
Foam Filled Tires - 7 ft 7 in (2.3 meters)
4 Wheel Steer - 6 ft 6 in (2.0 meters)

Lift Speed - 400RTS 1.4 LUBRICATION

Up - 42 - 50 seconds
Table 1-1. Hydraulic Oil
Down - 60 - 70 seconds
HYDRAULIC SYSTEM OPERAT- SAE VISCOSITY GRADE
Lift Speed - 500RTS ING
TEMPERATURE RANGE
Up - 65 - 80 seconds
0 to +23 degrees F 10W
Down - 70 - 80 seconds
(-18 to -5 degrees C)
Platform Capacity - Fixed Platform 0 to +210 degrees F 10W-20,10W-30
400RTS - 2,000 lb. (907 kg) (-18 to +100 degrees C)

500RTS - 2,500 lb. (1134 kg) +50 to +210 degrees F 20W-20

(+10 to +100 degrees C)
Platform Capacity - Traversing Platform
Extension (If Equipped) NOTE: Hydraulic oils must have anti-wear qualities at least
400RTS (With Deck Extended) to API Service Classification GL-3, and sufficien-
themical stability for mobile hydraulic system service.
Main Deck - 1,500 lb (680 kg) JLG Industries recommends Mobil 424 hydraulic oil,
Extension - 500 lb (227 kg) which has an SAE viscosity of 10W-20 and viscosity
index of 152.
500RTS (With Deck Extended)
NOTE: Aside from JLG recommendations, it is not advisable
Main Deck - 2,000 lb (907 kg)
to mix oils of different brands or types, as they may
Extension - 500 lb (227 kg) not contain the same required additives or be of
comparable viscosities. If use of hydraulic oil other

1-2 – JLG Sizzor – 3120696

 SECTION 1 - SPECIFICATIONS

than Mobil 424 is desired, contact JLG Industries for

proper recommendations. 1.7 LIMIT SWITCHES
The machine is equipped with the following limit switches:

1.5 LUBRICATION SPECIFICATIONS High Drive Speed Cut-Out

High drive speed is cut out when platform is raised above
Table 1-2. Lubrication Specifications
stowed (fully lowered) position.
KEY SPECIFICATIONS
Lift Cut-Out (If Equipped)
MPG Multipurpose Grease having a minimum dripping Lift is cut out at 22 ft (6.8 m) when leveling jacks are in the
point of 350 degrees F. Excellent water resistance stowed position.
and adhesive qualities, and being of extreme pres-
sure type. (Timken OK 40 pounds minimum.) Drive Cut-Out (If Equipped)
EPGL Extreme Pressure Gear Lube (oil) meeting API ser- Drive is cut out when platform is at 22 ft (6.8 m) above
vice classification GL-5 or MIL-Spec MIL-L-2105. stow position, or when leveling jacks are in the set posi-
tion.
EO Engine (crankcase) Oil. Gas - API SF/SG class, MIL-
L-2104. Diesel - API CC/CD class, MIL-L-2104B/ 400RTS Tilt Alarm - 5 ° (If Equipped)
MIL-L-2104C.
A horn is sounded and a warning light is illuminated when
HO Hydraulic Oil. API service classification GL-3, e.g. the machine is operated on a slope that exceeds 5 ° with
Mobil 424. the platform raised. If the machine is operated on a 5 °
slope with the platform completely lowered, only the warn-
ing light is illuminated.
NOTE: Refer to Figure 1-2 for specific lubrication proce-
dures. 500RTS - Tilt Alarm - 2 °
A horn is sounded and a warning light is illuminated when
the machine is operated on a slope that exceeds 2 ° with
1.6 PRESSURE SETTINGS the platform raised. If the machine is operated on a 2 °
slope with the platform completely lowered, only the warn-
NOTE: All pressures are given in pounds per square inch
ing light is illuminated.
(psi), with the metric equivalent, bar, in parentheses.

400RTS
Rexroth/Hydraforce Valve

Main Relief - 2250 psi (156 bar)

Steer Relief - 1500 psi (103 bar)

Steer Relief 4-W/S (If Equipped) - 1500 psi (103 bar)

Platform Extension (If Equipped) - 500 psi (34 bar)

500RTS
Rexroth/Hydraforce Valve

Main Relief - 2800 psi (193 bar)

Steer Relief - 1500 psi (103 bar)

Steer Relief 4-W/S (If Equipped) - 1500 psi (103 bar)

Platform Extension (If Equipped) - 500 psi (34 bar)

3120696 – JLG Sizzor – 1-3

 SECTION 1 - SPECIFICATIONS

Figure 1-1. Lubrication Diagram

1-4 – JLG Sizzor – 3120696

 SECTION 1 - SPECIFICATIONS

Table 1-3. Lubrication Chart

INDEX INTERVAL
COMPONENT NUMBER/TYPE LUBE POINTS LUBE METHOD
NO HOURS
1 Oscillating Axle Pivot Point (Optional) 1 Grease Fitting MPG - Pressure Gun 100
2 Lockout Cylinders (Optional) 2 Grease Fittings (1 each cylinder) MPG - Pressure Gun 100
3 Front Steering Spindles (2-W/D) 2 Grease Fittings MPG - Pressure Gun 100
4 Front Steering Spindles (4-W/D) 2 Grease Fittings MPG - Pressure Gun 100
(Optional)
5 Tow Bar Hitch (Optional) 1 Grease Fitting MPG - Pressure Gun 100
6 Wheel Bearings (2-W/D) N/A MPG - Repack 2000
7 *Wheel Drive Hub (4-W/D) (Optional) Fill Plug EPGL (SAE 90) 500
8 Hydraulic Oil Reservoir Fill Cap/Drain Plug HO - Check HO Level (See note 4)/ 10/500
HO - Change HO
9 ** Hydraulic Filter Element N/A Initial Change - 40 Hours 250
10 *Wheel Drive Hub Fill Plug EPGL (SAE 90) 500
11 Rear Steering Spindles (4-W/S) 2 Grease Fittings MPG - Pressure Gun 100
(Optional)
12 400 RTS Sizzor Arm Pivot Pins 30 Grease Fittings (400 RTS) MPG - Pressure Gun 100
500 RTS Sizzor Arm Pivot Pins 38 Grease Fittings (500RTS) MPG - Pressure Gun
13 Rail Slides N/A MPG - Brush 100
14 Platform Extension Slides (Optional) N/A MPG - Brush 100
15 Lift Cylinder 4 Grease Fittings MPG - Pressure Gun 100
16 Engine Crankcase Fill Cap/Drain Plug Check Engine Oil Level 10/100

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

2. Recommended lubricating intervals are based
MPG - Multi-purpose Grease
on machine operations under normal conditions.
EPGL - Extreme Pressure Gear Lube For machines used in multi-shift operations and/
or exposed to hostile environments or conditions,
HO - Hydraulic Oil (Mobil 424) lubrication frequencies must be increased accord-
ingly.
3. Operate hydraulic functions through one com-
*Torque Hubs should be 1/2 full of lubricant plete cycle before checking hydraulic oil level in
** JLG Industries recommends replacing the hydraulic tank. Oil should be visible in ADD sight window on
filter after the first 40 hours of operation and every 250 hydraulic tank. If oil is not visible, add oil until oil is
hours thereafter. visible in both ADD and FULL sight windows on
tank. Do not overfill tank.
4. Any time the pump coupling is removed, coat
splines of coupling with Texaco Code 1912
TO AVOID PERSONAL INJURY, USE SAFETY PROP FOR ALL grease prior to assembly. (gasoline or diesel
MAINTENANCE REQUIRING PLATFORM TO BE ELEVATED. engine only).

3120696 – JLG Sizzor – 1-5

 SECTION 1 - SPECIFICATIONS

Figure 1-2. Serial Number Location

1.8 SERIAL NUMBER LOCATIONS 1.9 CYLINDER SPECIFICATIONS

For machine identification, a serial number plate is affixed NOTE: All dimensions are given in inches (in), with the met-
to the machine. On gasoline or diesel powered machines, ric equivalent, centimeters (cm), in parentheses.
the plate is located on the right front side of the frame rail.
In addition, should the serial number plate be damaged or Table 1-4. Cylinder Specifications
missing, the machine serial number is stamped on the top
of frame between the front wheels. Description Bore Stroke Rod Dia

Lift Cylinder 5.0 78.5 3.5

(400RTS/500RTS) (12.7) (199) (8.9

Steer Cylinder 3.0 7.5 1.5

(7.6) (19.05) (3.8)

Lockout Cylinder 3.0 3.75 1.25

(Oscillating Axle) (7.6) (9.5) (3.2)

Leveling Jack 3.0 18.75 2.0

Cylinder (7.6) (47.6) (5.0)

Traversing Platform Cylinder 1.5 (3.8) 48 1.00

(121) (2.5)

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 SECTION 1 - SPECIFICATIONS

1.10 MAJOR COMPONENT WEIGHTS 1.11 CRITICAL STABILITY WEIGHTS

Table 1-5. Major Component Weights
DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS
Component Lb Kg
OF DIFFERENT WEIGHT OR SPECIFICATION (FOR EXAMPLE:
Fixed Platform (180 cm x 426 cm). 1235 560 FILLED TIRES, ENGINE) DO NOT MODIFY UNIT IN ANY WAY TO
AFFECT STABILITY.
Platform Extension. 275 125
Table 1-6. Critical Stability Weights
Arm Assembly - 400RTS - Includes 7750 3515
Lift Cylinder. Component Lb Kg
Arm Assembly - 500RTS - Includes 8699 3946 Tires (Balasted Only)12X16.5 295 134
Lift Cylinder.
Engine (Ford) 525 238
400RTS
Engine (Deutz) 600 272
Chassis - Includes Pneumatic Tires. 5450 2472

Chassis - Includes Foam-Filled Tires. 6154 2791

500RTS

Chassis - Includes Outriggers, 6052 2745

and Pneumatic Tires.

Chassis - Includes Outriggers, 6756 3065

and Foam-Filled Tires.

3120696 – JLG Sizzor – 1-7

 SECTION 1 - SPECIFICATIONS

Figure 1-3. Torque Chart

1-8 – JLG Sizzor – 3120696

 SECTION 2 - PROCEDURES

SECTION 2. PROCEDURES

and fittings themselves. As soon as a line or compo-

2.1 GENERAL nent is disconnected, cap or cover all openings to
This section provides information necessary to perform prevent entry of foreign matter.
maintenance on the sizzor lift. Descriptions, techniques
3. Clean and inspect all parts during servicing or main-
and specific procedures are designed to provide the saf-
tenance, and assure that all passages and openings
est and most efficient maintenance for use by personnel
are unobstructed. Cover all parts to keep them
responsible for ensuring the correct installation and oper-
clean. Be sure all parts are clean before they are
ation of machine components and systems.
installed. New parts should remain in their contain-
ers until they are ready to be used.

WHEN AN ABNORMAL CONDITION IS NOTED AND PROCEDURES Components Removal and Installation
CONTAINED HEREIN DO NOT SPECIFICALLY RELATE TO THE
NOTED IRREGULARITY, WORK SHOULD BE STOPPED AND 4. Use adjustable lifting devices, whenever possible, if
TECHNICALLY QUALIFIED GUIDANCE OBTAINED BEFORE WORK mechanical assistance is required. All slings (chains,
IS RESUMED. cables, etc.) should be parallel to each other and as
near perpendicular as possible to top of part being
The maintenance procedures included consist of servic- lifted.
ing and component removal and installation, disassembly
5. Should it be necessary to remove a component on
and assembly, inspection, lubrication and cleaning. Infor-
an angle, keep in mind that the capacity of an eye-
mation on any special tools or test equipment is also pro-
bolt or similar bracket lessens, as the angle between
vided where applicable.
the supporting structure and the component
becomes less than 90 degrees.

2.2 SERVICING AND MAINTENANCE 6. If a part resists removal, check to see whether all
GUIDELINES nuts, bolts, cables, brackets, wiring, etc., have been
removed and that no adjacent parts are interfering.
General
Component Disassembly and Reassembly
The following information is provided to assist you in the
When disassembling or reassembling a component, com-
use and application of servicing and maintenance proce-
plete the procedural steps in sequence. Do not partially
dures contained in this chapter.
disassemble or assemble one part, then start on another.
Always recheck your work to assure that nothing has been
Safety and Workmanship overlooked. Do not make any adjustments, other than
Your safety, and that of others, is the first consideration those recommended, without obtaining proper approval.
when engaging in the maintenance of equipment. Always
be conscious of weight. Never attempt to move heavy Pressure-Fit Parts
parts without the aid of a mechanical device. Do not allow
When assembling pressure-fit parts, use an anti-seize or
heavy objects to rest in an unstable position. When raising
molybdenum disulfide base compound to lubricate the
a portion of the equipment, ensure that adequate support
mating surface.
is provided.
Bearings
Cleanliness
1. When a bearing is removed, cover it to keep out dirt
1. The most important single item in preserving the
and abrasives. Clean bearings in nonflammable
long service life of a machine is to keep dirt and for-
cleaning solvent and allow to drip dry. Compressed
eign materials out of the vital components. Precau-
air can be used but do not spin the bearing.
tions have been taken to safeguard against this.
Shields, covers, seals, and filters are provided to 2. Discard bearings if the races and balls (or rollers)
keep air, fuel, and oil supplies clean; however, these are pitted, scored, or burned.
items must be maintained on a scheduled basis in
3. If bearing is found to be serviceable, apply a light
order to function properly.
coat of oil and wrap it in clean (waxed) paper. Do not
2. At any time when air, fuel, or oil lines are discon- unwrap reusable or new bearings until they are
nected, clear adjacent areas as well as the openings ready to install.

3120696 – JLG Sizzor – 2-1

 SECTION 2 - PROCEDURES

4. Lubricate new or used serviceable bearings before cleaning, thoroughly dry batteries and coat terminals with
installation. When pressing a bearing into a retainer an anti-corrosion compound.
or bore, apply pressure to the outer race. If the bear-
ing is to be installed on a shaft, apply pressure to the Lubrication and Servicing
inner race.
Components and assemblies requiring lubrication and
Gaskets servicing are shown in Section 1.

