JLG M4069 Service Manual

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Service & Maintenance Manual

Models

3369LE 4069LE

M3369 M4069

3121824

July 23, 2012

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

SECTION A. INTRODUCTION - MAINTENANCE SAFETY

PRECAUTIONS

AGENERAL

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 electrical, 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.

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 torelieve any system pressure prior to disconnecting or removing any portion of the system.

CMAINTENANCE

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.

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

• NEVER WORK UNDER AN ELEVATED BOOM UNTIL BOOM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING, OR BOOM SAFETY PROP HAS BEEN ENGAGED.

• BEFORE MAKING ADJUSTMENTS, LUBRICATING OR PERFORMING ANY OTHER MAINTENANCE, SHUT OFF ALL POWER CONTROLS.

• BATTERY SHOULD ALWAYS BE DISCONNECTED DURING REPLACEMENT OF ELECTRICAL COMPONENTS.

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

• USE ONLY APPROVED, NONFLAMMABLE CLEANING SOLVENTS.

3121824 – JLG LIft – a

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

REVISION LOG

Original Issue - January 31, 2001

Revision - April 25, 2001

Revision - June 21, 2002

Revision - October 15, 2002

Revision - May 2, 2003

Revision - December 10, 2003

Revision - May 11, 2004

Revision - January 24, 2005

Revision - February 15, 2005

Revision - February 22, 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 – 3121824

TABLE OF CONTENTS

SUBJECT - SECTION, PARAGRAPH PAGE NO.

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-a

B Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-a

C Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-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 Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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

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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

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

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TABLE OF CONTENTS

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

4-8. Piston Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

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

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 - (Sheet 1 of 2) (4069LE AUS Full Drive Height Only) . . . . . . . . . . . . . . . . .6-20

6-27. Electrical Schematic - (Sheet 2 of 2) (4069LE AUS Full Drive Height Only) . . . . . . . . . . . . . . . . .6-21

6-28. Electrical Schematic - Yanmar Engine (M3369 & 3369LE only). . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

.6-15

3121824 – JLG Lift – iii

TABLE OF CONTENTS (Continued)

6-29. Hydraulic Diagram - 3369LE and M3369 (Fixed Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24

6-30. Hydraulic Diagram - 3369LE and M3369 (Oscillating Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25

6-31. Hydraulic Diagram - 4069LE and M4069 (Fixed Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26

6-32. Hydraulic Diagram - 4069LE and M4069 (Oscillating Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27

6-33. Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-28

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 – 3121824

SECTION 1 - SPECIFICATIONS

SECTION 1. SPECIFICATIONS

1.1 SPECIFICATIONS

Table 1-1. Operating Specifications

Description 3369LE/M3369 4069LE/M4069

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

Maximum Occupants 2

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

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%

Maximum Operating Windspeed 12.5 m/sec (28 mph)

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

Maximum Platform Capacity

- Pl a t fo r m

-Platform Extension

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

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

Maximum Hydraulic System Pressure 207 bar (3000 psi)

Electrical System Voltage 48Vdc

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

Tilt Sensor Setting: Side to Side Fo r e a n d A f t

Ground Clearance 20 cm (8 in)

Wheelbase 2.3 m (91.5 in)

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

Machine Length (stowed) 3.1 m (121 in)

Machine Width 1.75 m (69 in)

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

2.3 m (7.5 ft)

4.9 m (16 ft)

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

3° 5°

3121824 – JLG Lift – 1-1

SECTION 1 - SPECIFICATIONS

1.2 CAPACITIES

Table 1-2. Capacities

Description 3369LE/M3369 4069LE/M4069

Hydraulic Tank

Hydraulic System approx. 32.1 liters (8.5 gal)

Torque Hubs (2) 0.5 liters (17 ounces)

31.2 liters (8.25 gal)

20.4 liters (5.4 gal) @ full mark

1.3 PRESSURE SETTINGS

Table 1-3. Pressure Settings

Description 3369LE/M3369 4069LE/M4069

Main Relief (±3.5 bar)

Steer Relief

Lift Relief

179 bar

(2600 psi)

207 bar

(3000 psi)

172 bar

(2500 psi)

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

193 bar

(2800 psi)

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 6.4 mm (1/4 inch) overall

Hydraulic Pump/Electric Motor Assembly

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

M4069/4069LE - 20 cm (8 in)

1.5 TORQUE SPECIFICATIONS

Table 1-4. Torque Specifications

DESCRIPTION

To rq ue H ub

Wheel Nuts

Fixed Axle Bolts

Drive Motor

Pump Motor Terminals

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

N/A

NOTE: When maintenance becomes necessary or a fas-

tener has loosened, refer to the Section 1.12, Torque

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.

Charts to determine proper torque value.

1-2 – JLG Lift – 3121824

SECTION 1 - SPECIFICATIONS

1.6 LUBRICATION

Table 1-5. Hydraulic Oil

Hydraulic System Operating

Temperature Range

-18°C to -5°C (0° F to 23° F) 10W

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

+10°C to +99°C (50° F to 210° F) 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 1-7. Mobil DTE 11M Specs

ISO Viscosity Grade #15

Gravity API 31.9

Pour Point, Max -40°C (-40°F)

Flash Point, Min. 166°C (330°F)

cp at -30° F 3.200

Viscosity Index 140

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

10.16 cm (4.00 in)

7.62 cm

(3.00 in)

10.16 cm (4.00 in)

5.08 cm

(2.00 in)

161.77 cm (63.69 in)

147.65 cm (58.13 in)

16.51 cm

(6.5 in)

6.98 cm (2.75 in)

5.71 cm (2.25 in)

2.86 cm

(1.125 in)

Table 1-6. Lubrication Specifications

KEY SPECIFICATIONS

EPGL

LL Synthetic Lithium Lubricant, Gredag 741 Grease.

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

NOTE: Refer to Lubrication Chart for specific lubrication pro-

ISO Viscosity Grade #15

Extreme Pressure Gear Lube (oil) meeting API service

c la ss if i ca ti on GL- 5 or MI L-S p ec MI L-L- 21 0 5

Hydraulic Oil. API service classification Gl-3, BP Ener-

gol SHS46.

cedures..

Table 1-7. Mobil DTE 11M Specs

Gravity API 31.9

Pour Point, Max -40°C (-40°F)

Flash Point, Min. 166°C (330°F)

Viscosity

at 40° C 15 cSt

at 100° C 4.1 cSt

at 100° F 80 SUS

at 210° F 43 SUS

1.8 MAJOR COMPONENT WEIGHTS

Table 1-9. Major Component Weights

Description 3369LE/M3369 4069LE/M4069

Platform 354 kg (780 lbs)

Platform Extension 163 kg (360 lbs)

Arm Assembly (Includes Lift Cylinders)

Chassis (Includes Battery Box and Foam filled Tires)

Foam Filled Tire and Wheel Assembly (each)

1451 kg

(3200 lbs)

2458 kg

(5420 lbs)

81.6 kg (180 lb.)

1.9 CRITICAL STABILITY WEIGHTS

Table 1-10. Critical Stability Weights

Description 3369LE/M3369 4069LE/M4069

Platform 354 kg (780 lbs)

Platform Extension 163 kg (360 lbs)

Foam Filled Tires 94 kg (207 lbs)

Battery (Each) 55 kg (122 lbs)

1769 kg

(3900 lbs)

2502 kg

(5517 lbs)

3121824 – JLG Lift – 1-3

SECTION 1 - SPECIFICATIONS

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

3,4

Figure 1-1. Lubrication Chart

1.10 LUBRICATION

Table 1-11. Lubrication Chart

INDEX

NUMBER

1 Sliding Wear Pads 8 Wear Pads MPG/Br ush 50 --

2 Hydraulic Oil Fill Level/Drain Plug

3 Wheel Bearings Front Wheels MPG - Repack 1200 --

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

COMPONENT

Spindles/Bushing

(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 op eration

Change oil after every 1000 hours of operation

Check oiul level at side plug daily.

Change after first 150 hours o f operation then every

Replace filter element after first 50 hours of operation

and every 1000 hours thereafter.

COMMENTS

1000 hours thereafter

1-4 – JLG Lift – 3121824

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.

