JLG Scissor Lifts 26MRT Service Repair Workshop Manual (P/N:3120892)

SERVICE & MAINTENANCE Model 26MRT 3120892 April 11, 2000 AUSTRALIAN OFFICE JLG INDUSTRIES, INC. P.O. Box 5119 11 Bolwarra Road Port Macquarie, Australia Telephone: 065 811111 Fax: 065 810122 EUROPEAN OFFICE JLG INDUSTRIES (EUROPE) Kilmartin Place, Tannochside Park Uddingston, Scotland, G71 5PH Telephone: 01698 811005 Main Fax: 01698 811055 Parts Fax: 01698 811455 CORPORATE OFFICE JLG INDUSTRIES, INC. 1 JLG Drive McConnellsburg, PA. 17233-9533 USA Telephone: (717) 485-5161 Fax: (717) 485-6417

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS 3120892 – JLG Sizzor – a SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A.A GENERAL This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others, or damage to the equipment. A maintenance program must be followed to ensure that the machine is safe to operate. MODIFICATION OF THE MACHINE WITHOUT CERTIFI- CATION BY A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST AS SAFE AS ORIGINALLY MANUFACTURED, IS A SAFETY VIOLATION. The specific precautions to be observed during maintenance are inserted at the appropriate point in the manual. These precautions are, for the most part, those that apply when servicing hydraulic and larger machine component parts. Your safety, and that of others, is the first consider- ation when engaging in the maintenance of equipment. Always be conscious of weight. Never attempt to move heavy parts without the aid of a mechanical device. Do not allow heavy objects to rest in an unstable position. When raising a portion of the equipment, ensure that adequate support is pro- vided. SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE FIELD INSPECTION AND MAINTENANCE, SAFETY IN THIS AREA RESPON- SIBILITY OF THE OWNER/OPERATOR. A.B HYDRAULIC SYSTEM SAFETY It should be noted that the machines hydraulic sys- tems operate at extremely high potentially danger- ous pressures. Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of the system. Relieve system pressure by cycling the applicable control several times with the engine stopped and ignition on, to direct any line pressure back into the reservoir. Pressure feed lines to system components can then be disconnected with minimal fluid loss. A.C MAINTENANCE FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION MAY RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A SAFETY VIOLATION. • NO SMOKING IS MANDATORY. NEVER REFUEL DUR- ING ELECTRICAL STORMS. ENSURE THAT FUEL CAP IS CLOSED AND SECURE AT ALL OTHER TIMES. • REMOVE ALL RINGS, WATCHES AND JEWELRY WHEN PERFORMING ANY MAINTENANCE. • DO NOT WEAR LONG HAIR UNRESTRAINED, OR LOOSE-FITTING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME CAUGHT ON OR ENTANGLED IN EQUIPMENT. • OBSERVE AND OBEY ALL WARNINGS AND CAU- TIONS ON MACHINE AND IN SERVICE MANUAL. • KEEP OIL, GREASE, WATER, ETC. WIPED FROM STANDING SURFACES AND HAND HOLDS. • USE CAUTION WHEN CHECKING A HOT, PRESSUR- IZED COOLANT SYSTEM. • NEVER WORK UNDER AN ELEVATED BOOM UNTIL BOOM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING, OR BOOM SAFETY PROP HAS BEEN ENGAGED. • BEFORE MAKING ADJUSTMENTS, LUBRICATING OR PERFORMING ANY OTHER MAINTENANCE, SHUT OFF ALL POWER CONTROLS. • BATTERY SHOULD ALWAYS BE DISCONNECTED DURING REPLACEMENT OF ELECTRICAL COMPO- NENTS. • KEEP ALL SUPPORT EQUIPMENT AND ATTACH- MENTS STOWED IN THEIR PROPER PLACE. • USE ONLY APPROVED, NONFLAMMABLE CLEANING SOLVENTS.