Check that holes in gaskets align with openings

in the mating parts. If it becomes necessary to
hand-fabricate a gasket, use gasket material or
2.3 LUBRICATION INFORMATION
stock of equivalent material and thickness. Be Hydraulic System
sure to cut holes in the right location, as blank
gaskets can cause serious system damage. 1. The primary enemy of a hydraulic system is contam-
ination. Contaminants enter the system by various
Bolt Usage and Torque Application means, e.g., using inadequate hydraulic oil, allowing
moisture, grease, filings, sealing components, sand,
5. Use bolts of proper length. A bolt which is too long etc., to enter when performing maintenance, or by
will bottom before the head is tight against its related permitting the pump to cavitate due to insufficient
part. If a bolt is too short, there will not be enough system warm-up or leaks in the pump supply (suc-
thread area to engage and hold the part properly. tion) lines.
When replacing bolts, use only those having the
2. The design and manufacturing tolerances of the
same specifications of the original, or one which is
component working parts are very close, therefore,
equivalent.
even the smallest amount of dirt or foreign matter
6. Unless specific torque requirements are given within entering a system can cause wear or damage to the
the text, standard torque values should be used on components and generally results in faulty opera-
heat-treated bolts, studs, and steel nuts, in accor- tion. Every precaution must be taken to keep
dance with recommended shop practices. hydraulic oil clean, including reserve oil in storage.
Hydraulic system filters should be checked,
Hydraulic Lines and Electrical Wiring cleaned, and/or replaced as necessary. Always
examine filters for evidence of metal particles.
Clearly mark or tag hydraulic lines and electrical wiring, as
well as their receptacles, when disconnecting or removing 3. Cloudy oils indicate a high moisture content which
them from the unit. This will assure that they are correctly permits organic growth, resulting in oxidation or cor-
reinstalled. rosion. If this condition occurs, the system must be
drained, flushed, and refilled with clean oil.
Hydraulic System
4. It is not advisable to mix oils of different brands or
1. Disassemble and reassemble parts on clean work types, as they may not contain the same required
surface. Clean all metal parts with non-flammable additives or be of comparable viscosities. Good
cleaning solvent. Lubricate components, as grade mineral oils, with viscosities suited to the
required, to aid assembly. ambient temperatures in which the machine is oper-
ating, are recommended for use.
2. Disassemble and reassemble parts on clean work
surface. Clean all metal parts with non-flammable NOTE: Metal particles may appear in the oil or filters of new
cleaning solvent. Lubricate components, as machines due to the wear-in of meshing compo-
required, to aid assembly. nents.

Lubrication Hydraulic Oil

Service applicable components with the amount, type,
and grade of lubricant recommended in this manual, at 1. Refer to Section 1 for recommendations for viscosity
the specified intervals. When recommended lubricants are ranges.
not available, consult your local supplier for an equivalent
2. JLG recommends Kendall Hyken 052 hydraulic oil,
that meets or exceeds the specifications listed.
which has an SAE viscosity of 10W-20 and a viscos-
ity index of 152.
Batteries
Clean batteries, using a non-metallic brush and a solution
of baking soda and water. Rinse with clean water. After

2-2 – JLG Sizzor – 3120696

 SECTION 2 - PROCEDURES

NOTE: Start-up of hydraulic system with oil temperatures

below -15 ° F (-26 ° C). is not recommended. If it is
2.4 CYLINDERS - THEORY OF OPERATION
necessary to start the system in a sub-zero environ- 1. Cylinders are of the double acting type. The Steer,
ment, it will be necessary to heat the oil with a low Leveling Jack, and Deck Extension systems incor-
density, 100VAC heater to a minimum temperature of porate double acting cylinders. A double acting cyl-
-15 ° F (-26 ° C). inder is one that requires oil flow to operate the
cylinder rod in both directions. Directing oil (by actu-
3. The only exception to the above is to drain and fill ating the corresponding control valve to the piston
the system with Mobil DTE 11 oil or its equivalent. side of the cylinder) forces the piston to travel
toward the rod end of the barrel, extending the cylin-
This will allow start up at temperatures down to -20 °
der rod (piston attached to rod). When the oil flow is
F (-29 ° C). However, use of this oil will give poor per-
stopped, movement of the rod will stop. By directing
formance at temperatures above 120° F (49° C). Sys-
oil to the rod side of the cylinder, the piston will be
tems using DTE 11 oil should not be operated at forced in the opposite direction and the cylinder rod
temperatures above 200° F (94° C). under any con- will retract.
dition.
NOTE: The Lift cylinder is a single acting cylinder which take
hydraulic pressure to extend and gravity to retract.
Changing Hydraulic Oil
2. A holding valve is used in the Lift, and Leveling Jack
4. Use of any of the recommended crankcase or circuit to prevent retraction of the cylinder rod
hydraulic oils eliminates the need for changing the should a hydraulic line rupture or a leak develop
oil on a regular basis. However, filter elements must between the cylinder and its related control valve.
be changed after the first 40 hours of operation and
every 250 hours thereafter. If it is necessary to
change the oil, use only those oils meeting or 2.5 VALVES - THEORY OF OPERATION
exceeding the specifications appearing in this man-
ual. If unable to obtain the same type of oil supplied Solenoid Control Valves(Bang Bang)
with the machine, consult local supplier for assis-
Control valves used are four-way three-position solenoid
tance in selecting the proper equivalent. Avoid mix-
valves of the sliding spool design. When a circuit is acti-
ing petroleum and synthetic base oils. JLG
vated and the control valve solenoid energizes, the spool
Industries recommends changing the hydraulic oil is shifted and the corresponding work port opens to per-
annually. mit oil flow to the component in the selected circuit, with
the opposite work port opening to reservoir. Once the cir-
5. Use every precaution to keep the hydraulic oil clean.
cuit is deactivated (control returned to neutral), the valve
If the oil must be poured from the original container spool returns to neutral (center) and oil flow is then
into another, be sure to clean all possible contami- directed through the valve body and returns to reservoir. A
nants from the service container. Always clean the typical control valve consists of the valve body, sliding
mesh element of the filter and replace the cartridge spool, and two solenoid assemblies. The spool is
any time the system oil is changed. machine fitted in the bore of the valve body. Lands on the
spool divide the bore into various chambers, which, when
6. While the unit is shut down, a good preventive main- the spool is shifted, align with corresponding ports in the
tenance measure is to make a thorough inspection valve body open to common flow. At the same time other
of all hydraulic components, lines, fittings, etc., as ports would be blocked to flow. The spool is spring-
well as a functional check of each system, before loaded to center position, therefore when the control is
placing the machine back in service. released, the spool automatically returns to neutral, pro-
hibiting any flow through the circuit.
Lubrication Specifications
Relief Valves
Specified lubricants, as recommended by the component Main relief valves are installed at various points within the
manufacturers, are always the best choice, however, hydraulic system to protect associated systems and com-
multi-purpose greases usually have the qualities which ponents against excessive pressure. Excessive pressure
meet a variety of single purpose grease requirements. can be developed when a cylinder reaches its limit of
Should any question arise regarding the use of greases in travel and the flow of pressurized fluid continues from the
maintenance stock, consult your local supplier for evalua- system control. The relief valve provides an alternate path
tion. Refer to Section 1 for an explanation of the lubricant for the continuing flow from the pump, thus preventing
key designations appearing in the Lubrication Chart. rupture of the cylinder, hydraulic line or fitting. Complete

3120696 – JLG Sizzor – 2-3

 SECTION 2 - PROCEDURES

failure of the system pump is also avoided by relieving cir- bled or replaced. Lubricate the splines with Texaco Code
cuit pressure. The relief valve is installed in the circuit 1912 Pump Coupling Grease ONLY. No other lubricant is
between the pump outlet (pressure line) and the cylinder recommended.
of the circuit, generally as an integral part of the system
valve bank. Relief pressures are set slightly higher than
the load requirement, with the valve diverting excess 2.9 CYLINDER CHECKING PROCEDURES
pump delivery back to the reservoir when operating pres-
sure of the component is reached. NOTE: Cylinder checks must be performed any time a cylin-
der component is replaced or when improper system
Crossover Relief Valves operation is suspected.
Crossover relief valves are used in circuits where the actu-
ator requires an operating pressure lower than that sup- Cylinder w/o Counterbalance Valves - Steer
plied to the system. When the circuit is activated and the Cylinder, Platform Ext. Cylinder, Axle
required pressure at the actuator is developed, the cross- Lockout Cylinder (If Equipped)
over relief diverts excess pump flow to the reservoir. Indi-
vidual, integral reliefs are provided for each side of the
circuit. NOTICE
OPERATE FUNCTIONS FROM GROUND CONTROL STATION
ONLY.
2.6 COMPONENT FUNCTIONAL
DESCRIPTION 1. Using all applicable safety precautions, activate
hydraulic system and fully extend cylinder to be
Piston Hydraulic Pump checked. Shut down hydraulic system.
The Sundstrand piston hydraulic pump is attached to and 2. Carefully disconnect hydraulic hose from retract port
driven by the gasoline or diesel engine. The pump is a 2.8 of cylinder. There will be initial weeping of hydraulic
in3 (45.9 cm3) displacement piston pump that powers the fluid which can be caught in a suitable container.
drive motors. After the initial discharge, there should be no further
leakage from the retract port.
Gear Hydraulic Pump
3. Activate hydraulic system and activate cylinder
The John Barnes gear pump is piggy-backed to the piston extend function. Check retract port for leakage.
pump, and operates all machine functions except drive.
The gear pump has a displacement of 0.6 in3 (10.5 cm3). 4. If cylinder leakage is 6-8 drops per minute or more,
piston seals are defective and must be replaced. If
Manual Descent Valve (If Equipped) cylinder retract port leakage is less than 6-8 drops
per minute, carefully reconnect hose to retract port
The manual descent valve is located on top of the holding and retract cylinder.
valve on the lift cylinder. The holding valve is a normally
closed solenoid valve, and holds the platform in place 5. With cylinder fully retracted, shut down hydraulic
when raised. When activated, the valve opens to permit lift system and carefully disconnect hydraulic hose
down. The holding valve is connected to the manual from cylinder extend port.
descent valve, which is connected to a cable which, when
pulled, manually opens the lift down port of the valve and 6. Activate motor and activate cylinder retract function.
allows the platform to be lowered in the event hydraulic Check extend port for leakage.
power is lost.
7. If cylinder leakage is 6-8 drops per minute or more,
piston seals are defective and must be replaced. If
extend port leakage is less than 6-8 drops per
2.7 SLIDING WEAR PADS minute, carefully reconnect hose to extend port,
The original thickness of the sliding pads is 3.5 in (90 then activate cylinder through one complete cycle
mm). Replace sliding pads when worn to 3.3 in (83 mm). and check for leaks.

Cylinders w/Single Counterbalance Valves -

2.8 PUMP COUPLING LUBRICATION Lift Cylinder, Leveling Jacks (If Equipped)
To insure proper operation and a long service life for the
Hayes pump coupling, it is necessary to lubricate the 1. Using all applicable safety precautions, activate
splines of the coupling any time the coupling is disassem- hydraulic system.

2-4 – JLG Sizzor – 3120696

 SECTION 2 - PROCEDURES

assembly. Using a suitable brass drift, drive out the

barrel end attach pin from the arm assembly.
WHEN WORKING ON THE LIFT CYLINDER, RAISE THE PLAT-
FORM COMPLETELY AND SUPPORT THE PLATFORM USING A 6. Carefully remove the cylinder from the Sizzor lift and
SUITABLE OVERHEAD LIFTING DEVICE. place in a suitable work area.

2. Raise platform completely and place a suitable over- Lift Cylinder Installation
head lifting device or prop approximately 1 in. (2.5
cm) below the platform. 1. Install lift cylinder in place using suitable slings or
supports, aligning barrel end attach pin mounting
NOTE: Step (3) applies to the leveling jacks only.
holes on lower arm assembly.
3. Fully extend leveling jacks to check. 2. Using a suitable drift, drive the barrel end attach pin
4. Shut down hydraulic system and allow machine to through the mounting holes in the lift cylinder and
sit for 10-15 minutes. Carefully remove hydraulic the lower arm assembly. Secure in place with the
hoses from cylinder port block. bolts, flatwashers, and lockwashers.

5. There will be initial weeping of hydraulic fluid, which 3. Remove cylinder port plugs and hydraulic line caps
can be caught in a suitable container. After the initial and correctly attach lines to cylinder ports.
discharge, there should not be any further leakage
from the ports. If leakage continues at a rate of 6-8 4. Extend the cylinder rod until the attach pin hole
drops per minute or more, cylinder repairs must be aligns with those in the upper arm assembly. Using a
made. If the retract port is leaking, the piston seals suitable drift, drive the cylinder rod attach pin
are defective and must be replaced. If the extend through the aligned holes. Secure the pin in place
port is leaking, the counterbalance valve is defective with the bolts, lockwashers, and flatwashers.
and must be replaced.
5. Lower platform to stowed position and shut down
6. If no repairs are necessary or when repairs have motor/engine. Check hydraulic fluid level and adjust
been made, carefully reconnect hydraulic hoses to accordingly.
the appropriate ports.

7. Remove lifting device from platform, activate hydrau-

lic system and run cylinder through one complete
2.11 CYLINDER REPAIR
cycle to check for leaks.
NOTE: The following are general procedures that apply to
all of the cylinders on this machine. Procedures that
apply to a specific cylinder will be so noted.
2.10 CYLINDER REMOVAL AND
INSTALLATION
Disassembly
Lift Cylinder Removal
NOTICE
1. Place the machine on a flat and level surface. Start DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON
the engine/motor and raise the platform. Shut down A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
the engine/motor and attach a suitable support
device to the platform.
1. Connect a suitable auxiliary hydraulic power source
2. Remove the locknut, bolts, flatwashers and keeper to the cylinder port block fitting.
shaft securing the cylinder rod attach pin to the
upper inner arm assembly. Using a suitable brass
drift, drive out the rod end attach pin from the arm
assembly. DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE.
RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES-
3. Retract the lift cylinder rod completely. SURE.

