JLG M4069 Service Manual

Service & Maintenance Manual

Models

3369LE
4069LE

M3369
M4069

3121122

July 23, 2012

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 main­tenance personnel pay strict attention to these warn­ings and precautions to avoid possible injury to
themselves or others, or damage to the equipment.
A maintenance program must be followed to ensure
that the machine is safe to operate.

MODIFICATION OF THE MACHINE WITHOUT CERTIFI­CATION 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 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.

SINCE THE MACHINE MANUFACTURER HAS NO
DIRECT CONTROL OVER THE FIELD INSPECTION
AND MAINTENANCE, SAFETY IN THIS AREA RESPON­SIBILITY OF THE OWNER/OPERATOR.

A.B HYDRAULIC SYSTEM SAFETY

It should be noted that the machines hydraulic sys­tems operate at extremely high potentially danger­ous pressures. Every effort should be made to
relieve any system pressure prior to disconnecting
or removing any portion of the system.

Relieve system pressure by cycling the applicable
control several times with the engine stopped and

ignition on, to direct any line pressure back into the
reservoir. Pressure feed lines to system components
can then be disconnected with minimal fluid loss.

A.C MAINTENANCE

FAILURE TO COMPLY WITH SAFETY PRECAUTIONS
LISTED IN THIS SECTION MAY RESULT IN MACHINE
DAMAGE, PERSONNEL INJURY OR DEATH AND IS A
SAFETY VIOLATION.

• NO SMOKING IS MANDATORY. NEVER REFUEL DUR­ING 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, PRESSUR­IZED 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 DUR­ING REPLACEMENT OF ELECTRICAL COMPONENTS.

• KEEP ALL SUPPORT EQUIPMENT AND ATTACH­MENTS STOWED IN THEIR PROPER PLACE.

• USE ONLY APPROVED, NONFLAMMABLE CLEANING
SOLVENTS.

3121122 – 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

Revision - July 23, 2012

b – JLG Lift – 3121122

TABLE OF CONTENTS

TABLE OF CONTENTS

SUBJECT - SECTION, PARAGRAPH PAGE NO.

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

A.A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A

A.B Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

A.C Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

SECTION 1 - SPECIFICATIONS

1.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.3 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.4 Component Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

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

1.6 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1.7 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1.8 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1.9 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1.10 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1.11 Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1.12 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

SECTION 2 - GENERAL

2.1 Machine Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.2 Service and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

2.3 Lubrication and Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

2.4 Cylinder Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

2.5 Pins and Composite Bearing Repair Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

2.6 Preventive Maintenance and Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

SECTION 3 - CHASSIS & SCISSOR ARMS

3.1 Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 Tilt Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.3 Battery Maintenance and Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

3.4 Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

3.5 Supplementary Fuse For APU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19

3.6 Joystick Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

3.7 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

3.8 Drive Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

3.9 Drive Brake - MICO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

3.10 Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.5 Component Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

4.6 Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

4.7 Motor Controller - Modes of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

4.8 Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

4.9 Cylinder Checking Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.10 Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

4.11 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

4.12 Steer Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4.13 Oscillation Cylinder Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

3121122 – JLG Lift – i

TABLE OF CONTENTS (Continued)

4.14 Cylinder Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

4.15 Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20

4.16 Drive Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

4.17 Drive Assist Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23

SECTION 5 - JLG CONTROL SYSTEM

5.1 Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.2 PC Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

5.3 Flash Codes/DTC’s and Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6

5.4 Ground Control Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.2 Multimeter Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.3 Applying Silicone Dielectric Compound To Amp Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5

6.4 Working With Deutsch Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

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

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

1-3. Torque Chart (SAE Fasteners - Sheet 1 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

1-4. Torque Chart (SAE Fasteners - Sheet 2 of 7)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

1-5. Torque Chart (SAE Fasteners - Sheet 3 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

1-6. Torque Chart (SAE Fasteners - Sheet 4 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9

1-7. Torque Chart (METRIC Fasteners - Sheet 5 of 7)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10

1-8. Torque Chart (METRIC Fasteners - Sheet 6 of 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

1-9. Torque Chart (METRIC Fasteners - Sheet 7 of 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

3-1. Tilt Sensor Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

3-2. Tilt Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

3-3. Tilt Sensor Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

3-4. Tilt Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

3-5. Remote LED Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

3-6. Battery Charger Location (M model shown). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

3-7. Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3-8. Batteries and Battery Charger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

3-9. Generator Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

3-10. Generator System Analyzer Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16

3-11. Joystick Controller - (JLG P/N 1600308) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

3-12. Joystick Controller - (JLG P/N 1600403) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22

3-13. Drive Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23

3-14. Power Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

3-15. Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

3-16. Brake Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

3-17. Torque Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30

3-18. Bolt Torquing Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31

3-19. Hub Main Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32

3-20. Output Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34

3-21. Input Carrier Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35

3-22. Hub-Spindle Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36

3-23. Cover Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37

3-24. Input Carrier Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

3-23. Output Carrier Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

3-24. Hub-Spindle Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-40

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3-25. Cover Sub-Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

3-26. Hub Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-42

4-1. Barrel Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4-2. Cap Screw Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4-3. Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

4-4. Oil-lite Bearing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

4-5. Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

4-6. Wiper Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4-7. Installation of Head Seal Kit (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

4-8. Piston Seal Kit Installation (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

4-9. Poly-Pak Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

4-10. Rod Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

4-11. Lift Cylinder - 3369LE & M3369. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

4-12. Lift Cylinder - 4069LE & M4069. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

4-11. Leveling Jack Cylinder (1001140600). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

4-13. Leveling Jack Cylinder - USA Built Machines S/N 0200112735 to Present) . . . . . . . . . . . . . . . . .4-15

4-14. Leveling Jack Cylinder - USA Built Machines S/N 0200104829 to S/N 0200112735 &

All Belgium Built Machines). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

4-15. Leveling Jack Cylinder - USA Built Machines Prior to S/N 0200104829 . . . . . . . . . . . . . . . . . . . .4-17

