Jlg 40RTS ANSI Service Manual User Manual

Service and Maintenance ManualANSIModel25RTS33RTS40RTS3120691September 25, 2002

SECTION 1 - SPECIFICATIONS1-2 – JLG Sizzor – 31206911.3 PERFORMANCE DATATravel SpeedGasoline 2 W/D - 8-10 seconds per 50 ft. (15 m) Gasoline 4 W/D - 1

SECTION 1 - SPECIFICATIONS3120691 – JLG Sizzor – 1-3Figure 1-1. Torque Chart

SECTION 1 - SPECIFICATIONS1-4 – JLG Sizzor – 3120691Figure 1-2. Lubrication Diagram

SECTION 1 - SPECIFICATIONS3120691 – JLG Sizzor – 1-5Table 1-2. Lubrication ChartINDEX NOCOMPONENT NUMBER/TYPE LUBE POINTS LUBE METHODINTERVAL HOURS1 O

SECTION 1 - SPECIFICATIONS1-6 – JLG Sizzor – 3120691NOTE: Aside from JLG recommendations, it is not advisableto mix oils of different brands or types,

SECTION 1 - SPECIFICATIONS3120691 – JLG Sizzor – 1-71.7 SERIAL NUMBER LOCATIONSFor machine identification, a serial number plate is affixedto the mach

SECTION 1 - SPECIFICATIONS1-8 – JLG Sizzor – 31206911.10 MAJOR COMPONENT WEIGHTS 1.11 CRITICAL STABILITY WEIGHTSDO NOT REPLACE ITEMS CRITICAL TO STABI

SECTION 2 - PROCEDURES3120691 – JLG Sizzor – 2-1SECTION 2. PROCEDURES2.1 GENERALThis section provides information necessary to performmaintenance on

SECTION 2 - PROCEDURES2-2 – JLG Sizzor – 31206913. If bearing is found to be serviceable, apply a lightcoat of oil and wrap it in clean (waxed) paper.

SECTION 2 - PROCEDURES3120691 – JLG Sizzor – 2-3NOTE: Metal particles may appear in the oil or filters of newmachines due to the wear-in of meshing co

SECTION 2 - PROCEDURES2-4 – JLG Sizzor – 3120691Relief ValvesMain relief valves are installed at various points within thehydraulic system to protect

SECTION 2 - PROCEDURES3120691 – JLG Sizzor – 2-51. Using all applicable safety precautions, activatehydraulic system and fully extend cylinder to bech

SECTION 2 - PROCEDURES2-6 – JLG Sizzor – 31206916. Carefully remove the cylinder from the Sizzor lift andplace in a suitable work area.Lift Cylinder I

SECTION 2 - PROCEDURES3120691 – JLG Sizzor – 2-7Figure 2-5. Arms and Platform Positioning and Support, Cylinder Repair

SECTION 2 - PROCEDURES2-8 – JLG Sizzor – 31206914. If applicable, remove the cartridge-type holdingvalve and fittings from the cylinder port block. Di

SECTION 2 - PROCEDURES3120691 – JLG Sizzor – 2-9Cleaning and Inspection1. Clean all parts thoroughly in an approved cleaningsolvent.2. Inspect the cyl

SECTION 2 - PROCEDURES2-10 – JLG Sizzor – 31206911. Place a new wear ring into the inner head diametergroove and a new o-ring on the outer diametergr

SECTION 2 - PROCEDURES3120691 – JLG Sizzor – 2-1111. Remove the cylinder rod from the holding fixture.12. Position the cylinder barrel in a suitable h

SECTION 2 - PROCEDURES2-12 – JLG Sizzor – 31206912.12 TILT ALARM SWITCHNOTE: The machine is equipped with a tilt alarm switch fac-tory set to activate

SECTION 2 - PROCEDURES3120691 – JLG Sizzor – 2-132.13 LIMIT SWITCH ADJUSTMENT PROCEDURENOTE: The high drive limit switch is located on top of theframe

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS3120691 – JLG Sizzor – aSECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSA.A GENERALThis section

SECTION 2 - PROCEDURES2-14 – JLG Sizzor – 3120691The inlet line leading from the reservoir to the pumpshould be filled prior to start-up. Check inlet

SECTION 2 - PROCEDURES3120691 – JLG Sizzor – 2-15Figure 2-18. Throttle Checks and Adjustments - FordE-301GAINSPEED(HI ENGINE)SPEED(LOW ENGINE)Figure

SECTION 2 - PROCEDURES2-16 – JLG Sizzor – 3120691E - 401HGAINFigure 2-20. Precision Governor Adjustments (1600325 Controller)

SECTION 2 - PROCEDURES3120691 – JLG Sizzor – 2-17Figure 2-21. Throttle Adjustments - Deutz

SECTION 2 - PROCEDURES2-18 – JLG Sizzor – 31206912.16 THROTTLE CHECKS AND ADJUSTMENTS - DEUTZ NOTE: Never run fuel tank dry. Diesel engines cannot ber