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS b – JLG Sizzor – 3120892 REVISON LOG Original Issue - April 11, 2000 (This manual split from manual 3120844)

3120892 – JLG Sizzor – i TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT - SECTION, PARAGRAPH PAGE NO. SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A.A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a A.B Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a A.C Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a SECTION 1 - SPECIFICATIONS 1.1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.2 Component Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.3 Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.4 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1.5 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1.6 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1.7 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1.8 Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1.9 Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1.10 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1.11 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 SECTION 2 - PROCEDURES 2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.2 Servicing and Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.3 Lubrication Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2.4 Cylinders - Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 2.5 Valves - Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 2.6 Component Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 2.7 Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 2.8 Cylinder Checking Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 2.9 Lift Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 2.10 Lift Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 2.11 Steer Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 2.12 Tilt Alarm Switch Adjustment (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 2.13 Limit Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 2.14 Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 2.15 Drive Axle Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 2.16 Brake Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 2.17 Throttle Checks and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 2.18 Control Card Setup and Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 2.19 Valve Driver Card Setup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29 2.20 Preventive Maintenance and Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31 SECTION 3 - TROUBLESHOOTING 3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.2 Troubleshooting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.3 Hydraulic Circuit Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

ii – JLG Sizzor – 3120892 TABLE OF CONTENTS LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 1-1. Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 1-2. Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 1-3. Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 2-1. Barrel Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 2-2. Cap Screw Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 2-3. Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 2-4. Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 2-5. Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 2-6. Poly-Pak Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 2-7. Wiper Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 2-8. Head Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 2-9. Piston Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 2-10. Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 2-11. Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 2-12. Steer Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 2-13. Tilt Switch Leveling - Manual Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 2-14. Tilt Switch Leveling - Voltmeter Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 2-15. Valve Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 2-16. Drive Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 2-17. Carrier Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 2-18. Ring Gear and Pinion Tooth Contact Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 2-19. Ring Gear Pattern Interpretation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 2-20. Brake Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 2-21. ADDCO Adjustments (Gasoline/Dual Fuel Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 2-22. ADDCO Adjustments (Diesel Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 2-23. Valve Driver Card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29 3-1. Electrical Schematic - Yanmar (Sheet of 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 3-2. Electrical Schematic - Yanmar (Sheet of 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 3-3. Electrical Schematic - Daihatsu (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 3-4. Electrical Schematic - Daihatsu (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 3-5. Hydraulic Schematic (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 3-6. Hydraulic Schematic (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 LIST OF TABLES TABLE NO. TITLE PAGE NO. 1-1 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1-2 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1-3 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1-4 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1-5 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1-6 Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 2-1 Cylinder Component Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 2-2 Holding Valve Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 2-3 Preventive Maintenance and Safety Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32 3-1 Elevation System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3-2 Chassis Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 3-3 Hydraulic System Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 3-4 Electrical System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

SECTION 1 - SPECIFICATIONS 3120892 – JLG Sizzor – 1-1 SECTION 1. SPECIFICATIONS 1.1 CAPACITIES Hydraulic Oil Tank 56.8 liters (15.0 gallons) Hydraulic System (Including Tank) Approximately 68.1 liters (18.0 gallons) Fuel Tank 29.5 liters (7.8 gallons) Drive Axle 6.4 liters (3 pints) 1.2 COMPONENT DATA Engine Daihatsu Gasoline/LP 3 cylinder, liquid-cooled 21 horsepower @ 3,000 rpm Idle - 1,500 rpm Mid Engine - 2,000 rpm High Engine - 3,000 rpm Alternator - 14 Amp Cooling System Capacity Engine - 1.8 liters (1.9 quarts) Crankcase Capacity - 3.0 liters (3.2 quarts) Yanmar Diesel 3 cylinder, liquid-cooled 22 horsepower @ 3,000 rpm Idle - 1,200 rpm Mid Engine - 2,000 rpm High Engine - 3,000 rpm Alternator - 40 Amp Cooling System Capacity 0.9 liters (1.0 quarts) - engine Crankcase Capacity - 2.4 liters (2.5 quarts) Drive Pump Closed loop piston type Output - 56.8 lpm (15 gpm) @ 3,000 rpm Displacement - 19.0 cm3/rev. (1.16 in.3/rev.) Lift/Steer Pump Gear type Output - 11.7 lpm (3.1 gpm) @ 3,000 rpm. Displacement - 4.0 cm3/rev. (0.24 in.3/rev.). Steer/Drive System Steer (Front) Tires - Dico Multi-Trac C/S 26 x 12.00 - 12 NHS; 6 ply; inflate to 2.8 bar (40 psi). Toe-In - Adjust to 6.4 mm (.25 in) overall. Drive (Rear) Tires - Dico Tru-Power TL 26 x 12.00 - 12 NHS; 6 ply; inflate to 2.8 bar (40 psi). Drive Brake - Mico hydraulic multi-disc. Drive Motor - Eaton 2000 Series; 131 cm3/rev. (8.0 in.3/ rev.). Drive Axle - Dana Model 44 rigid semi-float, no spin axle assembly; 5.89 ratio; oil capacity - 1.4 liters (3 pints). Hydraulic Filter - Inline Return - Bypass Type 10 Microns Nominal Platform Size Standard - 1.4 m x 2.2 m (54 in. x 88 in.) 1.3 PERFORMANCE DATA Travel Speed Maximum Speed - 7.2 kmh (4.5 mph) Elevated Speed - 1.1 kmh (0.7 mph) Gradeability 35% Turning Radius Inside - 2.5 m (8 ft. 1 in.) Outside - 4.7 m (15 ft. 4 in.)