4. Tag and disconnect, then cap the lift cylinder

hydraulic lines and ports. 2. Operate the hydraulic power source and extend the
cylinder. Shut down and disconnect the power
5. Remove the bolts, lockwashers, and flatwashers source. Adequately support the cylinder rod, if appli-
securing the barrel end attach pin to the lower arm cable.

3120696 – JLG Sizzor – 2-5

 SECTION 2 - PROCEDURES

13. Remove the rod from the holding fixture. Remove

the cylinder head gland and retainer, if applicable.
CYLINDERS WITH DOUBLE HOLDING VALVES. BEFORE REMOV- Discard the o-rings, back-up rings, rod seals, and
ING HOLDING VALVES CRACK BLEEDER TO RELEASE PRES- wiper seals.
SURE.
Cleaning and Inspection
3. If applicable, remove the cartridge-type holding
valve and fittings from the cylinder port block. Dis- 1. Clean all parts thoroughly in an approved cleaning
card o-rings. solvent.

4. Place the cylinder barrel into a suitable holding fix- 2. Inspect the cylinder rod for scoring, tapering, ovality,
ture. Tap around outside of cylinder head retainer or other damage. If necessary, dress rod with
with a suitable hammer to shatter loctite. Scotch Brite or equivalent. Replace rod if necessary.
3. Inspect threaded portion of rod for excessive dam-
5. Using a suitable spanner wrench, loosen the cylin-
age. Dress threads as necessary.
der head retainer, if applicable, and/or cylinder head
gland, and remove from cylinder barrel. 4. Inspect inner surface of cylinder barrel tube for scor-
ing or other damage. Check inside diameter for
NOTE: Steer Cylinder has two head retainers at each end of tapering or ovality. Replace if necessary.
cylinder.
5. Inspect threaded portion of barrel for damage. Dress
Platform Ext. Cylinder has a snap ring in barrel end threads as necessary.
of cylinder. Remove snap ring before withdraw of the 6. Inspect piston surface for damage and scoring and
rod. for distortion. Dress piston surface or replace piston
as necessary.
6. Attach a suitable pulling device to the cylinder rod
port block end or cylinder rod end, as applicable. 7. Inspect seal and o-ring grooves in piston for burrs
and sharp edges. Dress applicable surfaces as nec-
essary.
8. Inspect cylinder head inside diameter for scoring or
EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL-
other damage and for ovality and tapering. Replace
INDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFF-
as necessary.
CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND
CYLINDER BARREL SURFACES. 9. Inspect seal and o-ring grooves in head for burrs
and sharp edges. Dress applicable surfaces as nec-
7. With the barrel clamped securely, apply pressure to essary.
the rod pulling device and carefully withdraw the
10. If applicable, inspect cylinder head retainer or end
complete rod assembly from the cylinder barrel.
cap for surface or thread damage. Repair or replace
8. Using suitable protection, clamp the cylinder rod in as necessary.
a vise or similar holding fixture as close to the piston 11. Inspect cylinder head outside diameter for scoring
as possible. or other damage and ovality and tapering. Replace
as necessary.
NOTE: On the Steer Cylinder, the rod and piston are all one
unit. 12. If applicable, inspect thread ring for scoring or other
damage. Dress threads or applicable surfaces as
9. Remove the set screw(s), if applicable, and nut necessary.
which attach the piston to the rod, and remove the
13. If applicable, inspect rod and barrel bushings for
piston. Discard nylon point set screws.
signs of correct lubrication and excessive wear.
10. Remove the piston rings. Replace as necessary.

11. Remove and discard the piston o-rings, seal rings, 14. Inspect travel limiting collar or spacer for burrs and
and backup rings. sharp edges. If necessary, dress inside diameter
surface with Scotch Brite or equivalent.
12. Remove the set screw, if applicable, piston spacer,
15. If applicable, inspect port block fittings and holding
and wear ring, if applicable, from the rod.
valve. Replace as necessary.
16. Inspect the oil ports for blockage or the presence of
dirt or other foreign material. Repair as necessary.

2-6 – JLG Sizzor – 3120696

 SECTION 2 - PROCEDURES

17. If applicable, inspect piston rings for cracks or other 6. Using suitable protection, clamp the cylinder rod in
damage. Replace as necessary. a vise or similar holding fixture as close to the piston
as possible.
Assembly
Table 2-1. Cylinder Piston Nut Torque Specifications
NOTE: Prior to cylinder assembly, ensure that the proper
cylinder seal kit is used. Refer to the Illustrated Parts Nut Torque Setscrew
Description
manual. Value torque Value

Apply a light film of hydraulic oil to all components Lift Cylinder 400 ft lb 100 in lb
prior to assembly. (542 Nm) (12 Nm)

Lockout Cylinder N/A N/A

NOTICE Level Cylinder 400 ft lb 100 in lb
WHEN INSTALLING NEW POLY-PAK TYPE PISTON SEALS (AXLE (542 Nm) (12 Nm)
LOCKOUT CYLINDER), ENSURE SEALS ARE INSTALLED PROP-
ERLY. REFER TO FIGURE 2-1 FOR CORRECT SEAL ORIENTA- Platform Ext. Cylinder N/A N/A
TION. IMPROPER SEAL INSTALLATION COULD RESULT IN
Steer Cylinder N/A N/A
CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION.

Table 2-2. Holding Valve Torque Specifications

Description Torque Value

Sun - 7/8 hex M20 x 1.5 thds 30 - 35 ft lb 41 - 48 Nm

Sun - 1-1/8 hex 1 - 14 UNS thds 45 - 50 ft lb 61 - 68 Nm

Sun - 1-1/4 hex M36 x 2 thds 150 - 153 ft lb 204 - 207 Nm

Racine - 1-1/8 hex 1-1/16 - 12 thds 50 - 55 ft lb 68 - 75 Nm

Figure 2-1. Poly-Pak Seal Installation
Racine - 1-3/8 hex 1-3/16 - 12 thds 75 - 80 ft lb 102 - 109 Nm
1. Place a new wiper seal and rod seal into the applica-
ble cylinder head gland grooves. Racine - 1-7/8 hex 1-5/8 - 12 thds 100 - 110 ft lb 136 - 149 Nm

2. Carefully install the head gland on the rod, ensuring

that the wiper and rod seals are not damaged or dis- 7. Push the piston onto the rod until it abuts the spacer
lodged. Push the head along the rod to the rod end, end, apply locktite # 242 and install the attaching
as applicable. nut. Refer to Table 2-1, Cylinder Piston Nut Torque
Specifications.
3. Carefully slide the piston spacer on the rod. If appli-
cable, align the oil holes in the rod and the spacer. NOTE: On the Steer Cylinder, the rod and piston are all one
Secure the spacer, if applicable. unit.
4. If applicable, correctly place a new o-ring and back-
up rings in the inner piston diameter groove. 8. Prior to setscrew installation spot drill rod before
installing the setscrew(s) which secure the piston
5. Carefully place the piston on the cylinder rod, ensur-
attaching nut to the diameter groove.
ing that the o-ring and back-up rings are not dam-
aged or dislodged. 9. Remove the cylinder rod from the holding fixture.

10. Place new o-rings and seals in the applicable out-

side diameter grooves of both the piston and the cyl-
inder head.

3120696 – JLG Sizzor – 2-7

 SECTION 2 - PROCEDURES

11. Position the cylinder barrel in a suitable holding fix- 3. Individually push down on one corner at a time;
ture. there should be enough travel to cause the switch to
trip. If the switch does not trip in all three tests, the
NOTICE flange nuts have been tightened too far. Loosen the
nuts and repeat steps (2) and (3).
EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE
CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD
OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON
AND CYLINDER BARREL SURFACES.
2.13 PRESSURE SETTING PROCEDURES -
(400RTS)
12. With barrel clamped securely, and while adequately
supporting the rod, insert the piston end into the Rexroth/Hydraforce Valve
barrel cylinder. Ensure that the piston loading o-ring
and seal ring are not damaged or dislodged. 1. Install pressure gauge at port G on Rexroth/
Hydraforce Valve.
13. Continue pushing the rod into the barrel until the cyl-
inder head gland can be inserted into the barrel cyl- 2. Adjust both steer section crossover reliefs all the
inder. way in.

14. If applicable, secure the cylinder head retainer using 3. Adjust main relief cartridge out several turns.
a suitable spanner type wrench. 4. Activate engine and allow hydraulic system to come
15. After the cylinder has been reassembled, the rod up to operating temperature.
should be pushed all the way in (fully retracted) prior 5. Bottom out steer function. Adjust main relief to 2250
to the reinstallation of any holding valve or valves. psi (156 bar).
16. If applicable, install the cartridge-type holding valve 6. Bottom out Front Steer Right and Steer Left func-
and fittings in the port block using new o-rings as tions and adjust each Steer Crossover Relief to 1500
applicable. Refer toTable 2-2, Holding Valve Torque psi (103 bar).
Specifications.
7. Bottom out rear steer right and steer left functions
and adjust each steer crossover relief to 1500 psi
2.12 TILT ALARM SWITCH (103 bar).
8. Bottom out platform ext. extended functions and
NOTE: The machine may be equipped with a tilt alarm adjust each ext. crossover relief to 500 psi (34 bar).
switch (sensor), optional on 400RTS, which is fac-
tory set to activate at 5° on the 400RTS and 2° on 9. De-energize platform ext. function, shut down motor,
the 500RTS that will sound an alarm and illuminate a and disconnect pressure gauge.
warning light on the platform control console. Con-
sult factory for tilt sensor adjustment. The only field
adjustment necessary is leveling the switch on the 2.14 PRESSURE SETTING PROCEDURES -
spring loaded studs. (500RTS)

Rexroth/Hydraforce Valve
PERFORM TILT ALARM SWITCH LEVELING PROCEDURE A MINI- 1. Install pressure gauge at port G on Rexroth/
MUM OF EVERY SIX MONTHS TO ENSURE PROPER OPERATION Hydraforce Valve.
AND ADJUSTMENT OF SWITCH.
2. Adjust both steer section crossover reliefs all the
Manual Adjustment way in.
3. Adjust main relief cartridge out several turns.
1. Park the machine on a flat, level surface and ensure
machine is level. 4. Activate engine and allow hydraulic system to come
up to operating temperature.
NOTE: Ensure switch mounting bracket is level and securely
5. Bottom out steer function. Adjust main relief to 2800
attached.
psi (193 bar).
2. Level the base of the indicator by tightening the 6. Bottom out front steer right and steer left functions
three flange nuts. Tighten each nut until bubble in and adjust each steer crossover relief to 1500 psi
the indicator is in the center of indicator. (103 bar).

2-8 – JLG Sizzor – 3120696

 SECTION 2 - PROCEDURES

7. Bottom out Rear Steer Right and Steer Left functions 7. Jog or slowly rotate prime mover until charge pres-
and adjust each Steer Crossover Relief to 1500 psi sure starts to rise. Start prime mover and run at the
(103 bar). lowest possible RPM until charge pressure has been
established. Excess air may be bled from high pres-
8. Bottom out Platform Ext. Extended functions and sure lines through high pressure gauge ports
adjust each Ext. Crossover Relief to 500 psi (34 bar).

9. De-energize Platform Ext. function, shut down

motor, and disconnect pressure gauge.
DO NOT START PRIME MOVER UNLESS PUMP IS IN NEUTRAL
POSITION (0 DEGREES SWASHPLATE ANGLE). TAKE PRECAU-
TIONS TO PREVENT MACHINE MOVEMENT IN CASE PUMP IS
2.15 DRIVE PUMP START-UP PROCEDURE ACTUATED DURING INITIAL START-UP.

NOTICE 8. Once charge pressure has been established,

THE FOLLOWING PROCEDURE SHOULD ALWAYS BE PER- increase speed to normal operating RPM. Charge
FORMED WHEN STARTING A NEW PUMP OR WHEN RESTARTING pressure should be approximately 22 psi (15.5 bar)
AN INSTALLATION IN WHICH EITHER THE PUMP OR MOTOR minimum. If charge pressure is incorrect, shut down
HAVE BEEN REMOVED FROM THE SYSTEM. and determine cause for improper pressure.

THE FOLLOWING PROCEDURE MAY REQUIRE THE MACHINE TO INADEQUATE CHARGE PRESSURE WILL AFFECT THE OPERA-
BE DISABLED (WHEELS RAISED OFF THE GROUND, DRIVE TORS ABILITY TO CONTROL THE MACHINE.
FUNCTION DISCONNECTED, ETC.) WHILE PERFORMING THE
PROCEDURE IN ORDER TO PREVENT INJURY TO TECHNICIAN
9. Shut down prime mover and connect external con-
AND OTHER PERSONNEL. TAKE NECESSARY SAFETY PRECAU-
trol input signal. start prime mover, checking to be
TIONS BEFORE MOVING THE MACHINE.
certain pump remains in neutral. with prime mover at
normal operating speed, slowly check for forward
1. Prior to installing pump and/or motor, inspect unit(s)
and reverse machine operation.
for damage incurred during shipping and handling.
Make certain all system components (reservoir, 10. Charge pressure should remain at 22 psi to 24 psi
hoses, valves, fittings, heat exchanger, etc.) are (15.5 bar to 16.9 bar) minimum during forward or
clean prior to filling with hydraulic fluid. reverse operation. Continue to cycle slowly between
2. Fill reservoir with recommended hydraulic fluid, forward and reverse for at least five minutes.
which should be passed through a 10 micron (nomi-
11. Shut down prime mover, remove gauges, and plug
nal, no bypass) filter prior to entering the reservoir.
ports. Check reservoir level and add fluid if neces-
The use of contaminated fluid will cause damage to
sary.
components, which may result in unexpected
machine movement.

3. The inlet line leading from the reservoir to the pump

should be filled prior to start-up. Check inlet line for
properly tightened fittings and make sure it is free of
restrictions and air leaks.

4. Be certain to fill pump and/or motor housing with

clean hydraulic fluid prior to start-up. Fill housing by
pouring filtered oil into upper case drain port.

5. Install a 0 to 50 psi (0 to 35 bar) pressure gauge in

the charge pressure gauge port to monitor charge
pressure during start-up.

6. It is recommended that the external control input

signal electrical connections be disconnected at the
pump control until after initial start-up. This will allow
the pump to remain in its neutral position.