3121824 – 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

Vibra-TITE

121

Medium Strength (Blue)

0100019

271

Vibra-TITE

140

High Strength (Red)

0100071

262

Vibra-TITE

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

or Vibra-

TITE

131)

Torque

Lubricated

Torque

(Loctite® 242

or 271

OR Vibra-TITE

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

1-6 – JLG Lift – 3121824

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

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

or 271

OR Vibra-TITE

111 or

140) K=.18

Torque

(Loctite® 262

or Vibra-

TITE

131)

K=0.15

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

Torque

(Dry or Loctite® 263)

K= 0.20

3121824 – 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

or 271

OR Vibra-TITE

111 or

140 OR Precoat 85®

K=0.16

Torque

(Loctite® 262

or Vibra-

TITE

131)

K=0.15

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

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

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

1-8 – JLG Lift – 3121824

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 1 10 150 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

OR Vibra-TITE

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

or Vibra-

TITE

131)

K=0.15

SECTION 1 - SPECIFICATIONS

3121824 – 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

)

Torque

(Lub)

Torque

(Loctite® 262

OR Vibra-

TITE

131)

Torque

(Loctite®

242

or 271

OR Vibra-

TITE

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 AGA INST 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 – 3121824

SECTION 1 - SPECIFICATIONS

Size PITCH

Tensile

Stress

Area

Clamp

Load

Torque

(Dry or Loctite®

263

)

K = 0.20

Torque

(Lub OR Loctite®

242

or 271TM OR

Vibra-TITE

111 or

140)

K= 0.18

Torque

(Loctite® 262

Vibra-TITE

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 2 115 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 CAPABILI TY 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

3121824 – 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

)

K = .17

Torque

(Lub OR Loctite®

242

or 271

OR Vibra-TITE

111 or 140)

K = .16

Torque

(Loctite® 262

OR Vibra-TITE

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 – 3121824

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.

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-Trained 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-Certified 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

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.

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.

3121824 – 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

Cleanliness

Primary

Responsibility

User or Operator User or Operator Operator and Safety Manual

Owner, Dealer, or User

eign materials out of the vital components. Precautions have been taken to safeguard against this. Shields, covers, seals, and filters are provided to 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

Components Removal and Installation

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 for-

2-2 – JLG Lift– 3121824

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.

SECTION 2 - GENERAL

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. 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 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.

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.)

3121824 – 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.

3. 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 -29° C (-20° F). However, use of this oil will give poor performance at temperatures above 49° C (120° F). Systems using DTE 13 oil should not be operated at temperatures above 94° C (200° F) 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 -26° C (-15° F) 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

-26° C (-15° F).

2-4 – JLG Lift– 3121824

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. Lower booms (if equipped) slightly elevated, upper boom fully extended with the rated load in the platform and power off. 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 bearings 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.

3121824 – 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.

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.

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.

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

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.

2-6 – JLG Lift– 3121824

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.

3121824 – JLG Lift – 2-7

SECTION 2 - GENERAL

NOTES:

2-8 – JLG Lift– 3121824

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.

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

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.

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)

3121824 – JLG Lift – 3-1

SECTION 3 - CHASSIS & SCISSOR ARMS

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 – 3121824

SECTION 3 - CHASSIS & SCISSOR ARMS

1. Ground Control Box 2. Tilt Sensor

b. Tilt sensor mounting on machine or wedged

crooked in control box: If the machine mounting/grade appears acceptable, open the Ground Control box carefully. Observe whether the tilt sensor is properly seated.

1. On the 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.

b. Disconnect the sensor and clean any corrosion

off of the tilt sensor and control board connections.

c. Reassemble and test. If fault persists, replace tilt

sensor.

2. If 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 & Higher and P1.0 & Higher)

Using the Analyzer, in Access Level 1, go to MENU: CALIBRATION: JOYSTICK and press ENTER.

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 reading (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 calibrate are:

a. The surface the machine is sitting on is off level

by a few degrees (flat doesn’t imply level; parking 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 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.

For the following troubleshooting steps, a bubble level (smaller is better) will be needed and the machine must be on a level surface:

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 Joytstick 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 &

center and reverse must be atleast 1V.

3121824 – JLG Lift – 3-3

SECTION 3 - CHASSIS & SCISSOR ARMS

1. Ground Control Box

2. Tilt Sensor (JLG P/N 4000006)

Figure 3-1. Tilt Sensor Location

3 2

1. Tilt Sensor (JLG P/N 4000006)

2. Screw, 6-32 x 3/4

3. Lockwasher

Figure 3-2. Tilt Sensor Removal

3.2 TILT SENSOR

Tilt Sensor, JLG P/N 4000006:

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

NOTE: Follow the above procedures in reverse order when

Box.

installing the tilt sensor assembly. After installing, be sure to calibrate the tilt sensor (refer to Section 3.1, Calibrations).

Table 3-1. Tilt Sensor Harness Chart

Wire Color Function Connector Pin

Red VCC 1

Black Ground 4

Blue PWMX 2

Yel low P WM Y 3

3-4 – JLG Lift – 3121824

Tilt Sensor, JLG P/N 4000021:

1. Ground Control Box

2. Tilt Sensor Assembly (JLG P/N 1810140)

Figure 3-3. Tilt Sensor Location

1. Tilt Sensor (JLG P/N 4000021)

2. Sensor Mount

3. Screw, 6-32 x 1

4. Lockwasher

5. Standoff Insulator

6. Washer, 0.313 x 0.250 Nylon

7. Screw, M3.5 x 0.6 x 10

Figure 3-4. Tilt Sensor Removal

SECTION 3 - CHASSIS & SCISSOR ARMS

NOTE: Refer to Figure 3-4., 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 (3), Lockwashers (4), Standoff Insulators (5), and Washers (6) to remove the Tilt Sensor (1) and Sensor Mount (2) from the Ground Control Box.

4. The Tilt Sensor (1) can be removed from the Sensor

NOTE: Follow the above procedures in reverse order when

Mount (2) by removing the three Screws (7).

installing the tilt sensor assembly. After installing, be sure to calibrate the tilt sensor (refer to Section 3.1, Calibrations).

Table 3-2. Tilt Sensor Harness

Wire Color Function Connector Pin

Red VCC 1

Green PWMX 2

White PWMY 3

Black Ground 4

3121824 – JLG Lift – 3-5

SECTION 3 - CHASSIS & SCISSOR ARMS

3.3 BATTERY MAINTENANCE AND CHARGING

IF REPLACING A 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 IN A TIPOVER HAZARD WHICH COULD RESULT IN SERIOUS INJURY OR DEATH.

Battery Maintenance, Quarterly

1. Open battery compartment cover to allow access to battery terminals and vent caps.

WHEN ADDING WATER TO BATTERIES, ADD WATER UNTIL ELECTROLYTE COVERS PLATES. DO NOT CHARGE BATTERIES UNLESS ELECTROLYTE COVERS THE PLATES.

NOTE: When adding distilled water to batteries, non-metallic

containers and/or funnels must be used.

To avoid electrolyte overflow, add distilled water to batteries after charging. When adding water to the battery, fill only to level indicated or 3/8" above separators.

1. Remove all vent caps 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.

2. Remove battery cables from each battery post one at a time, negative first. Clean cables with acid neutralizing solution (e.g. baking soda and water or

ammonia) and wire brush. Replace cables and/or cable clamp bolts as required.

3. Clean battery post with wire brush then re-connect cable to post. Coat non-contact surfaces with mineral grease or petroleum jelly.

4. When all cables and terminal posts have been cleaned, ensure all cables are properly positioned and do not get pinched. Close battery compartment cover.

5. Start hydraulic system and ensure that it functions properly.

Optional On Board Generator

EXHAUST GAS HAZARD. RUN THE GENERATOR IN A WELL VENTILATED 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 BATTERIES REACH A LOW-CHARGE STATE AUTOMATICALLY CHARGING THE BATTERIES.

NOTE: The engine will automatically shut down under the

following conditions:

Charged Batteries High Engine Oil Temperature Low Engine Oil Pressure Engine Overspeed Generator Overvoltage

TO AVOID INJURY FROM AN EXPLOSION, DO NOT SMOKE OR ALLOW SPARKS OR A FLAME NEAR BATTERY DURING SERVICING. ALWAYS WEAR EYE AND HAND PROTECTION WHEN SERVICING 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.