SECTION 1 - SPECIFICATIONS 1-2 – JLG Sizzor – 3120892 Lift Up - 34-42 seconds Down - 31-39 seconds Platform Capacity Standard - 455 kg (1,000 lb.) Manual Platform Extension Capacity 115 kg (250 lb.) Machine Weight Approximately 2359 kg (5,200 lb.) Wheelbase 2.0 m (78.0 in.) Machine Height (Platform Fully Elevated) 7.9 m (26 ft.) Machine Height (Platform Lowered) 2.3 m (89.0 in.) Platform Railing Height 1.0 m (39.5 in.) Machine Length 2.7 m (105.0 in.) Machine Width 1.8 m (69.0 in.) Ground Clearance 14.0 cm (5.5 in.) Maximum Tire Load 921 kg (2,030 lb.) @ 1.3 bar (19 psi) 1.4 TORQUE REQUIREMENTS All wheel lug nuts should be torqued to 122 Nm (90 ft lb) every 150 hours. NOTE: When maintenance becomes necessary or a fas- tener has loosened, refer to the Torque Chart in this section to determine proper torque value. 1.5 LUBRICATION Hydraulic Oil NOTE: Hydraulic oils must have anti-wear qualities at least to API Service Classification GL-3, and sufficient chemical stability for mobile hydraulic system service. JLG Industries recommends Mobilfluid 424 hydraulic oil, which has an SAE viscosity of 10W-30 and a viscosity index of 152. Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities. If use of hydraulic oil other than Mobilfluid 424 is desired, contact JLG Indus- tries for proper recommendations. Table 1-1. Hydraulic Oil HYDRAULIC SYSTEM OPERATING TEMPERATURE RANGE SAE VISCOSITY GRADE 0 to +23 degrees F (-18 to -5 degrees C) 10W 0 to +210 degrees F (-18 to +100 degrees C) 10W-20,10W-30 +50 to +210 degrees F (+10 to +100 degrees C) 20W-20