3120696 – JLG Sizzor – 2-9

 SECTION 2 - PROCEDURES

ADJUST DECK EXT TO

34 BAR (500PSI)

ADJUST MAIN RELIEF TO 156 BAR

(2250 PSI) ON 400RTS AND 193 BAR PRESSURE PORT
(2800 PSI) ON 500RTS

ADJUST FRONT STEER

TO 90 BAR (1300 PSI)

ADJUST LIFT DOWN SPEED

ADJUST REAR STEER TO TO 70-60 SECONDS. ON 400RTS
90 BAR (1300 PSI) AND 80-70 SECONDS ON 500RTS

NOTE: Pressure on deck ext./retract, leveling jacks, lift up,

and overload all work off of system pressure

Figure 2-2. Pressure Adjustment Locations

2-10 – JLG Sizzor – 3120696

 SECTION 2 - PROCEDURES

2.16 THROTTLE CHECKS AND 2.17 THROTTLE CHECKS AND

ADJUSTMENTS - FORD ENGINE ADJUSTMENTS - DEUTZ F3L1011
NOTE: Never run fuel tank dry. Diesel engines cannot be
Throttle Checks restarted after running out of fuel until fuel system
has been air-vented or bled of air. (See Deutz Oper-
1. Check that anti-dieseling solenoid is operating. If ators Manual for procedure).
solenoid is operating, an audible click should be
heard when the ignition is switched ON and OFF. 1. Disconnect actuator cable from the throttle lever.
With the aid of an assistant, start the engine and
2. Check throttle linkage for smooth operation by rotat- allow it to come up to operating temperature. Adjust
ing throttle lever by hand to full throttle position, then throttle lever stop until engine runs at 2000 rpm.
slowly back to idle position, feeling closely for stick- Shut down engine. Reattach actuator cable to throt-
ing or binding. tle lever, making sure that low engine setting
remains the same. Restart engine and check set-
tings. If necessary, adjust slide pin to contact low
Throttle Adjustments - In Sequence engine limit switch at 2000 rpm. Shut down engine.
2. With the aid of an assistant, start engine from plat-
NOTE: Steps (1) and (2) are preliminary settings.
form and allow it to come up to operating tempera-
ture. Disconnect modular dump valve wire. Activate
1. Remove cover from controller. With engine shut
HIGH ENGINE switch. Activate and Drive Controller
down, turn gain CCW as far as it will go, then turn
and hold it in full drive position. Adjust slide pin to
screw slot CW until vertical. Gain may need fine tun- contact high engine limit switch at 3000 rpm. Shut
ing. off all switches and controllers. Reconnect modular
control dump valve wire.
2. Turn droop CCW as far as it will go. Then turn screw
slot CW until vertical. Droop should not need further NOTE: Actuator cable travel must stop slightly before lever
adjustment. makes contact with throttle lever stop. Failure to do
so will burn out actuator.
3. Turn idle adjusting screw on carburetor CCW all the
way out CCW until there is a gap between the screw
and stop plate.

4. Start engine and allow it to come up to operating

temperature.

5. Remove wire from no. 7 connector on controller,

which will switch engine speed to HIGH. Adjust
speed screw until engine runs at 3000 rpm.

NOTE: If engine surges, turn gain screw one or two degrees

CCW until surging stops, no more.

6. Replace wire no. 7 connector on controller, which

will return engine to LOW speed. Adjust remote until
engine runs at 2200 rpm.

7. Recheck speeds. When satisfied, apply a drop of fin-

gernail polish to all trimpot screws. Replace cover.

3120696 – JLG Sizzor – 2-11

 SECTION 2 - PROCEDURES

Figure 2-3. Throttle Checks and Adjustments - Ford VSG 413

Figure 2-4. Precision Governor Adjustments

2-12 – JLG Sizzor – 3120696

 SECTION 2 - PROCEDURES

Figure 2-5. Throttle Adjustments, Deutz F3L1011

3120696 – JLG Sizzor – 2-13

 SECTION 2 - PROCEDURES

4. Place drive controller to forward position and care-

2.18 OSCILLATING AXLE LOCKOUT fully drive machine up ascension ramp until left front
CYLINDER BLEEDING PROCEDURE - (IF wheel is on top of the 8 in (20 cm) high block.
EQUIPPED)
5. Raise machine platform approximately 2 ft (0.6 m);
NOTE: Ensure platform is fully lowered to open the cam ensure lockout cylinder cam valve is free of sizzor
valve prior to beginning oscillating axle lockout cylin- arm trip bar.
der bleeding procedure.
6. Place drive controller to reverse position and care-
fully drive machine off block and ramp.
NOTE: Making sure that machine is on a level surface and
rear wheels are blocked then disengage drive hubs. 7. Have an assistant check to see that left front wheel
Optional 4WD all drive hubs must be unlocked. remains locked in position off the ground.

1. Making sure that machine is on a level surface and 8. Lower machine platform; lockout cylinder should
rear wheels are blocked then disengage drive hubs. then release the wheel and allow it to rest on the
Optional 4WD all drive hubs must be disengaged. ground.

2. Activate machine hydraulic system from platform 9. Transfer the 8 in (20 cm) high block to front of right
control station. front wheel and repeat steps 1 through 8, substitut-
ing the word right for left in steps 1, 4 and 7.
3. Start the engine and place engine speed and drive
speed control switches to their respective low posi- 10. If lockout cylinder does not function properly, have
tions. qualified personnel correct the malfunction prior to
any further operation.
4. Depress the enable switch and activate drive con-
troller to forward position.
5. Using a suitable lifting equipment lift front of 2.20 PISTON DRIVE MOTOR - 2WD & 4WD
machine up and place an 8 in (20 cm) high block
under left front wheel. Disassembly
6. With the drive controller activated and engine at idle,
crack open both fittings at lockout cylinder, one at a 1. Clean outside of unit thoroughly.
time, and close when all air is dissipated (bled). 2. Clamp drive shaft in a protected jaw vise with back-
7. Using a suitable lifting equipment lift front of plate end up.
machine and remove the 8 in (20 cm) block. 3. Remove six cap screws from backplate.
8. Transfer the 8 in (20 cm) high block to right front
4. Use a plastic mallet and tap the backplate to loosen
wheel and repeat steps 1 through 6, substituting the
it.
word right for left in step 5.
5. Remove o-ring from backplate.
NOTE: After lockout cylinders are bled be sure to engage
drive hubs before removing stop block from rear 6. Remove complete piston block assembly from
wheels. housing assembly.

9. To check lockout cylinder after bleeding, perform the 7. Remove piston assemblies, spider, and pivot from
LOCKOUT CYLINDER CHECK in paragraph 2-19. piston block assembly.
8. The piston block assembly need not be disassem-
bled unless pins or spring are damaged.
2.19 LOCKOUT CYLINDER CHECK
NOTE: Ensure platform is completely lowered prior to begin-
ning lockout cylinder check. THE FOLLOWING PROCEDURE SHOULD BE USED IF THE
SPRING IS TO BE REMOVED FROM THE PISTON BLOCK. THE
1. Place a 8 in. (20 cm) high block with ascension S P R I N G I S H I G H LY C O M P R E S S E D A N D T H E S N A P R I N G
ramp in front of left front wheel. SHOULD NOT BE REMOVED WITHOUT COMPRESSING THE
SPRING.
2. Activate machine hydraulic system from platform
control station.
3. Place engine speed and drive speed control
switches to their respective low positions.

2-14 – JLG Sizzor – 3120696

 SECTION 2 - PROCEDURES

Figure 2-6. Piston Drive Motor

3120696 – JLG Sizzor – 2-15

 SECTION 2 - PROCEDURES

9. Disassemble the piston block as follows: Assembly

NOTE: The following parts will be needed to disassemble
the piston block: NOTE: Use filtered system oil to lubricate all critical moving
2 ea. 3/8 I.D. x 1-1/8 O.D. flat washers parts before assembly.
1 ea. 3/8 x 3-1/4 N.C. capscrew
1 ea. 3/8 N.C. nut 1. Install one snap ring in rear groove of drive shaft.
Install one thrust washer, thrust bearing, and second
a. Place one of the flatwashers over the 3/8 x 3-1/4 thrust washer on drive shaft. Install second snap ring
capscrew and place this through the center of in front groove on drive shaft.
the piston block.
2. Replace needle bearing in housing if necessary.
b. Place the other washer over the capscrew and Install shaft in housing assembly and install washer.
let it rest on the three pins. Oil I.D. of new shaft seal and press into position.
c. Screw nut on capscrew and compress the Retain with snap ring.
spring inside the piston block.
3. Compress pin keeper and install in spline area of
d. Using a pair of snap ring pliers, remove internal piston block.
snap ring.
e. Remove bolt, nut, and two washers. 4. Install three pins in special grooves of spline with
head end of pin toward inside of block.
f. Remove two washers, spring, three pins, and
pin keeper. 5. Install one washer, spring, and second washer. Use
two 3/8 I.D. washers, 3/8 N.C. nut and 3/8 x 3-1/4
10. Remove thrust race, shaft seal, washer, and drive
capscrew to compress spring and retain with snap
shaft from housing.
ring. Remove 3/8 N.C. nut, 3/8 x 3-1/4 capscrew and
11. Remove two snap rings, thrust washers, and thrust two washers.
bearing from drive shaft.
6. Install pivot, spider, and piston assemblies in piston
Inspection block assembly.

7. Lubricate thrust race and install in housing assem-

1. Wash all parts thoroughly in a suitable solvent. bly.
2. Examine needle bearings in housing and backplate.
8. Install piston block assembly in housing assembly.
If needles are free of excessive play and remain in
Piston shoes must contact thrust race. Be sure all
bearing cage, there is no need to replace bearing.
parts are in their proper position.
3. Inspect thrust washers and thrust bearing. All sur-
9. Install new needle bearing in backplate if necessary.
faces should be free of any signs of wear or fretting.
4. Inspect spider and pivot. Conical surfaces should be 10. Install new o-ring on backplate.
free of wear and score marks.
11. Install backplate on housing.
5. Inspect pistons. The O.D. surface should be smooth
12. Install six capscrews and torque to 15 - 18 ft lbs (20 -
and free of scoring. Shoes should be snug fit to pis-
24 Nm).
ton. Face of shoes should be flat and free of scoring
and flaking. Do not lap piston shoes.
6. Inspect piston block; bores should be free of scor- 2.21 DRIVE TORQUE HUB - 2WD/4WD REAR
ing. Surface that contacts backplate should be
smooth and free of grooves or metal build-up. Do
not lap piston block.
NOTICE
TORQUE HUB UNITS SHOULD ALWAYS BE ROLL AND LEAK
7. Inspect thrust race; surface should show no signs of TESTED BEFORE DISASSEMBLY AND AFTER ASSEMBLY TO
scoring or grooves. MAKE SURE THAT THE UNITS GEARS AND SEALANTS ARE
8. Inspect flat surface on backplate; it should be free of WORKING PROPERLY.
excessive scoring or metal build-up. Do not lap
backplate. NOTICE
9. Inspect drive shaft for fretting in bearing areas. WHEN REBUILDING A UNIT, USE NEW SEALS AND O-RINGS.
Check spline area for twisted or broken teeth. If NEVER RE-USE SEALS AND O-RINGS, AS THIS WOULD CAUSE
keyed shaft, check for cracked or chipped keyway. UNIT TO LEAK.

2-16 – JLG Sizzor – 3120696

 SECTION 2 - PROCEDURES

Figure 2-7. Drive Torque Hub - (2WD/4WD rear)

3120696 – JLG Sizzor – 2-17

 SECTION 2 - PROCEDURES

Disassembly NOTE: If roll pin isn’t driven all the way into the planet shaft,
carrier could be damaged when planet shaft is
1. Turn hub over on to its side. Remove coupling from removed from carrier.
wide end of spindle.
b. Using a punch and hammer, drive planet shaft
2. Mark location of shoulder bolt holes on outside of from carrier housing; one thrust washer, one
ring gear and hub for easy re-alignment when cluster gear, and one more thrust washer will
rebuilding. Remove four shoulder bolts and twelve come off planet shaft and come to rest inside
bolts from cover. carrier. Remove these parts from inside carrier.
3. Remove sixteen flat washers from cover assembly. c. Remove sixteen needle rollers from inside one
end of cluster gear. Discard needle rollers.
4. Lift cover assembly off of ring gear, and set cover on
d. Repeat steps (a) through (c) to remove and dis-
table, interior side facing up.
assemble two remaining cluster gears.
12. Remove thrust spacer from input shaft assembly in
middle of spindle.
BEWARE OF SHARP EDGES IN COUNTERBORE WHEN REMOV-
ING O-RING. 13. Lift input shaft assembly out of middle of spindle,
and stand input shaft on its splined end.
5. Remove o-ring from counterbore around edge of
cover. Discard o-ring.

NOTE: If o-ring is not in cover counterbore, it is in ring gear WEAR SAFETY GLASSES WHEN PERFORMING THE FOLLOW-
counterbore. Remove o-ring from hub and discard it. INGSTEP . BE AWARE THAT SPRING AND SPACERS COM-
PRESSED BY RETAINING RING MAY POP SUDDENLY OFF SHAFT
6. If necessary, disassemble cover as follows: WHEN RETAINING RING IS REMOVED.USING RETAINING RING
PLIERS, REMOVE RETAINING RING FROM GROOVE ON INPUT
a. Remove two bolts holding disconnect cap to SHAFT.
cover.
b. Remove disconnect cap from on top of cover 14. Remove one spacer, one spring, and other spacer
cap and cover. from input shaft.

c. Remove two bolts securing cover cap to cover. 15. Remove thrust washer from around spindle.
Remove cover cap.
16. Lift internal gear out of hub.
d. Remove disconnect rod from cover cap.
e. Pry o-ring from groove inside cover cap. Discard
o-ring. BEWARE OF SHARP EDGES IN COUNTERBORE WHEN REMOV-
f. Remove o-ring from flange of cover cap. Discard ING O-RING.
o-ring.
17. Remove o-ring from counterbore in hub. Discard o-
g. Remove pipe plug from cover.
ring.
7. Remove thrust washer from counterbore in top of
18. If necessary, disassemble hub-spindle assembly as
carrier assembly.
follows:
8. Remove input gear from middle of carrier assembly.
NOTE: Start with large end of hub facing up, large end of
9. Lift ring gear off of hub. spindle facing down.