3-6 – JLG Lift – 3121824

SECTION 3 - CHASSIS & SCISSOR ARMS

Figure 3-5. Remote LED Card

2. To charge the batteries, connect the charger to a 230 volt source with a 15 amp minimum capacity.

3. The charge cycle is complete when the 100% LED is lit. Any other reading indicates the charge cycle is not complete.

4. The Charger will shut off automatically when the batteries are fully charged.

Depleted batteries will take approximately 17 hours to charge.

Charging Sequence of Remote LED Card

1. Plug in charger.

2. All three LED’s (light emitting diode) flash three times.

3. 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.

Battery Charger (Delta-Q)

The battery charger is located on a tray behind the hinged JLG cover at the front of the machine, or on the sliding engine tray on the (M) model machines.

6. Yellow LED will stay on until fully charged and green LED will illuminate.

7. If Red LED remains on, this indicates a fault.

Figure 3-6. Battery Charger Location

(M model shown)

1. AC Voltage - Input Cable

2. Charger Interlock Cable

3. DC Power Cable to Batteries

4. LED Indicator Cable

Figure 3-7. Battery Charger

3121824 – JLG Lift – 3-7

SECTION 3 - CHASSIS & 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 1A

INPUT

AC Input Voltage 85-265VAC

Nominal AC Input Voltage 120VAC - 230VAC RMS

AC Input Frequency 45-65 HZ

Maximum AC Input Current 12A RMS@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 Current Limited

DC Overload Current Limited

MECHANICAL

Operating Temperature

Housing Shock and Water Resistant Aluminum

–22°F to +122°F (–30°C to +50°C)

Battery Charger Maintenance

USE CHARGER ONLY ON BATTERY SYSTEMS WITH AN ALGORITHM SELECTED THAT IS APPROPRIATE TO THE SPECIFIC BATTERY TYPE. OTHER USAGE MAY CAUSE PERSONAL INJURY AND DAMAGE.

LEAD ACID BATTERIES MAY GENERATE EXPLOSIVE HYDROGEN 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 PRECAUTIONS SUCH AS RECOMMENDED RATES OF CHARGE AND REMOVING OR NOT REMOVING CELL CAPS WHILE CHARGING.

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 UN-INSULATED PORTION OF OUTPUT CONNECTOR OR UN-INSULATED 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 CHILDREN.

1. 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 not expose charger to oil or to direct heavy water spraying when cleaning vehicle.

3-8 – JLG Lift – 3121824

SECTION 3 - CHASSIS & 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 connection 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 likelihood of a battery connection problem, it is always worthwhile to confirm that all connections are good before checking for any other problems.

[1 Flash] - High Battery Voltage

1. Indicates a high battery voltage. Check that the battery 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.

4. If this problem does not clear after the battery voltage is confirmed to be higher than 1.0V per cell and all connections are good, return the charger for service.

[3 Flashes] - Charge Timeout

Indicates the battery failed to charge within the allowed time. This could occur if 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 ambient temperature. It can also occur if the battery is damaged, old, or in poor condition.

1. Check the battery for damage such as shorted cells and insufficient water. Try the charger on a good battery.

2. If the 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. If a 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 occurring as the pack "recovers."

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. If this problem does not clear after the battery voltage 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 connected, or a lower than expected battery voltage. Check the battery and battery connections.

2. Check the nominal battery voltage. The first two digits of the four digit model name indicate the battery voltage the charger supports. Confirm that a nominal battery voltage is the same as the charger voltage.

3. This fault will clear automatically when the low battery voltage problem is rectified.

[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 connected.

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 the charger on a good battery.

5. If this fault occurs, the battery is likely in poor condition. 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 appropriate voltage - 6V per 6V battery, 12V per 12V string/ battery.

3121824 – JLG Lift – 3-9

SECTION 3 - CHASSIS & SCISSOR ARMS

[5 Flashes] - Over Temperature

This fault indicates the charger has become too hot during operation. Though not damaging 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 indication 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.

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 resistance connection.The most likely reason for this fault is a fault in the battery such as a bad battery connection, 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.

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 not too small - usually > 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 algorithm 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-section.

4. If the 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 number and charge algorithm setting available when calling.

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 – 3121824

SECTION 3 - CHASSIS & SCISSOR ARMS

Checking/Changing the Battery Charge Algorithm

The charger is pre-loaded with programming algorithms for the specific batteries detailed in Table 3-4, Battery Algorithms. Contact JLG if your specific battery model is not listed. Each time AC power is applied with the battery pack not connected, the charger enters an algorithm select/display mode for approximately 11 seconds. During this time, the current Algorithm # is indicated on the Yellow Charging LED. A single digit Algorithm # is indicated by the number of blinks separated by a pause. A two digit Algorithm # is indicated by the number of blinks for the first digit followed by a short pause, then the number of blinks for the second digit followed by a longer pause.

To check / change the charging algorithm:

1. Disconnect the charger positive connector from the battery pack. Apply AC power and after the LED test, the Algorithm # will display for 11 seconds.

2. To change the algorithm, touch the connector to the battery’s positive terminal for 3 seconds during the 11 second display period and then remove. The Algorithm # will advance after 3 seconds. Repeat this procedure until the desired Algorithm # is displayed. A 30 second timeout is extended for every increment. Incrementing beyond the last Algorithm will recycle back to the first Algorithm. When the desired Algorithm is displayed, touch the charger connector to the battery positive terminal until the output relay makes a clicking noise (approx. 10 seconds). The algorithm is now in the permanent memory.

3. Remove the AC power from the charger and reconnect the charger’s positive connector to the battery.

NOTE: It is recommended to check a newly changed algo-

rithm by repeating the above steps 1 and 3.

Table 3-4. Battery Algorithms

Algorithm # Battery Type

143 DISCOVER EVL1GA-A

43 Harris Battery Discover EVGGC6A-A

35 JLG P/N 0400242

23 Douglas Flooded (JLG def ault)

GES Battery A1055

Trojan T105

US BATT GC-110-WNL

Trojan T105 PLUS

Champion CHGC2 GC2

US BATT EV-1 45-WNL

8 Concorde 10xAh AGM

7 J305 DV/DT CP

6 DEKA 8G3 1 Gel

5 Trojan 30/31XHS

4 US Battery USB2200

3 T105 DV/DT CP

2 Trojan T105 tapped

1 Trojan T105

Battery Temperature Sensor

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 battery charger.

3121824 – JLG Lift – 3-11

SECTION 3 - CHASSIS & SCISSOR ARMS

BATTERY

CHARGER

BATTERY

BOX

BATTERY

TEMPERATURE

SENSOR

(DELTA-Q CHARGER)

BATTERY

BOX

ATTACHMENT

BOLTS

BATTERY

DISCONNECT

BATTERY

BOX

TO CONTACTOR

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 disconnect the batteries.

2. Remove the two attachment bolts that secure the battery box to the frame.

NOTE: The battery box and batteries complete weigh

approximately 670 lbs (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.

3-12 – JLG Lift – 3121824

SECTION 3 - CHASSIS & SCISSOR ARMS

3.4 GENERATOR

NOTE: Throughout the Generator section, the abbreviations

RBS and CTS are used. RBS stands for Rotary Battery 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 regulation and current limiting is provided by the Engine/Generator 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 controls. 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 provides mechanical power to crank the engine. Electrical power for the starter is provided by the start battery. 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 sensor 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 proportional 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 alternator output current 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/generator controller. This signal is used by the controller to determine 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 signal 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 1 Bar (14.2 psi).

3121824 – JLG Lift – 3-13

SECTION 3 - CHASSIS & SCISSOR ARMS

Figure 3-9. Generator Components

3-14 – JLG Lift – 3121824

SECTION 3 - CHASSIS & 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.

2. Time Delay Pre-Heat (TDPH)

TDPH, if enabled, occurs after TDES has elapsed and the 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 (Call to Start)

TDES (Engine Start)

Preheat Delay

RBS Startup Sequence

• RBS Startup Sequence

1. Crank Time

The RBS will crank for a period up to the crank time or until the engine starts.