4-16. Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

4-17. Axle Lockout Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19

4-18. Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21

4-19. Drive Assist Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23

5-1. Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5-2. PC Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

5-2. Analyzer Flow Chart - SW V13.X - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11

5-3. Analyzer Flow Chart - SW V13.X - Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12

5-4. Analyzer Flow Chart - SW V13.X - Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13

5-5. Analyzer Flow Chart - Software P1.X - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14

5-6. Analyzer Flow Chart - Software P1.X - Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15

5-7. Analyzer Flow Chart - Software P1.X - Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16

6-1. Voltage Measurement (DC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

6-2. Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-3. Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3

6-4. Current Measurement (DC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6-5. AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5

6-6. Connector Assembly (1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

6-7. Connector Assembly (2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

6-8. Connector Assembly (3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7

6-9. Connector Assembly (4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7

6-10. Connector Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6-11. Connector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9

6-12. DT/DTP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

6-13. DT/DTP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10

6-14. HD/HDP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10

6-15. HD/HDP Locking Contacts Into Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11

6-16. HD/HDP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11

6-17. HD/HDP Unlocking Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11

6-18. Electrical Components Installation - (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12

6-19. Electrical Components Installation - (Sheet 2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13

6-20. Electrical Components Installation - (Sheet 3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14

6-21. Electrical Components Installation - (Sheet 4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-22. Electrical Schematic - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16

6-23. Electrical Schematic - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17

6-24. Electrical Schematic - Kubota Generaltor - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18

6-25. Electrical Schematic - Kubota Generator - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-19

6-26. Electrical Schematic - Yanmar Engine (M3369 & 3369LE only). . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

6-27. Hydraulic Diagram - 3369LE and M3369 (Fixed Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22

.6-15

3121122 – JLG Lift – iii

TABLE OF CONTENTS (Continued)

6-28. Hydraulic Diagram - 3369LE and M3369 (Oscillating Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

6-29. Hydraulic Diagram - 4069LE and M4069 (Fixed Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24

6-30. Hydraulic Diagram - 4069LE and M4069 (Oscillating Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25

6-31. Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

1-1 Operating Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1-2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1-3 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1-4 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1-5 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-6 Lubrication Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-7 Mobil DTE 11M Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-8 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-9 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-10 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-11 Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

2-1 Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

2-2 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2-3 Preventive Maintenance and Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

3-1 Tilt Sensor Harness Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3-2 Tilt Sensor Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

3-3 Delta-Q - Battery Charger Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

3-4 Battery Algorithms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

3-5 RBS Pre start Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15

3-6 RBS Startup Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15

3-7 RBS Shutdown Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15

3-8 Generator System Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

3-9 Joystick Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

3-10 Joystick Plug Loading Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

3-11 Joystick Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22

3-12 Joystick Plug Loading Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22

3-13 Power Controller Cable Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

4-1 Cutout Heights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

4-2 Cylinder Piston Nut Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

4-3 Holding Valve Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

4-4 Valve Component Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

5-1 Flash Codes/DTC’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6

5-2 Power Module Diagnostic LED Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5-3 Machine Model Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17

5-4 Machine Configuration Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

5-5 J1 Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19

5-6 J2 Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20

5-7 J3 Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-21

5-8 J4 Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22

5-9 J5 Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22

5-10 J6 Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22

5-11 J1 Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-23

5-12 J2 Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24

5-13 J3 Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-25

5-14 J4 Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-26

5-15 J5 Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-26

5-16 J6 Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-26

iv – JLG Lift – 3121122

SECTION 1 - SPECIFICATIONS

SECTION 1. SPECIFICATIONS

1.1 SPECIFICATIONS

Table 1-1. Operating Specifications

Description 3369LE/M3369 4069LE/M4069

Maximum Platform Height 33 ft (10.1 m) 40 ft (12.2 m)

Maximum Occupants 2

Gross Machine Weight (minimum) 9760 lbs (4427 kg) 10,560 lbs (4790 kg)

Travel Speed:
High Drive Fwd/Rev (sec/50 ft)
Elevated Drive Fwd/Rev (sec/50 ft)

Lifting Speed:
N o L o a d
R at e d L o a d

Lowering Speed (no load) 43 - 48 sec 49 - 51 sec

Gradeability (platform stowed) 35%

Tu rn in g R ad iu s:
I ns i d e
O ut s i de

Maximum Platform Capacity

- Pl a t fo r m

-Platform Extension

Maximum Ground Bearing Pressure 57 psi (4 bar) 61 psi (4.3 bar)

Maximum Tire Load 3200 lbs (1452 kg) 3700 lbs (1680 kg)

Maximum Hydraulic System Pressure 3000 psi (207 bar)

Electrical System Voltage 48Vdc

Maximum Horizontal Manual Side Force 150 lb force (667 N) 120 lb force (534 N)

Tilt Sensor Setting:
Side to Side
F or e an d Af t

Ground Clearance 8 in (20 cm)

Wheelbase 91.5 in (2.3 m)

Machine Height (w/ rails folded) 76.5 in (1.9 m) 79 in (2.01 m)

Machine Length (stowed) 121 in (3.1 m)

Machine Width 69 in (1.75 m)

ANSI/CSA/Brazil: 1000 lbs (454kg)
CE/AUS: 1000 lbs (450kg)
ANSI/CSA/Brazil: 250 lbs (113kg)
CE/AUS: 250 lbs (120kg)

36 - 40 sec
38 - 44 sec

10.6 - 12 sec
40 - 44 sec

52 - 60 sec
54 - 62 sec

7.5 ft (2.3 m)

16 ft (4.9 m)

ANSI/CSA/Brazil: 800 lbs (363kg)
CE/AUS: 800 lbs (360kg)
ANSI/CSA/Brazil: 250 lbs (113kg)
CE/AUS: 250 lbs (120kg)