10. Lift carrier assembly out of hub.

11. If necessary, disassemble carrier assembly as fol-

WEAR SAFETY GLASSES WHILE PERFORMING THE FOLLOWING
lows:
STEP
NOTE: When removing needle rollers from cluster gears,
discard old needle rollers and use new ones during a. Remove retaining ring from around spindle in
re-assembly. hub.
b. Remove spacer from around spindle in hub.
a. Using a punch and hammer, drive roll pin into
planet shaft.

2-18 – JLG Sizzor – 3120696

 SECTION 2 - PROCEDURES

c. Remove retaining ring from around spindle in Assembly

hub.Remove spacer from around spindle in hub.
Set hub, small end/spindle facing down, up on
something that will support hubs flange while it
lifts hub up so spindle is not resting on anything. BEWARE OF SHARP EDGES IN COUNTERBORE WHEN INSTALL-
Carefully press or hammer spindle down out of ING O-RING.
hub. If seal and bearing cone come out of hub
and rest on spindle, remove these parts from 1. Assemble hub-spindle assembly as follows:
spindle and set them aside. Discard seal.
NOTE: Make sure cup sits square with counterbore before
d. If seal and bearing cone did not come out of pressing.
small end of hub when spindle was pressed out
of hub, remove seal and bearing cone from a. Set hub onto its large end. Press bearing cup
small end of hub. Discard seal. into counterbore in small end of hub.
e. Bearing cone should be lying loose in wide end b. Press nine studs into stud holes in hub.
of hub. Remove bearing cone from inside hub. c. Apply a light coat of Never-Seize to two pipe
plugs and tighten them into two pipe plug holes
NOTE: If hammer and punch are used to remove bearing in side of hub.
cups, make sure counterbore is not struck with
punch when removing bearing cup. NOTE: Make sure cup sits square with counterbore before
pressing.
f. Remove bearing cup from counterbore in small
end of hub. d. Turn hub over onto its small end. Press bearing
cup down into counterbore in deep end of hub.
g. Turn hub over and lift it out of flange-support.
e. Set hub onto its large end. Place bearing cone
Remove bearing cup from wide end of hub.
into bearing cup.
h. Press nine studs out of stud holes in hub. f. Press seal into small end of hub.
g. Oil spindle, then lower hub, small end down,
Roll Test onto spindle.
The purpose of a roll test is to determine if the h. Press bearing cone onto spindle in hub.
units gears are rotating freely and properly. i. Place spacer onto spindle in hub.
Gears should be able to be rotated by applying
a constant force to the roll checker. If more drag NOTE: Make sure the retaining ring is securely seated in
is felt in the gears only at certain points, then the groove in spindle.
gears are not rolling freely and should be exam-
ined for proper installation or defects. Some j. Place retaining ring over spacer onto spindle in
gear packages roll with more difficulty than oth- hub.
ers. Do not be concerned if gears seem to roll
2. Grease o-ring and place it into counterbore in hub.
hard as long as they roll with consistency.
NOTE: O-ring may be stretched or pinched together to make
Leak Test it fit counterbore exactly.

The purpose of the leak test is to make sure the 3. Oil all exposed surfaces inside hub.
unit is air tight. The unit has a leak if the pressure
gauge reading on the air checker starts to fall 4. Place internal gear into hub so that its internal
once the unit has been pressurized. Leaks will splines mesh with external splines of spindle. Oil
most likely occur at main seal or wherever o- internal gear.
rings or gaskets are located. The exact location 5. Place thrust washer around spindle so that it rests
of a leak can usually be detected by brushing a on bottom of internal gear.
soap and water solution around the main seal
and where o-rings or gaskets meet the exterior 6. Stand input shaft on its splined end. Place one
of the unit, then checking for air bubbles. If a spacer onto smooth end of input shaft.
leak is detected in a seal, o-ring, or gasket, the 7. Place one spring onto smooth end of input shaft.
part must be replaced.
8. Place other spacer onto smooth end of input shaft.

3120696 – JLG Sizzor – 2-19

 SECTION 2 - PROCEDURES

15. With internal splines facing up, counterbore end fac-

ing down, place input gear into mesh with carrier
SAFETY GLASSES MUST BE WORN DURING THE FOLLOWING assembly.
STEP. BE AWARE THAT SPRING AND SPACERS, COMPRESSED
BY RETAINING RING, MAY POP SUDDENLY OFF SHAFT IF RING IS 16. Oil all exposed surfaces inside hub. Place thrust
RELEASED BEFORE IT IS PROPERLY IN PLACE. washer into counterbore in top of carrier assembly.

17. Assemble cover as follows:

9. Using retaining ring pliers, insert retaining ring into
groove on input shaft by compressing spring and a. Using disconnect rod, push o-ring into groove
spacers together. inside cover cap.
10. With large, splined end down, place input shaft b. Place o-ring onto cover cap so it rests against
assembly into spindle. flange of cover cap.
11. Place thrust spacer onto input shaft. c. Insert disconnect rod into cover cap.
12. Set carrier assembly on work surface so that large d. Set cover on table, exterior side up. Place cover
ends of cluster gears face up. Locate punch marks cap onto cover, aligning pipe plug hole in cover
on face of each cluster gear and position them at 12 cap over pipe plug hole in cover.
o’clock. Refer to Figure 2-8., Torque Hub Carrier
e. Place two cover cap bolts into any two bolt holes
Timing
180 degrees apart on cover cap, then tighten
13. With X-marked side facing up, place ring gear bolts.
around cluster gears. NOTE: This will hold punch f. Torque both bolts to 36 - 49 in lbs (4 - 5 Nm).
marks in position while installing carrier into hub.
g. With large end down, place disconnect cap onto
14. Place carrier assembly and ring gear together into cover cap, aligning pipe plug hole in disconnect
mesh with internal gear, aligning X-marked shoulder cap over pipe plug hole in cover cap.
bolt in ring gear over one of the shoulder bolt holes
in hub. Mark location of shoulder bolt holes on out- h. Place two remaining bolts into bolt holes in dis-
side of ring gear and hub. connect cap, and tighten bolts.
i. Torque both bolts to 36 - 49 in lbs (4 - 5 Nm).
NOTE: Ring gear may be lifted off hub to align shoulder bolt
holes. Ring gear and carrier were installed together j. Apply a light coat of Never-Seize to pipe plug
only to keep punch marks on carrier in place and tighten it into pipe plug hole in cover.

Figure 2-8. Torque Hub Carrier Timing

2-20 – JLG Sizzor – 3120696

 SECTION 2 - PROCEDURES

a. Examine two brake ports on bottom of spindle/

brake. Bottom of one is tapered and bottom of
BEWARE OF SHARP EDGES IN COUNTERBORE WHEN INSTALL- other one is flat. Install hydraulic line of a hand
ING O-RING. pump into flat brake port.
b. Install a bleeder valve into tapered brake port.
18. Set cover assembly on table, interior side up.
c. Insert roll checker into spindle/brake. If brake is
Grease o-ring and place it into counterbore around
not working properly, roll checker should not
edge of cover.
turn.
NOTE: O-ring may be stretched or pinched together to make d. Set hand pump to PUMP.
it fit counterbore exactly. e. Increase hydraulic pressure in brake by pump-
ing gradually. At the same time, try to turn roll
19. Place cover assembly onto ring gear, aligning pipe checker. If brake is set correctly, roll checker
plug holes in cover and hub according to applicable should turn when pump pressure reaches 140 to
assembly print. Also, make sure shoulder bolt holes 160 psi (10-11 bar).
in cover and ring gear are aligned. f. Roll test brake in both clockwise and counter-
20. Place four flat washers on top of bolt holes in cover clockwise directions. Perform same number of
assembly. turns in each direction as ratio of unit. This num-
ber is the same as the last two digits of the
21. Place shoulder bolts into four shoulder bolt holes in model number found on the units ID tag. For
cover and tighten by hand. example, if units model number is W1BJ4U318,
then it should be rolled 18 times in both direc-
22. Place remaining twelve flat washers) onto remaining tions.
bolt holes in cover.
g. Set hand pump to RELEASE and check to see if
23. Place twelve bolts into remaining bolt holes in cover brake has reset itself. If brake has reset roll
and tighten. checker should not be able to turn.

24. Torque shoulder bolts to 18 - 25 ft lb (25 - 34 Nm). h. Remove roll checker from spindle/brake.
Torque bolts to 18 - 25 ft lb (25 - 34 Nm). i. Remove hydraulic line from its brake port.
j. Remove bleeder valve from its brake port.
25. Turn hub over on to its side. Insert coupling into end
of spindle. 3. Leak test unit at a pressure of 5 psi (0.4 bar) for 2 to
3 minutes.
26. Roll test unit in both clockwise and counter clock-
wise directions. Perform same number of turns in 4. Remove the twelve grade 8 bolts and four shoulder
each direction as ratio of unit. Ratio is last two digits bolts from cover.
of model number on units ID tag. For example, if
5. Remove flat washers from cover.
model number is W1BFF0335, then roll unit 35 times
in each direction. 6. Remove cover from hub.
27. Leak test unit at a pressure of 5 psi (0.4 bar) for 2-3 7. If necessary, disassemble cover as follows:
minutes.
a. Remove pipe plug from cover if it has not
already been removed.

2.22 DRIVE TORQUE HUB/BRAKE - 4WD b. Set cover down so that its open end faces up.
Remove o-ring from counterbore in cover. Dis-
FRONT card o-ring.
c. Turn cover over. Remove two bolts that hold dis-
NOTICE connect cap in place.
TORQUE HUB UNITS SHOULD ALWAYS BE ROLL AND LEAK
d. Remove disconnect cap from cover.
TESTED BEFORE DISASSEMBLY AND AFTER ASSEMBLY TO
MAKE SURE THAT THE UNITS GEARS AND SEALANTS ARE e. Remove two remaining bolts that hold cover cap
WORKING PROPERLY. in place.
f. Remove cover cap from cover.
Disassembly g. Remove disconnect rod from cover cap.
h. Remove o-ring from groove inside cover cap.
1. Remove pipe plug from cover and drain oil from unit. Discard o-ring.
2. Inspect spindle/brake as follows: i. Remove o-ring from outside of cover cap.

3120696 – JLG Sizzor – 2-21

 SECTION 2 - PROCEDURES

Figure 2-9. Drive Torque Hub/Brake - 4WD Front

2-22 – JLG Sizzor – 3120696

 SECTION 2 - PROCEDURES

8. Remove thrust washer from carrier assembly. 26. Using a slide hammer, remove seal from small end
of hub. Discard seal.
9. Remove thrust spacer from input shaft assembly.
27. Lift bearing cone off of spindle/brake.
10. Remove ring gear from mesh with carrier assembly.
28. Using a soft punch and hammer, remove bearing
11. Remove carrier assembly from hub.
cup from deep end of hub.
12. If necessary, disassemble carrier assembly as fol-
lows: NOTE: When using punch, be very careful not to strike
counterbore of hub where cup is located.
a. Locate roll pin in carrier housing. Drive roll pin
down into planet shaft until it bottoms against 29. Using a soft punch and hammer, remove bearing
carrier housing. If roll pin is not completely cup from shallow end of hub.
driven into planet shaft, damage to carrier could
occur when shaft is removed. NOTE: This cup can be reached by putting punch into small
access hole in bottom of hubs deep end.
b. Drive roll pin out of planet shaft. Roll pin must
come out through side of planet shaft that it orig-
inally went into. 30. Remove two pipe plugs from pipe plug holes in side
of hub.
c. Remove planet shaft from carrier housing. Two
tongued thrust washers and cluster gear will 31. Remove two magnetic pipe plugs from pipe plug
slide off. holes in flange of hub.
d. Remove needle rollers and spacer from inside
32. Hammer out nine wheel studs.
cluster gear.
e. Repeat steps (a) through (d) to remove two Roll Test
remaining cluster gears.
The purpose of a roll test is to determine if the units gears
13. Remove input gear from input shaft assembly. are rotating freely and properly. Gears should be able to
be rotated by applying a constant force to the roll checker.
14. Remove thrust spacer from input shaft assembly.
If more drag is felt in the gears only at certain points, then
15. Remove input shaft assembly from spindle/brake. the gears are not rolling freely and should be examined for
proper installation or defects. Some gear packages roll
16. If necessary, disassemble input shaft as follows: with more difficulty than others. Do not be concerned if
a. Remove retaining ring from input shaft. gears seem to roll hard as long as they roll with consis-
Discard retaining ring. tency.

b. Slide thrust spacer, spring, and other

Leak Test
thrust spacer off of input shaft.
The purpose of the leak test is to make sure the unit is air
17. Remove thrust washer from bottom of internal gear. tight. The unit has a leak if the pressure gauge reading on
18. Remove internal gear from hub. the air checker starts to fall once the unit has been pres-
surized. Leaks will most likely occur at main seal or wher-
19. Remove o-ring from counterbore in hub. Discard o- ever o-rings or gaskets are located. The exact location of
ring. a leak can usually be detected by brushing a soap and
water solution around the main seal and where o-rings or
20. Using a screwdriver or chisel and hammer,
gaskets meet the exterior of the unit, then checking for air
straighten out tang on lock washer which has been
bubbles. If a leak is detected in a seal, o-ring, or gasket,
bent into notch in locknut.
the part must be replaced.
21. Using an N-13 locknut wrench (tool no. T-141863),
loosen locknut. Remove locknut from spindle/brake Assembly
and discard.
1. Grease o-ring.
22. Remove lock washer from spindle/brake and dis-
card. 2. Place o-ring into counterbore in hub.
23. Remove tongued washer from spindle/brake.

24. Lift bearing cone out of hub.

BEWARE OF SHARP EDGES AND BURRS IN COUNTERBORE
25. Lift hub off of spindle/brake. WHEN INSTALLING O-RING.