2. Rest Time

If the engine does not successfully start, the RBS will wait for the rest time before attempting to crank the engine again.

3. 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.

• RBS Shutdown Sequence

Once all CTS conditions have been removed, the RBS will begin the shutdown sequence. If a CTS condition is initiated 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 condition is removed, the TDER period begins. This period ensures that no further CTS conditions occur prior to the cool down period.

2. 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. 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 connect the remaining end of the cable to the analyzer.

4. 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 normal 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

3121824 – JLG Lift – 3-15

SECTION 3 - CHASSIS & SCISSOR ARMS

Figure 3-10. Generator System Analyzer Flow Chart

3-16 – JLG Lift – 3121824

SECTION 3 - CHASSIS & SCISSOR ARMS

ANALYZER

CONNECTION

GROUND

CONTROL

The ground control module contains the settings for the generator.

NOTE: The cable has a four pin connector at each end of

the cable; the cable cannot be connected backwards.

2. Power up the Analyzer by pulling out the ground station EMS and positioning the Generator Enable switch on the platform control box to the "on" position. Refer to Figure 3-10., Generator System Analyzer Flow Chart.

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

1-2

1-3

1-4

1-5

2-1

2-2

2-3

2-4

Continuous

Off

Low Oil Pressure

High Engine Temperature

Engine Overspeed

Engine Underspeed/Overcrank

No Speed Signal

Overvoltage

Engine Starting System fault

Not Used

Loss of Voltage Sense

Unit Disabled

Shutdown due to low engine oil pressure

Shutdown due to high engine oil temperature

Shutdown due to high engine speed

Shutdown due to engine overcrank or underspeed

Shutdown due to loss of speed signal

Shutdown due to high output voltage

Alarm not a shutdown; Indicates problem with the engine starting system

Not Used

Shutdown due to loss of voltage sensing

No Faults. RBS enabled and can respond to any CTS

RBS off or disabled; Will not respond to 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 temperature 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.

3121824 – JLG Lift – 3-17

SECTION 3 - CHASSIS & SCISSOR ARMS

• Underspeed

Enabled once TDBP (time delay bypass) period has elapsed after engine startup. If the engine speed drops below the underspeed limit, the engine will stop immediately 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 shutdown and an engine no speed signal alarm will be indicated. 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 shutdown is delayed by a factory set period to ensure the fault was not caused by a transient condition. This feature protects 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.

• Finish Charging Current

The finish charging current determines the level of the current alternator output must drop below for a low battery voltage CTS to be removed. This ensures that the batteries have accepted sufficient charge prior to shutting down the RBS. This level is used along with the low battery voltage 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 operate 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.

• 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

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 alternator 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.

4. When fuel starts to flow out of the rubber line, reconnect the fuel line to the fuel injector pump.

5. Clean up any spilled fuel and try to start the generator 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 generator again.

3-18 – JLG Lift – 3121824

SECTION 3 - CHASSIS & SCISSOR ARMS

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.

10. Engine might run rough for 20 seconds or so, but it will clean out.

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 Controller for the APU.

Tools A nd Material

• - Weather proof fuse holder - JLG P/N 2400081

• - AGC1, 1 Amp fuse - JLG P/N 2400080

• - 45 cm of #16 AWG wire - JLG P/N 4920019

• - 2 X insulated butt splice connectors - JLG P/N 4460035

• - 6 X medium length wire ties - JLG P/N 4240033

• - Wire/Side cutters

• - 5/32” Allen Key

• - Crimping tool

1. Locate the harness at the rear of the APU.

2. Find where the harness attaches to the rear cover of the generator and the connection point for the new inline fuse.

Procedure

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 modification performed to an APU supplied in a JLG M450 lift.

3121824 – JLG Lift – 3-19

SECTION 3 - CHASSIS & SCISSOR ARMS

3. Remove the socket head drive screw with a 5/32” Allen key. Next remove the cable clamp from the harness.

4. Cut and remove the Wire Ties holding the Harness label to the harness. Next, remove the Wire Ties so that the cable sleeve can be moved, exposing the conductors of the harness.

5. Cut wire 106 going to the Engine/Generator Controller after the existing connection point and install the conductors that lead to the new inline fuse holder. Use insulated butt splice connectors for these conductors.

6. Re-install the harness with the new fuse in place.

7. Reconnect the lift and APU start battery. The APU is now ready for use.

3-20 – JLG Lift – 3121824

3.6 JOYSTICK CONTROLLER

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

SECTION 3 - CHASSIS & SCISSOR ARMS

Table 3-9. Joystick Specifications

Input Voltage 4.3V (±0.1V)

Centered Output Voltage 2.2V (±0.1V)

Full Positive (Rev) Deflection Output Voltage 4.0V (±0.1V)

Full Negative (Fwd) Output Voltage 0.4V (±0.1V)

Table 3-10. Joystick Plug Loading Chart

Te rm in al Color Function

1 Yellow Steer Right

2 Green Steer Lef t

3 Brown Pot Wiper

4RedHandle Common

5 N/A Not Connected

6 White/Red Pot (+)

7 Violet Trigger Switch

8 Blue Trigger Supply

9 White/Black Pot (-)

3121824 – JLG Lift – 3-21

SECTION 3 - CHASSIS & SCISSOR ARMS

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

Table 3-11. Joystick Specifications

Input Voltage 5V

Centered Output Voltage 4.25V to 2.60V

Reverse Voltage 4. 60V to 4.80V

Forward Voltage 0.40V to 0.60V

Table 3-12. Joystick Plug Loading Chart

Ter min al Color Function

1 Yellow Steer Right

2 Green Steer Left

3Brown 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 (-)

3-22 – JLG Lift – 3121824

SECTION 3 - CHASSIS & SCISSOR ARMS

TORQUE

HUB

ACT

NMOTO

DRIVE

BRAKE

POWER

CONTROLL ER

Figure 3-13. Drive Components

3121824 – JLG Lift – 3-23

SECTION 3 - CHASSIS & SCISSOR ARMS

Figure 3-14. Power Controller

Power Controller

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.

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.

Table 3-13. Power Controller Cable Descriptions

From To

Power Controller F2 Right Side Drive Motor F1

Right Side Drive Motor F2 Left Side Drive Motor F2

Power Controller F1 L eft Side Drive Motor F1

Power Controller S Left Side Drive Motor A2

Right Side Drive Motor A1 Left Side Drive Motor A1

Power Controller A Right Side Drive Motor A1

Left Side Drive Motor A2 Right Side Drive Motor A2

Power Controller B+ Contactor ++

3.7 TORQUE HUB

Disengaging for Towing

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 MOVED UNLESS IT IS SECURED TO THE TOWING VEHICLE TO PREVENT RUNAWAY.

2. Remove the cover.

ENSURE THE DISCONNECT MECHANISM IS ONLY OPERATED WITH THE MACHINE AT A STANDSTILL.

3-24 – JLG Lift – 3121824

3. Rotate the cover to show the inside diameter.

SECTION 3 - CHASSIS & SCISSOR ARMS

ENSURE THE DISCONNECT MECHANISM IS ONLY OPERATED WITH THE MACHINE AT A STAND STILL.

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.

ENSURE THE AREA SURROUNDING THE DISCONNECT IS CLEANED PRIOR TO OPERATION. ENSURE THAT DIRT OR OTHER CONTAMINANTS DO NOT ENTER THE GEAR DRIVE.

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 8.8 NM (6.3 ft. lbs) until they are flush with the cover.

6. The sun gear shaft and input shaft are now disconnected and the machine is ready to be towed.

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

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 8.8 NM (6.3 ft.lbs).

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.

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 components are returned to their original positions.

5. The gear drive should now be reengaged and the machine can be disconnected from the towing vehicle.

3121824 – JLG Lift – 3-25

SECTION 3 - CHASSIS & SCISSOR ARMS

Figure 3-15. Torque Hub

3-26 – JLG Lift – 3121824

SECTION 3 - CHASSIS & 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 transmitting 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. Position drive so that one of the fill holes is at the bottom of the end cover and drain the gear oil.