3°
5°

3121122 – JLG Lift – 1-1

SECTION 1 - SPECIFICATIONS

1.2 CAPACITIES

Table 1-2. Capacities

Description 3369LE/M3369 4069LE/M4069

Hydraulic Tank

Hydraulic System approx. 8.5 gal (32.1 liters)

Torque Hubs (2) 17 ounces (0.5 liters)

8.25 gal (31.2 liters)

5.4 gal (20.4 liters) @ full mark

1.3 PRESSURE SETTINGS

Table 1-3. Pressure Settings

Description 3369LE/M3369 4069LE/M4069

Main Relief (±50 psi)

Steer Relief

Lift Relief

2600 psi

(179 bar)

3000 psi

(207 bar)

2500 psi

(172 bar)

1.4 COMPONENT DATA

Battery Charger

Input 220 VAC, 50 HZ Input, (110 VAC,60 HZ)

Output, 48 VDC @ 23 Amp

2800 psi

(193 bar)

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

27.2/10.5LL-15.0 FF TURF - SLR - 4020 lb.@42 PSI

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

Hydraulic Pump/Electric Motor Assembly

Pump Output - 3.86 gpm (14.6 lpm) @ 2175 psi (150 bar)

1.5 TORQUE SPECIFICATIONS

Table 1-4. Torque Specifications

DESCRIPTION

To rq ue H ub

Wheel Nuts

Fixed Axle Bolts

Drive Motor

Pump Motor

Te rm ina ls

TORQUE VALUE

(DRY)

240 ft lbs
(336 Nm)

170 ft lbs
(238 Nm)

220 ft lbs
(308 Nm)

35 ft lbs
(49 Nm)

12-14 ft lbs
(14-19 Nm)

INTERVAL HOURS

500

50

500

N/A

N/A

Batteries

6 Volt, 370 Amp-hour - Quantity (8) - MAC Charger

JLG MACHINES EQUIPPED WITH DELTA Q BATTERY CHARGERS
ARE DESIGNED FOR THE BEST PERFORMANCE WITH OEM FAC­TORY APPROVED BATTERIES.
APPROVED JLG REPLACEMENT BATTERIES ARE AVAILABLE
THROUGH JLG' S AFTERMARKET PARTS DISTRIBUTION CEN­TERS 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 COM­PATIBILITY WITH THE ALGORITHM PROGRAMMING OF THE
DELTA Q BATTERY CHARGER TO OPTIMIZE BATTERY LIFE AND
MACHINE CYCLE TIMES. THE USE OF NON APPROVED BATTER­IES 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.

NOTE: When maintenance becomes necessary or a fas-

tener has loosened, refer to Section 1.12, Torque
Charts to determine proper torque value.

1-2 – JLG Lift – 3121122

SECTION 1 - SPECIFICATIONS

1.6 LUBRICATION

Table 1-5. Hydraulic Oil

Hydraulic System Operating

Temp era t ure Rang e

0° F to 23° F (-18°C to -5°C) 10W

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

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

NOTE: Hydraulic oils must have anti-wear qualities at least

to API Service Classification GL-3, and sufficient
chemical stability for mobile hydraulic system ser­vice. JLG Industries recommends 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.

SAE Viscosity Grade

Lubrication Specifications

Table 1-6. Lubrication Specifications

KEY SPECIFICATIONS

EPGL

HO

LL Synthetic Lithium Lubricant, Gredag 741 Grease.

Extreme Pressure Gear Lube (oil) meeting API service
c la ss if ic at io n G L-5 or MI L-S pe c M IL- L-21 05

Hydraulic Oil. API service classification Gl-3, BP Ener­gol SHS46.

1.7 CYLINDER SPECIFICATIONS

Table 1-8. Cylinder Specifications

DESCRIPTION BORE STROKE ROD DIA.

Lift Cylinder

(M3369/3369LE)

Upper Lift Cylinder

(M4069/4069LE)

Lower Lift Cylinder

(M4069/4069LE)

Steer Cylinder

4.00 in

(10.16 cm)

3.00 in

(7.62 cm)

4.00 in

(10.16 cm)

2.00 in

(5.08 cm)

63.69 in

(161.77 cm)

58.13 in

(147.65 cm)

58.13 in

(147.65 cm)

6.5 in

(16.51 cm)

1.8 MAJOR COMPONENT WEIGHTS

Table 1-9. Major Component Weights

Description 3369LE/M3369 4069LE/M4069

Platform 780 lbs (354 kg)

Platform Extension 360 lbs (163 kg)

Arm Assembly
(Includes Lift Cylinders)

Chassis (Includes Battery Box
and Foam filled Tires)

Foam Filled Tire and Wheel
Assembly (each)

3200 lbs

(1451 kg)

5420 lbs

(2458 kg)

180 lb. (81.6 kg)

(1769 kg)

(2502 kg)

2.75 in

(6.98 cm)

2.75 in

(6.98 cm)

2.25 in

(5.71 cm)

1.125 in

(2.86 cm)

3900 lbs

5517 lbs

* MPG may be substituted for these lubricants, if
necessary, but service intervals will be reduced.

NOTE: Refer to Lubrication Chart for specific lubrication pro-

cedures.