3120696 – JLG Sizzor – 2-23

 SECTION 2 - PROCEDURES

NOTE: O-rings may be stretched to fit counterbore. If an o- g. Following thrust washer, place cluster gear, with
ring has been stretched too much, simply squeeze o- needle rollers, onto planet shaft. Large end of
ring together bit by bit while placing it around coun- cluster gear should go onto shaft first.
terbore. It can be made to fit exactly. h. Following cluster gear, place one more thrust
washer onto planet shaft. Align thrust washer in
3. Oil exposed surfaces inside hub. same manner as described in step (f).
4. Mark four shoulder bolt holes on hub so for align- i. Insert planet shaft through opposite planet shaft
ment with shoulder bolt holes in ring gear and cover. hole in carrier housing. Use an alignment punch
or similar tool to align roll pin holes in carrier
5. Place internal gear into hub so its internal splines housing and planet shaft.
mesh with external splines of spindle/brake.
j. Drive roll pin down into aligned roll pin holes.
6. Oil internal gear. k. Repeat steps (a) through (j) to install two remain-
7. Place thrust washer onto spindle/brake so it rests on ing cluster gears.
bottom of internal gear. 13. Set carrier assembly on work surface so that large
8. Assemble input shaft as follows: end of cluster gears face up. Locate punch marks
on face of each cluster gear and position them at 12
a. Place one thrust spacer, spring, and other o’clock.
spacer, IN THAT ORDER, onto smooth end of
shaft. 14. With squared shoulder side down, place ring gear
into mesh with cluster gears in carrier. If ring gear is
on correctly, the X marking a shoulder bolt hole
should face up.
SAFETY GLASSES SHOULD BE WORN DURING FOLLOWING
PROCEDURE. NOTE: Make sure punch marks on cluster gears remain in
their correct positions when installing ring gear.
b. Place retaining ring onto input shaft. Using
retaining ring pliers, insert retaining ring into 15. Place carrier assembly and ring gear together into
groove on input shaft by compressing spring mesh with internal gear. Align shoulder bolt hole in
and spacers together. ring gear marked with an X over one of the shoulder
bolt holes in the hub.
9. With large, splined end down, place input shaft
assembly into spindle/brake. NOTE: Ring gear may be lifted off hub to align shoulder bolt
holes. Ring gear and carrier need to be installed
10. Place thrust spacer onto input shaft. together initially only so that punch marks on carrier
11. With internal splines facing up, place input gear into remain aligned.
mesh with input shaft assembly.
16. Oil all exposed surfaces inside hub.
12. Assemble carrier as follows:
17. Place thrust spacer onto input shaft assembly.
a. Apply grease to inside of one cluster gear.
18. Place thrust washer into counterbore in carrier.
b. Line one half of cluster gear with 16 needle roll-
ers. 19. Assemble cover as follows:
c. Place one thrust spacer inside cluster gear so it a. Place o-ring onto cover cap so it rests against
rests on top of needle rollers. flange of cover cap.
d. Line remaining half of cluster gear with 16 nee- b. Insert o-ring into groove inside cover cap.
dle rollers. c. Insert disconnect rod into cover cap.
e. Insert a planet shaft into one of the planet shaft d. Place cover cap into cover. Align pipe plug hole
holes in the carrier housing which has a roll pin in cover cap over pipe plug hole in cover.
hole. End of planet shaft that does not have a
roll pin hole should be inserted into carrier hous- e. Place two cover cap bolts into any two bolt holes
ing first. 180° apart on cover cap and tighten.

f. Place one thrust washer onto end of planet shaft f. Using a torque wrench, apply 36 - 49 in lb (4 - 5
which has been inserted through planet shaft Nm) torque to both bolts.
hole. Notice that thrust washer has a tang on it. g. With large end down, place disconnect cap onto
Tang should point straight so as to fit in slot on cover. Align pipe plug hole in disconnect cap
inside edge of planet shaft hole. over pipe plug hole in cover cap.

2-24 – JLG Sizzor – 3120696

 SECTION 2 - PROCEDURES

h. Place two remaining bolts into bolt holes in dis- m. Tighten pipe plug into pipe plug hole in cover.
connect cap and tighten.
i. Using a torque wrench, apply 36 - 49 in lbs (4 - 5 20. Place cover assembly onto ring gear. Align pipe plug
Nm) torque to both bolts. holes in cover and hub as shown in Figure 2-10.
Make sure shoulder bolt holes in cover and ring
j. Grease o-ring.
gear are aligned.
k. Place o-ring into counterbore around edge of
cover. 21. Place sixteen flatwashers on top of bolt holes in
cover assembly.

BEWARE OF BURRS AND SHARP EDGES AROUND COUNTER- 22. Place shoulder bolts into four shoulder bolt holes in
BORE WHEN INSTALLING O-RING. cover and tighten by hand.

23. Place grade 8 bolts into twelve bolt holes in cover

NOTE: O-rings may be stretched to fit counterbore. If an o-
ring has been stretched too much, simply squeeze o- and tighten.
ring together bit by bit while placing it around coun-
24. Apply 18 - 25 ft lbs (25 - 35 Nm) of torque to all bolts.
terbore. It can be made to fit exactly.
25. Leak test unit at a pressure of 5 psi (0.4 bar) for 2-3
l. Apply a light coat of never-seize to pipe plug.
minutes.
.

Figure 2-10. Torque Hub Cover Pipe Plug Alignment

3120696 – JLG Sizzor – 2-25

 SECTION 2 - PROCEDURES

3. Install new bearing and retaining ring on shaft.

2.23 DRIVE BRAKE - 2WD/4WD REAR
4. Insert shaft assembly and retaining ring in housing.
Disassembly 5. Insert dowel pins, guide retainer, and springs in
housing.
1. Remove end cover from housing by removing
washer head cap screws. NOTE: Be sure to use the same number of springs and
same spring pattern as recorded during disassem-
bly.

END COVER IS UNDER SPRING TENSION OF APPROXIMATELY 6. Position new large diameter return plate in housing
2000 LBS. (907 KG). THE FOUR WASHER HEAD CAP SCREWS with tabs guided by dowel pins until disc rests on
SHOULD BE LOOSENED EVENLY TO RELIEVE THIS FORCE. IF A springs.
HYDRAULIC PRESS IS AVAILABLE (3000 LBS. MIN.) (1361 KG
NOTE: Rotor discs and stator friction discs should remain
MINIMUM), COVER CAN BE HELD IN POSITION WHILE REMOVING
dry during installation. No oil residue should be
WASHER HEAD CAP SCREWS.
allowed to contaminate disc surfaces.

2. Remove case seal from housing, then remove 7. Place a new rotor disc on shaft until it contacts
bleeder screw from end cover. return plate.

3. Remove piston from end cover. 8. Add additional new stator discs and new rotor discs
as required to complete assembly.
4. Remove o-ring, back-up ring, o-ring and back-up
ring from piston. 9. Insert separators in holes of return plate.

5. Remove separators from housing. 10. Install new o-ring, new back-up ring, new o-ring, and
new back-up ring on piston. Note order of o-rings
6. Remove stack assembly, consisting of stator friction and back-up rings. Insert piston into end cover,
discs, return plate, and rotor discs from housing. being careful not to shear o-rings or back-up rings.

11. Install case seal in housing, then install bleeder

7. Remove dowel pins, springs, and spring retainer
screw in end cover.
from housing.
12. Position end cover on housing, aligning dowel pins
NOTE: Not all models use the same number of springs or with holes in end cover.
spring pattern. Record this information for assembly
purposes. 13. Install washer head cap screws and tighten evenly
to draw end cover to housing. Torque washer head
cap screws to 55 ft lbs (75 Nm).
8. Remove retaining ring from housing.
NOTE: If available, a hydraulic press will simplify installation
9. Remove shaft by pressing or using a soft mallet on of end cover on housing. Clamp cover in position
male end of shaft. while tightening washer head cap screws.

10. Remove retaining ring and bearing from shaft.

14. If hydrostatic bench testing is done on brake assem-
bly, release pressure should not exceed 2000 psi
11. Press rotary oil seal from housing.
(138 bar) unless two additional bolts are used for
supplemental clamping.
Assembly

NOTE: Lubricate all rubber components from repair kit with

clean hydraulic fluid of the type used in the system.

1. Clean all parts thoroughly before assembly.

2. Press new rotary oil seal into housing. Note direction

of seal.

2-26 – JLG Sizzor – 3120696

 SECTION 2 - PROCEDURES

Figure 2-11. Drive Brake - (2WD/4WD Rear)

3120696 – JLG Sizzor – 2-27

 SECTION 2 - PROCEDURES

Using Liquid Petroleum (LP) Gas

2.24 SPARK ARRESTOR MUFFLER
The multiple discs on these mufflers will require frequent
cleaning if used with oily or sooty exhaust, such as a die- CLOSE FUEL VALVE ON TANK WHEN PARKING SIZZOR LIFT
sel engine, or on malfunctioning engines, as evidenced by MORE THAN MOMENTARILY.
visible exhaust.
WHEN REFUELING LPG POWERED SIZZOR LIFTS, ALWAYS FOL-
LOW MANUFACTURERS SPECIFICATIONS AND/OR APPLICABLE
2.25 DUAL FUEL/LPG SYSTEM REGULATIONS.

1. If machine is to be left overnight or longer, it must be

parked outside or the LPG tank removed and stored
IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THE outside.
OTHER WITHOUT ALLOWING THE ENGINE TO STOP. EXTREME
CARE MUST BE TAKEN AND THE FOLLOWING INSTRUCTIONS 2. LPG is extremely flammable. No smoking.
MUST BE FOLLOWED.
3. Only trained and authorized personnel are permitted
to operate filling equipment.
Changing From Gasoline to LP Gas
4. Fill LPG tanks outdoors. Stay at least 50 ft (15 m)
from buildings, motor vehicles, electrical equipment
1. Start engine from ground control station.
or other ignition sources. Stay at least 15 ft (4.5 m)
from LPG storage tanks.
2. Open hand valve on LP gas supply tank by turning
valve counterclockwise. 5. During transfer of LPG, metal components can
become very cold. Always wear gloves when refilling
or changing tanks to prevent freeze burns to skin.
BE SURE ALL GASOLINE IS EXHAUSTED BEFORE SWITCHING 6. Do not store LPG tanks near heat or open flame. For
TO LP GAS. complete instructions on the storage of LPG fuels,
refer to ANSI/NEPA 58 & 505.
3. While engine is operating, place the three position
LPG/GASOLINE switch at ground control station to
center OFF position. Allow engine to operate, with-
DO NOT USE AN LPG TANK THAT IS DAMAGED. A DAMAGED
out load, until engine begins to stumble from lack of
TANK MUST BE REMOVED FROM SERVICE. FROST ON THE SUR-
gasoline.
FACE OF A TANK, VALVES, OR FITTINGS INDICATES LEAKAGE.
A STRONG ODOR OF LPG FUEL CAN INDICATE A LEAK.
4. As engine begins to stumble, place switch to LPG
position, allowing LP fuel to be sent to the fuel regu-
lator.
2.26 FREEWHEELING FEATURE
Changing From LP Gas to Gasoline
To Disengage Torque Hubs (Freewheel)
1. With engine operating on LP under a no-load condi-
1. Chock wheels securely.
tion, throw LPG/GASOLINE switch at ground control
station to GASOLINE position. 2. Disengage (reverse) disconnect caps on drive
torque hubs by removing two attaching capscrews,
2. If engine stumbles because of lack of gasoline, turning cap around, then reinstalling and tightening
place switch to LPG position until engine regains capscrews.
smoothness, then return switch to GASOLINE posi-
tion. 3. If desired, remove chocks and using suitable equip-
ment for assistance, move machine to an appropri-
3. Close hand valve on LP gas supply by turning clock- ate maintenance area. Again chock wheels securely.
wise.

2-28 – JLG Sizzor – 3120696

 SECTION 2 - PROCEDURES

2.27 LIMIT SWITCH ADJUSTMENT

PROCEDURE

Drive Cut-Out Switch

The drive cut-out switch is set at the following heights.

Table 2-3. Drive Cutout Heights

Model Cut-Out

400 RTS Not Required

400 RTS w/31 x 15.5 - 15 Tires 32 ft (9.8 m)

500RTS 22 ft (6.7 m)

Figure 2-12. Drive Hub Engaged

To Engage Torque Hubs

Engage (reverse) disconnect cap on both drive torque
hubs by removing two attaching capscrews, turning cap
around, then reinstalling and tightening capscrews.

Figure 2-14. Drive Cut-out Switch

Drive Speed Cutout

Drive speed limit switch set to actuate as soon as possible
after the platform lifts beyond the stowed position and
begins to elevate. Switch must activate prior to a maxi-
mum platform height of 14 ft (4.2 m).

Figure 2-13. Drive Hub Disengaged

Figure 2-15. Drive Speed Cutout Switch

3120696 – JLG Sizzor – 2-29

 SECTION 2 - PROCEDURES

d. The inspection and maintenance code numbers

2.28 PREVENTIVE MAINTENANCE AND are as follows:
INSPECTION SCHEDULE
1. Check for proper and secure installation.
a. The preventive maintenance and inspection
checks are listed and defined in the following 2. Check for visible damage and legibility.
table. This table is divided into two basic parts, 3. Check for proper fluid level.
the AREA to be inspected and the INTERVAL at
which the inspection is to take place. Under the 4. Check for any structural damage; cracked
AREA portion of the table, the various systems or broken welds; bent or warped surfaces.
along with the components that make up that
5. Check for leakage.
system are listed. The INTERVAL portion of the
table is divided into five columns representing 6. Check for presence of excessive dirt or for-
the various inspection time periods. The num- eign material.
bers listed within the interval column represent
the applicable inspection code for which that 7. Check for proper operation and freedom of
component is to be checked. movement.

b. The checks and services listed in this schedule 8. Check for excessive wear or damage.
are not intended to replace any local or regional
9. Check for proper tightness and adjustment.
regulations that may pertain to this type of
equipment nor should the lists be considered as 10. Drain, clean and refill.
all inclusive. Variances in interval times may
occur due to climate and/or conditions and 11. Check for proper operation while pump/
depending on the location and use of the motor is running.
machine. 12. Check for proper lubrication.
c. JLG Industries requires that a complete annual
13. Check for evidence of scratches, nicks or
inspection be performed in accordance with the
rust and for straightness of rod.
Annual Machine Inspection Report form. Forms
are supplied with each new machine and are 14. Check for condition of element; replace as
also available from JLG Customer Service. Form necessary.
must be completed and returned to JLG Indus-
15. Check for proper inflation.
tries.
16. Check Inspection Decal for current inspec-
NOTICE tion stamp.
JLG INDUSTRIES REQUIRES THAT A COMPLETE ANNUAL
INSPECTION BE PERFORMED IN ACCORDANCE WITH THE
ANNUAL MACHINE INSPECTION REPORT FORM.