SECTION 2 - PROCEDURES3120691 – JLG Sizzor – 2-192.18 HYDRAULIC COMPONENT START-UP PROCEDURES AND RECOMMENDATIONSFrom a hydrostatic component standpoi

SECTION 2 - PROCEDURES2-20 – JLG Sizzor – 3120691sure is inadequate, shut down and determine the causefor improper pressure.INADEQUATE CHARGE PRESSURE

SECTION 2 - PROCEDURES3120691 – JLG Sizzor – 2-21Figure 2-22. Pressure Adjustment Locations (2 W/S)

SECTION 2 - PROCEDURES2-22 – JLG Sizzor – 31206912.20 PRESSURE SETTING PROCEDURES - (4 W/S)Racine Three Stack Valve (If Equipped)1. Install pressure g

SECTION 2 - PROCEDURES3120691 – JLG Sizzor – 2-23Figure 2-24. Pressure Adjustment Locations (4 W/S)

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSb – JLG Sizzor – 3120691REVISON LOGOriginal Issue - June 1993Revised - August 24, 1999Revised - February

SECTION 2 - PROCEDURES2-24 – JLG Sizzor – 31206912. Activate machine hydraulic system from platformcontrol station.3. Start the Engine and place Engin

SECTION 2 - PROCEDURES3120691 – JLG Sizzor – 2-25THE FOLLOWING PROCEDURE SHOULD BE USED IF THESPRING IS TO BE REMOVED FROM THE PISTON BLOCK. THESPRIN

SECTION 2 - PROCEDURES2-26 – JLG Sizzor – 31206914. Install three pins in special grooves of spline withhead end of pin toward inside of block.5. Inst

SECTION 2 - PROCEDURES3120691 – JLG Sizzor – 2-27Figure 2-26. Piston Drive Motor

SECTION 2 - PROCEDURES2-28 – JLG Sizzor – 31206912.24 DRIVE TORQUE HUB - 2WD/4WD REARTORQUE HUB UNITS SHOULD ALWAYS BE ROLL AND LEAKTESTED BEFORE DISA

SECTION 2 - PROCEDURES3120691 – JLG Sizzor – 2-29BEWARE OF SHARP EDGES IN COUNTER BORE WHEN REMOV-ING O-RING.18. Remove o-ring from counter bore in hu

SECTION 2 - PROCEDURES2-30 – JLG Sizzor – 31206913. Apply a light coat of “Never-Seize” to two pipe plugsand tighten them into two pipe plug holes in

SECTION 2 - PROCEDURES3120691 – JLG Sizzor – 2-31NOTE: Make sure retaining ring is securely seated in groovein spindle.10. Place retaining ring over s

SECTION 2 - PROCEDURES2-32 – JLG Sizzor – 312069117. Place other spacer onto smooth end of input shaft.SAFETY GLASSES MUST BE WORN DURING THE FOLLOWIN

SECTION 2 - PROCEDURES3120691 – JLG Sizzor – 2-33Assemble carrier as follows:1. Apply grease to the inside of one cluster gear andline one half of clu

TABLE OF CONTENTS3120691 – JLG Sizzor – iTABLE OF CONTENTSSUBJECT - SECTION, PARAGRAPH PAGE NO.SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTI

SECTION 2 - PROCEDURES2-34 – JLG Sizzor – 312069110. Repeat steps 1-9 to assemble and install the tworemaining cluster gears.11. Set carrier assembly

SECTION 2 - PROCEDURES3120691 – JLG Sizzor – 2-353. Insert disconnect rod into cover cap.4. Set cover on table, exterior side up. Place cover caponto

SECTION 2 - PROCEDURES2-36 – JLG Sizzor – 312069112. Place cover assembly onto ring gear, aligning pipeplug holes in cover and hub according to applic

SECTION 2 - PROCEDURES3120691 – JLG Sizzor – 2-37Figure 2-27. Drive Torque Hub - 2WD/4WD Rear

SECTION 2 - PROCEDURES2-38 – JLG Sizzor – 3120691h. Remove roll checker from spindle/brake.i. Remove hydraulic line from its brake port.j. Remove blee

SECTION 2 - PROCEDURES3120691 – JLG Sizzor – 2-39Roll TestThe purpose of a roll test is to determine if the unit’s gearsare rotating freely and proper

SECTION 2 - PROCEDURES2-40 – JLG Sizzor – 312069113. Set carrier assembly on work surface so that largeend of cluster gears face up. Locate punch mark

SECTION 2 - PROCEDURES3120691 – JLG Sizzor – 2-41Figure 2-28. Drive Torque Hub/Brake - 4WD Front

SECTION 2 - PROCEDURES2-42 – JLG Sizzor – 31206912.26 DRIVE BRAKE - 2WD/2WS REARDisassembly1. Remove end cover from housing by removingwasher head cap