Table 1-7. Mobil DTE 11M Specs

ISO Viscosity Grade #15

Gravity API 31.9

Pour Point, Max -40°F (-40°C)

Flash Point, Min. 330°F (166°C)

Viscosity

at 40° C 15 cSt

at 100° C 4.1 cSt

at 100° F 80 SUS

at 210° F 43 SUS

cp at -30° F 3.200

Viscosity Index 140

1.9 CRITICAL STABILITY WEIGHTS

Table 1-10. Critical Stability Weights

Description 3369LE/M3369 4069LE/M4069

Platform 780 lbs (354 kg)

Platform Extension 360 lbs (163 kg)

Foam Filled Tires 2 07 lbs (94 kg)

Battery (Each) 122 lbs (55 kg)

3121122 – JLG Lift – 1-3

SECTION 1 - SPECIFICATIONS

Note:
500 Hrs. = 3 months
1000 Hrs. = 6 months
2000 Hrs. = 1 year
4000 Hrs. = 2 years

1

23

Figure 1-1. Lubrication Chart

1.10 LUBRICATION

Table 1-11. Lubrication Chart

INDEX

NUMBER

KEY TO LUBRICANTS:
HO - Hydraulic Oil - Mobil DTE - 11M
EPGL - Extreme Pressure Gear Lube
MPG - Multi Purpose Grease

COMPONENT

1 Sliding Wear Pads 8 Wear Pads MPG/Brush 50 --

2 Hydraulic Oil Fill Level/Drain Plug

3 Wheel Bearings Front Wheels MPG - Repack 1200 --

Spindles/Bushing

4

5

6

(not shown)

Wheel Drive Hub

(not shown)

*High Pressure

Filter (not shown)

NO/TYPE LUBE

POINTS

N/A LL

Fill Plug/Half Full EPGL 1200

N/A

LUBE/METHOD

HO - Check HO Level

HO - Change HO

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.

Replaceable

Element

INTERVAL

HOURS

10/500

At Spindle Bushing

Replacement

50/250

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, lubri­cating frequencies must be increased accordingly.
*The high pressure filter is located in the main con­trol valve. See figure title control valve in section 2.

Check oil every 10 hours of operation

Change oil after every 1000 hours of operation

Change after first 150 hours of operation then every

Replace filter element after first 5 0 hours of operation

and every 1000 hours thereafter.

COMMENTS

--

Check oil level at side plug daily.

1000 hours thereafter

1-4 – JLG Lift – 3121122

SECTION 1 - SPECIFICATIONS

SERIAL NUMBER

PLATE

SERIAL NUMBER

STAMPED

Figure 1-2. Serial Number Location

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 – JLG Lift – 1-5

SECTION 1 - SPECIFICATIONS

REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND

JLG P/N Loctite® P/N ND Industries P/N

Description

0100011

242

TM

Vibra-TITE

TM

121

Medium Strength (Blue)

0100019

271

TM

Vibra-TITE

TM

140

High Strength (Red)

0100071

262

TM

Vibra-TITE

TM

131

Medium - High Strength (Red)

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

In Sq In LB IN-LB [N.m] 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 0.1120 0.00661 420 9 1.0 7 0.8

6 32 0.1380 0.00909 580 16 1.8 12 1.4

40 0.1380 0.01015 610 18 2.0 13 1.5

8 32 0.1640 0.01400 900 30 3.4 22 2.5

36 0.1640 0.01474 940 31 3.5 23 2.6

10 24 0.1900 0.01750 1120 43 4.8 32 3.5

32 0.1900 0.02000 1285 49 5.5 36 4

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]

5/16 18 0.3125 0.0524 3340 17 23 13 18 19 26 16 22

24 0.3125 0.0580 3700 19 26 14 19 21 29 17 23

3/8 16 0.3750 0.0775 4940 30 41 23 31 35 48 28 38

24 0.3750 0.0878 5600 35 47 25 34 40 54 32 43

7/16 14 0.4375 0.1063 6800 50 68 35 47 55 75 45 61

20 0.4375 0.1187 7550 55 75 40 54 60 82 50 68

1/2 13 0.5000 0.1419 9050 75 102 55 75 85 116 68 92

20 0.5000 0.1599 10700 90 122 65 88 100 136 80 108

9/16 12 0.5625 0.1820 11600 110 149 80 108 120 163 98 133

18 0.5625 0.2030 12950 120 163 90 122 135 184 109 148

5/8 11 0.6250 0.2260 14400 150 203 110 149 165 224 135 183

18 0.6250 0.2560 16300 170 230 130 176 190 258 153 207

3/4 10 0.7500 0.3340 21300 260 353 200 271 285 388 240 325

16 0.7500 0.3730 23800 300 407 220 298 330 449 268 363

7/8 9 0.8750 0.4620 29400 430 583 320 434 475 646 386 523

14 0.8750 0.5090 32400 470 637 350 475 520 707 425 576

1 8 1.0000 0.6060 38600 640 868 480 651 675 918 579 785

12 1.0000 0.6630 42200 700 949 530 719 735 1000 633 858

1 1/8 7 1.1250 0.7630 42300 800 1085 600 813 840 1142 714 968

12 1.1250 0.8560 47500 880 1193 660 895 925 1258 802 1087

1 1/4 7 1.2500 0.9690 53800 1120 1518 840 1139 1175 1598 1009 1368

12 1.2500 1.0730 59600 1240 1681 920 1247 1300 1768 1118 1516

1 3/8 6 1.3750 1.1550 64100 1460 1979 1100 1491 1525 2074 1322 1792

12 1.3750 1.3150 73000 1680 2278 1260 1708 1750 2380 1506 2042

1 1/2 6 1.5000 1.4050 78000 1940 2630 1460 1979 2025 2754 1755 2379

12 1.5000 1.5800 87700 2200 2983 1640 2224 2300 3128 1974 2676

NO. 5000059 REV. J

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

SAE GRADE 5 BOLTS & GRADE 2 NUTS

Torque

(Dry)

Torque

(Loctite® 262

TM

or Vibra-

TITE

TM

131)

Torque

Lubricated

Torque

(Loctite® 242

TM

or 271

TM

OR Vibra-TITE

TM

111 or

140)

3. * ASSEMBLY USES HARDENED WASHER

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%

1.12 TORQUE CHARTS

Figure 1-3. Torque Chart (SAE Fasteners - Sheet 1 of 7)