2. Remove all bolts holding motor and remove motor from drive.

3. Compress the disc (59) using a simple fixture or other suitable device.

4. Remove snap ring (66) and release pressure on disc until loose. Remove tool and disc (59).

5. Remove the spring (55) from the input shaft (44)and turn the unit so that cover (8) is in the up position.

NOTE: The second stage planetary bearings (11) must be

replaced in sets of four pieces.

Disassembly of Cover Unit (8)

1. Loosen and remove hex. hd. bolts (53) and remove cover (51).

2. Remove Shaft rod (56), O-ring (54), and sleeve (52)

Disassembly of First Stage Planetary Assembly

1. Push the sun gear shaft (43) out of the first stage.

2. Remove snap rings (14) and press planet pins (5) out of planet carrier (7) and planet gears (2).

3. Pull cylindrical roller bearing (10) out of planet gears (2).

4. 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).

6. Remove screw plugs (22) and seal rings (21).

7. Remove snap ring (34), cover unit (8) from drive and O-ring (33).

8. Remove first stage planetary assembly (7).

9. Remove hex. hd. bolts (23) to remove gear (33) and O-ring (19).

10. Remove Snap rings (15) to pull off planet gears (1) together with cylindrical roller bearings (11) from spindle (60).

NOTE: Further disassembly of the hub is discouraged. Rein-

stallation of the shaft nut (4) requires a special tool and a torque of 876 Nm (626 ft lbs) for proper reassembly. These components WILL fail if not properly reassembled.

11. Inspect the planetary stage assemblies as complete units. Thoroughly clean and check both the gearing and the bearings for damage and apply new oil. If gears or bearings need replacing, they must be replaced as complete units.

NOTE: 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 manufacturer recommends changing the sun gear shaft (43) along with this set of planets.

3121824 – JLG Lift – 3-27

SECTION 3 - CHASSIS & SCISSOR ARMS

1. Retaining Screws

2. Washers

3. Pressure Plate

4. Case Seal

5. O-ring

6. Back-up Ring

7. Piston

8. O-ring

9. Back-up Ring

10. Shaft

11. Stator Disc

12. Sensor Ring

13. Rotor Disc

14. Plate

15. Springs

16. Spring Retainer

17. Retaining Ring

18. Bearing

19. Retaining Ring

20. Dowel Pins

21. Cover

22. Rotary Oil Seal

23. Brake to Hub Gasket

24. Brake to Motor Gasket

Figure 3-16. Brake Assembly

3-28 – JLG Lift – 3121824

SECTION 3 - CHASSIS & 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).

PRESSURE PLATE IS UNDER SPRING TENSION OF APPROXIMATELY 680 KG (1500 LB). THE FOUR CAP SCREWS SHOULD BE LOOSENED EVENLY TO RELIEVE THE FORCE. IF A HYDRAULIC PRESS IS AVAILABLE, 1361 KGF (3000 LBS) MINIMUM, THE PRESSURE PLATE CAN BE HELD IN POSITION WHILE REMOVING 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).

IF THE SENSOR RING (12) IS DAMAGED OR NEEDS REPLACED, THE ENTIRE BRAKE MUST BE REPLACED AS A UNIT. THE SENSOR 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).

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 to 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 contaminate 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 (21).

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 74.6 NM (55 lb ft ).

NOTE: A hydraulic press will simplify the installation of the

pressure plate. Clamp pressure plate in position while tightening the cap screws.

NOTE: Not all models use the same number of springs or

spring pattern. Record this information for reassembly purposes.

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.

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 pressurizing 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.)

3121824 – JLG Lift – 3-29

SECTION 3 - CHASSIS & SCISSOR ARMS

3.10 TORQUE HUB

1. Spindle

2. Lip Seal

3. Tapered Bearing Cone

4. Tapered Bearing Cup

5. Tapered Bearing cone

6. Ring Gear

7. Hub (Housing)

8. Stud

9. Retaining Ring, Ext.

10. Retaining Ring, Int.

11. Spring (1.460, 1.500)

12. Thrust Washer

13. Spacer

14. Seal Boot

15. Thrust Spacer

16. Input Carrier

17. Thrust Washer

18. Needle Bearing

19. Planet Shaft

20. Planet Gear

21. Output Carrier

22. Thrust Washer

23. Needle Bearing

24. Thrust Spacer

25. Planet Shaft

26. Planet Gear

27. Roll Pin

28. Thrust Washer

29. Retaining Ring, Ext.

30. Cover

31. Disengage Cap

32. Hex Bolt

33. Dowel Pin

34. O-ring

35. Retaining Ring, Int.

36. Coupling

37. Input Shaft

38. Input Sun Gear

39. Output Sun Gear

40. O-ring

41. O-ring

42. Retaining Ring, Ext.

Figure 3-17. Torque Hub Assembly

3-30 – JLG Lift – 3121824

SECTION 3 - CHASSIS & SCISSOR ARMS

Roll Test

The purpose of the roll test is to determine if the unit’s 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 leak checking fitting starts to fall after the unit has been pressurized and allowed to equalize. 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 the o-rings or gaskets meet on the exterior of the unit, then checking for air bubbles. If a leak is detected in a seal, oring or gasket, the part must be replaced, and the unit rechecked. Leak test at 10 psi (0.69 bar) for 20 minutes.

Tightening and Torquing Bolts

If an air impact wrench is used to tighten bolts, extreme care should be taken to ensure the bolts are not tightened beyond their specified torque.

5. Using the same sequence, crisscross around the bolt circle and apply an equal torque to the remaining bolts.

Figure 3-18. Bolt Torquing Sequence

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. Go to the opposite side of the bolt circle and tighten bolt "B" until equally snug.

3. Crisscross around the bolt circle and tighten remaining bolts.

4. Now use a torque wrench to apply a specified torque to bolt "A".

3121824 – JLG Lift – 3-31

SECTION 3 - CHASSIS & SCISSOR ARMS

1. Coupling

2. Retaining Ring

3. Ring Gear

4. Cover Subassembly

5. Washer

6. First Stage Sun Gear

7. Input Shaft

8. Carrier Subassembly

9. Second Stage Sun Gear

10. Output Stage Carrier Subassembly

11. Flat Head Bolts

12. Ring Gear

13. Housing

14. O-Ring

15. O-Ring

16. Retaining Ring, Ext.

17. Retaining Ring, Ext.

18. ID Plate

Figure 3-19. Hub Main Disassembly

Main Disassembly

3-32 – JLG Lift – 3121824

SECTION 3 - CHASSIS & SCISSOR ARMS

Disassembly Instructions:

1. Perform the Roll Check and Leak Check, if applicable 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).

NOTE: On units with a ratio 48:1, the Sun Gear (9) and the

Input Shaft (7) will need to be removed together.

10. Remove the Output Stage Carrier Subassembly (10).

11. Loosen and remove the three Flat Head Bolts (11) that retain the Ring Gear (12) to the Housing (13).

12. Lift the Ring Gear (12) off of the Housing (13).

13. Remove the O-ring (14) from between the Housing (13) and the Ring Gear (12).

3121824 – JLG Lift – 3-33

SECTION 3 - CHASSIS & SCISSOR ARMS

1. Roll Pin

2. Planet Shaft

3. Carrier

4. Needle Bearings

5. Thrust Washers

6. Thrust Spacer

7. Planet Gears

8. Thrust Washer

Figure 3-20. Output Carrier Disassembly

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 – 3121824

4. Slide the Planet Gear Sub-assembly (4 - 7) out of the Output Carrier (3) being careful to not drop the Needle Bearings (4) in the process.

5. Remove the 4 Thrust Washers (5), 28 Needle Rollers (4) and the Thrust Spacer (6) from the Second Stage Planet Gear (7).

6. Repeat Steps 1-5 for the remaining two Planet Gears (7).

7. Remove the Thrust Washer (8) from the counterbore in the Output Carrier (3).

Input Carrier Disassembly

1. Roll Pin

2. Planet Shaft

3. Carrier

4. Planet Gears

5. Thrust Spacer

6. Needle Bearings

Figure 3-21. Input Carrier Disassembly

SECTION 3 - CHASSIS & SCISSOR ARMS

1. Using a 1/8" diameter punch, drive the Roll Pin (1) into the Planet Shaft (2) until it bottoms against the Carrier (3).

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.