SECTION 2 - PROCEDURES3120691 – JLG Sizzor – 2-43NOTE: Be sure to use the same number of springs andsame spring pattern as recorded during disassem-bl

TABLE OF CONTENTSii – JLG Sizzor – 3120691SECTION 3 - TROUBLESHOOTING3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 - PROCEDURES2-44 – JLG Sizzor – 3120691Figure 2-29. Drive Brake - 2WD/2WS

SECTION 2 - PROCEDURES3120691 – JLG Sizzor – 2-4511. Install case seal in housing, then install bleederscrew in end cover.12. Position end cover on ho

SECTION 2 - PROCEDURES2-46 – JLG Sizzor – 31206912. LPG is extremely flammable. No smoking.3. Only trained and authorized personnel are permittedto op

SECTION 2 - PROCEDURES3120691 – JLG Sizzor – 2-472.30 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULEThe preventive maintenance and inspection checks a

SECTION 2 - PROCEDURES2-48 – JLG Sizzor – 3120691Table 2-3. Preventive Maintenance and Safety InspectionAREA INTERVAL10Hours(Daily)50 Hours(Weekly)200

SECTION 3 - TROUBLESHOOTING3120691 – JLG Sizzor – 3-1SECTION 3. TROUBLESHOOTING3.1 GENERALThis section contains troubleshooting information to beused

SECTION 3 - TROUBLESHOOTING3-2 – JLG Sizzor – 3120691Table 3-1. Platform Assembly - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYNo response to control

SECTION 3 - TROUBLESHOOTING3120691 – JLG Sizzor – 3-3Platform raises and lowers erraticallyHydraulic system low Replenish hydraulic oil as requiredRes

SECTION 3 - TROUBLESHOOTING3-4 – JLG Sizzor – 3120691Table 3-2. Chassis TroubleshootingTROUBLE PROBABLE CAUSE REMEDYDRIVE SYSTEMNo response to control

SECTION 3 - TROUBLESHOOTING3120691 – JLG Sizzor – 3-5Loose or damaged wire between platform and high speed solenoidEnsure proper connection of wire at

TABLE OF CONTENTS3120691 – JLG Sizzor – iiiLIST OF TABLESTABLE NO. TITLE PAGE NO.1-1 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 - TROUBLESHOOTING3-6 – JLG Sizzor – 3120691Machine will not steer left or rightEnable switch not activated Activate enable switchFunction no

SECTION 3 - TROUBLESHOOTING3120691 – JLG Sizzor – 3-7Table 3-3. Chassis TroubleshootingTROUBLE PROBABLE CAUSE REMEDYENGINEEngine will not startStation

SECTION 3 - TROUBLESHOOTING3-8 – JLG Sizzor – 3120691Table 3-4. Hydraulic System TroubleshootingTROUBLE PROBABLE CAUSE REMEDYHydraulic pump noisyAir e

SECTION 3 - TROUBLESHOOTING3120691 – JLG Sizzor – 3-9Table 3-5. Electrical System TroubleshootingTROUBLE PROBABLE CAUSE REMEDYHAND CONTROLLERRegardles

SECTION 3 - TROUBLESHOOTING3-10 – JLG Sizzor – 3120691Defective Platform/Ground select switch Replace Platform/Ground select switchNo voltage present

SECTION 3 - TROUBLESHOOTING3120691 – JLG Sizzor – 3-11Figure 3-1. Hydraulic Schematic - Sheet 1 of 3

SECTION 3 - TROUBLESHOOTING3-12 – JLG Sizzor – 3120691Figure 3-2. Hydraulic Schematic - Sheet 2 of 3

SECTION 3 - TROUBLESHOOTING3120691 – JLG Sizzor – 3-13Figure 3-3. Hydraulic Schematic - Sheet 3 of 3

SECTION 3 - TROUBLESHOOTING3-14 – JLG Sizzor – 3120691OUTRIGGERRELAYFigure 3-4. Electrical Schematic (Ford) - Sheet 1 of 2

SECTION 3 - TROUBLESHOOTING3120691 – JLG Sizzor – 3-151283062 FFigure 3-5. Electrical Schematic (Ford) - Sheet 2 of 2

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SECTION 3 - TROUBLESHOOTING3-16 – JLG Sizzor – 3120691Figure 3-6. Electrical Schematic (Deutz) - Sheet 1 of 2

SECTION 3 - TROUBLESHOOTING3120691 – JLG Sizzor – 3-17Figure 3-7. Electrical Schematic (Deutz) - Sheet 2 of 2

SECTION 3 - TROUBLESHOOTING3-18 – JLG Sizzor – 3120691This page intentionally left blank.

JLG Worldwide LocationsCorporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USAPhone: (717) 485-5161Fax: (717) 485-6417JLG Ind

SECTION 1 - SPECIFICATIONS3120691 – JLG Sizzor – 1-1SECTION 1. SPECIFICATIONS1.1 CAPACITIESHydraulic Oil TankApproximately 17 U.S. gallons (64.4 lite