1-6 – JLG Lift – 3121122

SECTION 1 - SPECIFICATIONS

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

In Sq In

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474

10 24 0.1900 0.01750

32 0.1900 0.02000

1/4 20 0.2500 0.0318

28 0.2500 0.0364

In Sq In

5/16 18 0.3125 0.0524

24 0.3125 0.0580

3/8 16 0.3750 0.0775

24 0.3750 0.0878

7/16 14 0.4375 0.1063

20 0.4375 0.1187

1/2 13 0.5000 0.1419

20 0.5000 0.1599

9/16 12 0.5625 0.1820

18 0.5625 0.2030

5/8 11 0.6250 0.2260

18 0.6250 0.2560

3/4 10 0.7500 0.3340

16 0.7500 0.3730

7/8 9 0.8750 0.4620

14 0.8750 0.5090

1 8 1.0000 0.6060

12 1.0000 0.6630

1 1/8 7 1.1250 0.7630

12 1.1250 0.8560

1 1/4 7 1.2500 0.9690

12 1.2500 1.0730

1 3/8 6 1.3750 1.1550

12 1.3750 1.3150

1 1/2 6 1.5000 1.4050

12 1.5000 1.5800

NO. 5000059 REV. J

3. * ASSEMBLY USES HARDENED WASHER

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

2. ALL TORQUE VA LUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]

1320 43 5

1580 60 7

1800 68 8
2860 143 16 129 15
3280 164 19 148 17

LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m

4720 25 35 20 25 20 25
5220 25 35 25 35 20 25
7000456040 553550
7900 50 70 45 60 35 50

9550 70 95 65 90 50 70
10700 80 110 70 95 60 80
12750 105 145 95 130 80 110
14400 120 165 110 150 90 120

16400 155 210 140 190 115 155

18250 170 230 155 210 130 175

20350 210 285 190 260 160 220

23000 240 325 215 290 180 245
30100 375 510 340 460 280 380
33600 420 570 380 515 315 430
41600 605 825 545 740 455 620
45800 670 910 600 815 500 680
51500 860 1170 770 1045 645 875
59700 995 1355 895 1215 745 1015
68700 1290 1755 1160 1580 965 1310
77000 1445 1965 1300 1770 1085 1475

87200 1815 2470 1635 2225 1365 1855
96600 2015 2740 1810 2460 1510 2055

104000 2385 3245 2145 2915 1785 2430

118100 2705 3680 2435 3310 2030 2760
126500 3165 4305 2845 3870 2370 3225
142200 3555 4835 3200 4350 2665 3625

Torque

(Loctite® 242

TM

or 271

TM

OR Vibra-TITE

TM

111 or

140) K=.18

Torque

(Loctite® 262

TM

or Vibra-

TITE

TM

131)

K=0.15

SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*

Torque

(Dry or Loctite® 263)

K= 0.20

3121122 – JLG Lift – 1-7

Figure 1-4. Torque Chart (SAE Fasteners - Sheet 2 of 7))

SECTION 1 - SPECIFICATIONS

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

See Note 4

In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474

10 24 0.1900 0.01750

32 0.1900 0.02000

1/4 20 0.2500 0.0318 2860 122 14 114 13

28 0.2500 0.0364 3280 139 16 131 15

In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]

5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25

24 0.3125 0.0580 5220 25 35 20 25 20 25

3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50

24 0.3750 0.0878 7900 40 55 40 55 35 50

7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70

20 0.4375 0.1187 10700 65 90 60 80 60 80

1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110

20 0.5000 0.1599 14400 100 135 95 130 90 120

9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155

18 0.5625 0.2030 18250 145 195 135 185 130 175

5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220

18 0.6250 0.2560 23000 205 280 190 260 180 245

3/4 10 0.7500 0.3340 30100 320 435 300 410 280 380

16 0.7500 0.3730 33600 355 485 335 455 315 430

7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620

14 0.8750 0.5090 45800 570 775 535 730 500 680

1 8 1.0000 0.6060 51500 730 995 685 930 645 875

12 1.0000 0.6630 59700 845 1150 795 1080 745 1015

1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310

12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475

1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855

12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055

1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430

12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760

1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225

12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625

NO. 5000059 REV. J

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.

SOCKET HEAD CAP SCREWS

Magni Coating (Ref 4150701)*

Torque

(Dry) K = .17

Torque

(Loctite® 242

TM

or 271

TM

OR Vibra-TITE

TM

111 or

140 OR Precoat 85®

K=0.16

Torque

(Loctite® 262

TM

or Vibra-

TITE

TM

131)

K=0.15

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM

1-8 – JLG Lift – 3121122

Figure 1-5. Torque Chart (SAE Fasteners - Sheet 3 of 7)

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

See Note 4

In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474

10 24 0.1900 0.01750

32 0.1900 0.02000

1/4 20 0.2500 0.0318 2860 143 16 129 15

28 0.2500 0.0364 3280 164 19 148 17

In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]

5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25

24 0.3125 0.0580 5220 25 35 25 35 20 25

3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50

24 0.3750 0.0878 7900 50 70 45 60 35 50

7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70

20 0.4375 0.1187 10700 80 110 70 95 60 80

1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110

20 0.5000 0.1599 14400 120 165 110 150 90 120

9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155

18 0.5625 0.2030 18250 170 230 155 210 130 175

5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220

18 0.6250 0.2560 23000 240 325 215 290 180 245

3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380

16 0.7500 0.3730 33600 420 570 380 515 315 430

7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620

14 0.8750 0.5090 45800 670 910 600 815 500 680

1 8 1.0000 0.6060 51500 860 1170 775 1055 645 875

12 1.0000 0.6630 59700 995 1355 895 1215 745 1015

1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310

12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475

1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855

12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055

1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430

12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760

1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225

12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625

NO. 5000059 REV. J

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.

