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JLG-3369LE-4069LE-M3369-M4069-SM-2011

1. 6 eu gt su 1 MO Kai Go Se 5 aum vs 5 E g 5 9 8 ER 5 SI 8 FE 3 B stre 3000 PSI p ECRT ONLY Xe m BERT dm m lt gt 2 V EI ST MACHINES ONL 40 4 ED OPTIONAL FRONT WHEEL ASS NES ONLY 74 994 2 Bi 2 N PNE MEE g m G 2792442_ Figure 6 30 Hydraulic Schematic 6 24 Lift 3121122 An Oshkosh Corporation Company Corporate Office JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 JLG Worldwide Locations JLG Industries Australia P O Box 5119 11 Bolwarra Road Port Macquarie N S W 2444 Australia 61 265 811111 61 2 65 810122 A JLG Latino Americana Ltda Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil 55 19 3295 0407 55 19 3295 1025 USA
2. 2 4 10 4 13 Oscillation Cylinder Bleeding 1 4 10 3121122 JLG Lift TABLE OF CONTENTS Continued 4 14 Cylinder Assemblies 14 4 12 4 15 Pressure Setting Procedures 4 19 4 16 Drive Torque H b nance Rex IRR eee been eee EEG 4 20 4 17 Drive Assist Valv si ssim SR ee ab eg eae 4 22 SECTION 5 JLG CONTROL SYSTEM 5 1 Hand Held Analyzer 22 ef whi eels meter eR RP wa Laney 5 1 5 2 Ee 5 5 5 3 Flash Codes DTC s and Descriptions 5 6 5 4 Ground Control Circuit 4 5 19 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 6 1 General mU 6 1 6 2 Multimeter Basics i puspa y ie ae PS Sd ee ee ee 6 1 6 3 Applying Silicone Dielectric Compound To Amp 6 5 6 4 Working With Deutsch Connectors 6 10 LIST OF FIGURES FIGURE NO TITLE PAGE NO 1 1 Lubrication ea ERE REM REM e e a eee tt 1 4 1 2 Serial Number 4 1 5 1 3 Torque Chart SAE Fasteners Sheet 1 7 1 6 1 4 Torque Char
3. PIN TAGNAME FUNCTION TYPE 1 B Control System Supply 48V POWER INPUT 2 GND Control System Ground POWER INPUT 3 LTS Steer Left Solenoid Valve DIGITAL OUTPUT 4 RTS Steer Right Solenoid Valve DIGITAL OUTPUT 5 DPS Flow Control Solenoid Valve FWM OUTPUT 6 BRS Brake Solenoid Valve DIGITAL OUTPUT 7 UPS Lift Up Solenoid Valve DIGITAL OUTPUT 8 DDNS Lift Down Solenoid Valve FWM OUTPUT 9 HORN Horn Relay 48V DIGITAL OUTPUT 10 GND Ground POWER OUTPUT 11 FCU Load Sensing System Function Cutout Input DIGITAL INPUT 12 BPS Brake Pressure Switch DIGITAL INPUT 13 ELPX Elevation Prox Switch DIGITAL INPUT 14 APWR 5V Analog Excitation for Elevation Angle Sensor POWER OUTPUT 15 ANGL Elevation Angle Sensor Analog Input 0 5VDC ANALOG INPUT 16 12V 12V Sensor Supply POWER OUTPUT 17 SPD 4 Wheel Assist Speed Sensor Analog Input ANALOG INPUT 18 CANH CANbus High SERIAL 10 19 CANL CANbus Low SERIAL VO 20 CANS CANbus Shield Ground POWER OUTPUT 21 IGN Ignition Power 12V POWER OUTPUT 22 IGN Ignition Power 12V POWER OUTPUT 23 IGN Ignition Power 12V POWER OUTPUT 24 GND Ground POWER OUTPUT 25 GND Ground POWER OUTPUT 26 PWRON Power On GNDS or PLTE Powered 1 8A Limit POWER OUTPUT 27 IGN Ignition Power 12V POWER OUTPUT 28 IGN Ignition Power 12V POWER OUTPUT 29 GND Ground POWER OUTPUT 30 GND Ground POWER OUTPUT 31 CHGI Charger Interlock Input DIGITAL INPUT 32 DI9 Spare High Sensing Digital Input 9 DIGITAL INPUT 33
4. RESISTORS lt a Gi 213 52 1 84 0 5V OUTPUT iE vM Fer Ge 2 5V 0 CENTER de d lt YELLOW 9 1 HI 10 E tet y fel DRIVE PI LIFT HORN DRIVE FLOR FROR P RLOR RROR RTP TELL OW 10 1 SELECT SELECT SPEED ASSIST SELECT TILT ALARM ORN RED 49 3 BLACK 28 WHT RFD 51 14 WHT RFD 51 WAT RED 51 4 BLACK m 4 J 1 A d 5 e aq 4 H E E d z E z z E SI sls 5 8 SS 8 5 3 4 DH FRONTO FRONTO FRONTO FRONTO REAR REAR REAR REAR a 5 di LEFT di LEFT di RIGHT di RIGHT di LEFT di LEFT jj RIGHT D RIGHT UP DOWN DOWN UP DOWN UP DOWN D 8 m fe e s m 9 9 5 H E gt gt AL LO BLACK 3 eee 55 98 25 229353 2 2 32140 WHI RED 51 1 pina 8 8 2 5 5 TILTX ORN RED 49 1 PING DUAL AXIS ANALOG TILTY PINS SENSOR GND PINI IGN RX T GND WHITE GROUND ie UPS IAN 3 ELECTRONICS e RTS YELLOW 10 118 YELLOW 9 DPS STEER STEER BRAKE LIFT LIFT UPPER ANAF LEFT RIGHT UP DOWN 5 AWAR 8 t t t 2 M OSAX i 2 BLACK A ORANGE 55 12 SST ORANGF 8 1 d E LT OSC AX LT OSC AX RT OSC RT OSC AWAS REV AWAS REV AWAS FWD AWAS FWD 19 VALVE 2 2 VALVE 1 VALVE 2 VALVE 1 VALVE VALVE 3 VALVE VALVE 3 i ANGLE SENSOR 3 GENERATOR 244 SPEED SENSOR NOTES ALL
5. Table 3 9 Joystick Specifications Table 3 10 Joystick Plug Loading Chart Input Voltage 4 3V 0 1V Terminal Color Function Centered Output Voltage 2 2V 0 1V 1 Yellow Steer Right Full Positive Rev Deflection Output Voltage 4 0V 0 1V 2 Green Steer Left Full Negative Fwd Output Voltage 0 4V 0 1V 3 Brown Pot Wiper 4 Red Handle Common 5 N A Not Connected 6 White Red Pot 7 Violet Trigger Switch 8 Blue Trigger Supply 9 White Black Pot 3121122 JLG Lift 3 21 SECTION 3 CHASSIS amp SCISSOR ARMS 49 9 ohm TRIGGER SUPPLY 2W TRIGGER SWITCH TRIGGER SWITCHES STEER LEFT V SUPPLY STEER ROCKER STEER RIGHT SWITCHES Figure 3 12 Joystick Controller JLG P N 1600403 Table 3 11 Joystick Specifications Table 3 12 Joystick Plug Loading Chart Input Voltage 5V Terminal Color Function Centered Output Voltage 4 25V to 2 60V 1 Yellow Steer Right Reverse Voltage 4 60V to 4 80V 2 Green Steer Left Forward Voltage 0 40V to 0 60V 3 Brown Pot Wiper 4 Red Handle Common 5 N A Not Connected 6 White Red Pot 4 7 Violet Trigger Switch 8 Blue Trigger Supply 9 White Black Pot 3 22 JLG Lift 3121122 SECTION 3 CHASSIS amp SCISSOR ARMS 3121122
6. 3 21 3 12 Joystick Controller JLG P N 1600403 3 22 3 13 Drive Corponenils x uu Sede ee Re ERENNERT ee ee eee E e ku 3 23 3 14 Power Controller ie ge ae a e eh Wee ie ie 3 24 3 15 ube ciues alhuwa he Gee ee Be D gs ROS 3 26 3 16 Brake Assembly recie eign tua tal asan S o RG ate dol ei d 3 28 3 17 Torque Hub Assembly 3 30 3 18 Bolt Torquing 3 31 3 19 Hub Main 1 3 32 3 20 Output Carrier Disassembly 2 3 34 3 21 Input Carrier 2 3 35 3 22 Hub Spindle 1 3 36 3 23 Cover 3 37 3 24 Input Carrier Sub Assembly 3 38 3 23 Output Carrier 5 2 3 39 3 24 Hub Spindle Sub Assembly 3 40 ii JLG Lift 3121122 TABLE OF CONTENTS 3 25
7. CONTROLLER TORQUE HUB FN 2 P TRACTION MOTOR INPUT OUTPUT GASKETS TRACTION MOTOR DRIVE TORQUE BRAKE HUB Figure 3 13 Drive Components JLG Lift 3 23 SECTION 3 CHASSIS amp SCISSOR ARMS Power Controller 27 OA F2 9 5 Figure 3 14 Power Controller Table 3 13 Power Controller Cable Descriptions From To Power Controller F2 RightSideDrive Motor F1 Right Side Drive Motor F2 Left Side Drive Motor F2 Power Controller F1 Left Side Drive Motor F1 Power Controller S LeftSide Drive Motor A2 Right Side Drive Motor 1 Left Drive Motor Al Power Controller A Drive Motor Left Side Drive Motor A2 RightSideDriveMotor A2 Power Controller B Contactor 3 7 TOWING Disengaging for Towing NOTICE PRIOR TO OPERATING THE DISCONNECT THE MACHINE HAS TO BE ON LEVEL GROUND AND COMPLETELY SECURED FROM ANY MOVEMENT I E VIA TOW BAR TO PULLING VEHICLE THE MACHINE SHOULD NOT BE MOV
8. 3121122 SECTION 1 SPECIFICATIONS Values for Zinc Yellow Chromate Fasteners Ref 4150707 CLASS 10 9 METRIC BOLTS CLASS 10 METRIC NUTS CLASS 12 9 SOCKET HEAD CAP SCREWS Torque em Torque Lub OR Loctite amp Torque Dry or Loctite 242 or 271 OR Loctite 262 OR Size PITCH Stress TM 7 TM INGA 263 Vibra TITE 111 or Vibra TITE 131 K 0 20 140 K 0 15 K 0 18 3 os sos s13 eT oz ez sea 0 8 25 2 22 7 18 9 1 25 36 5 32 8 DC BEEN PE 2 wm ze 200 1 150 e 2 157 98 SET HRE 55 ONT s 20 25 245 1525 on oe 460 24 3 2220 me 960 800 561 2095 1885 1575 694 2855 2570 2140 3665 3300 2750 4s n ewo ses 5 4395 NO 5000059 REV J NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED NJO Figure 1 8 Torque Chart METRIC Fasteners Sheet 6 of 7 3121122 JLG Lift 1 11 SECT
9. ATTA 140 LAS ATTA LAG LAS ATTA MOIS LAS mu zi uta anon 1 1 1 1 maa SE 1 ssr T wawas ul Jemen IN a ON 0 0 anon 0 o o o ses LIWET ISISSV H 1101 0 NONDNAA jH JV Tv WOTHINI YAIVA 1 4 SMOVE 9NTIHATI 120119 D HII TV 31211410 222152 UAINA 9 MAING 9 VIN D t WS JW ISNV T Cas 116907 veo o 1118 TAMON 41185 SINIBVI LASHS 3121122 JLG Lift 5 16 SECTION 5 JLG CONTROL SYSTEM Table 5 3 Machine Model Adjustment Adjustment Adjustment Range Default Values 3369LE Default Values 4069LE DRIVE ACCEL 1 0 5 0 sec 3 5 3 5 DECEL 0 1 5 0s sec 0 1 0 1 MINIMUM 1 696 4 4 MAXIMUM 30 100 100 100 ELEVATED 1 15 10 10 LOW MAX 35 65 50 50 BRAKE FLOW 15 100 75 75 OSC AXLE 15 100 50 50 OSC AXLE 0 1 5 0 sec 1 0 1 0 4WA MAX 35 6596 40 40 4WHEEL ASSIST ACCEL 1 0 5 0 sec 2 0 2 0 DECEL 0 1 5 0 sec 0 1 0 1 MIN 4WA 0 2596 16 16 MAX4WA 25 100 75
10. Drift is to be measured at the cylinder rod with a calibrated dial indicator The cylinder oil must be at ambient temper ature and temperature stabilized The cylinder must have the normal load which is the nor mal platform load applied If the cylinder passes this test it is acceptable NOTE This information is based on 6 drops per minute cyl inder leakage 3121122 SECTION 2 GENERAL 3121122 2 5 PINS AND COMPOSITE BEARING REPAIR GUIDELINES Filament wound bearings 1 Pinned joints should be disassembled and inspected if the following occurs a Excessive sloppiness in joints b Noise originating from the joint during operation 2 Filament wound bearings should be replaced if any of the following is observed a Frayed or separated fibers on the liner surface b Cracked or damaged liner backing c Bearings that have moved or spun in their hous ing d Debris embedded in liner surface 3 Pins should be replaced if any of the following is observed pin should be properly cleaned prior to inspection a Detectable wear in the bearing area b Flaking pealing scoring or scratches on the pin surface c Rusting of the pin in the bearing area 4 Re assembly of pinned joints using filament wound bearings a Housing should be blown out to remove all dirt and debris bearings and bearing housings must be free of all contamination b Bearing pins should be cleaned with a s
11. Load Dry Lubricated On sis aero E TITE 131 In Sq In IN LB N m IN LB N m IN LB N m 4 40 0 1120 0 00604 380 8 0 9 6 0 7 48 01120 000000 420 9 10 7 J 6 32 01380 000909 50 16 18 12 14 J J 40 01380 0 01015 60 18 20 13 15 36 0 1640 0 01474 940 81 3 5 23 2 6 10 24 01900 0 01750 112200 43 48 35 1 4 20 0 2500 0 0318 2020 96 10 8 75 9 105 12 28 0 2500 0 0364 2320 120 13 5 86 10 135 15 In Sq In LB FT LB N m FT LB N m FT LB N m FT LB N m 546 18 24 3 8 16 0 3750 0 0775 30 41 23 31 35 48 24 0 3750 0 0878 5600 35 47 25 34 40 54 32 43 716 14 04375 01063 6800 50 68 3 47 5 75 45 6 20 04375 01187 750 55 75 40 54 60 82 50 68 1 2 13 0 5000 01419 950 75 102 55 75 85 116 68 92 20 0 5000 0 1599 90 122 5 100 136 9 16 12 0 5625 0 1820 11600 110 149 108 120 163 98 133 18 05625 02030 12950 120 163 90 1 2 135 184 109 148 5 8 11 0 6250 0 2260 150 203 110 149 165 224 18 0 6250 0 2560 16300 170 230 130 176 190 258 153 207 3 4 10 16 7 8 9 14 0 8750 0 5090 470 637 350 475 520 707 1 8 1 0000 0 6060 38600 640 868 480 651 675 918 579 785 12 118 7 1 1250 0 7630 800 1085 600 813 840 1142 12 1 1250 0 8560 47500 880 1193 660 895 925 1258 802 1087 114 7 12 138 6 12 1 3750 1 3150 1680 2278 1260 1708 1750 2380 112 6 1 5000 1 4050 78000 19
12. NNO TAS fl 119001 H WO ONTHLANAAT ALL DEI TAS SOMLSONOVIC 56884 JLG Lift 5 14 SECTION 5 JLG CONTROL SYSTEM 10 pavo mew enda L33HS OL ANY 64 1 6 NI S3SNVHO NYO 12866 3000 H3dOHd JHL H314V JO Z 19995 X Ld 5 WeYD 9 6 e1nBi4 ST3A31 dNLIS 3NIHOVIN 13 31 401 TIOHOS NYO m SA3X MOHHV 3S3H1 ONISSAYd SISTHOISAH AVE L LAAHS 5 15 JLG Lift 3121122 SECTION 5 JLG CONTROL SYSTEM JO JOBS JezAyeuy 7 G oJnBi4 10 1 nuan ena qs ruc over ca 1 AD 104 OPON 416966 VSO pue YSN ISNV 1d 5x3 SIexIew ueder 1deox3 PWEN 30 ST3A31 dNLAS ANIHOVW JHL S39NVHO SMV 14266 H314V SANAN 13A31 401 IHL 1109905 NYO 6 3S3H1 ONISSAYd 100110 TIV 2 ATTA 1496 LAS ATTA 140 LAS
13. The flow to the lift cylinder s is provided by a solenoid operated 3 way spool valve When flow is required to lift the load the solenoid is energized in one direction When the solenoid is not energized the cylinder is held in place by the holding valve mounted on the cylinder The directional control valve for steer is a solenoid oper ated three position 4 way sliding spool type valve Ener gizing one of the electrical coils on a valve will divert the supply of hydraulic oil to provide motion of that function in one direction Energizing the other coil will divert the oil for motion in the other direction When neither coil is ener gized the supply of hydraulic oil is blocked 3121122 A solenoid operated three way spool valve controls flow to the brakes to release the brakes When energized it allows flow to the brake parts until the brake pressure switch is satisfied Pressure relief valves limit the pressure in the steer circuit and the rod end of each lift cylinder When the pressure in one of those circuits reaches the set point of the valve the valve opens allowing enough flow to return to the reser voir so that the set pressure is not exceeded An adjusting screw on each cartridge relief valve allows the set pres sure to be adjusted The aluminum manifold provides the passages through which the hydraulic oil is diverted to provide the desired movement of the actuators No moving parts of the valves slide against the ma
14. q gt WHT RED t mc 2 TRIGGE 5 5 5 T SWITC V GEN 3 ENABL d J 4 zl gr Au 2525 oa YEL RED 2 5 lt od 4 4 YELIRED 2 1 WHT YEL 48 1 fe UL 5 d ed Pa s D 2 a e gt a gt 3 2 8 8 3 d 5 a z s sl z 3 5 2 2 5 585 5 YEL RED 2 5 5 5 LIFT c H 2 BE GSD e s S S 2 2 5 5 J5 4 68052025 8 8 8 8 a e o o 2 lt WHT RED 51 1 15 5 IGN lt 15 60 lt Gnd A J5 8 DNG ESTOP Cj Sl EDK ure AT GROUND WHT YFI 48 5186 GROUND TELE RS J5 22 lt _ GNDE 10 mis Q ri x ELECTRONICS HOUR METER Ka 00000 BRUJORN 52 4 lt 05 15 lt HRMT 10 B 2 2 B ee SE 12 23 15 CONNECTED 5 01 29 168 TO A SPLICE IN THE ORN RED 52 2 CHASSIS HARNESS THIS 82 L UE ANE 02 1007 FCU SPLICE THE SUPPLIES 2 8 34 BLACK OPEN WHEN BRAKES fpaxe prego eM LLRED IGN VOLTAGE TO THE LSS E HAVE PRESSURE APPLIED N CONNECTOR AND THE 2 aan SWITCH ORANGE BPS ELEV PROX 3 NORMALLY OPEN SWITCH ELEV WHTIRED 51 11 02223 IGN m CLOSES WHEN PLATFORM 5 ze 5 15 STONED PRORA RIURED 49 5 ____ 02 14 ELPX 945 ties 2 ORN RED 49 M ES LINE S Om m om 2
15. 13 JLG Lift On units with a ratio 48 1 the Sun Gear 9 and the Input Shaft 7 wil need to be removed together Remove the Output Stage Carrier Subassembly 10 Loosen and remove the three Flat Head Bolts 11 that retain the Ring Gear 12 to the Housing 13 Lift the Ring Gear 12 off of the Housing 13 Remove the O ring 14 from between the Housing 13 and the Ring Gear 12 3 33 SECTION 3 CHASSIS amp SCISSOR ARMS Output Carrier Disassembly a Roll Pin Planet Shaft Carrier Needle Bearings 5 6 7 8 Thrust Washers Thrust Spacer Planet Gears Thrust Washer Figure 3 20 Output Carrier Disassembly 1 Using a 1 8 diameter punch drive the Roll Pin 1 into the Planet Shaft 2 until it bottoms against the Carrier refer to Figure 3 17 2 Using a soft face hammer tap the Planet Shaft 2 out of the Carrier 3 3 Using a 1 8 diameter punch drive the Roll Pin 1 out of the Planet Shaft 2 NOTE The Roll Pins 1 should not be reused when reas sembling the unit 3 34 JLG Lift 4 Slide the Planet Gear Sub assembly 4 7 out of the Output Carrier 3 being careful to not drop the Nee dle Bearings 4 in the process Remove the 4 Thrust Washers 5 28 Needle Rollers 4 and the Thrust Spacer 6 from the Second Stage Planet Gear 7 Repeat Steps 1 5 for the remaining two Planet Gears 7 Remove the
16. 717 485 5161 amp 717 485 6417 JLG Industries UK Ltd Bentley House Bentley Avenue Middleton Greater Manchester M24 2GP England 44 0 161 654 1000 44 0 161 654 1001 3121122 JLG France SAS 2 1 de Baulieu 47400 Fauillet France 28 33 0 5 53 88 31 70 33 0 5 53 88 31 79 JLG Deutschland GmbH Max Planck Str 21 D 27721 Ritterhude Ihlpohl Germany 49 0 421 69 350 20 49 0 421 69 350 45 JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong 852 2639 5783 El 852 2639 5797 JLG Industries Italia s r l Via Po 22 20010 Pregnana Milanese MI Italy FF 39 029 359 5210 39 029 359 5845 pia Oshkosh JLG Singapore Technology Equipment Pte Ltd 29 Tuas Ave 4 Jurong Industrial Estate 639379 Singapore 65 6591 9030 El 65 6591 9031 JLG Polska UI Krolewska 00 060 Warsawa Poland 48 0 914 320 245 48 0 914 358 200 JLG Industries Scotland Wright Business Centre 1 Lonmay Road Queenslie Glasgow G33 4EL Scotland 44 0 141 781 6700 El 444 0 141 773 1907 Plataformas Elevadoras JLG Iberica S L Trapadella 2 P I Castellbisbal Sur 08755 Castellbisbal Barcelona Spain 34 93 772 4700 EL 34 93 771 1762 i www
17. GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Voltage Measurement Resistance Measurement Figure 6 1 Voltage Measurement DC Figure 6 2 Resistance Measurement If meter is not auto ranging set it to the correct range First test meter and leads by touching leads together See multimeter s operation manual Resistance should read a short circuit very low resis Use firm contact with meter leads tance Circuit power must be turned OFF before testing resistance Disconnect component from circuit before testing f meter is not auto ranging set it to the correct range See multimeter s operation manual Use firm contact with meter leads 6 2 JLG Lift 3121122 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Continuity Measurement Current Measurement Figure 6 3 Continuity Measurement Figure 6 4 Current Measurement DC Some meters require a separate button press to Set up the meter for the expected current range enable audible continuity testing Be sure to connect the meter leads to the correct Circuit power must be turned OFF before testing con jacks for the current range you have selected tinuity If meter is not auto ranging set it to the correct range Disconnect component from circuit before testing See multi meter s operation manual Use firm contact with meter leads Use firm contact with meter leads First test m
18. High Battery Voltage 1 Indicates a high battery voltage Check that the bat tery charger voltage is consistent with the battery pack voltage The first two digits of the four digit model name indicate the battery voltage the charger supports 2 Check for wiring errors 3 This fault will automatically clear and the charger will restart charging when this problem is removed 4 High battery voltage could also occur if there is another source charging the battery Disconnect any other sources during charging 5 this problem does not clear after the battery volt age is confirmed to be less than 2 4V per cell return the charger for service 2 Flashes Low Battery Voltage 1 Indicates either a battery failure no battery con nected or a lower than expected battery voltage Check the battery and battery connections 2 Check the nominal battery voltage The first two dig its of the four digit model name indicate the battery voltage the charger supports Confirm that a nomi nal battery voltage is the same as the charger volt age 3 This fault will clear automatically when the low bat tery voltage problem is rectified 3121122 4 lf this problem does not clear after the battery volt age is confirmed to be higher than 1 0V per cell and all connections are good return the charger for ser vice 3 Flashes Charge Timeout Indicates the battery failed to charge within the allowed time This could occur i
19. The normal extended output voltage setting is the voltage at which the alternator changes under normal operating conditions Current Limit The current limit setting determines the maximum alterna tor output current High Voltage Shutdown Level This setting determines the alternator output voltage at which the high voltage shutdown occurs This protects the load from abnormally high voltages Finish Charging Current The finish charging current determines the level of the cur rent alternator output must drop below for a low battery 3 18 JLG Lift voltage CTS to be removed This ensures that the batter ies have accepted sufficient charge prior to shutting down the RBS This level is used along with the low battery volt age remove CTS level to determine when the RBS removes the CTS after a low battery voltage CTS If the charging current falls below the finish charging current while another CTS is active the RBS will continue to oper ate at the normal extended output voltage until all CTS s are removed Priming the Fuel Line The following procedure is for re priming the fuel line on the generator engine in the event fuel system components have been replaced or the unit has been run dry of fuel 1 Make sure the fuel line isn t blocked or kinked 2 Make sure fuel tank has fuel 3 Disconnect the rubber fuel line at the fuel injector pump EE 4 When fuel starts to flow out of the rubber line r
20. 3 26 4 1 4 2 4 4 4 5 4 7 4 8 4 10 4 11 4 12 4 13 4 14 4 15 4 16 4 17 4 18 4 19 5 1 5 2 5 3 5 4 5 6 5 7 6 1 6 2 6 3 6 5 6 6 6 8 6 9 6 10 6 11 6 12 6 13 6 14 6 15 6 16 6 17 6 18 6 19 6 20 6 21 6 22 6 23 6 24 6 25 6 26 6 27 6 28 3121122 Cover Hub Main Assembly l supupi su RU RU Ru ga sis ed Rue dee Barrel 5 itera ea ee vr Deu b rn wee EE coke yeaa nee eae a RE REX UR RUE asa sj S ppott SEET Oil lite Bearing Installation 00 0 RH HI Rod SealInstallatiOn deretur edie ar a Berney oe heen DP eres Wiper Seal Installation IH Hen Installation of Head Seal Kit Piston Seal Kit Installation Poly Pak Piston Seal 2 Rod Assembly Installation teens Lift Cylinder 3369LE amp 3369 Lift Cylinder 4069LE amp 4069 Leveling Jack Cylinder USA Built Machines S N 0200112735 to Present Leveling Jack Cylinder USA Built Machines S N 0200104829 to S N 0200112735
21. 3 38 Figure 3 24 Apply a liberal coat of grease to the bore of one Input Planet Gear 4 Line the inside of the Planet Gear with 14 Needle Bearings 6 The last roller installed must be installed end wise That is the end of the last roller must be placed in between the ends of the two rollers which form the space and then slid parallel to the other rollers into place Set Carrier 3 in an upright position Insert a Planet Shaft 2 into the planet shaft hole in the end of the Carrier opposite the splined end The end of the Planet Shaft that does NOT have the roll pin hole should be inserted into the carrier FIRST Place one Thrust Washer 5 onto the end of the Planet Shaft Make sure the flat faces towards the inside of the carrier and make sure the button fits in the pocket on the inside of the Carrier towards the OD 6 NOTE 10 NOTE JLG Lift Input Carrier Sub Assembly Following the Thrust Washer place the Planet Gear with Needle Bearings onto the Planet Shaft Following the Planet Gear place one more Thrust Washer onto the Planet Shaft Align the Thrust Washer in the same manner described in Step 5 Now insert the Planet Shaft through the opposite planet shaft hole on the Carrier Use an alignment punch or similar tool to align the roll pin holes on the Carrier and Planet Shaft Be sure not to hit the Planet Gears when driving in the Roll Pins 1 Drive the Roll Pins down into
22. 31211410 NIAE UAINA WHINTO MAINA 9 7 1 6 WS VS ISNY 0 18043 1 6907 1 1169 0 Den nm LI werden Haagen spe span uunm maa Haana aow 41135 WWII e L33HS 5 13 JLG Lift 3121122 JO 1 199US X Ld JezAjeuy S S 11866 QHOMSSVd 16011 HOLVH3dO JHL 1631 IN31SAS OL H3QHO NI 3LON 1691 T 3121122 SECTION 5 JLG CONTROL SYSTEM 0 Wey OL MOVE TIN WH OL WOVE OL 004 OL 004 TIND OL UN K REH 4044 1581 Wir Wow AOT 01 1 0 WOW IDTTS 4 0 AOU 188370 WAALS LET SSTULSIC SAS WAALS 1497 DU TIS 4445 109 NO 0 Wl r d 1 0 WU I NC 8 0 TA I d 1 0 T 1 DEED d 1 0 Wd I NOYO I 4413 074 dA Lar I MOTH 4084 NMOG LAIT I 4318 MI
23. CONTACTOR IS i 2 e Gd Je CONTI NUOUS V cor YEL RED 2 6 pue eene NHT YEL 48 2 L Je 2 de SDN uJ 1 EE HS MM EUN NHT YEL 48 4 LEFT LEFT RIGHT RIGHT 23 Fi F2 GITT lo 8 21 2 5 6 KL E We sassa 12222 CONNECTOR B CONNECTOR Aj i r ems 3 Wi Semel orte i CONTACTOR Fi 2 A 14 COIL RIGHT RIGHT MOTOR MOTOR A2 Al BLACK I Ee i 7 B R i 8 POWER CONTROLLER 9 0 2 uer MOTOR MOTOR A2 Al 2 I 5 2 CHARGER 0000 PUNP MOTOR 2 4 WHT RED 57 20 RED JHERNISIER ORN RED 43 6 Figure 6 22 Electrical Schematic Sheet 1 of 2 JLG Lift 3121122 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS ORN WHT 55 6 ORN WHT 55 5 ORN WHT 55 4 ORN WHT 55 ORANGE 55 BLU ORN 52 1 QRANGE 55 10 IAN 55 ORANGE a IK OHM POT W 150 OHM CURRENT LIMITING
24. In sequence a Green LED flashes once b Yellow LED flashes once c Red LED flashes once 4 All Three LED flash three times 5 Yellow LED comes on indicates charger is charging Figure 3 6 Battery Charger Location 6 Yellow LED will stay on until fully charged and green M model shown LED will illuminate 7 fRed LED remains on this indicates a fault GREEN CHARGE IS COMPLETE YELLOW CHARGE IN PROCESS RED FAULT CONDITION 1 AC Voltage Input Cable 3 DC Power Cable to Batteries Figure 3 5 Remote LED Card 2 Charger Interlock Cable LED Indicator Cable Figure 3 7 Battery Charger 3121122 JLG Lift 3 7 SECTION 3 CHASSIS amp SCISSOR ARMS Table 3 3 Delta Q Battery Charger Specs BATTERY CHARGER SPECIFICATION OUTPUT Nominal DC Output Voltage 48V Maximum DC Output Voltage 52V Maximum DC Output Current 20A Maximum Interlock Current 1 INPUT AC Input Voltage 85 265VAC Nominal AC Input Voltage 120VAC 230VAC RMS AC Input Frequency 45 65 HZ Maximum AC Input Current 12ARMS 108VAC OPERATION Charging Indicator Yellow LED 100 Charge Indicator Green LED Fault Indicator Red LED External Temp Sensor Automatic Input wire Output Connector PROTECTION Output Reverse Polarity Electronic Protection Automatic Reset Output Short Circuit Electronic Protection Automatic Reset AC Overload
25. Remove Seal from Hub NOTE The Seal should NOT be reused when reassembling Remove A position Bearing Cone 4 from Bearing 5 Lift Hub 6 off of Spindle 1 Remove Boot Seal 7 from Hub if applicable 6 If necessary press 9 Studs 8 out of Hub Locate Hub on Seal refer to Figure 3 17 end 3 36 JLG Lift the unit 8 Remove position Bearing Cone 9 from Hub 9 Using a soft steel rod knock both Bearing Cups 5 out of the Hub 3121122 SECTION 3 CHASSIS amp SCISSOR ARMS Cover Disassembly 1 O Ring 4 Hex Head Bolts 7 O ring 2 Cover 5 Disengage Cap 8 O ring Pipe Plugs 3 Thrust Washer 6 Disengage Rod Figure 3 23 Cover Disassembly 1 Remove O ring 1 from the groove in the Cover 2 4 Pull Disengage Rod 6 out of the Cover 2 Remove the Thrust Washer 3 from Cover pockets 5 Use an appropriate tool to remove the O ring 7 from the internal groove in th ver 3 Unscrew the two Hex Head Bolts 4 and remove the S Disengage 5 from the Cover 6 Remove the two O ring Pipe Plugs 8 from the Cover 3121122 JLG Lift 3 37 SECTION 3 CHASSIS amp SCISSOR ARMS Input Carrier Sub Assembly ge 2 4 6 PER ASST PER ASSY PLANET GEAR SUB ASSEMBLY 1 Roll Pin Planet Shaft Carrier Planet Gears Thrust Spacer gv Ad o Needle Bearings PLANET GEAR SUB ASEEMBLY NOTE
26. Ring Gear Cover Subassembly Washer First Stage Sun Gear 9 10 11 12 Input Shaft Carrier Subassembly Second Stage Sun Gear Output Stage Carrier Subassembly Flat Head Bolts Ring Gear Figure 3 19 Hub Main Disassembly Lift 13 14 15 16 17 18 Housing O Ring O Ring Retaining Ring Ext Retaining Ring Ext ID Plate 3121122 SECTION 3 CHASSIS amp SCISSOR ARMS Disassembly Instructions 1 Perform the Roll Check and Leak Check if applica ble prior to disassembling the unit 2 Drain oil from the unit 3 Remove the Coupling 1 from Spindle End first 4 Remove the Retaining Ring 2 by prying the open end of the Retaining Ring out of the groove in the Ring Gear 3 with a screwdriver then grasp the loose end with pliers and pull the Retaining Ring completely out of the groove 5 Remove the Cover Subassembly 4 from the unit The unit can be carefully pressurized with air to pop the cover out of the unit The Washer 5 may have to be removed separately because of the loose attachment 6 Remove the First Stage Sun Gear 6 if applicable NOTE On units with ratios greater than 36 1 numerically there will not be a separate First Stage Sun Gear 6 as the gear teeth will be integral to the Input Shaft 7 7 Remove the Input Carrier Subassembly 8 8 Remove the Second Stage Sun Gear 9 9 Remove the Input Shaft 7 3121122 NOTE 10 11 12