4. Slide the Planet Gear (4) and the two Thrust Washers (5) out of the Carrier (3).

5. Remove the 14 Needle Bearings (6) from the bore of the Planet Gear (4).

6. Repeat steps 1-5 for each of the two remaining Planet Gears.

3121824 – JLG Lift – 3-35

SECTION 3 - CHASSIS & SCISSOR ARMS

1. Spindle

2. Retaining Ring

3. Spacer

4. Bearing Cone

5. Bearing Cup

6. Hub

7. Boot Seal

8. Studs

9. Bearing Cone

Figure 3-22. Hub-Spindle Disassembly

Hub-Spindle Disassembly

1. Place unit on bench with Spindle (1) end down.

2. Remove Retaining Ring (2) with appropriate tool.

3. Remove Spacer (3).

4. Remove "A" position Bearing Cone (4) from Bearing Cup (5) in Hub (6).

5. Lift Hub (6) off of Spindle (1). Remove Boot Seal (7)

3-36 – JLG Lift – 3121824

from Hub if applicable.

6. If necessary, press 9 Studs (8) out of Hub. Locate Hub on Seal (refer to Figure 3-17.) end.

7. Remove Seal from Hub.

NOTE: The Seal should NOT be reused when reassembling

the unit.

8. Remove "B" position Bearing Cone (9) from Hub.

9. Using a soft steel rod, knock both Bearing Cups (5) out of the Hub.

Cover Disassembly

1. O-Ring

2. Cover

3. Thrust Washer

4. Hex Head Bolts

5. Disengage Cap

6. Disengage Rod

7. O-ring

8. O-ring Pipe Plugs

Figure 3-23. Cover Disassembly

SECTION 3 - CHASSIS & SCISSOR ARMS

1. Remove O-ring (1) from the groove in the Cover (2).

2. Remove the Thrust Washer (3) from Cover pockets.

3. Unscrew the two Hex Head Bolts (4) and remove the Disengage Cap (5) from the Cover.

3121824 – JLG Lift – 3-37

4. Pull Disengage Rod (6) out of the Cover.

5. Use an appropriate tool to remove the O-ring (7) from the internal groove in the Cover.

6. Remove the two O-ring Pipe Plugs (8) from the Cover.

SECTION 3 - CHASSIS & SCISSOR ARMS

1. Roll Pin

2. Planet Shaft

3. Carrier

4. Planet Gears

5. Thrust Spacer

6. Needle Bearings

Figure 3-24. Input Carrier Sub-Assembly

Input Carrier Sub-Assembly

1. Apply a liberal coat of grease to the bore of one Input Planet Gear (4).

2. Line the inside of the Planet Gear with 14 Needle Bearings (6).

NOTE: 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.

3. Set Carrier (3) in an upright position.

4. 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.

5. 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. Following the Thrust Washer, place the Planet Gear with Needle Bearings onto the Planet Shaft.

7. 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.

8. 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.

NOTE: Be sure not to hit the Planet Gears when driving in

the Roll Pins (1).

9. Drive the Roll Pins down into the aligned roll pin holes. Pin should be flush with the flat of the Carrier.

10. Repeat Steps 1-9 for the installation of the two remaining Planet Gears.

NOTE: Some grease may need to be applied to the thrust

washers to hold them in place while installing the Planet Gears.

3-38 – JLG Lift – 3121824

Output Carrier Sub-Assembly

1. Roll Pin

2. Planet Shaft

3. Carrier

4. Needle Bearings

5. Thrust Washers

6. Thrust Spacer

7. Planet Gears

8. Thrust Washer

Figure 3-23. Output Carrier Sub-Assembly

SECTION 3 - CHASSIS & SCISSOR ARMS

1. Apply a liberal coat of grease to the bore of one Output Planet Gear (7).

2. Line the inside of the Planet Gear with 14 Needle Bearings (4).

NOTE: 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.

3. Place the Spacer (6) into the bore of the Output Planet.

4. Repeat Step 2 to put in second roll of Needle Bearings.

5. Apply grease to hold two Thrust Washers together and onto Output Planet Gear counter-bore. Do the same to the other side.

6. Repeat Steps 1-5 to finish the assembly of the two remaining Output Planet Gears.

7. Place the Thrust Washer (8) into counter-bore of the Carrier (3). BE SURE the small diameter side of the Thrust Washer is facing the planet gear side.

8. 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.

9. 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.

10. 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.

NOTE: Be sure not to hit the Planet Gears when driving in

the Roll Pins (1).

11. Drive the Roll Pin down into the aligned roll pin holes. Pin should be flush with OD of Carrier.

12. Repeat Steps 7-11 for the installation of the two remaining Planet Gears.

3121824 – JLG Lift – 3-39

SECTION 3 - CHASSIS & SCISSOR ARMS

1. Spindle

2. Retaining Ring

3. Spacer

4. Bearing Cone

5. Bearing Cup

6. Hub

7. Boot Seal

8. Studs

9. Bearing Cone

Figure 3-24. Hub-Spindle Sub-Assembly

Hub-Spindle Sub-Assembly

NOTE: Apply a light coat of oil on all component parts dur-

ing assembly.

1. Place the Hub (6) into a pressing base. Press 9 Studs (8) into the Hub.

NOTE: Use enough pressure to press in studs. Don’t use

excessively high pressure to press in Studs as this may crack Hub.

Spray a generous amount of oil on bearings during installation.

2. Press Bearing Cup (5), position "A" into Hub using appropriate pressing tool.

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 "B".

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.

6. Press Seal Boot (7) onto Hub, if required. Turn Hub over and lower onto Spindle (1).

7. Install Bearing Cone (4) into Bearing Cup, position "A".

8. Place Bearing Spacer (3) on top of Bearing Cone.

9. Using appropriate tool, install Retaining Ring (2) into Spindle groove. Make sure ring is completely seated in groove.

NOTE: Extra bearing pre-load caused by using tool in Step

#9 must be removed. This should be done by placing a tool (NOT THE SAME TOOL USED IN STEP #9) on the end of the Spindle, and then striking the tool with a piece of bar stock. This should be adequate to remove any additional bearing pre-load.

3-40 – JLG Lift – 3121824

Cover Sub-Assembly

1. O-Ring

2. Cover

3. Thrust Washer

4. Hex Head Bolts

5. Disengage Cap

6. Disengage Rod

7. O-ring

8. O-ring Pipe Plugs

Figure 3-25. Cover Sub-Assembly

SECTION 3 - CHASSIS & SCISSOR ARMS

1. Grease O-Ring (7) and insert into groove in Cover (2).

2. Assemble Disengage Cap (5) onto Cover using two Hex Head Bolts (4). Torque bolts to 70-80 in-lbs (7.9

- 9 Nm).

3. Insert Disengage Rod (6) into hole in Cover until it touches the inside of the Disengage Cap.

NOTE: The Disengage Rod can be inserted either end first.

3121824 – JLG Lift – 3-41

4. Grease the face of the Thrust Washer (3) and place in the Cover making sure the tangs on the Washer seat into the pockets in the Cover.

5. Install the O-ring Pipe Plugs (8) into the Cover. The plugs should be hand tight according to SAE standard.

SECTION 3 - CHASSIS & SCISSOR ARMS

1. Coupling

2. Retaining Ring

3. Ring Gear

4. Cover Subassembly

5. Washer

6. First Stage Sun Gear

7. Input Shaft

8. Carrier Subassembly

9. Second Stage Sun Gear

10. Output Stage Carrier Subassembly

11. Flat Head Bolts

12. Ring Gear

13. Housing

14. O-Ring

15. O-Ring

16. Retaining Ring, Ext.

17. Retaining Ring, Ext.

18. ID Plate

Figure 3-26. Hub Main Assembly

Main Assembly

3-42 – JLG Lift – 3121824

SECTION 3 - CHASSIS & SCISSOR ARMS

NOTE: All components should receive a generous amount

of lubricant oil as they are being assembled.