SOCKET HEAD CAP SCREWS

Torque

(Dry)

K = .20

Torque

(Loctite® 242TM or 271

TM

OR Vibra-TITE

TM

111 or

140 OR Precoat 85®

K=0.18

Zinc Yellow Chromate Fasteners (Ref 4150707)*

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

*3. ASSEMBLY USES HARDENED WASHER OR F ASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM

Torque

(Loctite® 262

TM

or Vibra-

TITE

TM

131)

K=0.15

SECTION 1 - SPECIFICATIONS

3121122 – JLG Lift – 1-9

Figure 1-6. Torque Chart (SAE Fasteners - Sheet 4 of 7)

SECTION 1 - SPECIFICATIONS

Size PITCH

Tensile

Stress

Area

Clamp

Load

Torque

(Dry or Loctite®

263

TM

)

Torque

(Lub)

Torque

(Loctite® 262

TM

OR Vibra-

TITE

TM

131)

Torque

(Loctite®

242

TM

or 271

TM

OR Vibra-

TITE

TM

111 or

140)

Sq mm KN [N.m] [N.m] [N.m] [N.m]

3 0.5 5.03 2.19 1.3 1.0 1.2 1.4

3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3
4 0.7 8.78 3.82 3.1 2.3 2.8 3.4
5 0.8 14.20 6.18 6.2 4.6 5.6 6.8
6 1 20.10 8.74 11 7.9 9.4 12
7 1 28.90 12.6 18 13 16 19
8 1.25 36.60 15.9 26 19 23 28

10 1.5 58.00 25.2 50 38 45 55
12 1.75 84.30 36.7 88 66 79 97
14 2 115 50.0 140 105 126 154

16 2 157 68.3

219 164 197 241
18 2.5 192 83.5 301 226 271 331
20 2.5 245 106.5 426 320 383 469
22 2.5 303 132.0 581 436 523 639
24 3 353 153.5 737 553 663 811
27 3 459 199.5 1080 810 970 1130
30 3.5 561 244.0 1460 1100 1320 1530
33 3.5 694 302.0 1990 1490 1790 2090
36 4 817 355.5 2560 1920 2300 2690
42 4.5 1120 487.0 4090 3070 3680 4290

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.

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAW ALUMINUM

CLASS 8.8 METRIC BOLTS

CLASS 8 METRIC NUTS

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%

NO. 5000059 REV. J

Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 5 of 7))

1-10 – JLG Lift – 3121122

SECTION 1 - SPECIFICATIONS

Size PITCH

Tensile

Stress

Area

Clamp

Load

Torque

(Dry or Loctite®

263

TM

)

K = 0.20

Torque

(Lub OR Loctite®

242

TM

or 271TM OR

Vibra-TITE

TM

111 or

140)

K= 0.18

Torque

(Loctite® 262

TM

OR

Vibra-TITE

TM

131)

K=0.15

Sq mm KN [N.m] [N.m] [N.m]

3 0.5 5.03 3.13

3.5 0.6 6.78 4.22
4 0.7 8.78 5.47
5 0.8 14.20 8.85
6 1 20.10 12.5
7 1 28.90 18.0 25.2 22.7 18.9
8 1.25 36.60 22.8 36.5 32.8 27.4

10 1.5 58.00 36.1 70 65 55
12 1.75 84.30 52.5 125 115 95
14 2 1 15 71.6 200 180 150

16 2 157 97.8

315 280 235
18 2.5 192 119.5 430 385 325
20 2.5 245 152.5 610 550 460
22 2.5 303 189.0 830 750 625
24 3 353 222.0 1065 960 800
27 3 459 286.0 1545 1390 1160
30 3.5 561 349.5 2095 1885 1575
33 3.5 694 432.5 2855 2570 2140
36 4 817 509.0 3665 3300 2750
42 4.5 1120 698.0 5865 5275 4395

CLASS 10.9 METRIC BOLTS

CLASS 10 METRIC NUTS

CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*

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.

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAW ALUMINUM

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%

NO. 5000059 REV. J

3121122 – JLG Lift – 1-11

Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 6 of 7)

SECTION 1 - SPECIFICATIONS

Size PITCH

Tensile

Stress

Area

Clamp Load

See Note 4

Torque

(Dry or Loctite®

263

TM

)

K = .17

Torque

(Lub OR Loctite®

242

TM

or 271

TM

OR Vibra-TITE

TM

111 or 140)

K = .16

Torque

(Loctite® 262

TM

OR Vibra-TITE

TM

131)

K = .15

Sq mm kN [N.m] [N.m] [N.m]

30.55.03

3.5 0.6 6.78

40.78.78

50.814.20

6120.1012.5 13 12 11

7128.9018.0 21 20 19

8 1.25 36.60 22.8 31 29 27
10 1.5 58.00 36.1 61 58 54
12 1.75 84.30 52.5 105 100 95
14 2 115 71.6 170 160 150

16 2 157

97.8 265 250 235
18 2.5 192 119.5 365 345 325
20 2.5 245 152.5 520 490 460
22 2.5 303 189.0 705 665 625
24 3 353 220.0 900 845 790
27 3 459 286.0 1315 1235 1160
30 3.5 561 349.5 1780 1680 1575
33 3.5 694 432.5 2425 2285 2140
36 4 817 509.0 3115 2930 2750
42 4.5 1120 698.0 4985 4690 4395

CLASS 12.9 SOCKET HEAD CAP SCREWS

M6 AND ABOVE*

4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT

REPRESENT FULL STRENG TH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,

ADDITIONAL TESTING IS REQUIRED.