27. SECTION 5 JLG CONTROL SYSTEM Jo Z 199US X LA MS 2 4 3121122 Jo paven nual 5 1 L S13A31 40135 3NIHOVW ANY S3ILITVNOSH3d IHL SADNVHO 3XVIN NVO 12266 3009 IHL SNIH31N3 H314V SANAN T3A31dO1 TIOHOS NYO gt 3S3H1 ONISSSYd JLG Lift 2 133HS 4 SSC UK 5 JI 11666 L LAAHS 5 12 SECTION 5 JLG CONTROL SYSTEM JO 199US X ELA MS HEYD JazAjeuy t S o1nBi4 ue ___ ST3A31 40135 IHL NI SADNVHO NYO 12266 3009 H3dOHd IHL SNIH31N3 H314V SANIN T3A31 dO1 110825 3S3H1 ONISS3Hd TIV 10010 KU i ATTA 149 LAS ATTA 140 LAS ATTA 1406 LAS i ATTA LAS H ATTA MOIS LAS 1 d nuns 1 YED unam 1 me I SU i i ap s 4 wes 0 w 0 d mu TAI 0 ON 0 ON
28. from J2 1 POWER OUTPUT 2 GNDE Ground EMS to J1 20 J3 22 POWER INPUT 3 PLTS Platform Select Input to J1 1 POWER INPUT 4 GNDS Ground Select Input POWER INPUT 5 IGN Ignition Power 12V POWER OUTPUT 6 GND Ground POWER OUTPUT 7 UPG Ground Lift Up Switch DIGITAL INPUT 8 DNG Ground Lift Down Switch DIGITAL INPUT 9 FDH Full Drive Height Input DIGITAL INPUT 10 DI19 High Sensing Digitallnput 19 DIGITAL INPUT 11 0120 High Sensing Digital Input 20 DIGITAL INPUT 12 0121 High Sensing Digital Input 21 DIGITAL INPUT 13 GMST Generator Manual Start to J3 19 POWER 10 14 GFLT Generator Fault LED to J3 21 POWER 0 15 HRMT Hourmeter DIGITAL OUTPUT Table 5 16 J6 Connector PIN TAGNAME FUNCTION TYPE 1 12V Ignition Power 12V POWER OUTPUT 2 RX RS 232 Serial Receive SERIAL INPUT 3 TX RS 232 Serial Transmit SERIAL OUTPUT 4 GND Ground POWER OUTPUT JLG Lift 3121122 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 6 1 GENERAL This section contains schematics to be used for locating and correcting most of the operating problems which may develop If a problem should develop which is not presented in this section or which is not corrected by listed corrective actions tech nically qualified guidance should be obtained before proceeding with any maintenance NOTICE IT IS GOOD PRACTICE TO AVOID PRESSURE WASHING ELECTRICAL ELECTRONIC COMPONENTS IN THE EVEN
29. from J5 2 500mA Limit POWER OUTPUT 21 GINH Generator Inhibit Start Switch POWER 10 22 1 CANBUS High CH1 SERIAL 10 23 GND Ground POWER OUTPUT 24 CANL1 CANBUS High CH1 SERIAL 10 JLG Lift 5 23 SECTION 5 JLG CONTROL SYSTEM 5 24 Table 5 12 J2 Connector PIN TAGNAME FUNCTION TYPE 1 B Control System Supply 48V POWER INPUT 2 GND Control System Ground POWER INPUT 3 LTS Steer Left Solenoid Valve DIGITAL OUTPUT 4 RTS Steer Right Solenoid Valve DIGITAL OUTPUT 5 DPS Flow Control Solenoid Valve FWM OUTPUT 6 BRS Brake Solenoid Valve DIGITAL OUTPUT 7 UPS Lift Up Solenoid Valve DIGITAL OUTPUT 8 DDNS Lift Down Solenoid Valve FWM OUTPUT 9 HORN Horn Relay 48V DIGITAL OUTPUT 10 GND Ground POWER OUTPUT 11 FCU Load Sensing System Function Cutout Input DIGITAL INPUT 12 BPS Brake Pressure Switch DIGITAL INPUT 13 ELPX Elevation Prox Switch DIGITAL INPUT 14 APWR 5V Analog Excitation for Elevation Angle Sensor POWER OUTPUT 15 ANGL Elevation Angle Sensor Analog Input 0 5VDC ANALOG INPUT 16 12V 12V Sensor Supply POWER OUTPUT 17 SPD 4 Wheel Assist Speed Sensor Analog Input ANALOG INPUT 18 CANH CANbus High to Power Module SERIAL 10 19 CANL CANbus Low to Power Module SERIAL 10 20 CANS CANbus Shield Ground POWER OUTPUT 21 IGN Ignition Power 12V POWER OUTPUT 22 IGN Ignition Power 12V POWER
30. 0120 High Sensing Digital Input 20 DIGITAL INPUT 12 0121 High Sensing Digital Input 21 DIGITAL INPUT 13 GMST Generator Manual Start to J3 19 POWER 10 14 GFLT Generator Fault LED to J3 21 POWER 10 15 Hourmeter DIGITAL OUTPUT Table 5 10 J6 Connector PIN TAGNAME FUNCTION TYPE 1 12V Ignition Power 12V POWER OUTPUT 2 RX RS 232 Serial Receive SERIAL INPUT 3 TX RS 232 Serial Transmit SERIAL OUTPUT 4 GND Ground POWER OUTPUT JLG Lift 3121122 SECTION 5 JLG CONTROL SYSTEM Software Version P1 0 3121122 Table 5 11 J1 Connector PIN TAGNAME FUNCTION TYPE 1 PLTS Platform Select POWER OUTPUT 2 PLTE Platform EMS POWER INPUT 3 GND Ground POWER OUTPUT 4 COLO Column 0 Output DIGITAL OUTPUT 5 COL1 Column 1 Output DIGITAL OUTPUT 6 COL2 Column 2 Output DIGITAL OUTPUT 7 PCTL Joystick Input 0 5VDC ANALOG INPUT 8 ROWO Row 0 Input DIGITAL INPUT 9 ROW1 Row 1 Input DIGITAL INPUT 10 COL3 Column 3 Output DIGITAL OUTPUT 11 COL4 Column 4 Output DIGITAL OUTPUT 12 COL5 Column 5 Output DIGITAL OUTPUT 13 ROW2 Row 2 Input DIGITAL INPUT 14 LCLK LED Latch Clock Output DIGITAL OUTPUT 15 ALRM Platform Alarm DIGITAL OUTPUT 16 IGN Ignition Power 12V 750mA Limit POWER OUTPUT 17 GALR Ground Alarm DIGITAL OUTPUT 18 009 Spare High Side Digital Output 9 12V 5A DIGITAL OUTPUT 19 QPRX Trigger Switch POWER INPUT 20 GNDE Ground EMS
31. 1 1 Specifications c en glean dU a 1 1 1 2 Capacities EE 1 2 1 3 Pressure Settings i Li ea iy ey tete bee gs 1 2 1 4 Component Data uu 1 2 1 5 Torque Specifications uer RP Re ERR eR doe oe E Ron eee 1 2 1 6 Lubrication u Uu EEN 1 2 1 7 Cylinder 1 3 1 8 Major Component Weights 1 3 1 9 Critical Stability Weights 1 3 1 10 E briCatiOnr c 1 4 1 11 Serial Number 1 5 1 12 Reie e IER 1 6 SECTION 2 GENERAL 2 1 Machine Preparation Inspection and Maintenance 2 1 2 2 Service and BE en 2 2 2 3 Lubrication and Information 4 4 40 2 3 2 4 Cylinder Drift Testi ceu AE RIETI Rae aa hater Eee et ERES 2 4 2 5 Pins and Composite Bearing Repair Guidelines 2 5 2 6 Preventive Maintenance and Inspection 2 5 SECTION 3 CHASSIS amp SCISSOR ARMS 3 1 EE IER 3 1 3 2 TA 3 4 3 3 Battery Maintenance and Charging 3 6 3 4 Generator serere ru th ah ae do e
32. 2 Pull back on the contact wire with a force of 1 or 2 Ibs to be sure the retention fingers are holding the contact See Fig ure 6 7 Connector Assembly 2 of 4 3 After all required contacts have been inserted the wedge lock must be closed to its locked position Release the lock ing latches by squeezing them inward See Figure 6 8 Connector Assembly 3 of 4 4 Slide the wedge lock into the housing until it is flush with the housing See Figure 6 9 Connector Assembly 4 of 4 PULL BACK ON WIRE RETENTION FINGERS HOLDING CONTACT Figure 6 7 Connector Assembly 2 of 4 6 6 Lift 3121122 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 1257 ano Ry P r a 4 SQUEEZE LOCKING LATCHES TO SEAT WEDGE LOCK BOTH SIDES Figure 6 8 Connector Assembly 3 of 4 WEDGE LOCK FLUSH WITH S N PS SESS Figure 6 9 Connector Assembly 4 of 4 3121122 JLG Lift 6 7 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Disassembly 5 Insert a 4 8 mm 3 16 wide screwdriver blade between the mating seal and one of the red wedge lock tabs 6 Pry open the wedge lock to the open position 7 While rotating the wire back and forth over a half turn 1 4 turn in each direction gently pull the wire until the contact is removed SES Figure 6 10 Connector Disassembly NOTE The wedge lock should never be removed f
33. 2 Tilt Sensor Harness e d e eere s s e deer ore re ete e En ce 3 5 3 3 Delta Q Battery Charger Specs 3 8 3 4 Battery Algorithms ee uet er dex uqa EM ELE uiia 3 11 3 5 RBS Presstart Sequence i oria ee SLA Dio LCS RE 3 15 3 6 RBS Startup Geouence 3 15 3 7 RBS Shutdown 3 15 3 8 Generator System Flash 3 17 3 9 Joystick Specifications EE 3 21 3 10 Joystick Plug Loading Chart 3 21 3 11 Joystick Specifications 3 22 3 12 Joystick Plug Loading 3 22 3 13 Power Controller Cable Descriptions 3 24 4 1 C to t Heights at esters ma an Mar 4 4 4 2 Cylinder Piston Nut Torque 4 9 4 3 Holding Valve Torque Specifications 4 9 4 4 Valve Component Torque 4 4 19 5 1 Flash Codes DTG S i unius adds 5 6 5 2 Power Module Diagnostic LED Flash 5 10 5 3 Machine Model
34. 252 E gee B 5 5 2 z 5 Figure 6 25 Electrical Schematic Yanmar Engine M3369 4 33691 only JLG Lift 6 19 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS LIFT BRAKES REAR WHEELS HOLDING CHECK 2 VALVE 4 s BULKHEAD PLATE MAIN CONTROL VALVE 5A MP 2792443 E Figure 6 26 Hydraulic Diagram 3369LE and M3369 Fixed Axle 6 20 JLG Lift 3121122 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS LIFT BRAKES REAR WHEELS HOLDING CHECK O H VALVE E BULKHEAD PLATE 2 3 4 L H R H P Leto e Ce el 5A H MAIN CONTROL VALVE T 58 Le D T le 1 3 A L 4 H nr 245 H H TES EI 6 Ae N P P 5 Figure 6 27 Hyd
35. Cylinders OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY 1 When working on oscillating axle cylinder place machine on firm level surface 2 Using all applicable safety precautions activate hydraulic system 3 Shut down hydraulic system and allow machine to sit for 10 15 minutes This is done to relieve pressure in the hydraulic lines Carefully remove hydraulic hoses from appropriate cylinder port block 4 There will be initial weeping of hydraulic fluid which can be caught in a suitable container After the initial discharge there should not be any further leakage from the ports If leakage continues at a rate of 6 8 drops per minute or more the following cylinder repairs must be made If the retract port is leaking the piston is leaking the piston seals are defective and must be replaced If the extend port is leaking the counterbalance is defective and must be replaced 5 To check piston seals carefully remove the counter 1 Place the machine on flat and level surface Turn power on and raise the platform Turn power off and attach a suitable lifting device to the platform Remove the bolt locknut and keeper 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 Retract the cylinder rod completely Tag and disconnect then cap the lift cylinder hydraulic lines and ports Remove the
36. For flooded lead acid batteries regularly check water levels of each battery cell after charging and add distilled water as required to level specified by battery manufacturer Follow the safety instructions recommended by the battery manufacturer 2 Make sure charger connections to battery terminals are tight and clean 3 Do expose charger to oil or to direct heavy water spraying when cleaning vehicle 3121122 SECTION 3 CHASSIS amp SCISSOR ARMS Battery Charger Troubleshooting No Lights at all No Lights at all indicate that AC power to the charger is not connected or that the AC voltage is too low It could also indicate an internal failure in the charger 1 Check the connections to AC power Check for AC voltage between 90 and 260 VAC at the charger 2 If the AC voltage is verified to be correct at the con nection to the charger and the charger still displays no lights at all return the charger for service FAULT LED Flashing The Fault LED flashes to indicate the microcontroller inside the battery charger has detected a fault The fault detected is indicated by the number of flashes Count the number of flashes to determine the fault With any battery system the most common problem will be a faulty battery connection Because of the high likeli hood of a battery connection problem it is always worth while to confirm that all connections are good before checking for any other problems 1 Flash
37. I I yaviv TH 3 0 FI ATN AMIS 1 0 NANO 41714300 SAVIS ATTA DNN IASON al TIS 0 mu xd l 4 0 250 E OM ATTA Sud VYA UIS MAILS I CIAO sNOU 0 14 NG LITT IV 1496 113 CIAA 55481910 SAS MAIS LATT JSTON SAA WUVIV AN9 Dt A NO LG worm an 01 MNIS IVAH NG LATI DU TAS 43145 dA INI RECH A IV 1406 Dau DIE 109 NYOH MOTI 4084 4044 TV Lage Im agas um TAS HS Lar ms Wis LAT YEA ms A mun Lu DU DIr 2 133HS OL SISAL SIVALDV SOLISONDVIC 0 edeos3 ssid 039901 MO DNIHLAGTIAA ALINA 55484 5 11 JLG Lift 3121122
38. M3369 4069LE M4069 Platform 780105 354 kg Platform Extension 360 Ibs 163 kg Foam Filled Tires 207 105 94 kg Battery Each 122105 55kg 3121122 JLG Lift SECTION 1 SPECIFICATIONS 1 10 LUBRICATION Note 500 3 months 1000 Hrs 6 months 2000 Hrs 1 year 4000 Hrs 2 years gH Figure 1 1 Lubrication Chart Table 1 11 Lubrication Chart INDEX NO TYPE LUBE INTERVAL NUMBER COMPONENT POINTS LUBE METHOD HOURS COMMENTS 1 Sliding Wear Pads 8 Wear Pads MPG Brush 50 Check HO Level Check oil every 10 hours of operation I Hydraulic Oil HO Change 10500 Change oil after every 1000 hours of operation 3 Wheel Bearings Front Wheels MPG Repack 1200 4 Spindles Bushing N A LL AtSpindle Bushing not shown Replacement Check oiul level at side plug daily 5 Wo Ce Fill Plug Half Full EPGL 1200 Change after first 150 hours of operation then every 1000 hours thereafter 6 High Pressure N A Replaceable 50 250 Replace filter element after first 50 hours of operation Filter notshown Element and every 1000 hours thereafter KEY TOLUBRICANTS Hydraulic Oil Mobil DTE EPGL Extreme Pressure Gear Lube MPG Mult
39. Market The selection will default to STANDARD otherwise 4150352_G 5 18 JLG Lift 3121122 SECTION 5 JLG CONTROL SYSTEM 5 4 GROUND CONTROL CIRCUIT BOARD Software Version 13 6 Table 5 5 J1 Connector PIN TAGNAME FUNCTION TYPE 1 PLTS Platform Select POWER OUTPUT 2 PLTE Platform EMS POWER INPUT 3 GND Ground POWER OUTPUT 4 COLO Column 0 Output DIGITAL OUTPUT 5 COL1 Column 1 Output DIGITAL OUTPUT 6 COL2 Column 2 Output DIGITAL OUTPUT 7 PCTL Joystick Input 0 5VDC ANALOG INPUT 8 ROWO Row 0 Input DIGITAL INPUT 9 ROW1 Row 1 Input DIGITAL INPUT 10 COL3 Column 3 Output DIGITAL OUTPUT 11 COL4 Column 4 Output DIGITAL OUTPUT 12 COL5 Column 5 Output DIGITAL OUTPUT 13 ROW2 Row 2 Input DIGITAL INPUT 14 LCLK LED Latch Clock Output DIGITAL OUTPUT 15 ALRM Platform Alarm DIGITAL OUTPUT 16 IGN Ignition Power 12V 750mA Limit POWER OUTPUT 17 GALR Ground Alarm DIGITAL OUTPUT 18 D09 Spare High Side Digital Output 9 12V 5A DIGITAL OUTPUT 19 QPRX Trigger Switch POWER INPUT 20 GNDE Ground EMS from J5 2 500mA Limit POWER OUTPUT 21 GINH Generator Inhibit Start Switch POWER 10 22 GND Ground POWER OUTPUT 23 GND Ground POWER OUTPUT 24 GND Ground POWER OUTPUT 3121122 JLG Lift 5 19 SECTION 5 JLG CONTROL SYSTEM 5 20 Table 5 6 J2 Connector
40. Pressure Shutdown due to low engine oil pressure 12 High Engine Shutdown due to high engine oil Temperature temperature 1 3 Engine Overspeed Shutdown due to high engine speed Engine Underspeed Shutdown due to engine over 1 4 Overcrank crank or underspeed 15 Speed Signal Shutdown due to loss of speed signal 2 1 Overvoltage Shutdown due to high output volt age Engine Starting Alarm nota shutdown Indicates 2 2 System fault problem with the engine starting system 2 3 Not Used Not Used 24 Loss of Voltage Sense Shutdown due to loss of voltage sensing Unit Disabled No Faults RBS enabled and can Continuous respond to any CTS Of Unit Disabled RBS offor disabled Will not respondto any CTS Low Oil Pressure Enabled once TDBP time delay bypass period has elapsed after engine startup If the low engine oil pressure switch closes the engine will stop immediately and a low oil pressure alarm will be indicated High Engine Temperature If the engine oil temperature exceeds the high engine tem perature setting the engine will stop immediately and a low oil pressure alarm will be indicated Overspeed If the engine speed exceeds the overspeed limit the engine will stop immediately and an overspeed alarm will be indicated JLG Lift 3 17 SECTION 3 CHASSIS amp SCISSOR ARMS Underspeed Enabled once TDBP time delay bypass period has elapsed after engine startup If the engine speed dr
41. Thrust Washer 8 from the counterbore in the Output Carrier 3 3121122 SECTION 3 CHASSIS amp SCISSOR ARMS Input Carrier Disassembly E 2 16 PER 557 3 PER 557 PLANET GEAR SUB ASEEMBL Y PLANET GEAR 5UB ASSEMBLT NOTE 3121122 1 Roll Pin 2 Planet Shaft 3 Carrier 4 Planet Gears 5 Thrust Spacer 6 Needle Bearings Figure 3 21 Input Carrier Disassembly Using a 1 8 diameter punch drive the Roll Pin 1 into the Planet Shaft 2 until it bottoms against the Carrier 3 Using a soft face hammer tap the Planet Shaft 2 out of the Carrier 3 Using a 1 8 diameter punch drive the Roll Pin 1 out of the Planet Shaft 2 The Roll Pins 1 should not be reused when reas sembling the unit JLG Lift Slide the Planet Gear 4 and the two Thrust Wash ers 5 out of the Carrier 3 Remove the 14 Needle Bearings 6 from the bore of the Planet Gear 4 Repeat steps 1 5 for each of the two remaining Planet Gears 3 35 SECTION 3 CHASSIS amp SCISSOR ARMS Hub Spindle Disassembly 1 Spindle 2 Retaining Ring 3 Spacer 4 Bearing Cone 5 Bearing Cup 6 Hub 9 PER ASSEMBLY 7 Boot Seal 8 Studs 9 Bearing Cone Figure 3 22 Hub Spindle Disassembly 1 Place unit on bench with Spindle 1 end down Remove Spacer 3 Cup 5 Hub 6 Remove Retaining Ring 2 with appropriate tool 7
42. amp All Belgium Built Leveling Jack Cylinder USA Built Machines Prior to S N 0200104829 Steer Cylinder o RR REESE Qua EE Axle Lockout Cylinder cie edt EE Drive Assist Valve uuu antes DNE tua d ve eta x UO Ra REID Analyzer 2 ux a nee e ze E dee PELE tee b on ier Zoe EE eh EE xc Analyzer Flow Chart SW V13 X Sheet 1 Analyzer Flow Chart SW V13 X Sheet 2 of 3 Analyzer Flow Chart SW 13 Sheet 3 0f3 Analyzer Flow Chart Software P1 X Sheet 1013 Analyzer Flow Chart Software 1 Sheet 2of3 _ Analyzer Flow Chart Software 1 Sheet 3013 Voltage Measurement Resistance Measurement m Continuity Current Measurement DC S Connector Assembly 1 of 4 Co
43. be necessary to align shoulder bolt with hub counterbore Install bolts into remaining holes Pipe plugs are to be installed into input cover using a lubricant seal Torque bolts to 23 27 ft Ibs 31 36 NM Fill unit one half full with EP90 lubricant 4 21 SECTION 4 HYDRAULICS 4 17 DRIVE ASSIST VALVE TA 6 WA 17 M 5 iL MPR PR MPR VALVE SCHEMATIC Figure 4 19 Drive Assist Valve 4 22 Lift 3121122 SECTION 5 JLG CONTROL SYSTEM SECTION 5 JLG CONTROL SYSTEM 5 1 HAND HELD ANALYZER rrenu Analyzer Display gt HELP PRESS ENTER Escape Key Enter Key To return home or access Stores and selects Top Level Sub previous menu Level anditem menus Sub Level and item menus Left amp Right Arrow Keys P GH Used to move between Top Level Figure 5 1 Hand Held Analyzer To Connect the Hand Held Analyzer 2 Power up the Control System by turning the lower key to the platform position and pulling both emer 1 Connect the four pin end of the cable supplied with gency stop buttons on the analyzer to the four position connector on the PCB and connect the remaining end of the cable to the analyzer NOTE The cable has a four pin connector at each end of the cable the cable cannot be c
44. j j j T JJ 36 01640 001474 TO 10 24 01900 00175 III T T T 32 01900 j j j P 14 20 02500 00318 280 143 16 129 15 C 28 02500 00364 32800 164 19 148 17 J m Sam 18 omg Una 24 03125 00580 520 25 3 25 3 2 2 24 0350 00878 790 50 70 45 3 50 716 14 04375 01063 950 70 95 65 90 50 7 20 0437 01187 1070 80 10 70 95 60 80 v2 13 05000 01419 1250 105 145 95 130 80 10 20 05000 01599 1400 120 165 110 150 90 120 L 18 05625 02030 1 0 6250 0 2260 0 2030 2 18250 170 230 20350 210 285 8 12 7 12 12 6 2 6 5 8 190 260 160 220 18 0 6250 0 2560 215 290 180 245 3 4 10 0 7500 0 3340 340 460 280 380 16 0 7500 0 3730 380 515 315 430 14 0 8750 0 5090 45800 670 910 600 815 500 680 12 10000 06630 5970 95 1355 85 1215 745 1015 00021112 11250 08560 77000 1445 1965 1300 170 1085 1475 1 2500 1 0730 96600 2015 2740 1810 2460 1510 2055 NO 5000059 REV J NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 3121122 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 8 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST P
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46. the aligned roll pin holes Pin should be flush with the flat of the Carrier Repeat Steps 1 9 for the installation of the two remaining Planet Gears Some grease may need to be applied tothe Thrust Washers to hold them in place while installing the Planet Gears 3121122 SECTION 3 CHASSIS amp SCISSOR ARMS Output Carrier Sub Assembly NOTE 3121122 Figure 3 23 Outpu Apply a liberal coat of grease to the bore of one Out put Planet Gear 7 Line the inside of the Planet Gear with 14 Needle Bearings 4 The last roller installed must be installed end wise That is the end of th last roller must be placed in between the ends of the two rollers which form the space and then slid parallel to the other rollers into place Place the Spacer 6 into the bore of the Output Planet Repeat Step 2 to put in second roll of Needle Bear ings Apply grease to hold two Thrust Washers together and onto Output Planet Gear counterbore Do the same to the other side Repeat Steps 1 5 to finish the assembly of the two remaining Output Planet Gears a Roll Pin Planet Shaft Carrier Needle Bearings Thrust Washers Thrust Spacer Planet Gears Thrust Washer Noc o DN t Carrier Sub Assembly 10 NOTE 11 12 JLG Lift Place the Thrust Washer 8 into counterbore of the Carrier 3 BE SURE the small diameter side of the Thrust Washer is facing the planet gear side
47. 0 99 9S spuooes Od SHOA SINA GL uelis Beg 1000 GL duet uny duet jueiquy sJNOH 66914 ssed g GL peeds SINOH spuooes 29109 56914 sduy Bunei do GL dois peo11ndino 66660 spuoo s J91u3 88914 po yes AL puuO SOA 1ndino ON smeis epon spot 55865 N S 3121122 JLG Lift 3 16 SECTION 3 CHASSIS amp SCISSOR ARMS The ground control module contains the settings for the generator ANALYZER CONNECTION 9 GROUND CONTROL NOTE The cable has a four pin connector at each end of the cable the cable cannot be connected back wards 2 Power up the Analyzer by pulling out the ground sta tion EMS and positioning the Generator Enable switch on the platform control box to the on posi tion Refer to Figure 3 10 Generator System Ana lyzer Flow Chart 3121122 Alarms and Fault Flash Codes In the event of an RBS alarm a flash code will be issued and an alarm indicated on the analyzer NOTE Alarms must be reset once the fault has been cor rected Table 3 8 Generator System Flash Codes Code Alarm Description 1 1 Low Oil
48. 0110 Spare High Sensing Digital Input 10 DIGITAL INPUT 34 DI11 Spare High Sensing Digitallnput 11 DIGITAL INPUT 35 D017 Spare High Sensing Digital Output 17 12V 5A DIGITAL OUTPUT 36 D018 Spare High Sensing Digital Output 18 12V 5A DIGITAL OUTPUT JLG Lift 3121122 SECTION 5 JLG CONTROL SYSTEM Table 5 6 J2 Connector PIN TAGNAME FUNCTION TYPE 37 4WAF 4 Wheel Assist Forward Solenoid Valve DIGITAL OUTPUT 38 4AWR 4 Wheel Assist Reverse Solenoid Valve DIGITAL OUTPUT 39 OSAX Oscillating Axle Solenoid Valves DIGITAL OUTPUT 40 0022 Spare High Side Digital Otput 22 12V 5A DIGITAL OUTPUT Table 5 7 J3 Connector PIN TAGNAME FUNCTION TYPE 1 0023 High Side Digital Output 23 12V 5A DIGITAL OUTPUT 2 0024 High Side Digital Output 24 12V 5A DIGITAL OUTPUT 3 0025 High Side Digital Output 25 12V 5A DIGITAL OUTPUT 4 0026 High Side Digital Output 26 12V 5A DIGITAL OUTPUT 5 DI12 High Sensing Digital Input 12 DIGITAL INPUT 6 DI13 High Sensing Digital Input 13 DIGITAL INPUT 7 IGN Ignition Power 4 12V POWER OUTPUT 8 ORSTO Outrigger Set Input DIGITAL INPUT 9 ORSET Outrigger Stow Input DIGITAL INPUT 10 IGN Ignition Power 4 12V POWER OUTPUT 11 FLU Front Left O R Up Solenoid Valve DIGITAL OUTPUT 12 FLD Front Left 0 R Down Solenoid Valve DIGITAL OUTPUT 13 FRU Front Right 0 R Up Solenoid Valve DIGITAL OUTP
49. 1 10 Position pressure plate 3 on cover 21 aligning dowel pins 20 with holes in pressure plate 11 Install cap screws 1 and washers 2 and tighten evenly to draw pressure plate 3 to cover 21 Torque cap screws to 55 Ib ft 74 6 NM NOTE A hyaraulic press will simplify the installation of the pressure plate Clamp pressure plate in position while tightening the cap screws A CAUTION IF HYDROSTATIC BENCH TESTING IS PERFORMED ON THE BRAKE ASSEMBLY RELEASE PRESSURE SHOULD NOT EXCEED 2000 PSI 137 9 BAR UNLESS TWO ADDITIONAL BOLTS ARE USED FOR SUPPLEMENTAL CLAMPING Bleeding 1 Install brake in system and connect pressure lines 2 Bleed pressure release section of brake by pressur izing side inlet port and allowing air to escape from top port Pressure should not exceed 100 psi 6 9 bar during bleeding 3 Apply sufficient pressure to release brake and check for proper operation in system NOTE If damaged replace the input and output gaskets before assembling the brake to the hub and motor See Figure 3 13 and Figure 3 16 JLG Lift 3 29 SECTION 3 CHASSIS amp SCISSOR ARMS 3 10 TORQUE HUB 5k 3 30 ON 13 9 41 2726 24 22 1918 17 27 25 23 20 14 39 37 38 34 32 33 31 4 15 42 30 16 35 5 4 3 7 8 6 21 40 Spindle 12 Thrust Washer 23 Needl
50. 1 CAUTION IF THE CYLINDER IS TESTED PRIOR INSTALLATION ON THE MACHINE EXTREME CARE SHOULD BE USED TO INSURE THAT THE OUTER END OF THE ROD IS SUPPORTED USE EITHER A TRAVELING OVERHEAD HOIST FORKLIFT OR OTHER MEANS TO SUPPORT THE OVERHANGING WEIGHT OF THE 3 EXTENDING ROD 4 12 STEER CYLINDER REMOVAL 1 Park the machine on a firm and level surface 2 Using proper lifting devices raise the machine to access the steer cylinder form underneath 4 NOTE Be sure and use proper equipment to stabilize the machine while performing maintenance underneath 3 Remove both hydraulic lines from the steer cylinder 5 and allow excess oil in lines to drain into a suitable container 4 Remove the nut and bolt from the barrel end of the Run one side wheel onto a ramp or block of wood On the other side the lockout cylinder should be extended Block the rear wheels and disconnect the drive hubs Open up the bleeder screw on the bottom of the extended side lockout cylinder Disconnect coil on the flow control valve Have an assistant hold lift up switch causing pump to run continually for approx 10 seconds or until all the air bubbles are no longer visible Then close the bleeder screw while pump is running Open bleeder on the top of the retracted lockout inder Let hydraulic oil run for approx 10 seconds or until air bubbles are no longer visible Then close the bleeder screw Fully oscillate
51. 1122 JLG Lift elevating and lowering machine 4 5 SECTION 4 HYDRAULICS 4 11 CYLINDER REPAIR 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 Disassembly DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA 1 Operate the hydraulic power source and extend the cylinder Shut down and disconnect the power source Adequately support the cylinder rod if nec essary 2 If applicable remove the cartridge type holding valve and fittings from the cylinder port block Dis card o rings SUPPORT TABLE Figure 4 1 Barrel Support 3 Place the cylinder barrel into a suitable holding fix ture Apply Spanner Wrench Figure 4 2 Capscrew Removal 4 To aid in realignment mark cylinder head and barrel with a center punch 4 6 Lift 5 Using a suitable spanner wrench loosen the span ner nut retainer and remove the spanner nut from the cylinder barrel 6 Attach a suitable pulling device to the cylinder rod port block or cylinder rod end as applicable NOTICE EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL INDER ROD HEAD AND PISTON AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES SUPPORT Figu