NOTE: This machine requires periodic safety and mainte-

nance inspections by a JLG Dealer. A decal located
on the frame affords a place to record (stamp)
inspection dates. Notify dealer if inspection is over-
due.

2-30 – JLG Sizzor – 3120696

 SECTION 2 - PROCEDURES

Table 2-4. Preventive Maintenance and Safety Inspection

AREA INTERVAL
10Hours 50 Hours 200 Hours 500 Hours 1000 Hours
(Daily) (Weekly) (Monthly) (3 Month) (6 Month)
PLATFORM
1. Controller 1,11
2. Switches 1,11
3. Placards and Decals 1,2
4. Control Tags 1,2
5. Hoses and Cables 4,8
6. Wear Pads 8
7. Handrails and Chains 1,4
CHASSIS
1. Engine Oil 3 5
2. Battery 3 5
3. Air Cleaner 1 14
4. Exhaust System 1 1,5
5. Engine Mounts 1
6. Hydraulic Pump 1 5
7. Valves 1 5
8. Hydraulic Filter (See Lubrication Chart) 5,14 14
9. Hydraulic Hoses and Tubing 1 5
10. Hydraulic Oil Tank* 3 5 4
11. Hydraulic Tank Breather 6,14
12. Fuel Tank 3,5 4
13. Lift Cylinder 1,12 5,6,13 4
14. Limit Switch 1,7
15. Tilt Alarm Switch 1,7
16. Placards and Decals 1,2
17. Wheel and Tire Assemblies 1 8,9
18. Drive Motors 1,5,6
19. Drive Brakes 1,6 8
20. Drive Torque Hubs 1,3,5,6
21. Steer Cylinder 1 5,6,13 4
22. Steer Components 1 4,6 8
23. Wheel Bearings (2 Wheel Drive) 8 12
24. Sizzor Arms 1,4
25. Safety Props 1,4
26. Sliding Wear Pads 8
27. Pivot Pins/Bolts 1,4 7,8
28. Switches, Ground Control 1,11
29. Control Tags 1,2

*Inspection and Maintenance Code 10 to be performed

annually.

3120696 – JLG Sizzor – 2-31

 SECTION 2 - PROCEDURES

NOTES:

2-32 – JLG Sizzor – 3120696

 SECTION 3 - TROUBLESHOOTING

SECTION 3. TROUBLESHOOTING

It should be recognized that the majority of the problems

3.1 GENERAL arising in the machine will be centered in the hydraulic
This section contains troubleshooting information to be and electrical systems. For this reason, every effort has
used for locating and correcting most of the operating been made to ensure that all likely problems in these
problems which may develop in the aerial platform. If a areas are given the fullest possible treatment. In the
problem should develop which is not presented in this remaining machine groups, only those problems which
section or which is not corrected by listed corrective have more than one probable cause and remedy are
actions, technically qualified guidance should be obtained included. This means that problems for which the proba-
before proceeding with any maintenance. ble cause and remedy may be immediately obvious are
not listed in this section.
Troubleshooting and maintenance information pertaining
The first rule for troubleshooting any circuit that is hydrau-
to the prime mover (engine/motor) that are not contained
lically operated and electrically controlled is to determine
in this manual are contained in the applicable engine
if the circuit is lacking hydraulic oil and electrical power.
maintenance manual.
This can be ascertained by overriding the bypass valve
(mechanically or electrically) so that oil is available to the
function valve, then overriding the function valve mechani-
3.2 TROUBLESHOOTING INFORMATION cally. If the function performs satisfactorily, the problem
The troubleshooting procedures applicable to the aerial exists with the control circuit.
platform are listed and defined in Tables 3-1 through 3-4.
As an aid to table use, the platform sizzor is divided into 4
major groups, each covered separately within this section. 3.3 HYDRAULIC CIRCUIT CHECKS
These groups are as follows: Platform, chassis, hydraulic
The first reference for improper function of a hydraulic sys-
system and electrical system.
tem, where the cause is not immediately apparent, should
be the troubleshooting chart. The best place to begin the
Each malfunction within an individual group or system is
problem analysis is at the power source (pump) Once it is
followed by a listing of probable causes which will enable
determined that the pump is serviceable, then a system-
determination of the applicable remedial action. The prob-
atic check of the circuit components, beginning with the
able causes and remedial action should, where possible,
control, would follow. For aid in troubleshooting, refer to
be checked in the order listed in the tables.
the Illustrated Parts Manual for hydraulic diagram of the
It should be noted that there is no substitute for a thor- various circuits.
ough knowledge of the equipment and related systems.

3120696 – JLG Sizzor – 3-1

 SECTION 3 - TROUBLESHOOTING

Table 3-1. Platform Assembly - Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

No response to control switch

Enable switch not activated Activate enable switch
Function not activated within the 3 seconds after Reactivate enable switch
enable switch was depressed
Enable switch not functioning properly Replace enable switch circuit card
Lift control switch inoperative Repair or replace lift control switch
Hydraulic system oil low Replenish oil as necessary
No power supply See wiring diagram
Restricted or broken supply line on valve bank or Clean, repair or replace line
hydraulic pump
Control valve not functioning properly Repair or replace valve
Defective dump valve on cylinder Repair or replace dump valve
Lift cylinder not functioning properly Repair or replace lift cylinder
Hydraulic pump not functioning properly Repair or replace hydraulic pump
Platform will not raise
Enable switch not activated Activate enable switch
Function not activated within the 3 seconds after Reactivate enable switch
enable switch was depressed
Enable switch not functioning properly Replace enable switch circuit card
Load capacity exceeded. (Personnel and/or equip- Reduce load. (Refer to capacity placard.)
ment.)
Hydraulic system oil low Replenish oil as necessary
Broken or binding pivot pin Repair or replace pivot pin
Restricted or broken hydraulic line or fitting Clean, repair or replace line or fitting
Control valve not functioning properly Repair or replace control valve
Lift cylinder not functioning properly Repair or replace lift cylinder
Pump does not respond when lift control switch is Refer to electrical troubleshooting table
moved to the up position
No electrical signal being sent to lift up control valve Refer to electrical troubleshooting table
cartridge
Platform will not raise above 25 ft (7.6 m)
Leveling jacks not in contact with the ground to set Set leveling jacks
limit switches
Leveling jack limit switches not functioning prop- Repair or replace limit switch
erly
Machine is on an unlevel surface Lower platform and level machine
No power supply See wiring diagram
Platform will not lower
Enable switch not activated Activate enable switch
Function not activated within the 3 seconds after Reactivate enable switch
enable switch was depressed
Enable switch not functioning properly Replace enable switch circuit card
Pump does not respond when lift control switch is Refer to electrical troubleshooting table
moved to the down position

3-2 – JLG Sizzor – 3120696

 SECTION 3 - TROUBLESHOOTING

Table 3-1. Platform Assembly - Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

No electrical signal being sent to lift down control Refer to electrical troubleshooting table
valve cartridge
Lift down control valve cartridge not functioning Repair or replace lift down control valve cartridge
properly
Lift cylinder not functioning properly Repair or replace lift cylinder
Platform raises and lowers erratically
Hydraulic system low Replenish hydraulic oil as required
Restricted or broken hydraulic line or fitting Clean, repair or replace line or fitting
Lack of lubricant on lift cylinder attach pins Lubricate as required (Refer to lubrication chart)
Counterbalance valve on lift cylinder improperly Replace valve
adjusted or not functioning properly
Control valve not functioning properly Repair or replace valve
Sizzor arm pins not properly lubricated Lubricate as necessary
Worn seals in lift cylinder Replace seals
Cylinder not functioning properly Repair or replace lift cylinder
Platform drifts down
Manual lowering valve not functioning properly Repair or replace valve
Worn seals in lift cylinder Replace seals
Holding valve on lift cylinder not functioning prop- Repair or replace holding valve
erly
High drive does not operate below set height
Damaged wiring on limit switch Repair or replace wiring
Damage limit switch Replace limit switch

3120696 – JLG Sizzor – 3-3

 SECTION 3 - TROUBLESHOOTING

Table 3-2. Chassis Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

DRIVE SYSTEM
No response to control
Enable switch not activated Activate enable switch
Function not activated within the 3 seconds after Reactivate enable switch
enable switch was depressed
Enable switch not functioning properly Replace enable switch circuit card
Hydraulic system oil low Replenish oil as necessary
Drive hubs disengaged Engage hubs
Controller not properly adjusted Correctly adjust controller
Hydraulic pump not functioning properly Repair or replace pump
Restricted or broken pump supply line Clean, repair or replace line
Restricted or broken line on valve bank Clean, repair or replace line
Drive motor(s) not functioning properly Repair or replace motor(s)
Damaged wiring on controller Repair or replace wiring
Controller not functioning properly Repair or replace controller
Drive brake not releasing Determine cause and repair or replace brake
Machine drives erratically
Microswitch on controller improperly adjusted Adjust microswitch on controller for proper opera-
tion
Machine will not travel forward
Enable switch not activated Activate enable switch
Function not activated within the 3 seconds after Reactivate enable switch
enable switch was depressed
Enable switch not functioning properly Replace enable switch circuit card
Hydraulic system oil low Replenish oil as necessary
Restricted or broken hydraulic line or fitting Clean, repair or replace line or fitting
Controller not adjusted properly Correctly adjust controller
Control valve not functioning properly Repair or replace valve
Drive motor(s) not functioning properly Repair or replace motor(s)
Defective controller Repair or replace controller
Machine will not travel in reverse
See: Machine will not travel forward
High speed function does not operate
Loose or damaged wiring between controller and Ensure proper connection of wires. Using suitable
high speed switch test meter, perform continuity test on wiring
between controller and switches. Repair or
replace wires as necessary.
Defective high speed control switch Replace switch
Loose or damaged wire in control box wire har- Ensure proper connection of wire at the control
ness switch. Using suitable test meter, perform continu-
ity test on wire. repair or replace harness as neces-
sary.

3-4 – JLG Sizzor – 3120696

 SECTION 3 - TROUBLESHOOTING

Table 3-2. Chassis Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

Loose or damaged wire between platform and Ensure proper connection of wire at the platform
high speed solenoid and at the high speed solenoid. Using suitable test
meter, perform continuity test on wire. repair or
replace harness as necessary.
High speed solenoid not functioning properly Replace e solenoid
Loose or damaged wires between high sped relay Ensure proper connection of wires between high
and high speed limit switch speed relay and high speed limit switch. Using
suitable test meter, perform continuity test on wire.
repair or replace harness as necessary.
High speed limit switch not functioning properly Repair or replace limit switch
Loose or damaged wire in valve wiring harness Ensure proper connection of wires at the terminal
strip. Using suitable test meter, perform continuity
test on wire. repair or replace harness as neces-
sary.
STEERING SYSTEM
No response to control
Enable switch not activated Activate enable switch
Function not activated within the 3 seconds after Reactivate enable switch
enable switch was depressed
Enable switch not functioning properly Replace enable switch circuit card
Hydraulic system oil low Replenish oil as necessary
Damaged wiring on control switch or solenoid See proper wiring diagram
valve
Controller not functioning properly Replace controller
Restricted or broken hydraulic line on valve bank Clean repair or replace line
or hydraulic pump
Control valve not functioning properly Repair or replace valve
Steer cylinder not functioning properly Repair or replace steer cylinder
Machine hard to steer or steering is erratic
Hydraulic system oil low Replenish oil as necessary
Restricted hydraulic line or fitting Clean, repair or replace line or fitting
Lack of lubrication Lubricate as required (refer to lubrication chart)
Restricted crossover relief valve (pressure low) Clean or replace valve
Steer system pressure low Adjust pressure
Bent steering linkage Repair or replace linkage as required
Hydraulic pump not functioning properly Repair or replace pump
Steer cylinder not functioning properly Repair or replace cylinder
Tire pressure low Correct tire pressure
Bent or seized spindle Replace spindle
Steering inoperative
Damaged wiring on controller or solenoid valve See proper wiring diagram
Solenoid valve not functioning properly Repair or replace valve
Controller not functioning properly Replace controller
Relief valve improperly set or not functioning prop- Reset, repair or replace valves as required
erly
Steer cylinder not functioning properly Repair or replace steer cylinder

3120696 – JLG Sizzor – 3-5

 SECTION 3 - TROUBLESHOOTING

Table 3-2. Chassis Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

Machine will not steer left or right

Enable switch not activated Activate enable switch
Function not activated within the 3 seconds after Reactivate enable switch
enable switch was depressed
Enable switch not functioning properly Replace enable switch circuit card
Wiring on controller is damaged Repair or replace wiring
Wiring on solenoid valve is damaged Repair or replace wiring
Coil in solenoid is damaged Replace coil
Bent cylinder rod Repair or replace cylinder
Damaged steer linkage Repair or replace steer linkage
Crossover relief valve stuck Repair or replace crossover relief valve
Pressure setting incorrect Reset pressure setting
Machine wanders; steering not firm
Crossover relief valve set too low or not functioning Reset, repair or replace valve as required
properly
Steer linkages loose Tighten linkage
Steer wheel toe-in not set properly Adjust toe-in for 1/4 inch overall
Spindle bushings badly worn Replace bushings
Spindle bushings to tight Replace bushings
OSCILLATING AXLE (IF EQUIPPED)
Axle will not oscillate
Defective lockout cylinder Repair or replace cylinder
Lockout valve sticking Repair or replace valve
Lack of lubrication on axle pin Lubricate pin
Lockout valve defective Repair or replace valve
Axle will not lock
Air in lockout system Bleed lockout system
Defective lockout valve Repair or replace valve
Defective pressure reducing valve feeding lockout Repair or replace valve
system