SECTION 1 - SPECIFICATIONS 3120892 – JLG Sizzor – 1-3 Lubrication Specifications 1.6 CYLINDER SPECIFICATIONS NOTE: All dimensions are given in inches (in), with the met- ric equivalent, centimeters (cm), given in parenthe- ses. 1.7 PRESSURE SETTINGS Main Relief - 145 bar (2100 psi) Steer Relief - 103 bar (1500 psi) Lift Up Relief - 145 bar (2100 psi) Lift Down Relief - 62 bar (900 psi) 1.8 SERIAL NUMBER LOCATIONS For machine identification, a serial number plate is affixed to the machine. The plate is located on the rear center of the machine frame, just below the middle step of the lad- der. In addition, if the serial number plate is damaged or missing, the machine serial number is stamped on the right front frame rail, adjacent to the sizzor arms. 1.9 LIMIT SWITCHES The machine is equipped with the following limit switches: Tilt Alarm (Optional) - 5° - Illuminates a light on the platform and sounds an alarm when the machine is 5° out of level in any direction. High Drive Cut-Out - High drive speed is cut out when the platform is raised above the stowed position. 1.10 MAJOR COMPONENT WEIGHTS 1.11 CRITICAL STABILITY WEIGHTS DO NOT REPLACE ITEMS CRITICAL TO STABILITY, SUCH AS ENGINES, AXLES OR TIRES, WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION. DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY. Table 1-2. Lubrication Specifications KEY SPECIFICATIONS MPG Multipurpose Grease having a minimum dripping point of 350 degress F. Excellent water resistance and adhesive qualities, and being of extreme pressure type. (Timken OK 40 pounds minimum.) EPGL Extreme Pressure Gear Lube (oil) meeting API service classification GL-5 or MIL-Spec MIL-L-2105. EO Engine (crankcase) Oil. Gas - API SF/SG class, MIL- L-2104. Diesel - API CC/CD class, MIL-L-2104B/ MIL-L-2104C. HO Hydraulic Oil. API service classification GL-3, e.g. Mobil 424. Table 1-3. Cylinder Specifications Description Bore Stroke Rod Dia. Lift Cylinder 4.00 (10.2) 39.75 (101.0) 2.50 (6.4) Steer Cylinder (DoubleRrod) 2.00 (5.1) 2.69 (6.83) 1.25 (3.18) Table 1-4. Major Component Weights Component lb kg Platform 382 173 Manual Platform Extension 221 100 Arm Assembly (Includes Lift Cylinder) 1618 734 Chassis - w/Standard Tires 2979 1351 Table 1-5. Critical Stability Weights Component lb kg Tire and Wheel Assembly - Std (each) 50 23 Daihatsu Gasoline/LP Engine 132 60 Yanmar Diesel Engine 183 81 Dana Drive Axle 130 59

SECTION 1 - SPECIFICATIONS 1-4 – JLG Sizzor – 3120892 Figure 1-1. Lubrication Diagram Table 1-6. Lubrication Chart INDEX NO COMPONENT NUMBER/TYPE LUBE POINTS LUBE METHODS INTERVAL HOURS 1 Wheel Bearings 2- Front Wheels MPG - repack 1200 2 Hydraulic Oil Fill Cap/Drain Plug HO - Check HO Level HO - Change HO Daily/1200 3 Hydraulic Return Filter N/A N/A 50/300 4 Charge Pump Filter N/A N/A 50/300 5 Crankcase - Vanguard Gasoline/LP Engine FillCap/Drain Plug EO - Check EO Level EO - Change EO Daily/50/300 6 Crankcase - Yanmar Diesel Engine FillCap/Drain Plug EO - Check EO Level EO - Change EO Daily/50/300 7 Rear Axle FillCap/Drain Plug EPGL - Check EPGL Level EPGL - Change EPGL 150/1200 KEY TO LUBRICANTS: EO - Engine Oil EPGL - Extreme Pressure Gear Lubricant HO - Hydraulic Oil - Mobilfluid 424 MPG - Multi-purpose Grease TO AVOID PERSONAL INJURY, USE SAFETY PROP FOR ALL MAINTENANCE REQUIREING PLATFORM TO BE ELEVATED. NOTE: 1. Be sure to lubricate like items on each side. 2. Recommended lubricating intervals are based on maching operations under normal conditions. For machines used in multi-shift operations and/or exposed to hostile environments or conditions, lubrication frequencies must be increased accord- ingly. 3. Operate hydraulic functions through one com- plete cycle before checking hydraulic oil level in tank. Oil should be visible in ADD sight window on hydraulic tank. If oil is not visible, add oil until oil is visible in both ADD and FULL sight windows on tank. Do not overfill tank.

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JLG Scissor Lifts 26MRT Service Repair Workshop Manual (P/N:3120892)

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