52. 122 NOTE On the back of the control valve is a flow control valve This valve is used to adjust the lift down Speed Table 4 4 Valve Component Torque Values COMPONENT Ft Ib Nm Main Relief 25 35 Lift Relief 25 35 Steer Relief 20 28 Pressure Switch 12 16 8 Brake 20 28 High Pressure Filter 50 70 Steer 20 28 Lift 25 35 Flow Control 25 35 Coil Nuts 7 9 8 JLG Lift 4 19 SECTION 4 HYDRAULICS HIGH PRESSURE FILTER MP STEER a FLOW CONTROL PRESSURE SWITCH MAIN RELIEF du STEER RELIEF LIFT RELIEF Figure 4 18 Control Valve 4 16 DRIVE TORQUE HUB Disassembly 1 Loosen all cover bolts and drain oil from unit 2 Remove the cover bolts and lift off input cover Remove and discard o ring from counterbore of input cover 3 Remove sun gear and thrust washer 4 Lift out the carrier and thrust washer 5 Remove input spacer 6 Lift out internal gear and thrust washer 7 While wearing eye protection remove the retaining ring from the output shaft and discard 8 Remove thrust washer from the output shaft 9 The output shaft may now be pressed out of the housing 10 The bearing cups will remain in hub as will the inner bearing cone The outer bearing cone will remain on 4 20 NOTE 12 NOTE Lift the output shaft The lip seal will be automatically removed during this procedure If bearing replaceme
53. 13 6 NOTE NOTE NOTE NOTE 3121122 Make sure your analyzer is in ACCES LEVEL 1 When using the analyzer the terms referring to ROTARY amp PROXIMITY sensors are ELEV SEN SOR amp ELEV PROX Use ELEV SENSOR sub level menu for rotary switch adjustments Use SET ELEV SENSOR top level menu for proxim ity switch adjustment and final calibrations If the Always set the rotary switch first before the proximity switch because they back each other up in the case of a component failure When mounting make sure the rotary switch is aligned with the bladed pin mounted on the scissor arm There must be a preload when installing the rotary switch on the bladed pin bracket similar to a throttle actuator There are 3 3 8 mounting screws that hold the switch onto the scissor arm mounting lug make sure they are snug not loose so you are able to rotate the rotary switch Make sure the deck is fully lowered Plug in the ana lyzer and scroll through DIAGNOSTICS ELEV SEN SOR to ANGLE SNSR This should read 0 40v 0 45v Anytime the ground control board or if the rotary sen sor is replaced the rotary sensor must be reset zeroed out If the reading is not within the spec adjust the rotary switch by rotating the bracket and viewing the ana lyzer Loosen the hardware that holds the proximity switch and allow the switch to drop to the bottom of the slide bracket Using the analyzer press escape twice and scrol
54. 2 Try to clear the fault by unplugging the AC waiting 30 seconds and reconnecting the ac power 3 Check all battery connections Look for a high resis tance connection The most likely reason for this fault is a fault in the battery such as a bad battery con nection an open cell or insufficient water 4 This fault will occur if an internal fuse inside the charger blows If the green wire is shorted to ground even momentarily this fuse will blow To check the fuse measure with an ohmmeter between the green and red wires with the AC disconnected If a short circuit is not measured the fuse has blown Return unit to a service depot to have this fuse replaced 5 If this fault occurs after battery charging has started confirm that AC power was not interrupted and that all battery connections are good 6 If all battery connections are good an internal fault has been detected and the charger must be brought to a qualified service depot 3 10 JLG Lift Excessive Battery Watering Requirements or Strong Sulphur Rotten Egg Smell These symptoms indicate over charging or high battery temperature These symptoms are unlikely to be caused by too high a charge current since the maximum charge current of the charger will be small compared to even a moderately sized battery pack The most likely cause for this problem is incorrect charge algorithm setting and or high ambient temperatures 1 Confirm that the battery pack is n
55. 3750 0075 700 45 60 40 55 35 50 50 70 1 20 0437 01187 10700 80 110 70 95 60 80 1 2 13 110 120 155 3999 iro ae ps ato 175 210 285 190 220 240 325 215 245 375 510 340 380 420 570 380 430 um sis 50 66 i 0 5090 45800 670 910 600 815 500 680 875 1015 1310 1475 1855 2055 2430 2760 3225 3625 NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS NO 5000059 REV J 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER Figure 1 4 Torque Chart SAE Fasteners Sheet 2 of 7 JLG Lift SECTION 1 SPECIFICATIONS SOCKET HEAD CAP SCREWS Magni Coating Ref 4150701 Torque TM Torque Si TPI Bolt Di Tensile Clamp Load Torque gocmen Loctite 262 07778 Stress Area See Note 4 Dy K 17 ORVibra TITE 1110 or Vibra TITE 131 140 OR Precoat 85 0 01120 000604 Po 46 ooo J T T T 1 e 32 01380 00099 1 17 LL 8 32 0 1640 0 01400 L 10 24 0 1900 0 01750 32 01900 002000 T T j 1646 20 02500 00318 2860 122 14 1 T 28 02500 00364 3280 139 16 131 75 5 16 18 0 3125 0 0524 4720 20 25 20 25 20 25 24 0 3125 0 0
56. 4 8 Piston Seal Kit Installation A WARNING WHEN REBUILDING THE LIFT CYLINDER APPLY LOCTITE 242 TO TAPERED BUSHING BOLTS THEN TIGHTEN BOLTS SECURELY REFER TO TABLE 4 2 CYLINDER PISTON NUT TORQUE SPECIFICATIONS AND TABLE 4 3 HOLDING VALVE TORQUE SPECIFICATIONS FOR PROPER BOLT TORQUE VAL UES 10 Install the bolts into the bushing using Loctite 242 Refer to Cylinder Component Torque Specifications Table for proper bolt torque values 11 Remove the cylinder rod from the holding fixture 12 Place new guidelock and hydrolock seals in the applicable outside diameter grooves of both the pis ton and the cylinder head 13 Position the cylinder barrel in a suitable holding fix ture PISTON REF Figure 4 9 Poly Pak Piston Seal Installation JLG Lift 3121122 SECTION 4 HYDRAULICS NOTICE 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 CYLINDER HEAD ASSY CAP SCREWS BARREL 14 15 16 17 18 WASHER pt RING Figure 4 10 Rod Assembly Installation With the barrel clamped securely and while ade quately supporting the rod insert the piston end into the cylinder barrel Ensure that the piston loading o ring and seal ring are not damaged or dislodged Continue pushing the rod into the barrel until the cyl inder head gland can be inse
57. 40 2630 1460 1979 2025 2754 1755 2379 12 5000059 REV J NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 310 1 6 3 ASSEMBLY USES HARDENED WASHER JLG P N Loctite P N REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND 0100071 _ 262 242 27 262 Vibra TITE 140 High Strength Red Vibra TITE 131 Medium High Strength Red 0100011 242 1 121 Medium Strength Blue Figure 1 3 Torque Chart SAE Fasteners Sheet 1 of 7 JLG Lift 3121122 SECTION 1 SPECIFICATIONS 3121122 Values for Zinc Yellow Chromate Fasteners Ref 4150707 SAE GRADE 8 HEX HD BOLTS amp GRADE 8 NUTS Toga Torque Torque TM TM TM Size TP Dty of Loctite ede 262 Stress Area ase OR Vibra TITE 111 or TITE 131 140 K 18 K 0 15 et ee EE 4 40 0 1120 0 00604 _ 48 onzo p oost f 6 32 0130 000909 0130 001015 8 32 01640 001400 1 ss 01640 001444 55 5 10 24 0190 001750 1580 60 7 01800 002000 1800 68 8 1 4 20 EE 25 25 3 8 16 0
58. 5 O ring 13 Rotor Disc 21 Cover 6 Back up Ring 14 Plate 22 Rotary Oil Seal 7 Piston 15 Springs 23 8 O ring 16 Spring Retainer 24 Figure 3 16 Brake Assembly 3 28 JLG Lift 3121122 SECTION 3 CHASSIS amp SCISSOR ARMS 3 9 DRIVE BRAKE MICO Disassembly 1 After removing the brake from its installation place brake on a clean dry work bench with mounting plate uppermost 2 Remove pressure plate 3 from cover 21 by removing cap screws 1 and washers 2 CAUTION PRESSURE PLATE IS UNDER SPRING TENSION APPROXI MATELY 680 KG 1500 LB THE FOUR CAP SCREWS SHOULD BE LOOSENED EVENLY TO RELIEVE THE FORCE IF A HYDRAULIC PRESS IS AVAILABLE 3000 LBS 1361 KGF MINIMUM THE PRESSURE PLATE CAN BE HELD IN POSITION WHILE REMOV ING THE CAP SCREWS AND WASHERS 3 Remove case seal 4 from cover 21 4 Remove piston 7 from pressure plate 3 5 Remove o rings 5 8 and back up rings 6 9 from piston 7 NOTICE IF THE SENSOR RING 12 IS DAMAGED OR NEEDS REPLACED THE ENTIRE BRAKE MUST BE REPLACED AS A UNIT THE SEN SOR RING IS NOT AVAILABLE AS A SERVICE PART 6 Remove stack assembly consisting of stator disc 11 sensor ring 12 rotor disc 13 and plate 14 from cover 21 7 Remove dowel pins 20 springs 15 and spring retainer 16 from cover 21 NOTE Not all models use the same number of springs or spring pattern Record this information for reassem bly purpos
59. 580 5220 3 8 16 0 3750 0 0775 7000 50 35 50 35 50 7716 1 2 9 16 5 8 3 4 78 9 08750 04620 41600 515 70 485 660 45 620 1 8 1000 056060 5150 730 95 685 90 645 875 11 8 12 114 7 12 13 8 6 2300 3130 2165 2945 2030 2760 11 2 6 1 5000 1 4050 126500 2690 3660 2530 3440 2370 3225 NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS REV 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS 15 SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED Figure 1 5 Torque Chart SAE Fasteners Sheet 3 of 7 Lift 3121122 SECTION 1 SPECIFICATIONS SOCKET HEAD CAP SCREWS Zinc Yellow Chromate Fasteners Ref 4150707 Torque Torque TM TM T Bolt Dia Tensile Clamp Load 242 271 Loctite 262 Stress Area See Note 4 OR Vibra TITE 111 or or Vibra TITE 131 140 OR Precoat 85 K 0 15 PI K 0 18 Los sm 8 ma mm mas 4 40 01120 0 00604 T j O 01120 00661 J j j j j 6 32 01380 000909 T Jh j j j O 1 40 01380 001015 j j j j 8 32 01640 001400 _
60. 69LE M3369 4069LE M4069 Main Relief 2 50 psi Steer Relief SE Lift Relief EE 1 4 COMPONENT DATA Battery Charger Input 220 VAC 50 HZ Input 110 VAC 60 HZ Output 48 VDC 23 Amp Batteries 8 6 Volt 370 Amp hour JLG MACHINES EQUIPPED WITH DELTA Q BATTERY CHARGERS ARE DESIGNED FOR THE BEST PERFORMANCE WITH OEM FAC TORY APPROVED BATTERIES APPROVED JLG REPLACEMENT BATTERIES ARE AVAILABLE THROUGH JLG S AFTERMARKET PARTS DISTRIBUTION CEN TERS OR JLG S AFTERMARKET PROGRAMS FOR ASSISTANCE WITH PROPER BATTERY REPLACEMENT PLEASE CONTACT YOUR LOCAL JLG SUPPORT OFFICE BATTERIES APPROVED BY JLG HAVE BEEN TESTED FOR COM PATIBILITY WITH THE ALGORITHM PROGRAMMING OF THE DELTA Q BATTERY CHARGER TO OPTIMIZE BATTERY LIFE AND MACHINE CYCLE TIMES THE USE OF NON APPROVED BATTER IES IN YOUR JLG EQUIPMENT MAY RESULT IN PERFORMANCE ISSUES OR BATTERY CHARGER FAULT CODES JLG ASSUMES NO RESPONSIBILITY FOR SERVICE OR PERFORMANCE ISSUES ARISING FROM THE USE OF NON APPROVED BATTERIES 1 2 JLG Lift Drive System Drive Motor 48 VDC 11 8 H P peak 5 5 H P continuous rotation reversible Drive Brake 24 VDC spring applied hydraulically released Steer System Tires IN240 55 17 5 FF IN240 55 17 5 FF non marking Toe In 1 4 inch 6 4 mm overall Hydraulic Pump Electric Motor Assembly Pump Output 3 86 14 6 lpm 2175 psi 150 bar 1 5 TORQUE SPECIFICATIONS Table 1 4 Torque Spec
61. 75 ACCELERATOR THRESH 0 100 75 75 DRIVE SPEED 0 1 5MPH 0 5 0 5 LIFT ACCEL 0 2 5 0 sec 2 0 2 0 DECEL 0 2 5 0 sec 0 5 0 5 MIN UP 0 25 16 16 MAX UP 25 100 65 65 LOW MAX 35 65 35 35 STEER STATC LEFT 15 100 31 31 STATIC RIGHT 15 100 37 37 DRIVE LEFT 15 100 23 23 DRIVE RIGHT 15 100 25 25 JOYSTICK FWD MAX 0 5 0V 0 65 0 65 FWD MIN 0 5 0V 2 25 2 25 REV MIN 0 5 0V 2 80 2 80 REV MAX 0 5 0V 4 45 4 45 The 4 Wheel Assist Menu will not be available if the option is not configured 3121122 JLG Lift 4150351 E NOTE These settings may change in order to achieve optimal performance on a machine by machine basis SECTION 5 JLG CONTROL SYSTEM NOTE When configuring an LE scissors machine the machine configuration must be completed before any personality set tings can be changed Changing the personality settings first and then changing the model number of the machine con figuration will cause the personality settings to return to default Table 5 4 Machine Configuration Programming Information Default Number Configuration Digit Number Description 1 0 3369 0 MODEL 1 4069LE 0 ANSI USA 1 ANSI EXPORT 2 2 CSA 0 MARKET 3 CE 4 AUSTRALIA 5 JAPAN 3 0 NO Drive amp Lift Up not prevented when Tilted amp Elevated 51217 1 1 TILT CUTOUT 1 YES Drive amp Lift Up
62. Adjustment 2 1 5 17 5 4 Machine Configuration Programming 5 18 5 5 Connector u eret Sade Wen cea alec ated ad DICA en dee S SEE 5 19 5 6 J2 Elle 5 20 5 7 CONNCCION uud m c RU CEU ag PER E 5 21 5 8 JA GOnMOCIOR aac Cuy ata te 5 22 5 9 5 geil 5 22 5 10 Je Connector ana E 5 22 5 11 J1 Connector ia e eae te yet ei head on Porc e eS ER a 5 23 5 12 32 CONNOCTO E EDI LI 5 24 5 13 J9 ios ee ee Een Deua WE eid ot 5 25 5 14 34 Connector str stet LAE Le uer mte tare tutes rct eL most oL ea 5 26 5 15 J5 Gohnector Ade 5 26 5 16 JO CONNECTION cru ek I Rue ege Geer 5 26 iv JLG Lift 3121122 SECTION 1 SPECIFICATIONS 1 1 SPECIFICATIONS SECTION 1 SPECIFICATIONS Table 1 1 Operating Specifications Description 3369LE M3369 4069LE M4069 Maximum Platform Height 33 ft 10 1 m 40 ft 12 2 Maximum Occupants 2 Gross Machine Weight minimum 9760105 4427 kg 10 560 Ibs 4790 kg Travel Speed High Drive Fwd Rev sec 50 ft 10 6 12 sec Elevated Drive Fwd Rev sec 50 ft 40 44 sec Lifting Speed No Load 36 40 sec 52 60 sec Rated Lo
63. BATTERY EACH NEW BATTERY MUST WEIGH AT LEAST 52 KG 115 LB FAILURE TO REPLACE THE BATTERY WITH ONE OF THE CORRECT WEIGHT WILL RESULT INA TIPOVER HAZARD WHICH COULD RESULT IN SERIOUS INJURY OR DEATH JLG MACHINES EQUIPPED WITH DELTA Q BATTERY CHARGERS ARE DESIGNED FOR THE BEST PERFORMANCE WITH OEM FAC TORY APPROVED BATTERIES APPROVED JLG REPLACEMENT BATTERIES ARE AVAILABLE THROUGH JLG S AFTERMARKET PARTS DISTRIBUTION CEN TERS OR JLG S AFTERMARKET PROGRAMS FOR ASSISTANCE WITH PROPER BATTERY REPLACEMENT PLEASE CONTACT YOUR LOCAL JLG SUPPORT OFFICE BATTERIES APPROVED BY JLG HAVE BEEN TESTED FOR COM PATIBILITY WITH THE ALGORITHM PROGRAMMING OF THE DELTA Q BATTERY CHARGER TO OPTIMIZE BATTERY LIFE AND MACHINE CYCLE TIMES THE USE OF NON APPROVED BATTER IES IN YOUR JLG EQUIPMENT MAY RESULT IN PERFORMANCE ISSUES OR BATTERY CHARGER FAULT CODES JLG ASSUMES NO RESPONSIBILITY FOR SERVICE OR PERFORMANCE ISSUES ARISING FROM THE USE OF NON APPROVED BATTERIES Battery Maintenance Quarterly 1 Open battery compartment cover to allow access to battery terminals and vent caps wet batteries only A CAUTION WHEN ADDING WATER TO WET BATTERIES ADD WATER UNTIL ELECTROLYTE COVERS PLATES DO NOT CHARGE BAT TERIES UNLESS ELECTROLYTE COVERS THE PLATES NOTE When adding distilled water to wet batteries non metallic containers and or funnels must be used To avoid electrolyte overflow add distilled water to batteries after charging W
64. COOLANT SYSTEM NEVER WORK UNDER AN ELEVATED SIZZOR UNTIL PLATFORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING OR BOOM SAFETY PROP HAS BEEN ENGAGED BEFORE MAKING ADJUSTMENTS LUBRICATING OR PERFORMING ANY OTHER MAINTENANCE SHUT OFF ALL POWER CONTROLS BATTERY SHOULD ALWAYS BE DISCONNECTED DUR ING REPLACEMENT OF ELECTRICAL COMPONENTS e KEEP ALL SUPPORT EQUIPMENT AND ATTACH MENTS STOWED IN THEIR PROPER PLACE USE ONLY APPROVED NONFLAMMABLE CLEANING SOLVENTS JLG Lift a INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS REVISION LOG Original Issue February 5 2001 Revision April 25 2001 Revision September 17 2001 Revision June 21 2002 Revision October 15 2002 Revision December 10 2003 Revision February 17 2004 Revision May 11 2004 Revision December 21 2004 Revision January 24 2005 Revision February 2 2007 Revision April 17 2007 Revision October 11 2007 Revision November 28 2007 Revision March 17 2008 Revision January 14 2011 JLG Lift 3121122 TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT SECTION PARAGRAPH PAGE NO SECTION A INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS AA General EE 1 A B Hydraulic System 1 A C tco rete e t om Eo ostii De esit a Eh 1 a SECTION 1 SPECIFICATIONS
65. Current Limited DC Overload Current Limited MECHANICAL Operating Temperature EE 0 Housing Shock and Water Resistant Aluminum JLG Lift Battery Charger Maintenance A WARNING USE CHARGER ONLY ON BATTERY SYSTEMS WITH AN ALGO RITHM SELECTED THAT IS APPROPRIATE TO THE SPECIFIC BATTERY TYPE OTHER USAGE MAY CAUSE PERSONAL INJURY AND DAMAGE LEAD ACID BATTERIES MAY GENERATE EXPLOSIVE HYDRO GEN GAS DURING NORMAL OPERATION KEEP SPARKS FLAMES AND SMOKING MATERIALS AWAY FROM BATTERIES PROVIDE ADEQUATE VENTILATION DURING CHARGING NEVER CHARGE A FROZEN BATTERY STUDY ALL BATTERY MANUFACTURERS SPECIFIC PRECAU TIONS SUCH AS RECOMMENDED RATES OF CHARGE AND REMOVING OR NOT REMOVING CELL CAPS WHILE CHARGING A DANGER RISK OF ELECTRIC SHOCK CONNECT CHARGER POWER CORD TO AN OUTLET THAT HAS BEEN PROPERLY INSTALLED AND GROUNDED IN ACCORDANCE WITH ALL LOCAL CODES AND ORDINANCES A GROUNDED OUTLET IS REQUIRED TO REDUCE RISK OF ELECTRIC SHOCK DO NOT USE GROUND ADAPTERS OR MODIFY PLUG DO NOT TOUCH UNINSULATED PORTION OF OUTPUT CONNECTOR OR UNINSULATED BATTERY TERMINAL DISCONNECT THE AC SUPPLY BEFORE MAKING OR BREAKING THE CONNECTIONS TO THE BATTERY WHILE CHARGING DO NOT OPEN OR DISASSEMBLE CHARGER DO NOT OPERATE CHARGER IF THE AC SUPPLY CORD IS DAMAGED OR IF THE CHARGER HAS RECEIVED A SHARP BLOW BEEN DROPPED OR OTHERWISE DAMAGED IN ANY WAY REFER ALL REPAIR WORK TO QUALIFIED PERSONNEL NOT FOR USE BY CHIL DREN 1
66. DELINES General The following information is provided to assist you in the use and application of servicing and maintenance proce dures contained in this chapter Safety and Workmanship Your safety and that of others is the first consideration 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 provided Cleanliness 1 The most important single item in preserving the long service life of a machine is to keep dirt and for eign materials out of the vital components Precau tions have been taken to safeguard against this Shields covers seals and filters are provided to keep oil supplies clean however these items must be maintained on a scheduled basis in order to func tion properly 2 At any time when hydraulic oil lines are discon nected clear adjacent areas as well as the openings and fittings themselves As soon as a line or compo nent is disconnected cap or cover all openings to prevent entry of foreign matter 3 Clean and inspect all parts during servicing or main tenance and assure that all passages and openings are unobstructed Cover all parts to keep them clean Be sure all parts are clean before they are installed New parts should remain in their contain ers until they are r
67. ED UNLESS IT IS SECURED TO THE TOWING VEHICLE TO PREVENT RUNAWAY A CAUTION ENSURE THE DISCONNECT MECHANISM IS ONLY OPERATED WITH THE MACHINE AT A STANDSTILL 3 24 JLG Lift A WARNING THE GEAR DRIVE TEMPERATURE SHOULD BE CHECKED PRIOR TO ANY WORK BEING DONE THIS IS IMPORTANT IF THE GEAR DRIVE HAS RECENTLY BEEN OPERATED SINCE IT MAY BE HOT AND CAUSE INJURY A CAUTION ENSURE THE AREA SURROUNDING THE DISCONNECT IS CLEANED PRIOR TO OPERATION ENSURE THAT DIRT OR OTHER CONTAMINANTS DO NOT ENTER THE GEAR DRIVE 1 Remove the two hex head bolts from the cover _ BOLT 2 Remove the cover COVER 3 Rotate the cover to show the inside diameter 3121122 SECTION 3 CHASSIS amp SCISSOR ARMS COVER ROTATED 4 Press the cover sufficiently against the shift rod to insert the bolts at least 2 to 3 threads into the cover This will subject the shift rod to spring force 5 Install the bolts and torque 6 3 ft Ibs 8 8 Nm until they are flush with the cover 6 The sun gear shaft and input shaft are now discon nected and the machine is ready to be towed A WARNING BEFORE THE MACHINE IS SEPARATED FROM THE TOWING VEHICLE EITHER THE GEAR DRIVE HAS TO BE REENGAGED OR SUITABLE MEASURES MUST BE TAKEN TO SECURE THE MACHINE FROM MOVEMENT Engaging after Towing is Complete PRIOR TO OPERATING THE DISCONNECT THE MACHINE HAS TO BE ON LE
68. ER Figure 6 19 Electrical Components Installation Sheet 2 of 4 3121122 JLG Lift 6 13 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS TO GENERATOR MODULE M3369 amp M4069 23 AAR VALVE HARNESS TO PLATFORM GROUND CONTROL BOX Figure 6 20 Electrical Components Installation Sheet 3 of 4 3121122 JLG Lift 6 14 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS DRIVE CONTACTOR DRIVE CONTROLLER CIRCUIT BREAKER RECEPTACLE AT PLATFORM PLATFORM WORKLIGHTS Figure 6 21 Electrical Components Installation Sheet 4 of 4 3121122 JLG Lift 6 15 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 6 16 WHT RFD 57 5 A A A hi 25 5 28 5 5 5 5 2 Ff SG 25 PLATFORM DISPLAY 3 uum quam Se 52 GS
69. FT PERMANENTLY SELECTED Lift select switch in the platform control box closed at start up or for more than ten seconds Release switch to clear fault 2236 FUNCTION PROBLEM O R PERMANENTLY SELECTED An outrigger select switch in the platform control box closed start up or for more than ten seconds Release switch to clear fault 2237 JOYSTICK FAULTY STEER SWITCHES ACTIVE TOGETHER Both the steer left and steer rightinputs are closed at the same time A short in the steer switch wiring or a failed steer switch can cause this 2238 FUNCTIONS LOCKED OUT SHORT TO PLATFORM ROW INPUT A short circuit to IGN has been detected in the platform cable wiring 2239 FUNCTION PROBLEM JOYSTICK CALIBRATION FAULTY The Personalities for theJoystick are improperly adjusted or a joystick calibration attempt failed Re adjust or recalibrate 224 FUNCTION PROBLEM STEERLEFT PERMANENTLY SELECTED Steer left switch in the platform control box closed at start up Release switch to clear fault 225 FUNCTION PROBLEM STEER RIGHT PERMANENTLY SELECTED Steer right switch in the platform control box closed at start up Release switch to clear fault 226 ACCELERATOR or JOYSTICK FAULTY WIPER OUT OF RANGE The joystick wiper signal inputis outside the acceptable voltage range The wiper wire being off the wiper wire shorted to battery power or the wiper wire shorted to battery negative could cause this 228 FUNCTION LOCKED OUT JOYSTICK NOT CENTERED Selected function
70. HOURS MONTHLY 500 HOURS 3 MONTHS 1000 HOURS 6 MONTHS 1 Controller 1 11 2 Switches 1 11 3 Placards and Decals 1 2 4 Control Tags 1 2 5 Hoses and Cables 1 5 8 6 Wear Pads 7 Handrail and Chains CHASSIS 1 Batteries 2 Battery Charger 3 Hydraulic Pump Motor 4 Valves 5 Hydraulic Filter Also see note 6 Hydraulic Hoses and Tubing 7 Hydraulic Oil Tank 8 Breather Hydraulic Tank 9 Lift Cylinder 10 Limit Switch 1 7 11 Placards and Decals 1 2 12 Wheel and Tire Assemblies 8 9 13 Drive Motors 1 5 1 6 14 Drive Torque Hubs 1 3 5 1 3 5 6 15 Drive Brakes 1 6 16 Steer Cylinder 5 6 13 17 Steer Components 4 6 18 Wheel Bearings 4 9 Sizzor Arms 1 4 20 Safety Prop 1 4 21 Wear Pads 22 Pivot Pins Bolts 1 4 7 8 23 Switches Ground Control 1 11 24 Control Tags 12 25 Hose and Cable 1 4 8 nspection and Maintenance Code 10 to be performed annually JLG Lift NOTE If function speeds are slow on a fully charged machine a clogged filter may be indicated Change filter 3121122 SECTION 3 CHASSIS amp SCISSOR ARMS 3 1 SECTION 3 CHASSIS amp SCISSOR ARMS CALIBRATIONS Elevation Sensor Calibration Prior to Software V
71. ION 1 SPECIFICATIONS Magni Coating Ref 4150701 CLASS 12 9 SOCKET HEAD CAP SCREWS M6 AND ABOVE i TM I Tensile Dry or Loctite 242 or 271 Loctite 262 Size PITCH Stress OR Vibra TITE Anda OR Vibra TITE SEH pe or 140 15 678 78 8 78 36 60 12 5 18 0 22 8 36 1 52 5 115 e as mm sen em m NO 5000059 REV J NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED Figure 1 9 Torque Chart METRIC Fasteners Sheet 7 of 7 1 12 Lift 3121122 SECTION 2 GENERAL SECTION 2 GENERAL 2 1 MACHINE PREPARATION INSPECTION AND MAINTENANCE General This section provides the necessary information needed by those personnel that are responsible to place the machine in operation readiness and maintain its safe operating condition For maximum service life and safe operation ensure that all the necessary inspections and maintenance have been completed before placing the machine into service Preparation Inspectio
72. JLG Lift TABLE OF CONTENTS Continued 6 29 Hydraulic Diagram 4069LE and M4069 Oscillating 6 23 6 30 5 Lene NR Gad ER ade de ee a 6 24 LIST OF TABLES TABLE NO TITLE PAGE NO 1 1 Operating 5 n 1 1 1 2 Capacitl8eg uve EE Ee 1 2 1 3 Pressure Settings us ected pee ces ve ark Rose Lr aot eroe tee 1 2 1 4 Torque Spe cificalions c vL er hd be Sy ee ELEME LORS 1 2 1 5 Hydra liC Oil eee e ttem ey du ERU D dee 1 2 1 6 Lubrication 4 1 3 1 7 Mobil DTE 11M Specs ur en iR IEEE RE EXPE bI e arx ede 1 3 1 8 Cylinder Specifications reri E a eee a ce POSEE LR 1 3 1 9 Major Component Weights 1 3 1 10 Critical Stability 2 22 2 2 1 3 1 11 Lubrication Chart END Pan qoid Na Rae cepe PME 1 4 2 1 Inspection and Maimtenance m 2 2 2 2 Cylitider DIE ois Pe dn Rd book Lgs 2 4 2 3 Preventive Maintenance and Inspection Schedule 2 6 3 1 Tilt Sensor Harness Chart RE ere nile wath ys en 3 4 3
73. LATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED Figure 1 6 Torque Chart SAE Fasteners Sheet 4 of 7 JLG Lift SECTION 1 SPEC IFICATIONS Tensile Stress Area Values for Zinc Yellow Chromate Fasteners Ref 4150707 CLASS 8 8 METRIC BOLTS CLASS 8 METRIC NUTS Torque Loctite Loctite 2627 242 271 OR Vibra OR Vibra TITE 131 TITE 111 140 561 3 694 302 0 1990 1490 2090 14 23 0 7 8 78 3 82 3 4 6 8 6 0 874 n 79 12 19 125 36 60 15 9 28 55 12 175 8430 367 ss 66 97 154 241 331 469 22 303 639 24 353 811 27 459 1130 30 1530 33 36 42 5 i 4 817 355 5 2560 1920 2690 5 42 4 1120 487 0 4090 3070 4290 NO 5000059 REV J NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED Figure 1 7 Torque Chart METRIC Fasteners Sheet 5 of 7 JLG Lift
74. Locking Contacts Into Position NOTE For unused wire cavities insert sealing plugs for full environmental sealing HD30 HDP20 Series Disassembly zT Figure 6 16 HD HDP Contact Removal With rear insert toward you snap appropriate size extractor tool over the wire of contact to be removed 11 12 Slide tool along into the insert cavity until it engages contact and resistance is felt 18 Pull contact wire assembly out of connector TOOL INSERTED TO TOOL AND CONTACT UNLOCK CONTACT REMOVED Figure 6 17 HD HDP Unlocking Contacts NOTE Do Not twist or insert tool at an angle 3121122 JLG Lift 6 11 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS PUMP MOTOR gt DRIVE CONTACTOR BATTERY CHARGER PRESSURE TRANSDUCER OR gt OVERLOAD Rg ee CUT OUT Figure 6 18 Electrical Components Installation Sheet 1 of 4 6 12 JLG Lift 3121122 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS MOTOR GENERATOR GENERATOR MODULE TO ANALYZER PROXIMITY SENSOR SWITCH USA BUILT MACHINES S N 0200138293 TO PRESENT PROXIMITY SENSOR SWITCH USA BUILT OSCILLATING A MACHINES PRIOR TO AXLE S N 0200138293 amp ALL CYLINDERS S gt E BELGIUM BUILT MACHINES GROUND CONTROL BOX PC BOARD CONTROLLER ANALYZ
75. MENT 3 1 310 LINE CONTACTOR OPEN CIRCUIT 311 OPEN CIRCUIT LINE CONTACTOR Line contactor did not close 313 OPEN CIRCUIT PUMP CONTACTOR Pump contactor did not close 3 2 320 LINE CONTACTOR SHORT CIRCUIT 321 LINE CONTACTOR MISWIRED ON OR WELDED The line contactor is permanently closed or the coil is wired improperly 323 PUMP CONTACTOR MISWIRED ON OR WELDED The pump contactor is permanently closed or the auxiliary contacts are wired improperly 3 3 330 GROUND OUTPUT DRIVER 33330 SHORT CIRCUIT LINE PUMP CONTACTOR COIL The line or pump contactor coils are shorted to ground or mis wired 4 2 420 THERMAL LIMIT 421 POWER MODULE TOO HOT PLEASE WAIT The power module over the rear axle is too hot Allow to cool by powering down 425 POWER CONVERTER TOO HOT PLEASE WAIT Switching power supply in ground control box too hot Allow to cool by powering down to clear fault JLG Lift 3121122 SECTION 5 JLG CONTROL SYSTEM Table 5 1 Flash Codes DTC s FLASH CODE DTC HELP MESSAGE AND DESCRIPTION 4 4 440 BATTERY SUPPLY 441 BATTERY VOLTAGE TOOLOW SYSTEM SHUTDOWN Recharge batteries or check for damaged batteries 442 BATTERY VOLTAGE TOO HIGH SYSTEM SHUTDOWN Disconnect battery charger Check that the correct voltage batteries are being used N A BATTERY CHARGE TOOLOW SYSTEM SHUTDOWN 6 6 660 COMMUNICATION 661 CANBUS FAILURE POWER MODULE Lost communication to power module Check wiring at ground control and power module Recycle p