3-6 – JLG Sizzor – 3120696

 SECTION 3 - TROUBLESHOOTING

Table 3-3. Chassis Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

ENGINE
Engine will not start
Station power selector switch is not in required Actuate switch as required
position
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 repair or replace wiring
starter
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 star (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- Repair or replace wiring
nor solenoid
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

3120696 – JLG Sizzor – 3-7

 SECTION 3 - TROUBLESHOOTING

Table 3-4. Hydraulic System Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

Hydraulic pump noisy
Air entering system through broken line or fitting Repair or replace line or fitting
Air bubbles in oil Replenish oil as required
Faulty pump coupler Replace coupler
Defective pump bearing Repair or replace pump
Oil filter(s) dirty Clean and/or replace filter(s) as necessary
Pump cavitating (Vacuum in pump due to oil star-
vation
Restricted suction line Clean, repair, or replace line
OIl in reserve low Replenish oil to proper level
Restricted reservoir air vent Clean vent
Oil viscosity to high Drain system and replace with recommended oil
(Refer to hydraulic oils)
Leak in suction line or manifold Repair or replace line or manifold as necessary
System overheating
Oil viscosity to high Drain system and replace with recommended oil
(Refer to hydraulic oils)
Restricted or blocked hydraulic line Repair or replace line
Machine overloaded Check weight in platform
Main relief valve set too high Reset valve as required
Hydraulic system oil low Replenish oil as necessary
Pump not delivering oil
Restricted suction line Clean repair or replace line
Air entering system through broken line or fitting Replace or repair line or fitting
(suction side)
Oil level too low Replenish oil to proper level
Plugged strainer in tank Clean strainer
Pump coupling defective Replace pump coupling
Broken pump drive shaft Repair or replace pump
System pressure too low
Main relief valve set too low Reset valve as required
Main relief valve stuck in open position Clean, repair or replace valve (Check system oil for
contamination)
Hydraulic pump not functioning properly Repair or replace pump
Leak in component, line or fitting Repair or replace component, line or fitting
Scored valve spool; Scored cylinder Replace valve; Replace cylinder
System(s) operate erratically
Sticking or binding valve spools, piston rod, etc Clean, repair or replace components as required
Hydraulic oil not a t optimum operating tempera- Allow oil sufficient time to warm up
ture
Pump drive slipping Repair or replace drive

3-8 – JLG Sizzor – 3120696

 SECTION 3 - TROUBLESHOOTING

Table 3-5. Electrical System Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

HAND CONTROLLER
Regardless of which way handle is moved, only
one function occurs
Improper or loose wiring to the solenoid(s) Check all wiring for proper connections
Directional valve stuck in one direction Repair or replace valve
Valve will not function when handle is moved in
either direction
Enable switch not activated Activate enable switch
Function not activated within the 3 seconds after Reactivate enable switch
enable switch was depressed
Enable switch not functioning properly Replace enable switch circuit card
No electrical power to handle Check electrical input to hand controller (12V)
No electrical power to valve Check electrical output of printed circuit board and
electrical signal at the valve
Improper ground Check for proper grounding of handle
Defective controller Repair or replace controller
Microswitches on controller bad or need adjust- Adjust or replace switches
ment
CONTROL SWITCHES
No response to a function control switch
Emergency stop switch not positioned properly Place emergency stop switch to on
Platform/Ground select switch not positioned Place switch to platform or ground, as necessary
properly
Circuit breaker open Determine and correct cause. Reset circuit
breaker
No voltage present at emergency stop switch Check battery cable from battery to emergency
stop switch for proper connection or damage.
Repair or replace cable as necessary
Emergency stop switch not functioning properly Replace switch
No voltage supplied to start relay from emergency Check battery cable from switch to relay for proper
stop switch connection or damage. Repair or replace cable as
necessary
No voltage input at terminal strip Check wire from battery to terminal strip for proper
connection or damage. Repair or replace cable as
necessary
No voltage present at circuit breaker Check wire from terminal strip to battery for proper
connection or damage. Repair or replace cable as
necessary
Defective circuit breaker Replace circuit breaker
No voltage present at Platform/Ground select Unplug ground control box harness from platform
switch receptacle. check wire from applicable pin in plug
to control box power switch for proper connection.
Using suitable test meter, perform continuity test
on wire. Repair or replace harness as necessary

3120696 – JLG Sizzor – 3-9

 SECTION 3 - TROUBLESHOOTING

Table 3-5. Electrical System Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

Defective Platform/Ground select switch Replace Platform/Ground select switch
No voltage e present at function control switch Check wiring from power switch to function control
switch for proper connection or damage. Repair or
replace wiring as necessary
Defective function control switch Replace function control switch
No voltage present at applicable control valve coil Check applicable wire for proper connection at
terminal strip, valve harness plug pin, valve har-
ness receptacle pin and valve coil. Using suitable
test meter, perform continuity test on wire. Repair
or replace harness as necessary
No voltage supplied to motor from start relay Check battery cable from relay to motor for proper
connection or damage. Repair or replace cable as
necessary
Defective motor/pump assembly Replace motor/pump assembly
ENGINE STARTER SYSTEM
Engine will not crank
Discharged battery or loose battery terminals Check and charge battery or replace battery as
necessary. Clean and secure battery terminals
Starter relay faulty or faulty relay connections Using a test meter, check relay coil terminals for
presence of electrical power and for energization
of relay coil. Also check relay terminals for correct
switching of contacts. Replace relay as necessary
Malfunctioning starter solenoid or motor Replace solenoid or motor in accordance with
applicable manufacturer’s manual
Defective start lockout solenoid Replace start lockout solenoid
Malfunctioning ignition switch Using a test meter, check ignition switch for cor-
rect switching of contacts. replace switch as nec-
essary
Faulty ignition and/or starter circuit wiring Check wiring continuity. refer to wiring diagram
Defective ring gear or flywheel Replace ring gear
INSTRUMENTS AND INDICATORS
Ammeter inoperative
Damaged wiring in circuits Repair or replace wiring
Ammeter not functioning properly Replace ammeter
Alternator not charging Repair or replace alternator
Travel warning horn inoperative
Circuit breaker open Determine and correct cause
Damaged wiring in horn circuit Replace horn
Damaged wiring in hourmeter circuit Repair or replace wiring
Inoperative hourmeter Replace hourmeter

3-10 – JLG Sizzor – 3120696

 SECTION 3 - TROUBLESHOOTING

NOTES:

3120696 – JLG Sizzor – 3-11

 SECTION 3 - TROUBLESHOOTING

Figure 3-1. Hydraulic Schematic (Sheet 1 of 6)

3-12 – JLG Sizzor – 3120696

 SECTION 3 - TROUBLESHOOTING

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

3120696 – JLG Sizzor – 3-13

 SECTION 3 - TROUBLESHOOTING

Figure 3-3. Hydraulic Schematic (Sheet 3 of 6)

3-14 – JLG Sizzor – 3120696

 SECTION 3 - TROUBLESHOOTING

Figure 3-4. Hydraulic Schematic (Sheet 4 of 6)

3120696 – JLG Sizzor – 3-15

 SECTION 3 - TROUBLESHOOTING

Figure 3-5. Hydraulic Schematic (Sheet 5 of 6)

3-16 – JLG Sizzor – 3120696

 SECTION 3 - TROUBLESHOOTING

Figure 3-6. Hydraulic Schematic (Sheet 6 of 6)

3120696 – JLG Sizzor – 3-17

 SECTION 3 - TROUBLESHOOTING

Figure 3-7. Electrical Schematic - 400 RTS - Ford LRG (Sheet 1 of 4)

3-18 – JLG Sizzor – 3120696

 SECTION 3 - TROUBLESHOOTING

Figure 3-8. Electrical Schematic - 400 RTS - Ford LRG (Sheet 2 of 4)

3120696 – JLG Sizzor – 3-19

 SECTION 3 - TROUBLESHOOTING

Figure 3-9. Electrical Schematic - 400 RTS - Ford LRG (Sheet 3 of 4)

3-20 – JLG Sizzor – 3120696

 SECTION 3 - TROUBLESHOOTING

Figure 3-10. Electrical Schematic - 400 RTS - Ford LRG (Sheet 4 of 4)

3120696 – JLG Sizzor – 3-21

 SECTION 3 - TROUBLESHOOTING

Figure 3-11. Electrical Schematic - 400RTS - Ford LRG (Sheet 1 of 3)

3-22 – JLG Sizzor – 3120696

 SECTION 3 - TROUBLESHOOTING

1283067 D

Figure 3-12. Electrical Schematic - 400RTS - Ford LRG (Sheet 2 of 3)

3120696 – JLG Sizzor – 3-23

 SECTION 3 - TROUBLESHOOTING

1283067 D

Figure 3-13. Electrical Schematic - 400RTS - Ford LRG (Sheet 3 of 3)

3-24 – JLG Sizzor – 3120696

 SECTION 3 - TROUBLESHOOTING

NOTES:

3120696 – JLG Sizzor – 3-25

 SECTION 3 - TROUBLESHOOTING

Figure 3-14. Electrical Schematic - 400 RTS - Ford VSG (Sheet 1 of 4)

3-26 – JLG Sizzor – 3120696

 SECTION 3 - TROUBLESHOOTING

Figure 3-15. Electrical Schematic - 400 RTS - Ford VSG (Sheet 2 of 4)

3120696 – JLG Sizzor – 3-27

 SECTION 3 - TROUBLESHOOTING

Figure 3-16. Electrical Schematic - 400 RTS - Ford VSG (Sheet 3 of 4)

3-28 – JLG Sizzor – 3120696

 SECTION 3 - TROUBLESHOOTING

Figure 3-17. Electrical Schematic - 400 RTS - Ford VSG (Sheet 4 of 4)

3120696 – JLG Sizzor – 3-29

 SECTION 3 - TROUBLESHOOTING

Figure 3-18. Electrical Schematic - 400RTS - Deutz (Sheet 1 of 4)

3-30 – JLG Sizzor – 3120696

 SECTION 3 - TROUBLESHOOTING

Figure 3-19. Electrical Schematic - 400RTS - Deutz (Sheet 2 of 4)

3120696 – JLG Sizzor – 3-31

 SECTION 3 - TROUBLESHOOTING

Figure 3-20. Electrical Schematic - 400RTS - Deutz (Sheet 3 of 4)

3-32 – JLG Sizzor – 3120696

 SECTION 3 - TROUBLESHOOTING

Figure 3-21. Electrical Schematic - 400RTS - Deutz (Sheet 4 of 4)

3120696 – JLG Sizzor – 3-33

 SECTION 3 - TROUBLESHOOTING

Figure 3-22. Electrical Schematic - 400RTS - Deutz (Sheet 1 of 3)

3-34 – JLG Sizzor – 3120696

 SECTION 3 - TROUBLESHOOTING

1283066 C

Figure 3-23. Electrical Schematic - 400RTS - Deutz (Sheet 2 of 3)

3120696 – JLG Sizzor – 3-35

 SECTION 3 - TROUBLESHOOTING

1283066 C

Figure 3-24. Electrical Schematic - 400RTS - Deutz (Sheet 3 of 3)

3-36 – JLG Sizzor – 3120696

 SECTION 3 - TROUBLESHOOTING

NOTES:

3120696 – JLG Sizzor – 3-37

 SECTION 3 - TROUBLESHOOTING

Figure 3-25. Electrical Schematic - 500 RTS Ford LRG (Sheet 1 of 2)

3-38 – JLG Sizzor – 3120696

 SECTION 3 - TROUBLESHOOTING

Figure 3-26. Electrical Schematic - 500 RTS Ford LRG (Sheet 2 of 2)

3120696 – JLG Sizzor – 3-39

 SECTION 3 - TROUBLESHOOTING

Figure 3-27. Electrical Schematic - 500 RTS Ford LSG (Sheet 1 of 2)

3-40 – JLG Sizzor – 3120696

 SECTION 3 - TROUBLESHOOTING

1282341 C

Figure 3-28. Electrical Schematic - 500 RTS Ford LSG (Sheet 2 of 2)

3120696 – JLG Sizzor – 3-41

 SECTION 3 - TROUBLESHOOTING

Figure 3-29. Electrical Schematic - 500 RTS Ford VSG (Sheet 1 of 2)

3-42 – JLG Sizzor – 3120696

 SECTION 3 - TROUBLESHOOTING

Figure 3-30. Electrical Schematic - 500 RTS Ford VSG (Sheet 2 of 2)

3120696 – JLG Sizzor – 3-43

 SECTION 3 - TROUBLESHOOTING

Figure 3-31. Electrical Schematic - 500RTS Duetz (Sheet 1 of 2)

3-44 – JLG Sizzor – 3120696

 SECTION 3 - TROUBLESHOOTING

Figure 3-32. Electrical Schematic - 500RTS Duetz (Sheet 2 of 2)

3120696 – JLG Sizzor – 3-45

 SECTION 3 - TROUBLESHOOTING

Figure 3-33. Electrical Schematic - 500RTS Duetz (Sheet 1 of 2)

3-46 – JLG Sizzor – 3120696

 SECTION 3 - TROUBLESHOOTING

1283064 F

Figure 3-34. Electrical Schematic - 500RTS Duetz (Sheet 1 of 2)

3120696 – JLG Sizzor – 3-47

 SECTION 3 - TROUBLESHOOTING

NOTES:

3-48 – JLG Sizzor – 3120696

CALIFORNIAN PROPOSITION 65
BATTERY WARNING
Battery posts,
terminals and related
accessories contain
lead and lead compounds,
chemical known to the
State of Califormia
to cause cancer and
reproductive harm.

WASH HANDS
AFTER HANDLING!
 Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
(717) 485-5161
(717) 485-6417

JLG Worldwide Locations

JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) Ltd JLG France SAS
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11 Bolwarra Road 80-Suite 71 Bentley Avenue 47400 Fauillet
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+33 (0)5 53 88 31 79
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(852) 2639 5797

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UI. Krolewska Wright Business Centre JLG Iberica, S.L. Enkopingsvagen 150
00-060 Warsawa 1 Lonmay Road Trapadella, 2 Box 704
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+44 (0)141 781 6700
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+44 (0)141 773 1907
+34 93 771 1762

www.jlg.com