1. Place Hub-Spindle Sub-Assembly on a bench.

2. Grease O-Ring (14) and place it into the groove of the Housing (13).

3. Place the Ring Gear (12) onto the Hub. Align the 3 shipping cap screw holes on the Hub and Ring Gear.

4. Install the 3 Flat Head Bolts (11) into the Ring Gear and Hub. Torque the Bolts to 15-20 ft-lbs (20.3-27.1 Nm).

5. Place Output Stage Carrier Subassembly (10) into mesh with the Spindle splines.

6. Place the External Retaining Ring (16) over the 13T spline to the retaining groove on the Input Shaft (7).

NOTE: For ratio 48:1, assemble the Second Stage Sun

Gear (9) over the Input Shaft first, then install the External Retaining Ring.

7. Using an appropriate tool, install the Retaining Ring (17) into the groove on the Output Sun.

8. Place the Input Shaft spline end into mesh with the Internal Coupling (1) splines.

9. With the modified spline end facing up, place the Output Sun Gear into mesh with the Output Planet Gears.

10. 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).

11. Grease the O-Ring (15) and insert into the groove in the Cover Subassembly (4).

12. Install the Cover Subassembly into the Ring Gear (3) counterbore and install the Retaining Ring (2) into the groove in the Ring Gear.

13. Attach the ID Plate (18) onto the unit using the Drive Screw (not shown).

14. Check disconnect, roll and air check the unit, leak check the brake, and record release pressure.

15. Insert the Plastic Plug (not shown) into place, if applicable.

3121824 – JLG Lift – 3-43

SECTION 3 - CHASSIS & SCISSOR ARMS

NOTES:

3-44 – JLG Lift – 3121824

SECTION 4. HYDRAULICS

SECTION 4 - HYDRAULICS

4.1 SERVICING AND MAINTENANCE GUIDELINES

General

The following information is provided to assist you in the use and application of servicing and maintenance procedures 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 foreign materials out of the vital components. Precautions 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 function properly.

2. At any time when hydraulic 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.

Component Removal and Installation

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

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 be installed.

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

3121824 – 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 accordance with recommended shop practices.

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.

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 interval. When recommended lubricants are not available, consult your local supplier for an equivalent that meets or exceeds the specifications listed.

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 evidence of metal particles.

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.

2. JLG recommends DTE 11Hydraulic Oil, which has an SAE viscosity of 10W and a viscosity index of

140.

Batteries

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.

Lubrication and Servicing

Components and assemblies requiring lubrication and servicing are shown in Section 1.

4.2 LUBRICATION INFORMATION

Hydraulic System

1. The primary enemy of a hydraulic system is contamination. Contaminants enter the system by various means, e.g.; 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.

NOTE: Start-up of hydraulic system, not using DTE 11, with

oil temperatures below -26°C (-15°F) 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 -26°C (-15°F).

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 250 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 replace the filter cartridge any time the system oil is changed.

4-2 – JLG Lift – 3121824

SECTION 4 - HYDRAULICS

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 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.

4.3 CYLINDERS - THEORY OF OPERATION

1. Cylinders 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. Directing 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 cylinder 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 hydraulic system.

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.

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 reservoir so that the set pressure is not exceeded. An adjusting screw on each cartridge relief valve allows the set pressure 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 manifold 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 12.7 cm (5 in). Replace sliding pads when worn to 11.9 cm (4.7 in).

4.7 MOTOR CONTROLLER - MODES OF OPERATION

Traction Motor (Drive)

Drive in either forward or reverse will start only if the following 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 illuminates.

4. FWD or REV selected as appropriate.

The directional control valve for steer is a solenoid operated, three position, 4-way sliding spool type valve. Energizing 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 energized, the supply of hydraulic oil is blocked.

Once in “drive” mode, activating a function switch shall not cause drive mode to be exited, the pump/traction contactor drive shall not be energized it will be left at the traction position. If a function switch is selected during traction, a procedure fault will occur when neutral is selected, remaining until a function switch and both directions are no longer selected.

3121824 – JLG Lift – 4-3

SECTION 4 - HYDRAULICS

When the controller is returned to neutral, the controller will control smooth stopping of the machine, using plug braking, before the brake is allowed to operate.

NOTE: Depressing the lift function switch while driving will

not interrupt drive function.

Pump Motor (LIft)

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 illuminates.

NOTE: Depressing the drive function switch while lifting will

not interrupt lift function.

NOTE: Any time brushes are being replaced in a drive motor

or pump motor, all brushes in the motor should be replaced.

4.8 FEATURES

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.

Cylinder 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.

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 oscillation below elevation cutback speed only.

Table 4-1. Cutout Heights

Function M3369/3369LE M4069/4069LE

Elevated Cutback Height

Drive Cutout Height N/A

2.4 m - 2.9 m (8 ft - 9 ft 6 in)

2.9m - 3.6m

(9 ft 6 in - 11 ft 8 in)

8.5 m - 9.1m (28 ft - 30 ft)

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. If 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 suitable overhead lifting device approximately 2.5 cm (1 in) 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

4-4 – JLG Lift – 3121824

SECTION 4 - HYDRAULICS

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. 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 hydraulic system and run cylinder through complete cycle to check for leaks and operation.

Cylinders with Duel Counterbalance Valves (Oscillating 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.

5. To check piston seals, carefully remove the counterbalance valve from the retract port. After initial discharge there should not be any further leakage from the ports. If leakage occurs at a rate of 6-8 drops per minute or more, the piston seals are defective and must be replaced.

6. If no repairs are necessary or when repairs have been made, carefully reconnect hydraulic hoses to the appropriate ports.

7. Activate hydraulic system and run cylinder through complete cycle to check for leaks and operation

4.10 CYLINDER REMOVAL AND INSTALLATION

Lift Cylinder Removal

1. Place the machine on a flat and level surface. Turn power on and raise the platform. Turn power off and attach a suitable lifting device to the platform.

2. 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.

3. Retract the cylinder rod completely.

4. Tag and disconnect, then cap the lift cylinder hydraulic lines and ports.

5. Remove the 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.

6. 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.

2. 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.

3. Remove cylinder port plugs and hydraulic line caps and correctly attach lines to cylinder ports.

4. 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 assembly. Secure the pin in place with bolt, locknut and keeper shaft.

5. Lower platform to stowed position and shut down motor. Check hydraulic fluid level and adjust accordingly.

NOTE: Always check hydraulic fluid level after completely

elevating and lowering machine.

3121824 – JLG Lift – 4-5

SECTION 4 - HYDRAULICS

Figure 4-1. Barrel Support

Figure 4-2. Cap Screw Removal

Figure 4-3. Rod Support

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 necessary.

2. If applicable, remove the cartridge-type holding valve and fittings from the cylinder port block. Discard o-rings.

5. Using a suitable spanner wrench, loosen the spanner 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.

EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFFCENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.

3. Place the cylinder barrel into a suitable holding fixture.

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 piston 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 piston.

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.

4. To aid in realignment, mark cylinder head and barrel with a center punch.

15. Remove the rod from the holding fixture. Remove the cylinder head and retainer plate from the rod.

4-6 – JLG Lift – 3121824

SECTION 4 - HYDRAULICS

GARMAX

BUSHING

Figure 4-4. Oil-lite Bearing Installation

Figure 4-5. Rod Seal Installation

Cleaning and Inspection

1. Clean all parts thoroughly in an approved cleaning solvent.

2. Inspect the cylinder rod for scoring, tapering, ovality, or other damage. If necessary, dress rod with Scotch Brite or equivalent. Replace rod if necessary.

3. Inspect threaded portion of rod for damage. Dress threads as necessary.

4. Inspect inner surface of cylinder barrel tube for scoring or other damage. Check inside diameter for tapering or ovality. Replace if necessary.

5. Inspect threaded portion of barrel for damage. Dress threads as necessary.

6. Inspect piston surface for damage and scoring and for distortion. Dress piston surface or replace piston as necessary.

7. Inspect threaded portion of piston for damage. dress threads as necessary.

8. Inspect seal and o-ring grooves in piston for burrs and sharp edges. Dress applicable surfaces as necessary.

9. Inspect cylinder head inside diameter for scoring or other damage and for ovality and tapering. Replace as necessary.

10. Inspect threaded portion of head for damage. Dress threads as necessary.

NOTE: Install the cylinder pin into the Garmax bearing dry.

Lubrication is not required with chrome pins and bearings.

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.