76. MG An Oshkosh Corporation Company Service amp Maintenance Manual Models 3369LE 4069LE M3369 M4069 3121122 January 14 2011 MG An Oshkosh Corporation Company INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS SECTION A INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS A A GENERAL This section contains the general safety precautions which must be observed during maintenance of the aerial platform It is of utmost importance that main tenance personnel pay strict attention to these warn ings and precautions to avoid possible injury to themselves or others or damage to the equipment A maintenance program must be followed to ensure that the machine is safe to operate A WARNING MODIFICATION OF THE MACHINE WITHOUT CERTIFI CATION BY A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST AS SAFE AS ORIGINALLY MANUFACTURED IS A SAFETY VIOLATION The specific precautions to be observed during maintenance are inserted at the appropriate point in the manual These precautions are for the most part those that apply when servicing hydraulic and larger machine component parts Your safety and that of others is the first consider ation when engaging in the maintenance of equip ment Always be conscious of weight Never attempt to move heavy parts without the aid of a mechanical device Do not allow heavy objects to rest in an unstable position When raising a portion of the equipment ensure that adequate support is pr
77. MY 3 3121122 SECTION 3 CHASSIS amp SCISSOR ARMS Tilt Sensor JLG P N 4000021 1 Ground Control Box 2 Tilt Sensor Assembly JLG P N 1810140 Figure 3 3 Tilt Sensor Location NOTE Refer to Figure 3 4 Tilt Sensor Removal for num bers in parenthesis a Tilt Sensor JLG P N 4000021 Sensor Mount 1 Disconnect the batteries Screw 6 32 x 1 2 Open the Ground Control Box to gain access to the Tilt Sensor Assembly Lockwasher Standoff Insulator Washer 0 313 x 0 250 Nylon Screw M3 5 x 0 6 x 10 3 Remove the four Screws 3 Lockwashers 4 Standoff Insulators 5 and Washers 6 to remove the Tilt Sensor 1 and Sensor Mount 2 from the Ground Control Box a N 4 The Tilt Sensor 1 can be removed from the Sensor Figure 3 4 Tilt Sensor Removal Mount 2 by removing the three Screws 7 9 NOTE Follow the above procedures in reverse order when installing the tilt sensor assembly After installing be sure to calibrate the tilt sensor refer to Section 3 1 Table 3 2 Tilt Sensor Harness Calibrations Wire Color Function Connector Pin Red VCC 1 Green PWMX 2 White PWMY 3 Black Ground 4 3121122 JLG Lift 3 5 SECTION 3 CHASSIS amp SCISSOR ARMS 3 3 BATTERY MAINTENANCE AND CHARGING A WARNING IF REPLACING A
78. NDER ASSEMBLIES Barrel Weldment 2 Rod Weldment 3 Garmax Bushings 4 Locknut 5 Piston 6 O Ring 7 Wear Ring 8 Seal 9 Spacer 10 Head 11 Wear Ring 12 Back Up Ring 13 O Ring 14 O Ring 15 Seal 16 Wiper 17 Check Restrictor Valve 18 Manual Descent Cable 19 Jam Nut 1 4 28F 20 Flatwasher 1 4 21 Bracket 22 Bolt 5 16 18NC x 3 4 23 Cotter Pin 1 8 x 1 1 4 24 Adapter 25 Solenoid Valve Figure 4 11 Lift Cylinder 3369LE amp M3369 NOTE Torque Locknut 4 to 1125 1375 ft Ibs 1525 3 1864 Nm Approximate cylinder dry weight 220 Ibs 99 8 kg HOLDING CHECK Operating Pressure 2100 psi 145 bar m VALVE 4 12 JLG Lift 3121122 SECTION 4 HYDRAULICS a Barrel Weldment 2 Rod Weldment 3 Garmax Bushings 22 CYLINDER a 4 Locnut OR 5 Piston GH 7 Wear Ring 8 Seal 9 Spacer 10 Head 11 Wear Ring 12 Back Up Ring 13 O Ring 14 O Ring 15 Seal 16 Wiper 17 Relief Valve 18 Manual Descent Cable 19 Flatwasher 1 4 20 Jam Nut 1 4 28NF 21 Bracket 22 Bolt 5 16 18NC x 3 4 23 Cotter Pin 1 8 x 1 1 4 24 Adapter 25 Solenoid Valve Lower Cylinder 26 Solenoid Valve Upper Cylinder Figure 4 12 Lift Cylinder 4069LE amp M4069 NOTE Torque Locknut 4 to 1125 1375 ft Ibs 1525 3 1864
79. Nm Approximate cylinder dry weight 224 Ibs 101 6 kg Operating Pressure 2100 psi 145 bar 3121122 JLG Lift 4 13 SECTION 4 HYDRAULICS 21 M e bk o Im n cn ech cn cl c n xb IX OV ru deus 29 Cylinder Barrel Jack Pad Special Screw 1 2 13NC x 1 1 4 Cylinder Rod Retaining Ring Plate End Cap Locknut Piston Flatwasher 1 1 4 Wear Ring Piston Seal O Ring Head Wear Ring O Ring Polyseal Wiper Seal Plug Counter Balance Valve see note Check Valve see note Figure 4 13 Leveling Jack Cylinder USA Built Machines S N 0200112735 to Present NOTE Torque Locknut 8 to 400 ft Ibs 542 3 Nm Torque Counter Balance Valve 20 and Check Valve 4 14 21 to 30 35 ft Ib 40 47 Nm When servicing apply a light coat of grease to the Jack Pad 2 before installing JLG Lift 8 0 1 E e L 1 e gt SCHEMATIC FOR PORT BLOCK 3121122 SECTION 4 HYDRAULICS a Cylinder Barrel Jack Pad Special Screw 1 2 13NC x 1 1 4 Cylinder Rod Retaining Ring Plate End Cap Head Hydrolock o0 uod PF oO Wiper Seal 11 O Ring 12 Wear Ring 13 Locknut 14 Flatwasher 1 1 4 15 Piston 16 Guidelock 17 Polyseal 18 O Ring 19 Plugs 20 Counter Balance Valve see not
80. ORMANCE OF YOUR MACHINE The flash code is indicated on the face of the platform control box as shown SYSTEM FAULT NOTE For machines with software prior to P1 0 flash codes are also displayed on the handheld analyzer For descriptions see Table 5 1 Flash Codes DTC s IT IS A GOOD PRACTICE TO AVOID PRESSURE WASHING ELEC TRICAL ELECTRONIC COMPONENTS SHOULD PRESSURE WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRI CAL ELECTRONIC COMPONENTS JLG INDUSTRIES INC REC OMMENDS A MAXIMUM PRESSURE OF 750 PSI 52 BAR AT A MINIMUM DISTANCE OF 12 INCHES 30 5 CM AWAY FROM THESE COMPONENTS IF ELECTRICAL ELECTRONIC COMPONENTS ARE SPRAYED SPRAYING MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION 3121122 5 2 PC BOARDS PCB JLG P N 0610143 Figure 5 2 PC Boards NOTE Figure 5 2 PC Boards is shown for part distinguish ing purposes PC Board p n 1001099428 is used on machines with Software P1 0 and higher PC Board p n 0610143 is used on machines prior to Software P1 0 Visually reference the circuits and chips circled in Figure 5 2 to determine which PC Board is in the machine JLG Lift 5 5 SECTION 5 JLG CONTROL SYSTEM 5 3 FLASH CODES DTC S AND DESCRIPTIONS NOTE Machines with software prior to P1 0 will display the NOTE Diagnostic Trouble Codes DTC s will only show Flash Code on the JLG Analyzer as shown below machines with software P1 0 and a
81. OUT is set to 0 NO 004 DRIVING AT CUTBACK ABOVE ELEVATION Platform is elevated and the machine is in the drive mode of operation 005 DRIVE amp LIFT UP PREVENTED TILTED amp ELEVATED Machine is exceeding tilt allowance and platform is elevated above allowed height Applicable when Machine Setup s TILT CUTOUTis setto 1 YES 009 DRIVE PREVENTED ELEVATED ABOVE DRIVE CUTOUT HEIGHT Machinis elevated above the drive cutout height Not applicable when Machine Setup s MODEL is set to 0 3369LE JLG Lift 3121122 SECTION 5 JLG CONTROL SYSTEM Table 5 1 Flash Codes DTC s FLASHCODE DTC HELP MESSAGE AND DESCRIPTION 2 1 210 POWER UP 211 POWER CYCLE Anew system power up has occurred since the last help message 212 KEYSWITCH FAULTY Both Platform and Ground modes are selected simultaneously 2 2 220 PLATFORM CONTROLS 221 FUNCTION PROBLEM HORN PERMANENTLY SELECTED Horn switch in platform control box closed at start up Release switch to clear fault 2210 TRIGGERCLOSED TOOLONG WHILE IN NEUTRAL Trigger switch in the platform control box closed for more than ten seconds while the joystick is in the neutral position Release switch to clear fault 2234 FUNCTION PROBLEM DRIVE PERMANENTLY SELECTED Drive select switch in the platform control box closed at start up or for more than ten seconds Release switch to clear fault 2235 FUNCTION PROBLEM LI
82. OUTPUT 23 IGN Ignition Power 12V POWER OUTPUT 24 GND Ground POWER OUTPUT 25 GND Ground POWER OUTPUT 26 PWRON Power On GNDS or PLTE Powered 1 8A Limit POWER OUTPUT 27 IGN Ignition Power 12V POWER OUTPUT 28 IGN Ignition Power 12V POWER OUTPUT 29 GND Ground POWER OUTPUT 30 GND Ground POWER OUTPUT 31 CHGI Charger Interlock Input DIGITAL INPUT 32 DI9 Spare High Sensing Digital Input 9 DIGITAL INPUT 33 0110 Spare High Sensing Digital Input 10 DIGITAL INPUT 34 DI11 Spare High Sensing Digitallnput 11 DIGITAL INPUT 35 D017 Spare High Sensing Digital Output 17 12V 5A DIGITAL OUTPUT 36 D018 Spare High Sensing Digital Output 18 12V 5A DIGITAL OUTPUT 37 4WAF 4 Wheel Assist Forward Solenoid Valve DIGITAL OUTPUT JLG Lift 3121122 SECTION 5 JLG CONTROL SYSTEM Table 5 12 J2 Connector PIN TAGNAME FUNCTION TYPE 38 4AWR 4 Wheel Assist Reverse Solenoid Valve DIGITAL OUTPUT 39 OSAX Oscillating Axle Solenoid Valves DIGITAL OUTPUT 40 D022 Spare High Side Digital Otput 22 12V 5A DIGITAL OUTPUT Table 5 13 J3 Connector PIN TAGNAME FUNCTION TYPE 1 0023 High Side Digital Output 23 12V 5A DIGITAL OUTPUT 2 0024 High Side Digital Output 24 12V 5A DIGITAL OUTPUT 3 D025 High Side Digital Output 25 12V 5A DIGITAL OUTPUT 4 0026 High Side Digital Output 26 12V 5A DIGITAL OUTPUT 5 DI12 High Sensing Digit
83. OUTPUTS ARE I2VDC EXCEPT WERE NOTED 2 ALL INPUTS ARE 12VDC EXCEPT WERE NOTED 1870130 F 3121122 Figure 6 23 Electrical Schematic Sheet 2 of 2 JLG Lift 6 17 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS ce ET lt lt a o o d o 5 E x xu EI S x lt 5 o m 5 e I S gt gt a lt lt 9 8 3 51 1 1 8 65 8 mu S lt 2 45 DN lt uu 4 o lt a Luo o o fut o 5 r 5 Ze EE E EE EE D ER d E E E EE EE EE EE Sk op qq EE EE EE _ lli 3 a al pum sl T PO YR EES Lk P H e LFL aks 1 PES 1 02 5 8 gt Dim 2225 9 i 8 s lt 5 g3 T 89 836 5 19 2 a 5 2 I 5 A 2 lt 8 w Z 2 ERR 2 5 S en
84. P OONN O 19 Sun Gear Shaft Nut Planet Bolt Support Ring Planet Carrier Cover Not Used Roller Bearing Roller Bearing Tapered Roller Bearing Not Used Retaining Ring Retaining Ring Retaining Ring 17 Support Disc 18 Not Used 19 O Ring 20 Ring Seal 21 Screw Plug 22 Seal Ring 23 Bolt 24 Ball 25 Expander 26 thru 29 Not Used 30 Ring Gear 31 thru 32 Not Used 33 O Ring 34 Spring 35 thru 42 Not Used 43 Sun Gear 44 45 t 49 50 51 52 53 54 55 56 57 1 59 60 61 62 63 Figure 3 15 Torque Hub JLG Lift 8 34 Input Shaft hru 48 Not Used Washer Not Used Cover Disc Bolt Ball Pressure Spring Shaft Rod hru 58 Not Used Rotor Disc Spindle Brake Coupler Not Used 64 Plate Back Up 65 Plate Back Up 66 Retaining Ring 67 Retaining Ring 68 thru 70 Not Used 71 Plug 72 thru 80 Not Used 81 Bearing 82 Retaining Ring 83 Retaining Rings 84 Ring Seal 85 thru 87 Not Used 88 Stud Wheel 89 thru 98 Not Used 99 Plug 3121122 SECTION 3 CHASSIS amp SCISSOR ARMS 3 8 DRIVE HUB The final drive consists of two stages with an integrated disconnect mechanism Each stage incorporates a set of matched planetary gears which provide an equal load of distribution All torque trans
85. Place the Planet Gear Sub assembly into the Carrier Visually align the planet gear bore with one of the planet shaft holes on the Carrier Insert a Planet Shaft 2 into the planet shaft hole described in Step 8 on the Carrier The end of the planet shaft that does NOT have the roll pin hole should be inserted into the Carrier FIRST Now insert the Planet Shaft through the first set of Thrust Washers Planet Gear then the second set of Thrust Washers Use an alignment punch or similar tool to align the roll pin holes on the Carrier and Planet Shaft Be sure not to hit the Planet Gears when driving in the Roll Pins 1 Drive the Roll Pin down into the aligned roll pin holes Pin should be flush with OD of Carrier Repeat Steps 7 11 for the installation of the two remaining Planet Gears 3 39 SECTION 3 CHASSIS amp SCISSOR ARMS Hub Spindle Sub Assembly Spindle Retaining Ring Spacer Bearing Cone Bearing Cup Hub Boot Seal Studs Bearing Cone 9 PER ASSEMBLY Figure 3 24 Hub Spindle Sub Assembly NOTE Apply a light coat of oil on all component parts dur 6 Press Seal Boot 7 onto Hub if required Turn Hub ing assembly over and lower onto Spindle 1 7 Install Bearing Cone 4 into Bearing Cup position 1 Place the Hub 6 into a pressing base Press 9 9 4 Studs 8 into the Hub 8 Place Bearing Spacer 3 on top of Bearing Cone NOTE Use eno
86. S LAAT 133 8 OL ONIS ATA ISAL edeos3 88914 SAL WALSAS Nf I 1601 Auo uondo en WHZKIVNV ME 014 TI SMIVES ATTE HDD AM SALVIS NOT Au wt WOULSAOL OW 0163 0 NOII 0 0 DECH 110119 T 1 0 TILL SISSVH dl T 1 0 XXe DU 1019 FINI NOI O 413410 WH9WVH 990 3 0 avol dl 14 0 MINIS IVAH UD LOND ATTA 280 Sud 4140 Ke Wow won ASISSV MP WAVIV DM 30011 EECH A T 149 NG LITT 113 ANA 0140 IS IINE A TWO 140 LIII WIVIV 14114165 WINGY A TWO 1406 avd TV 1460 MOTI 4084 MOUK NAOH ATA NYOH d l TAS 3345 Ll A TV MOIS HI 13315 A 13818 DO 4804
87. T PRESSURE WASH ING THE MACHINE IS NEEDED ENSURE THE MACHINE IS SHUT DOWN BEFORE PRESSURE WASHING SHOULD PRESSURE WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRICAL ELECTRONIC COMPONENTS JLG INDUSTRIES INC RECOMMENDS A MAXI MUM PRESSURE OF 750 PSI 52 BAR AT A MINIMUM DISTANCE OF 12 INCHES 30 5 CM AWAY FROM THESE COMPONENTS IF ELEC TRICAL ELECTRONIC COMPONENTS ARE SPRAYED SPRAYING MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION 6 2 MULTIMETER BASICS A wide variety of multimeters or Volt Ohm Meters VOM can be used for troubleshooting your equipment A digital meter with reasonable accuracy within 796 is recommended for the measurements in these procedures This section shows dia grams of a common digital VOM configured for several different circuit measurements Instructions for your VOM may vary Please consult the meter operator s manual for more information Grounding Grounding the meter means to take the black lead which is connected to the COM common or negative port and touch it to a good path to the negative side of the voltage source Backprobing To backprobe means to take the measurement by accessing a connector s contact on the same side as the wires the back of the connector Readings can be done while maintaining circuit continuity this way If the connector is the sealed type great care must be taken to avoid damaging the seal around the wire It is best to use probes or p
88. UT 14 FRD Front Right O R Down Solenoid Valve DIGITAL OUTPUT 15 RLU Rear Left O R Up Solenoid Valve DIGITAL OUTPUT 16 RLD Rear Left O R Down Solenoid Valve DIGITAL OUTPUT 17 RRU Rear Right O R Up Solenoid Valve DIGITAL OUTPUT 18 RRD Front Right O R Down Solenoid Valve DIGITAL OUTPUT 19 GMST Generator Manual Start to J5 13 POWER 10 20 GINH Generator Inhibit Start to J1 21 POWER 10 21 GFLT Generator Fault LED to J5 14 POWER 10 22 GNDE Ground EMS from J5 2 500mA Limit POWER OUTPUT 23 GND Ground POWER OUTPUT 24 GND Ground POWER OUTPUT 3121122 JLG Lift 5 21 SECTION 5 JLG CONTROL SYSTEM 5 22 Table 5 8 J4 Connector PIN TAGNAME FUNCTION TYPE 1 12V 12V Sensor Supply POWER OUTPUT 2 TILTX X Axis Tilt Input PWM ANALOG INPUT 3 TILTY Y Axis Tilt Input PWM ANALOG INPUT 4 GND Ground POWER OUTPUT Table 5 9 J5 Connector PIN TAGNAME FUNCTION TYPE 1 B Master Supply Connection from J2 1 POWER OUTPUT 2 GNDE Ground EMS to J1 20 J3 22 POWER INPUT 3 PLTS Platform Select Input to J1 1 POWER INPUT 4 GNDS Ground Select Input POWER INPUT 5 IGN Ignition Power 12V POWER OUTPUT 6 GND Ground POWER OUTPUT 7 UPG Ground Lift Up Switch DIGITAL INPUT 8 DNG Ground Lift Down Switch DIGITAL INPUT 9 FDH Full Drive Height Input DIGITAL INPUT 10 DI19 High Sensing Digitallnput 19 DIGITAL INPUT 11
89. V SENSOR press ENTER Check to see that the following items are reading correctly ANGLE SNSR 0 40 0 45 ZEROED 0 00V SENSOR OK STOWED YES ELEVATED NO DRIVE YES CALIB 0 40 0 45 If CALIB reads whatever you set your rotary switch to 0 40 0 45 then press ENTER Press ESCAPE until you arrive at DIAGNOSTICS then scroll over to top level menu SET ELV SEN SOR press ENTER an alarm will sound off if your machine is equipped with one The analyzer will now ask to SET ELEV SENSOR At this point press ENTER key If everything tested properly the ana lyzer will read COMPLETE Now lift the machine up until it stops lifting measure the cutback height M3369 3369LE 8 ft 9 5 ft 2 4 2 9 m M4069 4069LE 9 5 ft 11 7 ft 2 9 3 6 m 3 1 SECTION 3 CHASSIS amp SCISSOR ARMS 13 Press ESCAPE remove analyzer and assure all hardware is tight Elevation Sensor Calibration Software V13 6 and Higher Using the Analyzer in Access Level 1 go to MENU CALI BRATION 1 SET STOW ELEV a Completely lower platform to stowed position b Enter YES on the Analyzer c COMPLETE will show on the analyzer when cali brated 2 SET 25FT ELEV 3369LE or SET 30FT ELEV 4069LE a Raise platform to a height of 25 feet for the 3369LE or 30 feet for the 4069LE measured deck to ground b Enter YES on the Analyzer c COMPLETE will show on the analyzer when cali brated 3 SET 30FT ELEV 3369LE
90. VEL GROUND AND COMPLETELY SECURED FROM ANY MOVEMENT I E VIA TOW BAR TO PULLING VEHICLE THE MACHINE SHOULD NOT BE MOVED UNLESS IT IS SECURED TO THE TOWING VEHICLE TO PREVENT RUNAWAY 3121122 A CAUTION ENSURE THE DISCONNECT MECHANISM IS ONLY OPERATED WITH THE MACHINE AT A STAND STILL A WARNING THE GEAR DRIVE TEMPERATURE SHOULD BE CHECKED PRIOR TO ANY WORK BEING DONE THIS IS IMPORTANT IF THE GEAR DRIVE HAS RECENTLY BEEN OPERATED SINCE IT MAY BE HOT AND CAUSE INJURY A CAUTION ENSURE THE AREA SURROUNDING THE DISCONNECT IS CLEANED PRIOR TO OPERATION ENSURE THAT DIRT OR OTHER CONTAMINANTS DO NOT ENTER THE GEAR DRIVE A WARNING THE COVER IS UNDER SPRING FORCE 1 Remove the 2 hex head bolts securing the cover evenly and remove the cover 2 Rotate the cover 180 and secure with the two hex head bolts 3 Torque the hex head bolts 6 3 ft Ibs 8 8 Nm PULL VERY SLOWLY WITH THE TOWING VEHICLE CONNECTED TO THE MACHINE TO ALLOW THE SPLINE OF THE SUN GEAR SHAFT TO ENGAGE WITH THE SPLINE OF THE INPUT SHAFT A CAUTION DO NOT OPERATE THE MOTOR TO MAKE THE SUN GEAR SHAFT TO ENGAGE WITH THE SPLINE OF THE INPUT SHAFT 4 Check to ensure all bolts are tight and all compo nents are returned to their original positions 5 The gear drive should now be reengaged and the machine can be disconnected from the towing vehi cle JLG Lift 3 25 SECTION 3 CHASSIS amp SCISSOR ARMS 3 26 AIDE Ch eeh DATA O O
91. a 5 32 Allen key Next remove the cable clamp from the harness 5 32 Allen Key EN Wire Side cutters Crimping tool Procedure A WARNING BEFORE BEGINNING THIS PROCEDURE ENSURE THAT ALL SOURCES OF POWER ARE DISCONNECTED FROM THE APU This procedure is common for all applications of the APU The photos contained in this document illustrate the mod ification performed to an APU supplied in a JLG M450 lift 1 Locate the harness at the rear of the APU 3121122 JLG Lift 3 19 SECTION 3 CHASSIS amp SCISSOR ARMS 4 Cut and remove the Wire Ties holding the Harness 5 Cut wire 106 going to the Engine Generator Control label to the harness Next remove the Wire Ties so ler after the existing connection point and install the that the cable sleeve can be moved exposing the conductors that lead to the new inline fuse holder conductors of the harness Use insulated butt splice connectors for these con ductors 7 Reconnect the lift and APU start battery The APU is now ready for use 3 20 JLG Lift 3121122 SECTION 3 CHASSIS amp SCISSOR ARMS 3 6 JOYSTICK CONTROLLER 150 ohm 2W WIPER 150 ohm 2W TER TAP GGER SUPPLY TRIGGER GGER SWITCH SWITCHES STEER LEFT V SUPPLY STEER STEER RIGHT ROCKER SWITCHES Figure 3 11 Joystick Controller JLG P N 1600308
92. ad 38 44 sec 54 62 sec Lowering Speed no load 43 48 sec 49 51 sec Gradeability platform stowed 35 Turning Radius Inside 7 5 ft 2 3 Outside 16 ft 4 9 m Maximum Platform Capacity Platform ANSI CSA Brazil 1000 Ibs 454kg ANSI CSA Brazil 800 Ibs 363kg CE AUS 1000 Ibs 450kg CE AUS 800 Ibs 360kg Platform Extension ANSI CSA Brazil 250105 113kg ANSI CSA Brazil 250 Ibs 113kg CE AUS 250105 120kg CE AUS 250 Ibs 120kg Maximum Ground Bearing Pressure 57 psi 4 bar 61 psi 4 3 bar Maximum Tire Load 3200 Ibs 1452 kg 3700105 1680 kg Maximum Hydraulic System Pressure 3000 psi 207 bar Electrical System Voltage 48Vdc Maximum Horizontal Manual Side Force 150 Ib force 667 N 120 0 force 534 Tilt Sensor Setting Side to Side 3 Fore and Aft Ground Clearance 8in 20cm Wheelbase 91 5in 2 3 Machine Height w rails folded 76 5in 1 9 m 79 in 2 01 Machine Length stowed 121 in 3 1 m Machine Width 69 in 1 75 m 3121122 Lift SECTION 1 SPECIFICATIONS 1 2 CAPACITIES Table 1 2 Capacities 3369LE M3369 4069LE M4069 8 25 gal 31 2 liters 5 4 gal 20 4 liters full mark approx 8 5 gal 32 1 liters Description Hydraulic Tank Hydraulic System Torque Hubs 2 17 ounces 0 5 liters 1 3 PRESSURE SETTINGS Table 1 3 Pressure Settings Description 33
93. al Input 12 DIGITAL INPUT 6 DI13 High Sensing Digital Input 13 DIGITAL INPUT 7 IGN Ignition Power 4 12V POWER OUTPUT 8 ORSTO Outrigger Set Input DIGITAL INPUT 9 ORSET Outrigger Stow Input DIGITAL INPUT 10 IGN Ignition Power 4 12V POWER OUTPUT 11 FLU Front Left O R Up Solenoid Valve DIGITAL OUTPUT 12 FLD Front Left O R Down Solenoid Valve DIGITAL OUTPUT 13 FRU Front Right 0 R Up Solenoid Valve DIGITAL OUTPUT 14 FRD Front Right O R Down Solenoid Valve DIGITAL OUTPUT 15 RLU Rear Left O R Up Solenoid Valve DIGITAL OUTPUT 16 RLD Rear Left O R Down Solenoid Valve DIGITAL OUTPUT 17 RRU Rear Right O R Up Solenoid Valve DIGITAL OUTPUT 18 RRD Front Right O R Down Solenoid Valve DIGITAL OUTPUT 19 GMST Generator Manual Start to J5 13 POWER 10 20 GINH Generator Inhibit Start to J1 21 POWER 10 21 GFLT Generator Fault LED to J5 14 POWER 10 22 GNDE Ground EMS from J5 2 500mA Limit POWER OUTPUT 23 GND Ground POWER OUTPUT 24 GND Ground POWER OUTPUT 3121122 JLG Lift 5 25 SECTION 5 JLG CONTROL SYSTEM 5 26 Table 5 14 J4 Connector PIN TAGNAME FUNCTION TYPE 1 12V 12V Sensor Supply POWER OUTPUT 2 TILTX X Axis Tilt Input PWM ANALOG INPUT 3 TILTY Y Axis Tilt Input PWM ANALOG INPUT 4 GND Ground POWER OUTPUT Table 5 15 J5 Connector PIN TAGNAME FUNCTION TYPE 1 B Master Supply Connection
94. ant Illumination No Fault Normal Condition LED Extinguished Internal Controller Fault 1 Flash Personality Out of Range 2 Flashes Illegal Start Condition or Illegal Steer Switch Input 3 Flashes MOSFET Short Circuit 4 Flashes Contactor Faultor Motor Open Circuit 5 Flashes Not Used 6 Flashes Accelerator Steer Potor Speed Probe Wire Default 7 Flashes Low or High Battery Voltage or BDI Cut Out Operating 8Flashes Over Temperature 9 Flashes Contactor Coil Short Circuit 12 Flashes CAN Bus Fault JLG Lift 3121122 SECTION 5 JLG CONTROL SYSTEM JO 19995 X LA MS HEYD Joz Ajeuy 2 6 911614 11866 QHOMSSVd H31N3 LSNW HO1VH3dO JHL 51831 W31SAS OL H3QHO NI 31ON pON uuopeld ur 1691 xxx vum POW 1891 um uondo OL MOVA TIN JO SALVIS NDI Se Ol Luel OLIVA eq d A Our OL UN VAP AVI 4740 mua pe 5 ____ GE da E OL 04181011 SS oC MIN 01 MIND NA Y4 4 0 10011 DU NW SISAL TIN 4014 1531 4 993 0 0 xNOTHW O TILL sign A ACEN soo wama d 1 0 NOYA 0
95. attery 5 this fault occurs the battery is likely in poor condi tion Try to recover the pack with a charger that can charge the individual cells such as an automotive charger Be sure to set this charger to the appropri ate voltage 6V per 6V battery 12V per 12V string battery JLG Lift 3 9 SECTION 3 CHASSIS amp SCISSOR ARMS 5 Flashes Over Temperature This fault indicates the charger has become too hot during operation Though not damanging to the charger charge time will be extended significantly 1 This fault indication will not clear automatically but the charger will restart charging automatically when the temperature drops The fault indicaiton must be cleared manually by unplugging the AC waiting 30 seconds and reconnecting the AC power 2 If possible move the machine to a cooler location 3 Confirm that dirt or mud is not blocking the cooling fins of the charger Clean the charger Rinse the charger with a low pressure hose if required Do no use high pressure Do not us a pressure washer 6 Flashes Over Load Over Temperature This fault indicates that the batteries will not accept charge current or an internal fault has been detected in the charger This fault will nearly always be set within the first 30 seconds of operation If it occurs after the charger has started charging normally be sure to make a note of it 1 Remove excessive AC loads from inverter if installed
96. aulic system with oil temperatures below 15 F 26 C is not recommended If it is nec essary to start the system in a sub zero environ ment it will be necessary to heat the oil with a low density 100VAC heater to a minimum temperature of 15 F 26 C The only exception to the above is to drain and fill the system with Mobil DTE 13 oil or its equivalent This will allow start up at temperatures down to 20 F 29 C However use of this oil will give poor per formance at temperatures above 120 F 49 C Sys tems using DTE 13 oil should not be operated at temperatures above 200 F 94 C under any condi tion Changing Hydraulic Oil 1 2 4 Use of any of the recommended hydraulic oils elim inates the need for changing the oil on a regular basis However filter elements must be changed after the first 50 hours of operation and every 300 hours thereafter If it is necessary to change the oil use only those oils meeting or exceeding the specifi cations appearing in this manual If unable to obtain the same type of oil supplied with the machine con sult local supplier for assistance in selecting the proper equivalent Avoid mixing petroleum and syn thetic base oils JLG Industries recommends chang ing the hydraulic oil annually Use every precaution to keep the hydraulic oil clean If the oil must be poured from the original container JLG Lift into another be sure to clean all possible contami nants f
97. ble lifting devices whenever possible if mechanical assistance is required All slings chains cables etc should be parallel to each other and as near perpendicular as possible to top of part being lifted 2 Should it be necessary to remove a component on an angle keep in mind that the capacity of an eye bolt or similar bracket lessens as the angle between the supporting structure and the component becomes less than 90 3 part resists removal check to see whether all nuts bolts cables brackets wiring etc have been removed and that no adjacent parts are interfering 3121122 SECTION 2 GENERAL Component Disassembly and Reassembly When disassembling or reassembling a component com plete the procedural steps in sequence Do not partially disassemble or assemble one part then start on another Always recheck your work to assure that nothing has been overlooked Do not make any adjustments other than those recommended without obtaining proper approval Pressure Fit Parts When assembling pressure fit parts use an anti seize or molybdenum disulfide base compound to lubricate the mating surface Bearings 1 When a bearing is removed cover it to keep out dirt and abrasives Clean bearings in nonflammable cleaning solvent and allow to drip dry Compressed air can be used but do not spin the bearing 2 Discard bearings if the races and balls or rollers are pitted scored or burned 3 If bea