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAW ALUMINUM

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%

NO. 5000059 REV. J

Magni Coating (Ref 4150701)*

Figure 1-9. Torque Chart (METRIC Fasteners - Sheet 7 of 7)

1-12 – JLG 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, Inspection, and Maintenance

It is important to establish and conform to a comprehen­sive inspection and preventive maintenance program.
The following table outlines the periodic machine inspec­tions and maintenance recommended by JLG Industries,
Inc. Consult your national, regional, or local regulations
for further requirements for aerial work platforms. The fre­quency 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 per­form a Pre-Start Inspection of the machine prior to use
daily or at each change of operator. Reference the Opera­tor’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 per­forming 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 recog­nized 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 pro­cedures are performed in the same manner, but at differ­ent times. 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 ser­vice 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 perfor­mance of these inspections. Reference the appropriate
areas of this manual for servicing and maintenance proce­dures.

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 Indus­tries, Inc. recognizes a Factory-Trained Service Technician
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 performance 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 this man­ual 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, mainte­nance 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, train­ing, 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

Typ e Frequency

Pre-Start Inspection

Pre-Delivery

Inspection

Frequent Inspection

Annual Machine

Inspection

Preventative

Maintenance

Prior to use each day; or

At each Operator change.

Prior to each sale, lease, or

rental delivery.

In service for 3 months or 150 hours,

whichever comes first; or

Out of service for a period of more than 3

months; or

Purchased used.

Annually, no later than 13 months from the

date of the prior inspection.

At intervals as specified in the Service and

Maintenance Manual.

2.2 SERVICE AND GUIDELINES General

The following information is provided to assist you in the
use and application of servicing and maintenance proce­dures 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 adequate support
is provided.

Primary

Responsibility

User or Operator User or Operator Operator and Safety Manual

Owner, Dealer, or User

Owner, Dealer, or User

Owner, Dealer, or User

Owner, Dealer, or User

keep air, fuel, and oil supplies clean; however, these
items must be maintained on a scheduled basis in
order to function properly.

2. At any time when air, fuel, or oil lines are discon­nected, clear adjacent areas as well as the openings
and fittings themselves. As soon as a line or compo­nent is disconnected, cap or cover all openings to
prevent entry of foreign matter.

3. Clean and inspect all parts during servicing or main­tenance, 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 contain­ers until they are ready to be used.

Service

Qualification

Qualified JLG

Mechanic

Qualified JLG

Mechanic

Factory-Trained

Service Technician

(recommended)

Qualified JLG

Mechanic

Reference

Service and Maintenance

Manual and applicable JLG

inspection form.

Service and Maintenance

Manual and applicable JLG

inspection form.

Service and Maintenance

Manual and applicable JLG

inspection form.

Service and Maintenance

Manual

Cleanliness

IT IS GOOD PRACTICE TO AVOID PRESSURE-WASHING ELEC­TRICAL/ELECTRONIC COMPONENTS. IN THE EVENT PRES­SURE-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/ELEC­TRONIC 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 for­eign materials out of the vital components. Precau­tions have been taken to safeguard against this.
Shields, covers, seals, and filters are provided to

Components 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 eye­bolt 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, com­plete the procedural steps in sequence. Do not partially
disassemble or assemble one part, then start on another.

2-2 – JLG Lift– 3121122

SECTION 2 - GENERAL

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 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 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 bear­ing is to be installed on a shaft, apply pressure to the
inner race.

Hydraulic System

1. Keep the system clean. If evidence of metal or rub­ber 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.

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 accor­dance with recommended shop practices. (See
Torque Chart Section 1.)

Hydraulic Lines and Electrical Wiring

Clearly mark or tag hydraulic lines and electrical wiring, as
well as their receptacles, when disconnecting or removing
them from the unit. This will assure that they are correctly
reinstalled.

3121122 – JLG Lift – 2-3

SECTION 2 - GENERAL

2.3 LUBRICATION AND INFORMATION

Hydraulic System

1. The primary enemy of a hydraulic system is contam­ination. 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 (suc­tion) 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 opera­tion. 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 speci­fied intervals required in the Lubrication Chart in
Section 1. Always examine filters for evidence of
metal particles.

3. Cloudy oils indicate a high moisture content which
permits organic growth, resulting in oxidation or cor­rosion. 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
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 oper­ating, are recommended for use.

NOTE: Metal particles may appear in the oil or filters of new

machines due to the wear-in of meshing compo­nents.

Hydraulic Oil

1. Refer to Section 1 for recommendations for viscosity
ranges.

This will allow start up at temperatures down to -20°
F (-29° C). However, use of this oil will give poor per­formance at temperatures above 120°F (49°C). Sys­tems using DTE 13 oil should not be operated at
temperatures above 200°F (94°C) under any condi­tion.

Changing Hydraulic Oil

1. Use of any of the recommended hydraulic oils elim­inates 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 specifi­cations appearing in this manual. If unable to obtain
the same type of oil supplied with the machine, con­sult local supplier for assistance in selecting the
proper equivalent. Avoid mixing petroleum and syn­thetic base oils. JLG Industries recommends chang­ing the hydraulic oil annually.

2. 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 contami­nants from 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 main­tenance 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 evalua­tion. Refer to Section 1 for an explanation of the lubricant
key designations appearing in the Lubrication Chart.

2. JLG recommends Mobilfluid 424 hydraulic oil, which
has an SAE viscosity of 10W-30 and a viscosity
index of 152.

NOTE: Start-up of hydraulic system with oil temperatures

below -15°F (-26°C) is not recommended. If 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 minimum temperature of

-15°F (-26°C).

3. The only exception to the above is to drain and fill
the system with Mobil DTE 13 oil or its equivalent.

2-4 – JLG Lift– 3121122

SECTION 2 - GENERAL

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 ele­vate the platform. Maximum allowable drift is 2 in. (5 cm)
in 10 minutes. If the machine does not pass this test, pro­ceed with the following.

Cylinder Drift

Table 2-2. Cylinder Drift

Cylinder Bore Diameter

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

Drift is to be measured at the cylinder rod with a calibrated
dial indicator. The cylinder oil must be at ambient temper­ature and temperature stabilized.

The cylinder must have the normal load, which is the nor­mal 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.

Max. Acceptable Drift

in 10 Minutes

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 solvent

to remove all grease and oil...filament wound
bearing are a dry joint and should not be lubri­cated.

c. Pins should be inspected to ensure it is free of

burrs, nicks, and scratches which would dam­age the bearing during installation and opera­tion.

3121122 – JLG Lift – 2-5

SECTION 2 - GENERAL

2.6 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE

The preventive maintenance and inspection checks are
listed and defined in Table 2-3, Preventive Maintenance
and Inspection Schedule. 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 depend­ing 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
Service. Forms must be completed and returned to JLG
Industries.

JLG INDUSTRIES REQUIRES THAT A COMPLETE ANNUAL
INSPECTION BE PERFORMED IN ACCORDANCE WITH THE
“ANNUAL MACHINE INSPECTION REPORT” FORM.

The inspection and maintenance code numbers for Table
2-3, Preventive Maintenance and Inspection Schedule, are
as follows:

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.

5. Check for leakage.

6. Check for presence of excessive dirt or foreign
material.

7. Check for proper operation and freedom of move­ment.

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 neces­sary.

15. Check for proper inflation.

16. Clean or replace suction screen.

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 over­due.

2-6 – JLG Lift– 3121122

SECTION 2 - GENERAL

Table 2-3. Preventive Maintenance and Inspection Schedule

AREA INTERVAL

PLATFORM

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 8

7. Handrail and Chains 1, 4

CH AS S IS

1. Batteries 3 5

2. Battery Charger 1

3. Hydraulic Pump/Motor 1 5

4. Valves 1 5

5. Hydraulic Filter* (Also see note) 5, 14 14

6. Hydraulic Hoses and Tubing 1 5

7. Hydraulic Oil Tank* 3 5 4

8. Breather - Hydraulic Tank 6, 14

9. Lift Cylinder 1 5, 6,13 4

10. Limit Switch 1, 7

11. Placards and Decals 1, 2

12. Wheel and Tire Assemblies 1 8, 9

13. Drive Motors 1, 5 1, 6

14. Drive Torque Hubs 1, 3, 5 1, 3, 5, 6 6

15. Drive Brakes 1, 6 8

16. Steer Cylinder 1 5, 6, 13 4

17. Steer Components 1 4 , 6 8

18. Wheel Bearings 8

19. Sizzor Arms 1, 4

20. Safety Prop 1, 4

21. Wear Pads 8

22. Pivot Pins/Bolts 1, 4 7, 8

23. Switches, Ground Control 1, 11

24. Control Tags 1,2

25. Hose and Cable 1 4, 8

* Inspection and Maintenance Code 10 to be performed annually.

10 HOURS

DAILY

50 HOURS

WEEKLY

200 HOURS

MONTHLY

500 HOURS

3 MONTHS

1000 HOURS

6 MONTHS

NOTE: If function speeds are slow on a fully charged

machine a clogged filter may be indicated. Change
filter.

3121122 – JLG Lift – 2-7

SECTION 2 - GENERAL

NOTES:

2-8 – JLG Lift– 3121122

SECTION 3 - CHASSIS & SCISSOR ARMS

SECTION 3. CHASSIS & SCISSOR ARMS

3.1 CALIBRATIONS

Elevation Sensor Calibration (Prior to Software V13.6)

NOTE: Make sure your analyzer is in ACCES LEVEL 1.

When using the analyzer the terms referring to
ROTARY & PROXIMITY sensors are ELEV SEN­SOR & ELEV PROX.

Use ELEV SENSOR sub level menu for rotary switch
adjustments.

Use SET ELEV SENSOR top level menu for proxim­ity switch adjustment and final calibrations.

NOTE: 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.

1. 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.

2. 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.

3. Make sure the deck is fully lowered. Plug in the ana­lyzer and scroll through DIAGNOSTICS/ELEV SEN­SOR to ANGLE SNSR. This should read 0.40v -

0.45v.

NOTE: Anytime the ground control board or if the rotary sen-

sor is replaced the rotary sensor must be reset
(zeroed out).

4. If the reading is not within the spec, adjust the rotary
switch by rotating the bracket and viewing the ana­lyzer.

5. 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 scroll 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.

NOTE: If your machine does not have a motion alarm, the

following procedures will still apply.

6. Lift the platform up until it stops lifting, this will be the
lift cut-out height.

7. Using the analyzer, press ESCAPE, scroll to DIAG­NOSTICS, 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 ele­vated platform will read 2.95 volts.

8. 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.

NOTE: If the gap ever increases beyond 5/16 in., the switch

may cause intermittent operation.

9. Completely lower the platform. Using the analyzer
press escape and scroll through DIAGNOSTICS and
then go to ELEV 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

10. If CALIB; reads whatever you set your rotary switch
to (0.40 - 0.45) then press ENTER.

11. Press ESCAPE until you arrive at DIAGNOSTICS,
then scroll over to top level menu SET ELV SEN­SOR, 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 ana­lyzer will read COMPLETE.

12. 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)

3121122 – JLG Lift – 3-1

SECTION 3 - CHASSIS & SCISSOR ARMS

2

1

1. Ground Control Box

2. Digital Level

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: CALI­BRATION:

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) or SET 36FT ELEV
(4069LE);

Tilt Sensor Calibration:

1. Drive the machine onto a measured level surface
(±0.5° for both x and y axis).

2. Using the Analyzer, go to MENU: CALIBRATION;
TILT SENSOR. Press Enter. LEVEL VEHICLE will dis­play. Press Enter again to calibrate.

3. Both axis’ raw angles need to be within 5.0°, other­wise the machine is to unlevel and the software will
prohibit calibration. Should this occur, attempt to
dissect 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.

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 Sen­sor.

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. If 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

NOTE: If replacing the speed sensor, the new sensor will

the motor on the brass feral.

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.

3-2 – JLG Lift – 3121122