98. bolt locknut and keeper shaft securing the cylinder barrel attach pin to the upper inner arm assembly Using a suitable brass drift drive out the rod end attach pin from the arm assembly Carefully remove the cylinder from the scissor lift and place in a suitable work area Lift Cylinder Installation 1 Install lift cylinder in place using a suitable slings aligning barrel end attaching pin mounting holes on lower arm assembly Using a suitable drift drive the barrel end attach pin through the mounting holes in the lift cylinder and the lower arm assembly Secure in place with bolt locknut and keeper shaft Remove cylinder port plugs and hydraulic line caps and correctly attach lines to cylinder ports Extend the cylinder rod until the attach pin hole aligns with those in the upper arm assembly Using a suitable drift drive the cylinder rod attach pin through the aligned holes taking care to align the pin retaining holes with the hole on the arm assem bly Secure the pin in place with bolt locknut and keeper shaft der 5 Lower platform to stowed position and shut down balance valve from the retract port After initial dis motor Check hydraulic fluid level and adjust accord charge there should not be any further leakage from ingly the ports If leakage occurs at a rate of 6 8 drops per minute or more the piston seals are defective and NOTE Always check hydraulic fluid level after completely must be replaced 312
99. bove The 3 to 5 The 2 digit Flash Code is scrolled at the end of the digit DTC will display in parenthesis on the JLG Ana Help Message Refer to Flash Code column of lyzer in the upper right corner of the display screen Table 5 1 as shown below Refer to Table 5 1 for ME 267 hel p hel p ng change 2 2 ever yt hing ok ENTER Table 5 1 Flash Codes DTC s FLASHCODE DTC HELP MESSAGE AND DESCRIPTION No Flash 000 HELP COMMENT Code 001 EVERYTHINGOK The normal help message in Plaform Mode 002 GROUND MODE OK The normal help message in Ground Mode 0022 DIFFERENT FUNCTION SELECTED amp IGNORED A function i e Drive Lift etc is active and the operator has selected another function The system has ignored the new selec tion 0023 FUNCTION SELECTED BUT TRIGGER SWITCH OPEN A function i e Drive Lift etc has been selected by the operator but the trigger switch is not active closed 0024 JOYSTICK MOVED BUT NO FUNCTION SELECTED The joystick was moved out ofthe center position before a function was selected 0025 ALARM SOUNDING PLATFORM OVERLOADED Load Sensing System indicates that the platform is overloaded Applicable when Machine Setup s Loadis set to 1 CUTOUT PLT and the vehicle is operating in Ground Mode 003 ALARM SOUNDING TILTED amp ABOVE ELEVATION Platform is elevated and the chassis is not level Applicable when Machine Setup s TILT CUT
100. box has corrupted electrical connections or caused a tilt sensor or ground control board failure observe any cracks in the box e The Ground Control Box as mounted on the machine does not allow the tilt sensor to be level 3121122 For the following troubleshooting steps a bubble level smaller is better will be needed and the machine must be on a level surface 1 Onthe Analyzer go to Diagnostics System and read the tilt angle If either angle reports 20 0 there is an electrical electronic failure tilt sensor control board electrical connections a Open the Ground Control Box b Disconnect the sensor and clean any corrosion off of the tilt sensor and control board connec tions c Reassemble and test If fault persists replace tilt sensor 2 the Analyzer displays angles other than 20 0 attempt to calibrate If machine will not calibrate note the reason displayed on Analyzer a SENSOR FAILURE tilt sensor internal fre quency is out of range replace sensor b NOT LEVEL tilt sensor has either developed an Offset or it is to unlevel as mounted on the machine Joystick Calibration SW V13 5 amp Higher and P1 0 amp Higher Using the Analyzer in Access Level 1 go to MENU CALI BRATION JOYSTICK and press ENTER 1 Following the analyzer screen prompts a Move the Joystick FORWARD and press ENTER b Allow Joystick to be in CENTER position and press ENTER c Move the Joyts
101. d it is necessary to start the system in a sub zero environment it will be necessary to heat the oil with a low density 100VAC heater to a mini mum temperature of 15 F 26 Changing Hydraulic Oil Use of any of the recommended hydraulic oils elimi nates the need for changing the oil on a regular basis However filter elements must be changed after the first 50 hours of operation and every 250 hours thereafter If it is necessary to change the oil use only those oils meeting or exceeding the specifi cations appearing in this manual If unable to obtain the same type of oil supplied with the machine con sult local supplier for assistance in selecting the proper equivalent Avoid mixing petroleum and syn thetic base oils JLG Industries recommends chang ing the hydraulic oil annually Use every precaution to keep the hydraulic oil clean If the oil must be poured from the original container into another be sure to clean all possible contami nants from the service container Always replace the filter cartridge any time the system oil is changed 3121122 SECTION 4 HYDRAULICS 3 While the unit is shut down a good preventive main tenance measure is to make a thorough inspection of all hydraulic components lines fittings etc as well as a functional check of each system before placing the machine back in service Lubrication Specifications Specified lubricants as recommended by the component manufact
102. e 21 Check Valve see note Figure 4 14 Leveling Jack Cylinder USA Built Machines S N 0200104829 to S N 0200112735 amp All Belgium Built Machines NOTE Torque Locknut 8 to 400 ft Ibs 542 3 Nm Torque Counter Balance Valve 20 and Check Valve ss 21 to 30 35 ft Ib 40 47 Nm K gt y When servicing apply a light coat of grease to the K Jack Pad 2 before installing Dr SCHEMATIC FOR PORT BLOCK 3121122 JLG Lift 4 15 SECTION 4 HYDRAULICS 1 3 not used 9 Barrel 16 Retainer Ring 23 Polyseal 4 Trailer Ball 10 Plug 17 Locking Screw 24 Hydrolock 5 Bolt 3 8 16NC Grade 8 11 notused 18 Wear Ring 25 Spacer Tube 6 Cap 12 Nut 19 Guidelock 26 Counter Balance Valve 7 Head 18 Jack Pad 20 O Ring EE 8 Rod 14 Piston 21 O Ring flee CHOU VANE 15 Plate 22 Wiper Seal NOTE 4 16 Figure 4 15 Leveling Jack Cylinder USA Built Machines Prior to S N 0200104829 Torque Nut 12 to 400 ft Ibs 542 3 Nm Torque Locking Screw 17 to 100 in Ibs 11 3 Nm Torque Counter Balance Valve 26 and Check Valve 27 to 30 35 ft Ib 40 47 Nm JLG Lift 3121122 SECTION 4 HYDRAULICS _ Barrel Rod Guide Locknut Piston Piston Seal O Ring Back Up Ring oa A VMN Seal 10 Wiper 11 Retainer Ring 12 O Ring F
103. e Bearing 34 O ring Lip Seal 13 Spacer 24 Thrust Spacer 35 Retaining Ring Int Tapered Bearing Cone 14 Seal Boot 25 Planet Shaft 36 Coupling Tapered Bearing Cup 15 Thrust Spacer 26 Planet Gear 37 Input Shaft Tapered Bearing cone 16 Input Carrier 27 Roll Pin 38 Input Sun Gear Ring Gear 17 Thrust Washer 28 Thrust Washer 39 Output Sun Gear Hub Housing 18 Needle Bearing 29 Retaining Ring Ext 40 O ring Stud 19 Planet Shaft 30 Cover 41 O ring Retaining Ring Ext 20 Planet Gear 31 Disengage Cap 42 Retaining Ring Ext Retaining Ring Int 21 Output Carrier 32 Hex Bolt Spring 1 460 1 500 22 Thrust Washer 33 Dowel Pin Figure 3 17 Torque Hub Assembly JLG Lift 3121122 SECTION 3 CHASSIS amp SCISSOR ARMS Roll Test The purpose of the roll test is to determine if the unit s BOLT A gears are rotating freely and properly You should be able to rotate the gears in your unit by applying constant force to the roll checker If you feel more drag in the gears only at certain points then the gears are not rolling freely and should be examined for improper installation or defects Some gear packages roll with more difficulty than others Do not be concerned if the gears in your unit seem to roll hard as long as they roll with consistency Leak Test Main Unit The purpose of a leak test is to make sure the unit is air tight You can tell if your unit has a leak if the pressure gauge reading on your lea
104. e Oil Temperature Low Engine Oil Pressure Engine Overspeed Generator Overvoltage A WARNING TO AVOID INJURY FROM AN EXPLOSION DO NOT SMOKE OR ALLOW SPARKS OR A FLAME NEAR BATTERY DURING SERVIC ING ALWAYS WEAR EYE AND HAND PROTECTION WHEN SER VICING BATTERIES Battery Charging On Board Charger MAC 1 For maximum battery life a Avoid completely discharging the batteries b Fully charge the batteries each day the machine is used c Charge the batteries at available times between charging d Be sure the battery fluid covers the battery plates before charging but to avoid overflow do not top off the fluid level until charging 3121122 SECTION 3 CHASSIS amp SCISSOR ARMS 2 To charge the batteries connect the charger to a Battery Charger Delta Q 230 voltso ree witha 1S amp mninimum capacity The battery charger is located on a tray behind the hinged 3 The charge cycle is complete when the 100 LED is JLG cover at the front of the machine or on the sliding lit Any other reading indicates the charge cycle is engine tray on the M model machines not complete 4 The Charger will shut off automatically when the teries are fully charged Depleted batteries will take approximately 17 hours to charge Charging Sequence of Remote LED Card y A N ae 1 Plug in charger 2 All three LED s light emitting diode flash three times 3
105. e ee E Ye o e eect ete eet 3 13 3 5 Supplementary Fuse For APU 3 19 3 6 Joystick Controller a EI ud eee et GI ME eee 3 21 3 7 TOWING ec ule nu a ctas etit EE 3 24 3 8 Deckt suu eigenen td aede eR 3 27 3 9 Drive Brake MICO ul poe Neue bo E PS ants eee 3 29 3 10 Torque H b asawa aa a c UAR a ae ES 3 30 SECTION 4 HYDRAULICS 4 1 Servicing and Maintenance Guidelines 4 1 4 2 Lubrication Information 4 2 4 3 Cylinders Theory of Operation 4 3 4 4 Valves Theory 4 3 4 5 Component Functional Description 4 3 4 6 Wear Pads umu aS oe Ies Me ATE Wa ea UI e Ay a E Re IR dod eek DRE Pad 4 3 4 7 Motor Controller Modes of 2 4 3 4 8 MD PIC aed hua ss 4 4 4 9 Cylinder Checking 4 4 4 10 Cylinder Removal and Installation 4 5 4 11 Cylinder Re palit wh pu pusay 4 6 4 12 Steer Cylinder
106. e iS D 2 B BER 2 ER Set 8 E I ai 3 22 BLACK TO POWER CONTROLLER B TO POWER CONTACTOR B Figure 6 24 Electrical Schematic Kubota Engine M3369 amp 3369LE only 6 18 JLG Lift 3121122 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 3121122 ce ce lt lt a o lt o z SH Sx gt 2 lt 225 25 gt ha z 5 gt a fer lt lt lt gt EH arti cu EECH m lt gt 5 2 45 lt lt lt oc ua le 5 s o jas 1 1 1 1 o 0 5 51515 5 E N 1 1 ELE 82 ch m HE m ES AE z Ce S gee 11 Ll less gt s 5 1 lt a 5 Se 2
107. e over head lifting device approximately 1 in 2 5 cm below the platform 3 After completing the above shut down hydraulic system and allow machine to sit for 10 15 minutes This is done to relieve pressure in the hydraulic 3121122 SECTION 4 HYDRAULICS lines Carefully remove hydraulic hoses from appro priate cylinder port block 4 There will be initial weeping of hydraulic fluid which can be caught in a suitable container After the initial discharge there should not be any further leakage from the ports If leakage continues at a rate of 6 8 6 If no repairs are necessary or when repairs have been made carefully reconnect hydraulic hoses to the appropriate ports Activate hydraulic system and run cylinder through complete cycle to check for leaks and operation drops per minute or more the following cylinder 4 10 CYLINDER REMOVAL AND repairs must be made If the retract port is leaking the piston is leaking the piston seals are defective and must be replaced If the extend port is leaking INSTALLATION the counterbalance is defective and must be Lift Cylinder Removal replaced 5 If no repairs are necessary or when repairs have been made carefully reconnect hydraulic hoses to the appropriate ports 6 Remove lifting device from platform activate hydrau lic system and run cylinder through complete cycle to check for leaks and operation Cylinders with Duel Counterbalance Valves Oscillating
108. e support is provided Cleanliness IT IS GOOD PRACTICE TO AVOID PRESSURE WASHING ELEC TRICAL ELECTRONIC COMPONENTS IN THE EVENT PRES SURE WASHING THE MACHINE IS NEEDED ENSURE THE MACHINE IS SHUT DOWN BEFORE PRESSURE WASHING SHOULD PRESSURE WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRICAL ELECTRONIC COMPONENTS JLG INDUSTRIES INC RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI 52 BAR AT A MINIMUM DISTANCE OF 12 INCHES 30 5 CM AWAY FROM THESE COMPONENTS IF ELECTRICAL ELEC TRONIC COMPONENTS ARE SPRAYED SPRAYING MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION 1 The most important single item in preserving the long service life of a machine is to keep dirt and for eign materials out of the vital components Precau tions have been taken to safeguard against this 2 2 JLG Lift order to function properly 2 At any time when air fuel or oil lines are discon nected clear adjacent areas as well as the openings and fittings themselves As soon as a line or compo nent is disconnected cap or cover all openings to prevent entry of foreign matter 3 Clean and inspect all parts during servicing or main tenance and assure that all passages and openings are unobstructed Cover all parts to keep them clean Be sure all parts are clean before they are installed New parts should remain in their contain ers until they are ready to be used Components Removal and Installation 1 Use adjusta
109. eady to be used Component Removal and Installation 1 Use adjustable lifting devices whenever possible if mechanical assistance is required All slings chains cables etc should be parallel to each other and as near perpendicular as possible to top of part being lifted 2 Should it be necessary to remove a component on an angle keep in mind that the capacity of an eye bolt or similar bracket lessens as the angle between the supporting structure and the component becomes less than 90 3 If a part resists removal check to see whether all nuts bolts cables brackets wiring etc have been removed and that no adjacent parts are interfering Component Disassembly and Reassembly When disassembling or reassembling a component com plete the procedural steps in sequence Do not partially disassemble or assemble one part then start on another Always recheck your work to assure that nothing has been overlooked Do not make any adjustments other than those recommended without obtaining proper approval Pressure Fit Parts When assembling pressure fit parts use an anti seize or molybdenum disulfide base compound to lubricate the mating surface Bearings 1 When a bearing is removed cover it to keep out dirt and abrasives Clean bearings in nonflammable cleaning solvent and allow to drip dry Compressed air can be used but do not spin the bearing 2 Discard bearings if the races and balls or rollers are
110. econ nect the fuel line to the fuel injector pump 5 Clean up any spilled fuel and try to start the genera tor again 6 If the engine still doesn t start remove the steel line from the fuel injectoe pump 7 Once fuel starts to flow reconnect the fuel line to the fuel injector pump 8 Clean up any spilled fuel and try to start the genera tor again 9 If no fuel flows there are some possibilities a There is no fuel getting to the injector pump No fuel in tank or obstruction in fuel line or clogged in line fuel filter b The engine camshaft rotation is not opening the injection fuel pump Using the recoil starter rotate the engine 1 3 of a turn and fuel should spill from the fuel injector pump 3121122 SECTION 3 CHASSIS amp SCISSOR ARMS 10 Engine might run rough for 20 seconds or so but it 2 Find where the harness attaches to the rear cover of will clean out the generator and the connection point for the new inline fuse 3 5 SUPPLEMENTARY FUSE FOR APU The purpose of this section is to describe the procedure to add a supplementary fuse for the Engine Generator Con troller for the APU Tools And Material Weather proof fuse holder JLG P N 2400081 e AGC1 1 Amp fuse JLG P N 2400080 45 cm of 16 AWG wire JLG P N 4920019 e 2 X insulated butt splice connectors JLG P N 4460035 e 6 X medium length wire ties JLG P N 4240033 3 Remove the socket head drive screw with
111. ell as their receptacles when disconnecting or removing them from the unit This will assure that they are correctly reinstalled hydraulic oil clean including reserve oil in storage Hydraulic system filters should be checked cleaned and or replaced at the specified intervals required in Section 1 Always examine filters for evi dence of metal particles Cloudy oils indicate a high moisture content which permits organic growth resulting in oxidation or cor rosion If this condition occurs the system must be drained flushed and refilled with clean oil 4 It is not advisable to mix oils of different brands or Hydraulic System types as they may not contain the same required y y additives or be of comparable viscosities Good 1 Keep the system clean If evidence of metal or rub grade mineral oils with viscosities suited to the ber particles are found in the hydraulic system drain ambient temperatures in which the machine is oper and flush the entire system ating are recommended for use 2 Disassemble and reassemble parts on clean work NOTE Metal particles may appear in the oil or filters of new surface Clean all metal parts with non flammable machines due to the wear in of meshing compo cleaning solvent Lubricate components as nents required to aid assembly Hydraulic Oil Lubrication Service applicable components with the amount type and grade of lubricant recommended in this manual at the specified interval W
112. er Without Counterbalance Valves Steer 1 Using all applicable safety precautions activate hydraulic system and fully extend cylinder to be checked Shut down hydraulic system 2 Carefully disconnect hydraulic hose from retract port of cylinder There will be initial weeping of hydraulic fluid which can be caught in a suitable container After initial discharge there should be no further leakage from the retract port 3 Activate hydraulic system and activate cylinder extend function 4 If cylinder retract port leakage is less than 6 8 drops per minute carefully reconnect hose to retract port and retract cylinder If leakage continues at a rate of 6 8 drops per minute or more cylinder repairs must be made 5 With cylinder fully retracted shut down motor and carefully disconnect hydraulic hose from cylinder extend port 6 Activate hydraulic system and activate cylinder retract function Check extend port for leakage 7 f extend port leakage is less than 6 8 drops per minute carefully reconnect hose to extend port then activate cylinder through one complete cycle and check for leaks If leakage continues at a rate of 6 8 drops per minute or more cylinder repairs must be made Cylinders With Single Counterbalance Valve Lift Cylinder OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY 1 Using all applicable safety precautions activate hydraulic system 2 Raise platform completely and place a suitabl
113. es 8 Remove retaining ring 17 from cover 21 9 Remove shaft 10 by pressing or using a soft mallet on male end of shaft 10 10 Remove retaining ring 19 and bearing 18 from shaft 10 11 Press rotary oil seal 22 from cover 21 Assembly NOTE Lubricate all rubber type components from repair kit with clean type fluid used in the system 1 Clean all parts thoroughly before assembly 2 Press new rotary oil seal 22 into cover 21 taking note to direction of seal 3121122 3 Install new bearing 18 and retaining ring 19 on shaft 10 4 Install shaft assembly and retaining ring 17 in cover 21 5 Install dowel pins 20 spring retainer 16 and springs 15 in cover 21 NOTE Be sure io use the same number of springs and spring pattern as recorded during disassembly 6 Position plate 14 on springs 15 Hole in plate 14 must line up with hole in cover 21 NOTE Discs 13 11 and plate 14 must remain dry during installation No oil residue must be allowed to con taminate disc surfaces 7 Press sensor ring 12 on rotor disc 13 Place a new rotor disc 13 on shaft 10 until it contacts plate 14 Install stator disc 11 8 Install new o rings 5 8 and new back up rings 6 9 on piston 7 Note order of o rings and back up rings Insert piston 7 into pressure plate 3 Be careful not to shear o rings or back up rings 9 Install new case seal 4 in cover 2
114. eter and leads by touching leads together Meter should produce an audible alarm indicating continuity 3121122 JLG Lift 6 3 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Continuity Measurement Over Long Distances When trying to determine continuity of a harness or wire longer than the reach of standard instrument leads is possible to perform the check without excessively long leads Using the other wires in the harness one can determine the condition of a particular wire in the harness Requirements Harness with at least three separate wires including the wire under test These wires must be able to be isolated from other wires etc Jumper or method to connect contacts on one side of harness Meter that can measure resistance or continuity Procedure Test multimeter leads resistance Subtract this value from the measured resistance of the wires to get a more accurate mea surement Consult the circuit schematic to determine which wires to use in addition to wire under test here called wire 1 and wire 2 and how to isolate these wires These wires should appear in the same connectors as the wire under test or are within reach of the jumper 1 Disconnect all connections associated with the wire under test and the two additional wires If harness is not com pletely isolated disconnect battery terminals also as a precaution 2 Measure continuity between all three wires the wire under test
115. ex Head Bolts 4 Torque bolts to 70 80 in Ibs 5 Install the O ring Pipe Plugs 8 into the Cover The 3 Insert Disengage Rod 6 into hole in Cover until it houl h tight ina to SAE stan touches the inside of the Disengage Cap Sg Ge ge NOTE The Disengage Rod can be inserted either end first 3121122 JLG Lift 3 44 SECTION 3 CHASSIS amp SCISSOR ARMS Main Assembly 3 42 17 Coupling Retaining Ring Ring Gear Cover Subassembly Washer First Stage Sun Gear 9 10 11 12 Input Shaft Carrier Subassembly Second Stage Sun Gear Output Stage Carrier Subassembly Flat Head Bolts Ring Gear Figure 3 26 Hub Main Assembly Lift 13 14 15 16 17 18 Housing O Ring O Ring Retaining Ring Ext Retaining Ring Ext ID Plate 3121122 SECTION 3 CHASSIS amp SCISSOR ARMS NOTE NOTE 3121122 All components should receive a generous amount of lubricant oil as they are being assembled Place Hub Spindle Sub Assembly on a bench Grease O Ring 14 and place it into the groove of the Housing 13 Place the Ring Gear 12 onto the Hub Align the 3 shipping cap screw holes on the Hub and Ring Gear Install the 3 Flat Head Bolts 11 into the Ring Gear and Hub Torque the Bolts to 15 20 ft Ibs Place Output Stage Carrier Subassembly 10 into mesh with the Spindle splines Place the External Retaining Ring 16 over t
116. f the battery is of larger capacity than the algorithm is intended for In unusual cases it could mean charger output is reduced due to high ambi ent temperature It can also occur if the battery is dam aged old or in poor condition 1 Check the battery for damage such as shorted cells and insufficient water Try the charger on a good bat tery 2 Ifthe same fault occurs on a good battery check the connections on the battery and connection to AC and the AC voltage itself 3 Confirm that the nominal battery pack voltage is the same as the battery charger voltage 4 This fault must be cleared manually by unplugging the AC waiting 30 seconds and reconnecting the AC power 5 Ifa charger displays this fault on a battery pack and the pack is of questionable status reset the charger by disconnecting AC for 30 seconds and then reconnect the AC to start a new charge cycle After a few charge cycles this problem could stop occur ring as the pack recovers 4 Flashes Check Battery This fault indicates the battery pack could not be trickle charged up to the minimum level required for the normal charge cycle to be started 1 Check that none of the battery pack connections between modules are reversed or incorrectly con nected 2 Check that one or more cells in the battery are no shorted 3 Confirm that the nominal battery pack voltage is the same as the battery charger voltage 4 Try charger on a good b
117. g and the bearings for damage and apply new oil If gears or bearings need replacing they must be replaced as complete units The first stage planetary bearings 10 must be replaced in sets of three pieces The first stage planetary gears 11 must be changed as a complete set of four and the manufac turer recommends changing the sun gear shaft 43 along with this set of planets NOTE The second stage planetary bearings 11 must be replaced in sets of four pieces Disassembly of Cover Unit 8 1 2 Loosen and remove hex hd bolts 53 and remove cover 51 Remove Shaft rod 56 O ring 54 and sleeve 52 Disassembly of First Stage Planetary Assembly 1 2 Push the sun gear shaft 43 out of the first stage Remove snap rings 14 and press planet pins 5 out of planet carrier 7 and planet gears 2 Pull cylindrical roller bearing 10 out of planet gears 2 Remove snap ring 16 from sun gear 3 and remove the thrust washer 49 Disassembly of the Second Stage Planet Gears 1 Press cylindrical roller bearings out of planet gears 1 JLG Lift 3 27 SECTION 3 CHASSIS amp SCISSOR ARMS NOTE Speed sensor port in cover should be 180 from brake release port in pressure plate 1 Retaining Screws 9 Back up Ring 17 Retaining Ring 2 Washers 10 Shaft 18 Bearing 3 Pressure Plate 11 Stator Disc 19 Retaining Ring 4 Case Seal 12 Sensor Ring 20 Dowel Pins
118. ground or sensor not properly mounted 2512 ELEVANGLE SENSORNOT DETECTING CHANGE Platform elevated for 5 sec and elevation voltage change not detected Fault sensor wire harness or ground module Return platform to stowed position to clear Reset Model or recalibrate elev angle sensor 252 ELEV ANGLE SENSOR HAS NOT BEEN CALIBRATED Calibrate elevation rotary sensor using calibration procedure 2535 SHORT DETECTED ON IGNITION WIRING CHECK HARNESS Ashortto ground has been detected on one of the following J2 21 J2 22 J2 23 J2 27 J2 28 J3 7 J3 10 J5 5 2536 ALLFUNCTIONS PREVENTED FUNCTION CUTOUT ACTIVE Machine Setup s FUNCTION CUTOUT is set for 2 ALL FUNCTIONS and Ground Module J2 11 is de energized by an exter nal safety device 2537 DRIVE amp LIFT UP PREVENTED FUNCTION CUTOUT ACTIVE Machine Setup s FUNCTION CUTOUT is set for 1 DRV amp LFT UP and Ground Module J2 11 is de energized by an external safety device 2538 FUNCTION PREVENTED CHARGER CONNECTED Disconnect AC line from charger to clear fault 255 PLATFORM OVERLOADED Machine Setup s LOAD is setto 1 CUTOUT PLT or 2 CUTOUT ALL and the Load Sensing System indicates that the plat formis overloaded 257 ELEV PROX PERMANENTLY CLOSED CHECK PROX AND ANGLE ADJUSTMENT Elevation proximity sensor closed This could be due to a misadjustment of the prox or angle mount sensor or metal debris on the prox N A ELEV PROX PERMANENTLY OPEN CHECK PROX AND ANGLE ADJUST
119. he 13T spline to the retaining groove on the Input Shaft 7 For ratio 48 1 assemble the Second Stage Sun Gear 9 over the Input Shaft first then install the External Retaining Ring Using an appropriate tool install the Retaining Ring 17 into the groove on the Output Sun 10 11 12 13 14 15 JLG Lift Place the Input Shaft spline end into mesh with the Internal Coupling 1 splines With the modified spline end facing up place the Output Sun Gear into mesh with the Output Planet Gears Place the Input Carrier Sub Assembly 8 onto the Output Sun Gear splines Drop the First Stage Sun Gear 6 into mesh with the planet gears for specific ratios if required No timing required Grease the O Ring 15 and insert into the groove in the Cover Subassembly 4 Install the Cover Subassembly into the Ring Gear 3 counterbore and install the Retaining Ring 2 into the groove in the Ring Gear Attach the ID Plate 18 onto the unit using the Drive Screw not shown Check disconnect roll and air check the unit leak check the brake and record release pressure Insert the Plastic Plug not shown into place if applicable 3 43 SECTION 3 CHASSIS amp SCISSOR ARMS NOTES 3 44 Lift 3121122 SECTION 4 HYDRAULICS SECTION 4 HYDRAULICS 4 1 SERVICING AND MAINTENANCE GUI
120. he engine temperature is below the factory set engine preheat temperature setting The engine pre heater will be energized for the factory set preheat delay period Table 3 5 RBS Pre start Sequence CTS Callto Start TDES Engine Start Preheat Delay RBS Startup Sequence RBS Startup Sequence 1 3121122 Crank Time The RBS will crank for a period up to the crank time or until the engine starts Rest Time If the engine does not successfully start the RBS will wait for the rest time before attempting to crank the engine again Crank Cycles The RBS will attempt to start the engine up until the number of crank cycles is reached If the RBS does not start an Overcrank fault is indicated Time Delay Bypass TDBP Once the engine starts TDBP must elapse before low oil pressure and underspeed shutdowns are activated This allows the engine to come up to nor mal operating conditions before enabling these shutdowns are monitored Table 3 6 RBS Startup Sequence Crank Time Rest Time Until Engine Start or of Crank Cycles TDBP Bypass Normal Running Operation RBS Shutdown Sequence Once all CTS conditions have been removed the RBS will begin the shutdown sequence If a CTS condition is initi ated during the shutdown sequence the RBS will return to normal running operation until the CTS is removed 1 Time Delay Engine Run TDER Once the CTS conditio
121. hem from the unit This will assure that they are correctly reinstalled Hydraulic System 1 Keep the system clean If evidence of metal or rub ber particles are found in the hydraulic system drain and flush the entire system 2 Disassemble and reassemble parts on clean work surface Clean all metal parts with non flammable cleaning solvent Lubricate components as required to aid assembly Lubrication Service applicable components with the amount type and grade of lubricant recommended in this manual at the specified intervals When recommended lubricants are not available consult your local supplier for an equivalent that meets or exceeds the specifications listed Battery Clean battery using a non metallic brush and a solution of baking soda and water Rinse with clean water After cleaning thoroughly dry battery and coat terminals with an anti corrosion compound Lubrication and Servicing Components and assemblies requiring lubrication and servicing are shown in the Lubrication Chart in Section 1 2 3 LUBRICATION AND INFORMATION Hydraulic System 1 The primary enemy of a hydraulic system is contam ination Contaminants enter the system by various means e g using inadequate hydraulic oil allowing moisture grease filings sealing components sand etc to enter when performing maintenance or by permitting the pump to cavitate due to insufficient system warm up or leaks in the pump supply suc tion
122. hen adding water to the battery fill only to level indicated or 3 8 above separators 2 Remove all vent caps wet batteries only and inspect electrolyte level of each cell Electrolyte level should be to the ring approximately one inch from top of battery Fill batteries with distilled water only Replace and secure all vent caps 3 Remove battery cables from each battery post one at a time negative first Clean cables with acid neu tralizing solution e g baking soda and water or 3 6 Lift ammonia and wire brush Replace cables and or cable clamp bolts as required 4 Clean battery post with wire brush then re connect cable to post Coat non contact surfaces with min eral grease or petroleum jelly 5 When all cables and terminal posts have been cleaned ensure all cables are properly positioned and do not get pinched Close battery compartment cover 6 Start hydraulic system and ensure that it functions properly Optional On Board Generator A WARNING EXHAUST GAS HAZARD RUN THE GENERATOR IN A WELL VEN TILATED AREA ONLY WHEN THE GENERATOR ENABLE CONTROL LOCATED IN THE PLATFORM CONTROL BOX IS IN THE ON POSITION AND THE GROUND EMERGENCY STOP SWITCH IN ON PULLED OUT THE GENERATOR WILL START AUTOMATICALLY WHEN THE BAT TERIES REACH A LOW CHARGE STATE AUTOMATICALLY CHARGING THE BATTERIES NOTE The engine will automatically shut down under the following conditions Charged Batteries High Engin
123. hen recommended lubricants are 2 not available consult your local supplier for an equivalent that meets or exceeds the specifications listed Batteries NOTE Clean batteries using a non metallic brush and a solution of baking soda and water Rinse with clean water After cleaning thoroughly dry batteries and coat terminals with an anti corrosion compound 1 Lubrication and Servicing Components and assemblies requiring lubrication and servicing are shown in Section 1 1 4 2 LUBRICATION INFORMATION Hydraulic System 1 The primary enemy of a hydraulic system is contam ination Contaminants enter the system by various means e g inadequate hydraulic oil allowing mois ture grease filings sealing components sand etc to enter when performing maintenance or by per mitting the pump to cavitate due to insufficient sys tem warm up 2 The design and manufacturing tolerances of the component working parts are very close therefore even the smallest amount of dirt or foreign matter entering a system can cause wear or damage to the components and generally results in faulty opera tion Every precaution must be taken to keep 4 2 JLG Lift Refer to Section 1 for recommendations for viscosity ranges JLG recommends DTE 11Hydraulic Oil which has an SAE viscosity of 10W and a viscosity index of 140 Start up of hydraulic system not using DTE 11 with oil temperatures below 15 F 26 C is not recom mende
124. i Purpose Grease A WARNING TO AVOID PERSONAL INJURY USE SAFETY PROP FOR ALL MAINTENANCE REQUIRING PLATFORM TO BE ELEVATED NOTE Be sure to lubricate like items on each side of the machine JLG Lift NOTE Recommended lubricating intervals are based on machine operations under normal conditions For machines used in multi shift operations and or exposed to hostile environments or conditions lubri cating frequencies must be increased accordingly The high pressure filter is located in the main con trol valve See figure title control valve in section 2 3121122 SECTION 1 SPECIFICATIONS 1 11 SERIAL NUMBER LOCATIONS For machine identification a serial number plate is affixed to the front of the frame If the serial number plate is damaged or missing the machine serial number is stamped on the left front of the machine frame 3121122 SERIAL NUMBER PLATE SERIAL NUMBER STAMPED Figure 1 2 Serial Number Location JLG Lift SECTION 1 SPECIFICATIONS 1 12 TORQUE CHARTS Values for Zinc Yellow Chromate Fasteners Ref 4150707 SAE GRADE 5 BOLTS amp GRADE 2 NUTS Torque T Tensile Torque Torque Loctite 242 271 SCH UNE
125. icated on the Yellow Charging LED A single digit Algorithm is indicated by the number 43 Harris Battery Discover EVGGC6A A of blinks separated by a pause A two digit Algorithm is 35 JLG P N 0400242 indicated by the number of blinks for the first digit followed 23 Douglas Flooded JLG default by a short pause then the number of blinks for the second GES Battery A1055 digit followed by a longer pause TrojanT105 To check change the charging algorithm US BATT GC 110 WNL Trojan T105 PLUS 1 Disconnect the charger positive connector from the Champion CHGC2 GC2 battery pack Apply AC power and after the LED test US BATT EV 145 WNL the Algorithm will display for 11 seconds 8 Concorde 10xAh AGM 2 To change the algorithm touch the connector to the 7 J305 DV DT CP battery s positive terminal for 3 seconds during the 6 DEKA 8G31 Gel 11 second display period and then remove The Algorithm will advance after 3 seconds Repeat 9 Trojan 30 31XHS this procedure until the desired Algorithm is dis 4 US Battery USB2200 played A 30 second timeout is extended for every 3 T105DV DT CP increment Incrementing beyond the last Algorithm will recycle back to the first Algorithm When the Eppes desired Algorithm is displayed touch the charger 1 Trojan 105 connector to the battery positive terminal until the output relay makes a clicking noise approx 10 sec onds The algorithm is now in the permanent mem Batter
126. ides mechanical power to crank the engine Electrical power for the starter is provided by the start bat tery The starter is energized by the start control relay Start Control Relay The start control relay energizes the solenoid of the engine starter and the pull coil of the engine fuel solenoid The start control relay is located on the fuel solenoid bracket on the right side of the engine The start control relay is energized by the engine generator controller Fuel Control Relay The fuel control relay energizes the hold coil of the fuel solenoid The fuel control relay is energized by the engine generator controller Fuel Solenoid The fuel solenoid actuates the run stop lever of the engine This solenoid has a pull and hold coil The pull coil is energized by the start control relay and the hold coil is energized by the fuel control relay Engine Oil Temperature Sensor The engine oil temperature sensor is used to sense the temperature of the oil in the sump of the engine This sen sor provides a signal to the engine generator controller for high engine temperature shutdown Alternator Output Current Sensor The alternator output current sensor provides a signal pro portional to the output current of the alternator to the engine generator controller This signal is used by the controller to regulate the current output of the alternator The output current is regulated at 55 Amps DC The alter nator output curre
127. ifications DESCRIPTION INTERVAL HOURS DRY 240 ftlbs Torque Hub 336 Nm 500 1701105 Wheel Nuts 238 Nm 50 220 ftlbs Fixed Axle Bolts 308 Nm 500 35 ftlbs Drive Motor 49 Nm N A Pump Motor 12 14 ftlbs N A Terminals 14 19 Nm NOTE When maintenance becomes necessary or a fas tener has loosened refer to the Torque Chart to determine proper torque value 1 6 LUBRICATION Table 1 5 Hydraulic Oil Hydraulic System Operating Temperature Range 0 Fto 23 F 18 C to 5 C 10W 0 Fto 210 F 18 C to 99 C 10W 20 10W 0 50 F to 210 F 10 C to 99 C 20W 20 SAE Viscosity Grade NOTE Hydraulic oils must have anti wear qualities at least to API Service Classification GL 3 and sufficient chemical stability for mobile hydraulic system ser vice JLG Industries recommends Mobil DTE 11M hydraulic oil which has an SAE viscosity index of 140 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 3121122 SECTION 1 SPECIFICATIONS Lubrication Specifications Table 1 6 Lubrication Specifications KEY SPECIFICATIONS EPGL Extreme Pressure Gear Lube oil meeting API service classification GL 5 or MIL Spec MIL L 2105 HO Hydraulic Oil API service classification 61 3 BP Ener gol SHS46 LL S
128. igure 4 16 Steer Cylinder 3121122 JLG Lift 4 17 SECTION 4 HYDRAULICS 10 7924 WZ 8 NOTE Torque Capscrews 3 to 30 ft lbs 41 Nm Torque Thermal Relief Valve 22 to 20 25 ft Ibs 27 34 Nm 4 18 15 00 Ou Figure 4 17 Axle Lockout Cylinder Barrel Weldment Washer Ring Capscrews 5 16 18NC x 1 Cylinder Rod Jam Nut 3 4 16NF Rollpin Rod End Composite Bearing Head Piston Wear Ring T Seal Wear Ring O Ring Back Up Ring Rod Seal Wiper Seal O Ring Plug 6 O Ring Plug 4 Bleeder Valve Bushing Thermal Relief Valve 3121122 SECTION 4 HYDRAULICS 4 15 PRESSURE SETTING PROCEDURES Main Relief at Pump 1 Install pressure gauge at port MP on control valve 2 Remove the plug from the lift coil 3 Activate and bottom out Lift Up Adjust Main Relief to 3000 psi 207 bar 4 Replace the plug on the lift coil Lift Relief 1 With pressure gauge at MP port on control valve activate and bottom out Lift Up 2 Adjust Lift Relief to 2500 psi 172 bar on the M3369 3369LE and 2800 psi 193 bar on the M4069 4069LE Steer Relief 1 With pressure gauge at MP port on control valve activate and bottom out Steer Left 2 Adjust Steer Relief to 2500 psi 172 bar Repeat step one activating Steer Right 4 Shut down hydraulic system and remove pressure gauge 3121
129. imately 7 ft 2 1 m on the 3369LE or 9 ft 2 7 m on the 4069LE 5 Place DRIVE control switch to REVERSE position and carefully drive the machine off the block and ramp 6 Have an assistant check to see that the left front wheel remains locked in position off the ground 7 Lower the machine platform the lockout cylinder should then release and allow wheel to rest on the ground It may be necessary to activate DRIVE to release cylinders 10 11 12 13 14 15 3121122 JLG Lift Place the 6 inch 15 2 cm high block with ascension ramp in front of right front wheel From platform control station select LOW drive speed Place DRIVE control switch to FORWARD position and carefully drive the machine up ascension ramp until right front wheel is on top of block Raise machine platform approximately 7 ft 2 1 m on the 3369LE or 9 ft 2 7 m on the 4069LE Place DRIVE control switch to REVERSE position and carefully drive the machine off the block and ramp Have an assistant check to see that the right front wheel remains locked in position off the ground Lower the machine platform the lockout cylinder should then release and allow wheel to rest on the ground It may be necessary to activate DRIVE to release cylinders If the lockout cylinders do not function properly have qualified personnel correct the malfunction prior to any further operation 4 11 SECTION 4 HYDRAULICS 4 14 CYLI
130. int the analyzer will display the highest priority active fault if any are present You may scroll through the fault logs to view what the last 15 faults were Use the right and left arrow keys to scroll through the fault logs The active faults are listed before the first POWER CYCLE To return to the top menu press ESC two times When a top level menu is selected a new set of menu items may be offered If for example you choose Personal ities DRIVE LIFT STEER JOYSTICK Pressing ENTER with any of the above displayed menus will display additional sub menus within the selected menu In some cases the next level is the parameter or information to be changed Refer to the flow chart for what menus are available within the top level menus You may only view the personality settings for selected menus 3121122 SECTION 5 JLG CONTROL SYSTEM while in access level 2 Remember you may always can cel a selected menu item by pressing the ESC key Once the correct password is displayed press ENTER The access level should display the following if the pass word was entered correctly Changing the Access Level of the Hand Held Analyzer MG When the analyzer is first connected you will be in access level 2 which enabl to only vi t configurati VENU ch enables you to only view most configuration ACCESS LEVEL 1 settings which cannot be changed until you enter a pass word to advance to a lower level This ensu
131. is man ual for servicing and maintenance procedures For the purpose of receiving safety related bulletins it is important that JLG Industries Inc has updated ownership information for each machine When performing each Annual Machine Inspection notify JLG Industries Inc of the current machine ownership Preventative Maintenance In conjunction with the specified inspections mainte nance shall be performed by a qualified JLG equipment mechanic JLG Industries Inc recognizes a qualified JLG equipment mechanic as a person who by possession of a recognized degree certificate extensive knowledge train ing or experience has successfully demonstrated the ability and proficiency to service repair and maintain the subject JLG product model Reference the Preventative Maintenance Schedule and the appropriate areas of this manual for servicing and maintenance procedures The frequency of service and maintenance must be increased as environment severity and frequency of usage requires 3121122 JLG Lift 2 1 SECTION 2 GENERAL Table 2 1 Inspection and Maintenance Type Frequenc Fay Reference 95618 Responsibility Qualification Priorto use each day or Pre Start Inspection Ateach Operator change User or Operator User or Operator Operator and Safety Manual Pre Delivery Prior to each sale lease or Qualified JLG Serviceand Owner Dealer or User Manual a
132. is not allowed because the joystick is not centered Return joystick to center and reselect function 229 FUNCTION PROBLEM TRIGGER PERMANENTLY CLOSED Trigger switch in the platform control box closed at start up Release switch to clear fault ELEV ANGLE SENSOR NOT DETECTING CHANGE Platform elevated for 5 sec and elevation voltage change not detected Faulty sensor wire harness or ground module Return platform to stowed position to clear Reset model or recalibrate elev angle sensor TRIGGER CLOSED TOO LONG WHILE IN NEUTRAL Trigger switch in the platform control box closed for more than ten seconds while the joystick is in the neutral position Release switch to clear fault 2 3 230 GROUND CONTROLS 231 FUNCTION PROBLEM LIFT PERMANENTLY SELECTED Lift switch up or down in the ground control box closed at start up Release switch to clear fault N A SENSOR NOT CONNECTED OR FAULTY No signal from the tilt switch Check wiring and plug connections at the level sensor and at the ground control board 3121122 JLG Lift 5 7 SECTION 5 JLG CONTROL SYSTEM Table 5 1 Flash Codes DTC s FLASHCODE DTC HELP MESSAGE AND DESCRIPTION 2 5 250 FUNCTION PREVENTED 251 ELEV ANGLE SESOR FAULTY VOLTAGE OUT OF RANGE The sensor signal input voltage is outside acceptable range This could be a short to IGN short to B short to
133. issect the three areas of error to find the primary contributor a Machine mounting and or grade With a digital level measure the top of the Ground Control box for levelness If unable to get a good reading check the box s mounting surface for levelness 3 2 JLG Lift 1 Ground Control Box 2 Digital Level 3121122 SECTION 3 CHASSIS amp SCISSOR ARMS b Tilt sensor mounting on machine or wedged crooked in control box If the machine mounting grade appears accept able open the Ground Control box carefully Observe whether the tilt sensor is properly seated 1 Ground Control Box 2 Tilt Sensor c Tilt sensor has developed an offset shift Remove the tilt sensor from the Ground Control box but keep both the tilt sensor and Ground Control box electrically connected Level one axis of the tilt sensor and observe the raw read ing should be within 2 0 Do the same for the other axis If either axis is greater than 2 0 replace the tilt sensor Some possible reasons that the tilt sensor will not cali brate are a The surface the machine is sitting on is off level by a few degrees flat doesn t imply level park ing lots are often not level b The tilt sensor has failed one or both of the channels X axis and Y axis c Tilt sensor has moisture intrusion that has shifted its output d Water and or corrosion in the
134. k checking fitting starts to fall after the unit has been pressurized and allowed to equal ize Leaks will most likely occur at the pipe plugs the main seal or wherever o rings or gaskets are located The exact location of a leak can usually be detected by brushing a soap and water solution around the main seal and where 229 the o rings or gaskets meet on the exterior of the unit then checking for air bubbles leak is detected in a seal o ring or gasket the part must be replaced and the unit rechecked Leak test at 10 psi for 20 minutes Figure 3 18 Bolt Torquing Sequence Tightening and Torquing Bolts If an air impact wrench is used to tighten bolts extreme care should be taken to ensure theat the bolts are not tightened beyond their specified torque The following steps describe how to tighten and torque bolts or socket head cap screws in a bolt circle 1 Tighten but do not torque bolt A until snug 2 Goto the opposite side of the botl circle and tighen bolt B until equally snug 3 Crisscross around the bolt circle and tighen remain ing bolts 4 Now use a torque wrench to apply a specified torque to bolt A 5 Using the same sequence crisscross around the bolt circle and apply an equal torque to the remain ing bolts 3121122 JLG Lift 3 31 SECTION 3 CHASSIS amp SCISSOR ARMS Main Disassembly 3 32 17 Coupling Retaining Ring
135. ke is allowed to operate NOTE Depressing the lift function switch while driving will not interrupt drive function Pump Motor Pump motor drive will start only if the following conditions are satisfied 1 Accelerator in neutral position 2 Traction mode off brake applied 3 Depress lift select the lights indicating lift select at the platform control will flash The accelerator must be moved within 3 seconds after the lift light illumi nates NOTE Depressing the drive function switch while lifting will not interrupt lift function Any time brushes are being replaced in a drive motor or pump motor all brushes in the motor should be replaced 4 8 FEATURES Traction Mode NOTE The lift up and drive functions are proportional The drive function is fully proportional with automatic speed cutback above elevation The system is designed for maximum traction to be delivered to both wheels at all times Machines equipped with oscillating axle will have oscilla tion below elevation cutback speed only Table 4 1 Cutout Heights Function M3369 3369LE M4069 4069LE 8ft 9ft6in 9ft6in 11 ft8in Elevated Cutback Height 2 4m 2 9m 2 9m 3 6m 28ft 30ft Drive Cutout Height N A 8 5m 9 1m 4 4 JLG Lift 4 9 CYLINDER CHECKING PROCEDURES NOTE Cylinder checks must be performed any time a cylin der component is replaced or when improper system operation is suspected Cylind
136. l through ACCESS LEVEL 2 enter the password to get into ACCESS LEVEL 1 Scroll to SET ELEV SENSOR and after pressing ENTER you should hear the motion alarm sounding off This puts the machine in adjustment mode If your machine does not have a motion alarm the following procedures will still apply NOTE 10 11 12 JLG Lift Lift the platform up until it stops lifting this will be the lift cut out height Using the analyzer press ESCAPE scroll to DIAG NOSTICS press ENTER scroll to ELEV SENSOR and press ENTER You should now see ANGLE SNSR The setting here should be 0 60v 0 70v This is the rotary switch output voltage that is being sent to J2 15 of GEC at the lift cutout mark A fully ele vated platform will read 2 95 volts Press ESCAPE on the analyzer scroll to SYSTEM then to ELEV PROX OPEN Now manually adjust the proximity switch until you see the analyzer read ELEV PROX CLOSED At this point make sure you have the maximum 5 16 in of clearance between the eye of the proximity switch and the scissor arm If you don t shim it If everything is okay at this point tighten it down this setting is required in case the rotary switch fails The proximity switch is a back up to assure proper lift cut out If the gap ever increases beyond 5 16 in the switch may cause intermittent operation Completely lower the platform Using the analyzer press escape and scroll through DIAGNOSTICS and then go to ELE
137. le out side diameter grooves of both the piston and the inder head Position the cylinder barrel in a suitable holding fix ture NOTICE 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 22 23 24 25 26 JLG Lift With barrel clamped securely and while adequately supporting the rod insert the piston end into the cyl inder barrel Ensure that the piston loading o ring and seal ring are not damaged or dislodged Continue pushing the rod into the barrel until the cyl inder head gland can be inserted into the barrel cyl inder or if applicable until the cylinder head threads engage the barrel threads If applicable apply loctite 222 and secure the inder head retainer using a suitable chain wrench Insert the other cylinder head gland into the barrel cylinder Secure the cylinder head retainer using a suitable chain wrench After the cylinder has been reassembled the rod should be pushed all the way in fully retracted prior to the reinstallation of any holding valves SECTION 4 HYDRAULICS 27 applicable install the cartridge type holding valve 4 13 OSCILLATION CYLINDER BLEEDING and fittings in the rod port block using new o rings as applicable Refer to Table 4 3 Holding Valve Torque Specifications for proper torque Bleeding Procedure
138. lines 2 The design and manufacturing tolerances of the component working parts are very close therefore even the smallest amount of dirt or foreign matter entering a system can cause wear or damage to the components and generally results in faulty opera tion Every precaution must be taken to keep hydraulic oil clean including reserve oil in storage Hydraulic system filters should be checked cleaned and or replaced as necessary at the speci fied intervals required in the Lubrication Chart in JLG Lift 2 3 SECTION 2 GENERAL NOTE Section 1 Always examine filters for evidence of metal particles Cloudy oils indicate a high moisture content which permits organic growth resulting in oxidation or cor rosion If this condition occurs the system must be drained flushed and refilled with clean oil 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 Good grade mineral oils with viscosities suited to the ambient temperatures in which the machine is oper ating are recommended for use Metal particles may appear in the oil or filters of new machines due to the wear in of meshing compo nents Hydraulic Oil 1 NOTE Refer to Section 1 for recommendations for viscosity ranges JLG recommends Mobilfluid 424 hydraulic oil which has an SAE viscosity of 10W 30 and a viscosity index of 152 Start up of hydr
139. mes The Pre Delivery Inspection shall be performed prior to each sale lease or rental delivery The Frequent Inspection shall be accomplished for each machine in ser vice for 3 months or 150 hours whichever comes first out of service for a period of more than 3 months or when purchased used The frequency of this inspection must be increased as environment severity and frequency of usage requires Reference the JLG Pre Delivery and Frequent Inspection Form and the Inspection and Preventative Maintenance Schedule for items requiring inspection during the perfor mance of these inspections Reference the appropriate areas of this manual for servicing and maintenance proce dures Annual Machine Inspection JLG recommends that an annual machine inspection be performed by a Factory Certified Service Technician on an annual basis no later than thirteen 13 months from the date of the prior Annual Machine Inspection JLG Indus tries Inc recognizes a Factory Certified Service Techni cian as a person who has successfully completed the JLG Service Training School for the subject JLG product model Reference the machine Service and Maintenance Manual and appropriate JLG inspection form for perfor mance of this inspection Reference the JLG Annual Machine Inspection Form and the Inspection and Preventative Maintenance Schedule for items requiring inspection during the performance of this inspection Reference the appropriate areas of th
140. mitting components are made of forged quenched and tempered high alloy steels External gears are carborized Precision roller bearings are used exclusively Two large tapered roller bearings support the sprocket or wheel loads A shaft seal protects the unit against contamination Disassembly 1 10 NOTE 11 NOTE 3121122 Position drive so that one of the fill holes is at the bottom of the end cover and drain the gear oil Remove all bolts holding motor and remove motor from drive Compress the disc 59 using a simple fixture or other suitable device Remove snap ring 66 and release pressure on disc until loose Remove tool and disc 59 Remove the spring 55 from the input shaft 44 and turn the unit so that cover 8 is in the up position Remove screw plugs 22 and seal rings 21 Remove snap ring 34 cover unit 8 from drive and O ring 33 Remove first stage planetary assembly 7 Remove hex hd bolts 23 to remove gear 33 and O ring 19 Remove Snap rings 15 to pull off planet gears 1 together with cylindrical roller bearings 11 from spindle 60 Further disassembly of the hub is discouraged Rein stallation of the shaft nut 4 requires a special tool and a torque of 626 ft Ibs 876 Nm for proper reas sembly These components WILL fail if not properly reassembled Inspect the planetary stage assemblies as complete units Thoroughly clean and check both the gearin
141. n and Maintenance It is important to establish and conform to a comprehen sive inspection and preventive maintenance program The following table outlines the periodic machine inspec tions and maintenance recommended by JLG Industries Inc Consult your national regional or local regulations for further requirements for aerial work platforms The fre quency of inspections and maintenance must be increased as environment severity and frequency of usage requires Pre Start Inspection It is the User s or Operator s primary responsibility to per form a Pre Start Inspection of the machine prior to use daily or at each change of operator Reference the Opera tor s and Safety Manual for completion procedures for the Pre Start Inspection The Operator and Safety Manual must be read in its entirety and understood prior to per forming the Pre Start Inspection Pre Delivery Inspection and Frequent Inspection The Pre Delivery Inspection and Frequent Inspection shall be performed by a qualified JLG equipment mechanic JLG Industries Inc recognizes a qualified JLG equipment mechanic as a person who by possession of a recog nized degree certificate extensive knowledge training or experience has successfully demonstrated the ability and proficiency to service repair and maintain the subject JLG product model The Pre Delivery Inspection and Frequent Inspection pro cedures are performed in the same manner but at differ ent ti
142. n is removed the TDER period begins This period ensures that no further CTS conditions occur prior to the cool down period Time Delay Cool down TDC Once the TDER period ends the alternator output is reduced to a minimal level in order to allow the engine to cool down for the TDC period If a CTS is received during the TDC period the CTS must last for at least the TDES period for the RBS to return to normal running operation Table 3 7 RBS Shutdown Sequence Remove CTS TDER Engine Run TDC Cool down Engine Stop To Connect the JLG Control System Analyzer to the Generator The JLG Control System Analyzer can be used to monitor generator settings and conditions Connect the analyzer as follows 1 JLG Lift Connect the four pin end of the cable supplied with the analyzer to the connector behind the ground control module located on the right side of the machine next to the ground control station and con nect the remaining end of the cable to the analyzer 3 15 SECTION 3 CHASSIS amp SCISSOR ARMS Heya sazAjeuy 1018Joues 01 2 911514 JOLOIBUSH SUL Set IezA puv 10 JOPIO Ul ISNW YOLIMS PUD eq IST SWF SUL ALON syuesg SuoN S O O yuRID HEIS OUI snes 4ueJ9 UOUMS 1
143. nd applicable JLG Inspection rental delivery Mechanic inspection form In service for 3 months or 150 hours whichever comes first or Qualified JLG Service and Maintenance Frequent Inspection Outofserviceforaperiodofmorethan3 Owner Dealer or User Mechanic Manualandapplicable JLG months or inspection form Purchasedused ee Service and Maintenance Annual Machine Annually later than 13 months from the Service Technician or Owner Dealer or User Manual and applicable JLG Inspection date ofthe prior inspection a Qualified JLG inspection form Mechanic Preventative Atintervals as specifiedin the Service and Qualified JLG Service and Maintenance Owner Dealer or User Maintenance Maintenance Manual Mechanic Manual 2 2 SERVICE AND GUIDELINES Shields covers seals and filters are provided to keep air fuel and oil supplies clean however these General items must be maintained on a scheduled basis in The following information is provided to assist you in the use and application of servicing and maintenance proce dures contained in this book Safety and Workmanship Your safety and that of others is the first consideration 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 adequat
144. nifold and so it is not subject to wear 4 5 COMPONENT FUNCTIONAL DESCRIPTION Hydraulic Pump The single stage gear pump is attached to the electric motor located in the left side tray of the machine Manual Descent The manual descent cable handle is located at the rear of the machine frame 4 6 WEAR PADS The original thickness of the sliding wear pads is 5 in 12 7 cm Replace sliding pads when worn to 4 7 in 11 9 cm 4 7 MOTOR CONTROLLER MODES OF OPERATION Traction Motor Drive Drive in either forward or reverse will start only if the fol lowing conditions are satisfied 1 Function switches off 2 No procedure or diagnostic faults present 3 Depress drive select Lights indicating drive at the platform control will flash The controller must be moved within 3 seconds after the drive select illumi nates 4 FWD or REV selected as appropriate Once in drive mode activating a function switch shall not cause drive mode to be exited the pump traction con tactor drive shall not be energized it will be left at the trac tion position If a function switch is selected during traction a procedure fault will occur when neutral is JLG Lift 4 3 SECTION 4 HYDRAULICS selected remaining until a function switch and both direc tions are no longer selected When the controller is returned to neutral the controller will control smooth stopping of the machine using plug braking before the bra
145. nnector Assembly 2 of 4 Connector Assembly 3 of 4 1 Connector Assembly 4 of 4 Connector Disassembly Connector Installation sexe IR kc gk QURE PAEA E DI DIP Contact Installation quas DT DTP Contact HD HDP Contact Installation ett tenes HD HDP Locking Contacts Into Position 2 HD HDP Contact u quce Electrical Components Installation Sheet 2 4 Electrical Components Installation Sheet 3 4 Electrical Schematic Kubota Engine M3369 amp 3369LE Electrical Schematic Yanmar Engine M3369 amp 3369LE Hydraulic Diagram 3369LE and M3369 Fixed Hydraulic Diagram 3369LE and M3369 Oscillating Hydraulic Diagram 4069LE and M4069 Fixed
146. nt is necessary the bearing cups can be removed with a slide hammer puller or driven out with a punch To remove the cluster gears from the carrier drive the roll pin into the planet shaft The planet shaft may now be tapped out of the carrier After planet shaft has been removed the roll pin can be driven out The cluster gear can now be removed from the carrier The tanged thrust washer will be removed from the cluster gear The needle bearings and thrust spacer are now removed from cluster gear When rebuilding or repairing the unit the retaining ring o rings and seal should always be replaced 3121122 SECTION 4 HYDRAULICS Assembly 1 With the hub shaft sub assembly resting on the shaft install internal gear The spline of the internal gear bore will mesh with the spline of the output shaft Thrust washer is installed on the face of the output shaft Sufficient grease or petroleum jelly should be used to hold thrust washer in place Place o ring into hub counterbore Use petroleum jelly to hold in place Locate and mark the four counter beamed holes in the face of the housing This is for identification later in the assembly Thrust spacer is installed into the bore of the output shaft This should be a slip fit and the thrust spacer should rotate in this location Place carrier assembly on a flat surface with the gear cluster up Find the punch marked tooth on each large gear and locate at 12 o clock
147. nt sensor is located inside the rear cover of the alternator Engine Speed Sensor The engine speed sensor provides a signal proportional to the rotational speed of the engine to the engine genera tor controller This signal is used by the controller to deter mine starter cut out overspeed fault and underspeed fault This signal has failsafe protection if it is not present at the controller the unit will fault with a loss of speed sig nal indication The engine speed sensor is located inside the recoil starter cover at the front of the engine Engine Low Oil Pressure Switch The engine is equipped with a low oil pressure switch The switch is closed when the oil pressure is below 14 2 psi 1 Bar JLG Lift 3 13 SECTION 3 CHASSIS amp SCISSOR ARMS FUEL SOLENOID eg CONTROL FUSE UA ENGINE LOW Mees OIL PRESSURE SWITCH q FUEL CONTROL RELAY 89 ALTERNATOR ___ d Ey i w DYNAMO OUTPUT FUSE E DYNAMO VOLTAGE REGULATOR Figure 3 9 Generator Components 3 14 JLG Lift 58 ENGINE STARTER ENGINE OIL TEMPERATURE 3121122 SECTION 3 CHASSIS amp SCISSOR ARMS Timing Sequences RBS Pre start Sequence 1 Time Delay Engine Start TDES TDES is the period which the RBS waits to verify that the CTS is valid rather than a transient condition Time Delay Pre Heat TDPH TDPH if enabled occurs after TDES has elapsed and t
148. ntact Installation 1 Grasp crimped contact about 25mm behind the contact barrel 2 Hold connector with rear grommet facing you 3 Push contact straight into connector grommet until a click is felt A slight tug will confirm that it is properly locked in place 4 Once all contacts are in place insert wedgelock with arrow pointing toward exterior locking mechanism The wedge lock will snap into place Rectangular wedges are not oriented Thy may go in either way NOTE The receptacle is shown use the same procedure for plug DT DTP Series Disassembly Figure 6 13 DT DTP Contact Removal 5 Remove wedgelock using needlenose pliers or a hook shaped wire to pull wedge straight out 6 To remove the contacts gently pull wire backwards while at the same time releasing the locking finger by moving it away from the contact with a screwdriver 7 Hold the rear seal in place as removing the contact may displace the seal HD30 HDP20 Series Assembly Figure 6 14 HD HDP Contact Installation 8 Grasp contact about 25mm behind the contact crimp barrel 9 Hold connector with rear grommet facing you 6 10 JLG Lift 3121122 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 10 Push contact straight into connector grommet until a positive stop is felt A slight tug will confirm that it is properly locked in place LOCKING FINGERS CONTACT UNLOCKED POSITION CONTACT LOCKED IN POSITION Figure 6 15 HD HDP
149. o vided A WARNING 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 3121122 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 A WARNING FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION MAY RESULT IN MACHINE DAMAGE PERSONNEL INJURY OR DEATH AND ISA 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 CAUTIONS 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
150. of rod for damage Dress threads as necessary Inspect inner surface of cylinder barrel tube for scor ing or other damage Check inside diameter for tapering or ovality Replace if necessary Inspect threaded portion of barrel for damage Dress threads as necessary Inspect piston surface for damage and scoring and for distortion Dress piston surface or replace piston as necessary Inspect threaded portion of piston for damage dress threads as necessary Inspect seal and o ring grooves in piston for burrs and sharp edges Dress applicable surfaces as nec essary Inspect cylinder head inside diameter for scoring or other damage and for ovality and tapering Replace as necessary Inspect threaded portion of head for damage Dress threads as necessary Inspect seal and o ring grooves in head for burrs and sharp edges Dress applicable surfaces as nec essary Inspect cylinder head outside diameter for scoring or other damage and ovality and tapering Replace as necessary If applicable inspect rod and barrel bearings for signs of correct lubrication and excessive wear If necessary replace bearings as follows a Thoroughly clean steel bushing hole of burrs dirt etc to facilitate bearing installation b Inspect steel bushing for wear or other damage If steel bushing is worn or damaged rod or bar rel as applicable must be replaced c Using arbor of the correct size carefully press the bearing into the s
151. olvent to remove all grease and oil filament wound bearing are a dry joint and should not be lubri cated c Pins should be inspected to ensure it is free of burrs nicks and scratches which would dam age the bearing during installation and opera tion 2 6 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE The preventive maintenance and inspection checks are listed and defined in the following table This table is divided into two basic parts the AREA to be inspected and the INTERVAL at which the inspection is to take place Under the AREA of the table the various systems along with components that make up that system are listed The INTERVAL portion of the table is divided into five columns representing the various inspection time periods The numbers listed within the interval column represent the applicable inspection code for which that component is to be checked The checks and services listed in this schedule are not intended to replace any local or regional regulations that may pertain to this type of equipment nor should the lists be considered as all inclusive Variances in interval times may occur due to climate and or conditions and depend ing on the location and use of the machine JLG Industries requires that a complete annual inspection be performed in accordance with the Annual Machine Inspection Report form Forms are supplied with each new machine and are also available from JLG Customer Ser
152. onnected back wards 3121122 JLG Lift 5 1 SECTION 5 JLG CONTROL SYSTEM Using the Analyzer With the machine power on and the analyzer connected properly the analyzer will display the following 4 LG MENU HELP PRESS ENTER DI j HELP PRESS ENTER At this point using the RIGHT and LEFT arrow keys you can move between the top level menu items To select a displayed menu item press ENTER To cancel a selected menu item press ESC then you will be able to scroll using the right and left arrow keys to select a different menu item The top level menus are as follows HELP DIAGNOSTICS ACTIVATE TESTS ACCESS LEVEL PERSONALITIES MACHINE SETUP CALIBRATION Access level 1 only If you press ENTER at the HELP PRESS ENTER display and a fault is present the analyzer display will scroll the fault across the screen If more than one fault is present only the highest priority fault will show The other active faults are viewable in Logged Help If there was no fault detected the display will read 5 2 JLG Lift In platform mode HELP EVERYTHING OK In ground mode HELP GROUND MODE OK If ENTER is pressed again the display moves to the fol lowing display og 1 Startup 2 1 Sex A et LOGGED HELP 1 STARTUP 2 1 Or last recorded fault At this po
153. ops below the underspeed limit the engine will stop immedi ately and an engine underspeed alarm will be indicated Overcrank If the engine fails to start after a set number of start attempts the RBS will cease attempts to restart and an engine overcrank alarm will be indicated No Speed Signal In the event of a loss of speed signal the RBS will shut down and an engine no speed signal alarm will be indi cated This shutdown is delayed by a factory set period to ensure the fault was not momentary Overvoltage If the voltage measured at the alternator output exceeds the high voltage setting the RBS will stop immediately and an RBS high output alarm will be indicated This shut down is delayed by a factory set period to ensure the fault was not caused by a transient condition This feature pro tects the batteries and load from high DC voltages Engine Starting System Fault Indicates a problem with either the engine start battery engine magneto or magneto voltage regulator Loss Of Voltage Sense If the voltage measured at the alternator output is less than half of the system nominal voltage the RBS will stop immediately and an RBS loss of voltage sense alarm will be indicated This feature protects the batteries and load from high DC voltages due to a loss of output control Run Inhibited The RBS unit is disabled by the run inhibited input Output Current and Voltage Settings Normal Extended Output Voltage
154. or SET 36FT ELEV 40691 a Raise platform to a height of 30 feet on the 3369LE or 36 feet for the 4069LE measured deck to ground b Enter YES on the Analyzer c COMPLETE will show on the analyzer when cali brated NOTE Elevation Proximity Switch must be mounted and functioning properly to calibrate the Elevation Sen sor Speed Sensor The speed sensor is located at the lower side of the left front drive motor If removing the speed sensor for any reason use the following procedure 1 Using an 18mm wrench remove the speed sensor from the left front drive motor 2 reusing the speed sensor note the location of the brass feral on the sensor Do not remove this will be the depth gauge when you replace the sensor 3 When replacing seat the sensor so that it fits snug in the motor on the brass feral NOTE If replacing the speed sensor the new sensor will have a wax pill on the end of the sensor Tighten down until you feel the wax pill bottom out inside the motor 4 Tighten up the packing nut Tilt Sensor Calibration 1 Drive the machine onto a measured level surface 0 5 for both x and y axis Using the Analyzer go to MENU CALIBRATION TILT SENSOR Press Enter LEVEL VEHICLE will dis play Press Enter again to calibrate Both axis raw angles need to be within 5 0 other wise the machine is to unlevel and the software will prohibit calibration Should this occur attempt to d
155. ot too small usu ally gt 50Ah 2 Confirm that the nominal battery voltage matches the charger output voltage 3 Confirm the correct battery charge algorithm If the battery pack is new the algorthm will need to be changed if the pack is not the same as the old one for instructions on how to determine and change the battery charge algorithm see the following sub sec tion 4 Ifthe output voltage of the charger seems excessive return the charger for service Contact JLG to get the expected battery voltage settings for the charger in question Be sure to have the charger s serial num ber and charge algorithm setting available when calling 3121122 SECTION 3 CHASSIS amp SCISSOR ARMS Checking Changing the Battery Charge Algo 3 Remove the AC power from the charger and recon rithm nect the charger s positive connector to the battery The charger is pre loaded with programming algorithms NOTE It is recommended to check a newly changed algo for the specific batteries detailed in Table 3 4 Battery rithm by repeating the above steps 1 and 3 Algorithms Contact JLG if your specific battery model is not listed e Table 3 4 Battery Algorithms Each time AC power is applied with the battery pack not connected the charger enters an algorithm select display Algorithm Battery Type mode for approximately 11 seconds During this time the 143 DISCOVER EVL1GA A current Algorithm is ind
156. ower to clear fault 7 7 770 ELECTRIC MOTOR 773 CAPACITOR BANK FAULT CHECK POWER CIRCUITS Check power wiring If no error in power wiring replace power controller 775 OPEN CIRCUIT FIELD or TRACTION WIRING Open circuit between F1 and F2 terminals on power module and the drive motors Check wiring 8 1 810 TILT SENSOR 812 NO DATA FROM TILT SENSOR NOT CONNECTED OR FAULTY No signal from the tilt switch Check wiring and plug connections at the level sensor and at the ground control box 9 9 990 HARDWARE 995 POWER MODULE FAILURE PERSONALITY RANGE ERROR Toggle MODEL then re configure Machine Setup and Personalities If this does not resolve issue replace power controller 996 POWER MODULE FAILURE INTERNAL ERROR Toggle MODEL then re configure Machine Setup and Personalities If this does not resolve issue replace power controller 997 POWER MODULE FAILURE CHECK POWER CIRCUITS OR MOSFET SHORT CIRCUIT Check power wiring If no error in power wiring module replace power controller 9980 POWERMODULE FAILURE PERSONALITY CRC ERROR Toggle MODEL then re configure Machine Setup and Personalities If this does not resolve issue replace power controller POWER MODULE FAILURE CAPACITOR BANK FAULT Replace power module 3121122 JLG Lift 5 9 SECTION 5 JLG CONTROL SYSTEM 5 10 Table 5 2 Power Module Diagnostic LED Flash Codes Flash Code Fault Const
157. oxidation and low level conductivity silicone dielectric grease must be packed completely around male and female pins on the inside of the connector after the mating of the housing to the header This is easily achieved by using a syringe to fill the header with silicone dielectric compound to a point just above the top of the male pins inside the header When assembling the housing to the header it is possible that the housing will become air locked thus preventing the housing latch from engaging 2 Pierce one of the unused wire seals to allow the trapped air inside the housing to escape 3 Install a hole plug into this and or any unused wire seal that has silicone dielectric compound escaping from it PLUG AND HEADER ASSEMBLY COLORS ARE MECHANICALLY KEYED TO MATE ONLY WITH IDENTICAL COLORS MATING SEAL PLUG ASSEMBLY RETENTION LEG WEDGE LOCK HOUSING Figure 6 5 AMP Connector 3121122 JLG Lift 6 5 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Assembly Check to be sure the wedge lock is in the open or as shipped position See Figure 6 6 Connector Assembly 1 of 4 Pro ceed as follows CONTACT PARTIALLY INSERTED RETENTION FINGERS DIAPHRAGM MATING SEAL WEDGE LOCK SHOWN IN OPEN POSITION Figure 6 6 Connector Assembly 1 of 4 1 To insert a contact push it straight into the appropriate circuit cavity as far as it will go See Figure 6 7 Connector Assembly 2 of 4
158. pitted scored or burned 3 If bearing is found to be serviceable apply a light coat of oil and wrap it in clean waxed paper Do not unwrap reusable or new bearings until they are ready to be installed 4 Lubricate new or used serviceable bearings before installation When pressing a bearing into a retainer or bore apply pressure to the outer race If the bear ing is to be installed on a shaft apply pressure to the inner race Gaskets 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 stock of equivalent material and thickness Be sure to cut holes in the right location as blank gaskets can cause serious system damage Bolt Usage and Torque Application 1 Use bolts of proper length A bolt which is too long will bottom before the head is tight against its related part If a bolt is too short there will not be enough thread area to engage and hold the part properly When replacing bolts use only those having the same specifications of the original or one which is equivalent 3121122 JLG Lift 4 1 SECTION 4 HYDRAULICS 2 Unless specific torque requirements are given within the text standard torque values should be used on heat treated bolts studs and steel nuts in accor dance with recommended shop practices Hydraulic Lines and Electrical Wiring 5 Clearly mark or tag hydraulic lines and electrical wiring as w
159. prevented when Tilted amp Elevated 4 0 NO Leveling Jacks are not installed 0 LEVELING JACKS 1 YES Leveling Jacks are installed 5 0 DRIVE Drive is prevented when the vehicle is being charged 1 CN CHARGER INTRLOK DRIVE amp LIFT Drive amp Lift Up are prevented when the vehicle is being 0 charged 6 0 NOT INSTALLED The Ground Alarm shall sound 1 DESCENT The Ground Alarm shall sound during Lift Down 1 1 1 1 2 GROUND ALARM 2 MOTION The Ground Alarm shall sound during any vehicle motion 0 NONE 7 1 DRV amp LFT UP Only allows Lift Down when Function Cutout is active 0 FUNCTION CUTOUT 2 ALL FUNCTIONS All functions are prevented when Function Cutout is active 8 0 NO The 4 Wheel Assist option is not installed 0 4 WHEEL ASSIST 1 YES The 4 Wheel Assist option is installed 0 NOT INSTALLED Load Sensing System LSS is not fitted to the vehicle 1 CUTOUT PLT LSS is fitted and Platform Controls are prevented in the 9 event of an Overload Ground Controls remain functional This is the 01110 0 1 LOAD default setting for CE machines 2 CUTOUT ALL LSS is fitted Platform and Ground Controls are prevented in the event of an Overload 0 STANDARD Normal tilt limits 1 SPECIAL 1 Vehicle tilt limits restricted to allow operation of a standard 10 3369LE in 16 7 m s wind speeds for the CE Market TILT LIMIT NOTE Tilt Limit selection is only visible for the 3369LE con figured for the CE
160. raulic Diagram 3369LE and M3369 Oscillating Axle 2792444 G 3121122 JLG Lift 6 21 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 5A 58 6 22 HOLDING CHECK VALVE HOLDING CHECK VALVE he BULKHEAD PLATE BRAKES REAR WHEELS MAIN CONTROL VALVE MP uu 2792445 F Figure 6 28 Hydraulic Diagram 4069LE and M4069 Fixed Axle JLG Lift 3121122 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS LIFT LIFT HOLDING CHECK HOLDING CHECK VALVE VALVE BULKHEAD PLATE BRAKES REAR WHEELS 5B MAIN CONTROL VALVE 2792446_H Figure 6 29 Hydraulic Diagram 4069LE and M4069 Oscillating Axle 3121122 JLG Lift 6 23 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS E pa Ai P d 1 BRAKES REAR WHEELS
161. re 4 3 Rod Support 7 With the barrel clamped securely apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel 8 Using suitable protection clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible 9 If applicable loosen and remove the nut which attaches the piston to the rod then remove the pis ton from the rod 10 If applicable loosen and remove the cap screw s securing the tapered bushing to the piston 11 Insert the capscrew s in the threaded holes in the outer piece of the tapered bushing Progressively tighten the cap screw s until the bushing is loose on the piston then remove the bushing from the pis ton 12 Screw the piston counter clockwise by hand and remove the piston from the cylinder rod 13 Remove and discard the piston o rings back up rings guidelock rings and hydrolock seals 14 If applicable remove the piston spacer from the rod 15 Remove the rod from the holding fixture Remove the cylinder head and retainer plate from the rod 3121122 SECTION 4 HYDRAULICS Cleaning and Inspection 1 10 11 12 13 NOTE 3121122 Clean all parts thoroughly in an approved cleaning solvent Inspect the cylinder rod for scoring tapering ovality or other damage If necessary dress rod with Scotch Brite or equivalent Replace rod if necessary Inspect threaded portion
162. res that a set ting cannot be accidentally altered To change the access level the correct password must be entered To enter the password scroll to the ACCESS LEVEL menu For exam ple 4 3 MENU H ACCESS LEVEL 2 S ACCESS LEVEL 1 Repeat the above steps if the correct access level is not displayed or you can not adjust the personality settings MENU ACCESS LEVEL 2 Press ENTER to select the ACCESS LEVEL menu Using the UP or DOWN arrow keys enter the first digit of the password 3 Then using the RIGHT arrow key position the cursor to the right one space to enter the second digit of the pass word Use the UP or DOWN arrow key to enter the second digit of the password which is 3 Repeat this process until you have entered all five digits of the password which is 33271 3121122 JLG Lift 5 3 SECTION 5 JLG CONTROL SYSTEM Adjusting Parameters Using the Hand Held Analyzer Once you have gained access to level 1 and a personality item is selected press the UP or DOWN arrow keys to adjust its value for example f PERSONALITIES DRIVE ACCEL 1 0s e PERSONALITIES DRIVE ACCEL 1 0s There will be a minimum and maximum for the value to ensure efficient operation The Value will not increase if the UP arrow is pressed when at the ma
163. ring is found to be serviceable apply a light coat of oil and wrap it in clean waxed paper Do not unwrap reusable or new bearings until they are ready to install 4 Lubricate new or used serviceable bearings before installation When pressing a bearing into a retainer or bore apply pressure to the outer race If the bear ing is to be installed on a shaft apply pressure to the inner race Gaskets 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 stock of equivalent material and thickness Be sure to cut holes in the right location as blank gaskets can cause serious system damage Bolt Usage and Torque Application 1 Use bolts of proper length A bolt which is too long will bottom before the head is tight against its related part If a bolt is too short there will not be enough thread area to engage and hold the part properly When replacing bolts use only those having the same specifications of the original or one which is equivalent 2 Unless specific torque requirements are given within the text standard torque values should be used on heat treated bolts studs and steel nuts in accor dance with recommended shop practices See Torque Chart Section 1 3121122 Hydraulic Lines and Electrical Wiring Clearly mark or tag hydraulic lines and electrical wiring as well as their receptacles when disconnecting or removing t
164. robe tips specifically designed for this technique especially on sealed connectors Whenever possible insert probes into the side of the connec tor such that the test also checks both terminals of the connection It is possible to inspect a connection within a closed con nector by backprobing both sides of a connector terminal and measuring resistance Do this after giving each wire a gentle pull to ensure the wires are still attached to the contact and contacts are seated in the connector Min Max Use of the Min Max recording feature of some meters can help when taking measurements of intermittent conditions while alone For example you can read the voltage applied to a solenoid when it is only operational while a switch far from the solenoid and meter is held down Polarity Finding a negative voltage or current reading when expecting a positive reading frequently means the leads are reversed Check what reading is expected the location of the signal and that the leads are connected to the device under test cor rectly Also check that the lead on the COM port goes to the ground or negative side of the signal and the lead on the other port goes to the positive side of the signal Scale M Mega 1 000 000 Displayed Number k kilo 1 000 Displayed Number m milli Displayed Number 1 000 micro Displayed Number 1 000 000 Example 1 2 kQ 1200 Example 50 mA 0 05 A 3121122 JLG Lift 6 1 SECTION 6
165. rom the housing for insertion or removal of the contacts Wedge Lock The wedge lock has slotted openings in the forward or mating end These slots accommodate circuit testing in the field by using a flat probe such as a pocket knife DO NOT use a sharp point such as an ice pick 6 8 Lift 3121122 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Service Voltage Reading A CAUTION DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS It has been common practice in electrical troubleshooting to probe wires by piercing the insulation with a sharp point This practice should be discouraged when dealing with the AMPSEAL plug assembly or any other sealed connector system The resulting pinholes in the insulation will allow moisture to invade the system by traveling along the wire strands This nullifies the effectiveness of the connector seals and could result in system failure WIRE STRANDS MUST BE VISIBLE IN THIS AREA WIRE STRANDS AND INSULATION MUST C gt BOTH BE VISIBLE IN THIS AREA CUTOFF TAB MUST BE VISIBLE SCREWDRIVER SLOT LOCKING LATCH MUST BE TO LIFT LATCH FOR SECURELY FASTENED UNMATING FOR MATING PLUG AND HEADER MUST BE OF IDENTICAL COLOR IN ORDER FOR THEM TO MATE Figure 6 11 Connector Installation 3121122 JLG Lift 6 9 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 6 4 WORKING WITH DEUTSCH CONNECTORS DT DTP Series Assembly Figure 6 12 DT DTP Co
166. rom the service container Always clean the mesh element of the filter and replace the cartridge any time the system oil is changed 3 While the unit is shut down a good preventive main tenance measure is to make a thorough inspection of all hydraulic components lines fittings etc as well as a functional check of each system before placing the machine back in service Lubrication Specifications Specified lubricants as recommended by the component manufacturers are always the best choice however multi purpose greases usually have the qualities which meet a variety of single purpose grease requirements Should any question arise regarding the use of greases in maintenance stock consult your local supplier for evalua tion Refer to Section 1 for an explanation of the lubricant key designations appearing in the Lubrication Chart 2 4 CYLINDER DRIFT TEST Maximum acceptable cylinder drift is to be measured using the following methods Platform Drift Measure the drift of the platform to the ground Fully ele vate the platform Maximum allowable drift is 2 in 5 cm in 10 minutes If the machine does not pass this test pro ceed with the following Cylinder Drift Table 2 2 Cylinder Drift Max Acceptable Drift Cylinder Bore Diameter in 10 Ge inches mm inches mm 3 76 2 0 026 0 66 3 5 89 0 019 0 48 4 101 6 0 015 0 38 5 127 0 009 0 22 6 152 4 0 006 0 15 7 177 8 0 005 0 13
167. rted into the cylinder barrel Secure the cylinder head gland using the washer ring and socket head bolts After the cylinder has been reassembled the rod should be pushed all the way in fully retracted prior to the reinstallation of any holding valve or valves If applicable install the cartridge type holding valve and fittings in the port block using new o rings as applicable A WARNING WHEN REBUILDING THE LIFT CYLINDERS APPLY LOCTITE 242 TO PISTON NUT AND SETSCREWS Table 4 2 Cylinder Piston Nut Torque Specifications 3121122 MI Nut Torque Value Description Wet Lift Cylinder 800 1000 ftlbs 3369 1120 1400 Nm Lift Cylinder 1125 1375 ftlbs 4069 1575 1925 Nm 150 ftlbs Steer Cylinder 210Nm Table 4 3 Holding Valve Torque Specifications Description Torque Value 30 35ftlbs Sun 7 8 hex 20 x1 5 thds 41 48 45 50 ftlbs Sun 1 1 8hex 1 14 UNS thds 61 68 150 160 ftlbs Sun 1 1 4 hex M36 x 2 thds 204 207 Nm 50 55 ftlbs Racine 1 1 8 hex 1 1 16 12 thds 68 75 Nm 75 80ftlbs Racine 1 3 8 hex 1 3 16 12 thds 102 109 100 110ftlbs Racine 1 7 8 hex 1 5 8 12 thds 136 149 Nm NOTE 19 20 21 These cylinders use setscrews which should be dis carded and replaced whenever they are removed Remove cylinder rod from the holding fixture Place new o rings and seals in the applicab
168. ry System which is the generator system CTS stands for Call To Start which is the electronic inputs which signal the generator to start and charge the batteries The generator consists of a drive engine controller and related components Alternator The alternator is a brushless DC output alternator The 3 phase output of the alternator is full wave rectified and directed to the output terminator The output rating is 58 volts DC at 45 amps Voltage regu lation and current limiting is provided by the Engine Gen erator Controller The rectifier diodes and output current sensor are located in the alternator end Dynamo and Dynamo Voltage Regulator The engine is equipped with a 12 Volt 15 Amp DC output dynamo Dynamo Output Fuse The dynamo output fuse is used to protect the output of the dynamo This fuse is rated at 20 Amps DC slow blow and is located on the left side of the engine Control Fuse This fuse provides power to the engine generator and the relays for start control fuel control and pre heater This fuse is rated at 15 Amps DC and is located on the right side of the engine Start Battery A 12 volt lead acid battery is utilized to provide starting power for the generator and power for the generator con trols This battery is charged by the engine dynamo and dynamo regulator when the engine is running Engine Starter The engine is equipped with a 12 Volt DC starter This starter prov
169. straight up from each planet pin With shoulder side of ring gear facing down place ring gear over into mesh with cluster gear Be sure that punch marks remain in correct location during installation The side of the ring gear with an X stamped on it should be up While holding ring gear and cluster gear in mesh place small side of cluster gear into mesh with the internal gear and sun gear On the ring gear locate the hole marked X over one of the marked coun terbored holes in hub NOTE If gears do not mesh easily or carrier assembly does 3121122 not rotate freely then remove the carrier and ring gear and check the cluster gear timing 10 11 12 13 14 15 16 JLG Lift Sun gear is installed meshing with the teeth of the large diameter cluster gear The counterbore on the sun gear locates on the shoulder of the input spacer This is to be a slip fit and should operate freely Thrust washer is installed onto the sun gear and should locate on the gear teeth shoulder Thrust washer is installed into the counterbore of the carrier Place o ring into input cover counterbore Use petro leum jelly to hold o ring in place The input cover is now installed on this assembly Taking care to correctly align pipe plug hole with those in the hub usually 90 to one another locate the four counterbore holes in housing marked in step 3 and install four shoulder bolts A tap with a hammer may
170. t SAE Fasteners Sheet 2 7 1 7 1 5 Torque Chart SAE Fasteners Sheet 3 7 1 8 1 6 Torque Chart SAE Fasteners Sheet 4 7 1 9 1 7 Torque Chart METRIC Fasteners Sheet 5 7 1 10 1 8 Torque Chart METRIC Fasteners Sheet 6 7 1 11 1 9 Torque Chart METRIC Fasteners Sheet 7 7 1 12 3 1 ipo erdt eras S d A ewe ae Eegen 3 4 3 2 Tilt Sensor Removal ire pu eed e UI pi ME edad REM 3 4 3 3 Tilt Sensor Eocation oce toe et b BS 3 5 3 4 Tilt Sensor Removal 3 5 3 5 Remote LED Card donde qua i e ku du dtp Oe halal cgo a alg 3 7 3 6 Battery Charger Location M model 3 7 3 7 Battery Charger EE EENS FO Oa 3 7 3 8 Batteries and Battery 0 3 12 3 9 Generator Components 3 14 3 10 Generator System Analyzer Flow 3 16 3 11 Joystick Controller JLG P N 1600308
171. t mallet tap a new wiper seal into the applicable cylinder head gland groove Install a new wear ring into the applicable head gland groove CYLINDER MALLET HEAD Note When installing wiper seal ensure seal are installed properly Install seal so that the flat part of seal is facing into head Figure 4 6 Wiper Seal Installation 3 Place a new o ring and back up seal in the applica ble outside diameter groove of the cylinder head CYLINDER HEAD BACKUP RING Figure 4 7 Installation of Head Seal Kit 4 Install a washer ring onto the rod then carefully install the head gland on the rod ensuring that the wiper and rod seals are not damaged or dislodged Push the head along the rod to the rod end as applicable 5 Carefully slide the piston spacer onto the rod 6 If applicable correctly place a new o ring and back up rings in the inner piston diameter groove 7 Using suitable protection clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible 8 Carefully thread the piston on the cylinder rod hand tight ensuring that the o ring and back up rings are not damaged or dislodged 9 Thread the piston onto the rod until it abuts the spacer end and install the tapered bushing NOTE When installing the tapered bushing the piston and 4 8 mating end of the rod must be free of oil GUIDE LOCK RING SEAL BACK UP GUIDE LOCK RING Figure
172. teel bushing Install the cylinder pin into the Garmax bearing dry Lubrication is not required with chrome pins and bearings STEEL GARMAX BUSHING BUSHING ARBOR Figure 4 4 Oil lite Bearing Installation 14 Inspect travel limiting collar or spacer for burrs and sharp edges If necessary dress inside diameter surface with Scotch Brite or equivalent 15 If applicable inspect port block fittings and holding valve Replace as necessary 16 Inspect the oil ports for blockage or the presence of dirt or other foreign material Repair as necessary 17 If applicable inspect piston rings for cracks or other damage Replace as necessary Assembly NOTE Prior to cylinder assembly ensure that the proper cylinder seal kit is used Apply a light film of hydraulic oil to all components prior to assembly Using a special tool pictured in the following illustra tion install a new rod seal into the applicable cylin der head gland groove Refer to the following illustration for the proper tool size SEAL TOOL 1 7004275 1 1 2 7004276 2 7002826 CYLINDER HEAD Figure 4 5 Rod Seal Installation NOTICE WHEN INSTALLING NEW POLY PAK TYPE PISTON SEALS ENSURE SEALS ARE INSTALLED PROPERLY SEE FIGURE 4 9 FOR CORRECT SEAL ORIENTATION IMPROPER SEAL INSTALLA TION COULD RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION JLG Lift 4 7 SECTION 4 HYDRAULICS 2 Using a sof
173. the axle in the opposite direction and repeat step three Checking Oscillation Cylinders cylinder from underneath the machine After bleeding the lockout cylinders check to see that they are holding their position when oscillated 5 Remove the nut and bolt from the rod end of the cyl inder from out at the spindle 1 6 Remove cylinder from machine 4 10 JLG Lift Run one wheel onto a ramp or a block of wood mark the retracted cylinder with a marker elevate platform above high speed cutout Back the unit off of the ramp check the retracted cylinder for drive more than 12 Repeat this procedure for the other side If the lock out cylinders do not hold repeat the bleeding proce dure or check for the following a Air in lockout system b Bad oylinder seals c Bad holding valves 3121122 SECTION 4 HYDRAULICS Oscillating Axle Lockout Test If Equipped LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY ANY TIME A SYSTEM COMPONENT IS REPLACED OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED NOTE Ensure platform is fully lowered prior to beginning lockout cylinder test 1 Place a 6 inch 15 2 cm high block with ascension ramp in front of left front wheel 2 From platform control station select LOW drive speed 3 Place DRIVE control switch to FORWARD position and carefully drive the machine up ascension ramp until left front wheel is on top of block 4 Raise machine platform approx
174. tick REVERSE and press ENTER 2 CAL COMPLETE or CAL FAILED will display on the analyzer 3 Possible reasons if calibration failed a The forward position must be a lower voltage than reverse position b The difference between center and forward amp center and reverse must be atleast 1V JLG Lift 3 3 SECTION 3 CHASSIS amp SCISSOR ARMS 3 2 TILT SENSOR Tilt Sensor JLG P N 4000006 1 Ground Control Box 2 Tilt Sensor JLG P N 4000006 Figure 3 1 Tilt Sensor Location Tilt Sensor Removal NOTE Refer to Figure 3 2 Tilt Sensor Removal for num bers in parenthesis 1 Disconnect the batteries 2 Open the Ground Control Box to gain access to the Tilt Sensor Assembly 3 Remove the four Screws 2 and Lockwashers 3 to remove the Tilt Sensor 1 from the Ground Control Box NOTE Follow the above procedures in reverse order when installing the tilt sensor assembly After installing be sure to calibrate the tilt sensor refer to Section 3 1 Calibrations 3 4 JLG Lift 1 Tilt Sensor JLG P N 4000006 2 Screw 6 32 x 3 4 3 Lockwasher Figure 3 2 Tilt Sensor Removal Table 3 1 Tilt Sensor Harness Chart Wire Color Function Connector Pin Red VCC 1 Black Ground 4 Blue PWMX 2 Yellow PW
175. ugh pressure to press in studs Don t use excessively high pressure to press in Studs as this 9 Using appropriate tool install Retaining Ring 2 into may crack Hub Spindle groove Make sure ring is completely seated in groove Spray a generous amount of oil on bearings during NOTE Extra bearing pre load caused by using tool in Step installation 9 must be removed This should be done by placing a tool NOT THE SAME TOOL USED IN STEP 9 2 Press Bearing Cup 5 position A into Hub using on the end of the Spindle and then striking the tool appropriate pressing tool with a piece of barstock This should be adequate to E remove any additional bearing pre load 3 Turn Hub over and press Bearing Cup position B into Hub using appropriate pressing tool 4 Place Bearing Cone 9 into Bearing Cup position D 5 Grease Seal refer to Figure 3 17 lip and press Seal into Hub using appropriate tool until seal is flush with end of Hub 3 40 JLG Lift 3121122 SECTION 3 CHASSIS amp SCISSOR ARMS Cover Sub Assembly 1 O Ring 4 Hex Head Bolts 7 O ring 2 Cover 5 Disengage Cap 8 O ring Pipe Plugs 3 Thrust Washer 6 Disengage Rod Figure 3 25 Cover Sub Assembly 1 Grease O Ring 7 and insert groove in Cover 2 4 Grease the face of the Thrust Washer 3 and place in the Cover making sure the tangs on the Washer 2 Assemble Disengage Cap 5 onto Cover using two seat into the pockets in the Cover H
176. urers are always the best choice however multi purpose greases usually have the qualities which meet a variety of single purpose requirements Should any question arise regarding the use of greases in mainte nance stock consult your local supplier for evaluation Refer to Section 1 for an explanation of the lubricant key designations appearing in the Lubrication Chart 4 3 CYLINDERS THEORY OF OPERATION 1 Oylinders are of the double acting type The Lift and Steer systems incorporate double acting cylinders A double acting cylinder is one that requires oil flow to operate the cylinder rod in both directions Direct ing oil by actuating the corresponding control valve to the piston side of the cylinder forces the piston to travel toward the rod end of the barrel extending the cylinder rod piston attached to rod When the oil flow is stopped movement of the rod will stop By directing oil to the rod side of the cylinder the piston will be forced in the opposite direction and the cylin der rod will retract 2 Holding valves are used in the lift circuits to prevent retraction of the cylinder rod should a hydraulic line rupture or leak develop between the cylinder and its related control valve 4 4 VALVES THEORY OF OPERATION Control Valves The main control valve consists of cartridge type valves in an aluminum manifold The cartridge valves provide for control of flow volume of flow and pressure in the hydrau lic system
177. vice Forms must be completed and returned to JLG Industries NOTICE 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 The inspection and maintenance code numbers are as fol lows 1 Check for proper and secure installation 2 Check for visible damage and legibility 3 Check for proper fluid level 4 Check for any structural damage cracked or broken welds bent or warped surfaces Check for leakage 6 Check for presence of excessive dirt or foreign material 7 Check for proper operation and freedom of move ment 8 Check for excessive wear or damage 9 Check for proper tightness and adjustment 10 Drain clean and refill 11 Check for proper operation while unit power is on 12 Check for proper lubrication 13 Check for evidence of scratches nicks or rust and for straightness of rod 14 Check for condition of element replace as neces sary 15 Check for proper inflation 16 Clean or replace suction screen JLG Lift 2 5 SECTION 2 GENERAL Table 2 3 Preventive Maintenance and Inspection Schedule AREA INTERVAL PLATFORM 10 HOURS DAILY 50 HOURS WEEKLY 200
178. wire 1 and wire 2 These should be open If not repair the shorted wires or replace the harness 3 Onone side jumper from contact of wire 1 and wire 2 4 Measure continuity between wire 1 and wire 2 If there is continuity both wires are good and can be used for this test If there is not continuity either wire could be bad Check connections and measurement setup Redo measure ment If still no continuity repair wires or consult schematic for other wires to use for test 5 Jumper from wire under test to wire 1 6 Measure continuity If there is continuity the wire under test is good Resistance of a wire increases as the length increases and as the diameter decreases One can find the continuity of two wires here 1 and 2 at once by following steps 1 through 4 If there is a problem the third wire is used to troubleshoot the other wires To find the problem start at step 1 and use the entire procedure 6 4 JLG Lift 3121122 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 6 3 APPLYING SILICONE DIELECTRIC COMPOUND TO AMP CONNECTORS Silicone Dielectric Compound must be used on the AMP connections for the following reasons To prevent oxidation at the mechanical joint between male and female pins To prevent electrical malfunction caused by low level conductivity between pins when wet Use the following procedure to apply Silicone Dielectric Compound to the electrical connectors 1 To prevent
179. ximum value nor will the value decrease if the DOWN arrow is pressed and the value is at the minimum value for any particular per sonality If the value does not change when pressing the up and down arrows check the access level to ensure you are at access level 1 Machine Setup When a machine digit item is selected press the UP or DOWN arrow keys to adjust its value for example A WARNING FAILURE TO MAKE THE PROPER SETTINGS FOR THE PARTICU LAR MACHINE CAN RESULT IN IMPROPER OPERATION 5 MG GROUND ALARM 12MOTION iw GROUND ALARM 1 DESCENT The effect of the machine digit value is displayed along with its value The above display would be selected if the machine was equipped with a ground alarm and you wanted it to sound when driving There are certain set tings allowed to install optional features or select the machine model When selecting the machine model to match the size of the machine the personality settings will return to default settings 5 4 JLG Lift 3121122 SECTION 5 JLG CONTROL SYSTEM NOTE Refer to Table 5 3 Machine Model Adjustment and Table 5 4 Machine Configuration Programming Information for the default settings Password 33271 will give you access to level 1 which will permit you to change all machine person ality and or machine setup settings A WARNING CHANGING THESE SETTINGS MAY ADVERSELY AFFECT THE PERF
180. y Temperature Sensor Ory Machines equipped with the Delta Q battery charger include a battery temperature sensor The sensor is mounted to the negative terminal post of the inboard front battery on the machine s left side mounted battery pack See Figure 3 8 The sensor is wired directly to the bat tery charger 3121122 JLG Lift 3 11 SECTION 3 CHASSIS amp SCISSOR ARMS BATTERY CHARGER L BATTERY TEMPERATURE SENSOR DELTA Q CHARGER ATTACHMENT BOLTS TO CONTACTOR BATTERY DISCONNECT ee iU BATTERY BOX D BATTERY BOX BATTERY BOX Figure 3 8 Batteries and Battery Charger Removing the Battery Box To remove the battery box perform the following steps 1 Pull the handle on the battery disconnect to discon nect the batteries 2 Remove the two attachment bolts that secure the battery box to the frame 3 12 JLG Lift NOTE The battery box and batteries complete weigh approximately 670 Ibs 304 kg 3 Using a forklift lift the battery box up enough to clear the brackets on the back of the battery box and remove the battery box from the machine NOTE To make battery box removal easier when possible raise the arms of the machine and install the safety prop 3121122 SECTION 3 CHASSIS amp SCISSOR ARMS 3121122 3 4 GENERATOR NOTE Throughout the Generator section the abbreviations RBS and CTS are used RBS stands for Rotary Bat te
181. ynthetic Lithium Lubricant Gredag 741 Grease MPG may be substituted for these lubricants if neces sary but service intervals will be reduced NOTE Refer to Lubrication Chart for specific lubrication pro cedures Table 1 7 Mobil DTE 11M Specs 1 7 CYLINDER SPECIFICATIONS Table 1 8 Cylinder Specifications DESCRIPTION BORE STROKE ROD DIA Lift Cylinder 4 00 in 63 69 in 2 75 in M3369 3369LE 10 16cm 161 77 cm 6 98 cm Upper Lift Cylinder 3 00 in 58 13 in 2 75 in M4069 4069LE 7 62 cm 147 65 cm 6 98 cm Lower Lift Cylinder 4 00 in 58 13 in 2 25 in M4069 4069LE 10 16cm 147 65cm 5 71 cm 1 2 00 in 6 5in 1 125in SteerCylinder 08cm 1651cm 286cm 1 8 MAJOR COMPONENT WEIGHTS Table 1 9 Major Component Weights I0 Viscosity Grade 15 Description 3369LE M3369 4069LE M4069 Gravity API 31 9 Platform 780 Ibs 354 kg Pour Point Max 40 F 40 C Platform Extension 360 Ibs 163 kg Flash Point Min 330 F 166 C Arm Assembly 3200 Ibs 3900 105 USOS Includes Lift Cylinders 1451 kg 1769 kg e Chassis Includes Battery Box 5420 105 5517 105 at 40 C 15051 and Foam filled Tires 2458 kg 2502 kg at 100 C 4 1 cSt at 100 F 80 SUS 1 9 CRITICAL STABILITY WEIGHTS at210 F 43 SUS Table 1 10 Critical Stability Weights cp at 30 F 3 200 Viscosity Index 140 Description 3369LE

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JLG 3369LE 4069LE M3369 M4069 SM 2011

JLG-3369LE-4069LE-M3369-M4069-SM-2011

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