11. Inspect seal and o-ring grooves in head for burrs and sharp edges. Dress applicable surfaces as necessary.

12. Inspect cylinder head outside diameter for scoring or other damage and ovality and tapering. Replace as necessary.

13. 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 barrel (as applicable) must be replaced.

c. Using arbor of the correct size, carefully press

the bearing into the steel bushing.

Apply a light film of hydraulic oil to all components prior to assembly.

1. Using a special tool, pictured in the following illustration, install a new rod seal into the applicable cylinder head gland groove. Refer to the following illustration for the proper tool size.

3121824 – JLG Lift – 4-7

SECTION 4 - HYDRAULICS

Figure 4-6. Wiper Seal Installation

Figure 4-7. Installation of Head Seal Kit

Figure 4-8. Piston Seal Kit Installation

WHEN INSTALLING NEW “POLY-PAK” TYPE PISTON SEALS, ENSURE SEALS ARE INSTALLED PROPERLY. (SEE FIGURE 4-9.) FOR CORRECT SEAL ORIENTATION. IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION.

2. Using a soft mallet, tap a new wiper seal into the applicable cylinder head gland groove. Install a new wear ring into the applicable head gland groove.

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

mating end of the rod must be free of oil.

3. Place a new o-ring and back-up seal in the applicable outside diameter groove of the cylinder head.

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 backup 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.

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 VALUES.

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 piston and the cylinder head.

13. Position the cylinder barrel in a suitable holding fixture.

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.

4-8 – JLG Lift – 3121824

SECTION 4 - HYDRAULICS

Figure 4-9. Poly-Pak Piston Seal Installation

Figure 4-10. Rod Assembly Installation

Table 4-2. Cylinder Piston Nut Torque Specifications

14. With the barrel clamped securely, and while adequately supporting the rod, insert the piston end into the cylinder barrel. Ensure that the piston loading oring and seal ring are not damaged or dislodged.

15. Continue pushing the rod into the barrel until the cylinder head gland can be inserted into the cylinder barrel.

16. Secure the cylinder head gland using the washer ring and socket head bolts.

17. 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.

18. If applicable, install the cartridge-type holding valve and fittings in the port block using new o-rings as applicable.

Description

Lift Cylinder

(3369)

LIft Cylinder

(4069)

Steer Cylinder See Applicable Figure

Table 4-3. Holding Valve Torque Specifications

Description Tor qu e Va lu e

Sun - 7/8 hex M20 x1.5 thds

Sun - 1-1/8 hex 1 - 14 UNS th ds

Sun - 1-1/4 hex M36 x 2 thds

Racine - 1-1/8 hex 1-1/16 - 12 thds

Racine - 1-3/8 hex 1-3/16 - 12 thds

Racine - 1-7/8 hex 1-5/8 - 12 thds

NOTE: These cylinders use setscrews which should be dis-

carded and replaced whenever they are removed.

19. Remove cylinder rod from the holding fixture.

20. Place new o-rings and seals in the applicable outside diameter grooves of both the piston and the cylinder head.

21. Position the cylinder barrel in a suitable holding fixture.

Nut Torque Value

(Wet)

1120 - 1400 Nm

(800 - 1000 ft lbs)

1575 - 1925 Nm

(1125 - 1375 ft lbs)

41 - 48 Nm

(30 - 35 ft lbs)

61 - 68 Nm

(45 - 50 ft lbs)

204 - 207 Nm

(150 - 160 ft lbs)

68 -75 Nm

(50 - 55 ft lbs)

102 - 109 Nm (75 - 80 ft lbs)

136 - 149 Nm

(100 - 110 ft lbs)

WHEN REBUILDING THE LIFT CYLINDERS, APPLY LOCTITE 242 TO PISTON NUT AND SETSCREWS.

3121824 – JLG Lift – 4-9

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.

SECTION 4 - HYDRAULICS

22. With barrel clamped securely, and while adequately 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.

23. Continue pushing the rod into the barrel until the cylinder head gland can be inserted into the barrel cylinder or if applicable until the cylinder head threads engage the barrel threads.

24. If applicable, apply loctite #222 and secure the cylinder head retainer using a suitable chain wrench.

25. Insert the other cylinder head gland into the barrel cylinder. Secure the cylinder head retainer using a suitable chain wrench.

26. 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.

27. If applicable, install the cartridge type holding valve 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.

4.13 OSCILLATION CYLINDER BLEEDING

NOTE: The oscillating axle must be checked daily for proper

operation.

Bleeding Procedure

1. Run one side wheel onto a ramp or block of wood. On the other side, the lockout cylinder should be extended.

2. Block the rear wheels and disconnect the drive hubs.

3. 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.

4. Open bleeder on the top of the retracted lockout cylinder. Let hydraulic oil run for approx. 10 seconds or until air bubbles are no longer visible. Then close the bleeder screw.

IF THE CYLINDER IS TO BE TESTED PRIOR TO 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 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.

NOTE: Be sure and use proper equipment to stabilize the

machine while performing maintenance underneath.

3. Remove both hydraulic lines from the steer cylinder and allow excess oil in lines to drain into a suitable container.

4. Remove the nut and bolt from the barrel end of the cylinder from underneath the machine.

5. Fully oscillate the axle in the opposite direction and repeat step three.

Checking Oscillation Cylinders

After bleeding the lockout cylinders, check to see that they are holding their position when oscillated.

1. Run one wheel onto a ramp or a block of wood, mark the retracted cylinder with a marker, elevate platform above high speed cutout.

2. Back the unit off of the ramp, check the retracted cylinder for drive no more than ½".

3. Repeat this procedure for the other side. If the lockout cylinders do not hold, repeat the bleeding procedure or check for the following:

a. Air in lockout system

b. Bad cylinder seals

c. Bad holding valves

5. Remove the nut and bolt from the rod end of the cylinder from out at the spindle.

6. Remove cylinder from machine.

4-10 – JLG Lift – 3121824

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 approximately 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.

8. Place the 6 inch (15.2 cm) high block with ascension ramp in front of right front wheel.

9. From platform control station, select LOW drive speed.

10. Place DRIVE control switch to FORWARD position and carefully drive the machine up ascension ramp until right front wheel is on top of block.

11. Raise machine platform approximately 7 ft (2.1 m) on the 3369LE or 9 ft (2.7 m) on the 4069LE.

12. Place DRIVE control switch to REVERSE position and carefully drive the machine off the block and ramp.

13. Have an assistant check to see that the right front wheel remains locked in position off the ground.

14. 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.

15. If the lockout cylinders do not function properly, have qualified personnel correct the malfunction prior to any further operation.

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.

3121824 – JLG Lift – 4-11

SECTION 4 - HYDRAULICS

1. 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 & M3369

4.14 CYLINDER ASSEMBLIES

NOTE: Torque Locknut (4) to 1525.3 - 1864 Nm (1125 -

1375 ft-lbs).

• Approximate cylinder dry weight = 101.6 kg (224 lbs).

• Operating Pressure = 145 bar (2100 psi)

4-12 – JLG Lift – 3121824

LOWE R LIFT

CYLINDER

UPPER LIFT

CYLINDER

1. Barrel Weldment

2. Rod Weldment

3. Garmax Bushings

4. Locnut

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. 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 & M4069

SECTION 4 - HYDRAULICS

NOTE: Torque Locknut (4) to 1525.3 - 1864 Nm (1125 -

1375 ft-lbs).

• Approximate cylinder dry weight = 101.6 kg (224 lbs)

• Operating Pressure = 145 bar (2100 psi)

3121824 – JLG Lift – 4-13

SECTION 4 - HYDRAULICS

SCHEMATIC FOR PORT BLOCK

1. Jack Pad

2. Lock Washers

3. Round Head Hex Screws

4. Snap Ring

5. Rod Protector Plate

6. Snap Ring

7. Cylinder Rod

NOTE: Torque piston head nut (17) to 295 ft lb (400 Nm), Head Gland (8) to 590 ft. lb. (800 Nm), Counter Balance Valve (25)

8. Rod Gland

9. O-Ring

10. Snap Ring

11. Outer Rod Seal

12. Inner Rod Seal

13. O-Ring

14. Backing Ring

and Check Valve (24) to 33 ft. lb. (45 Nm). Apply a light coat of grease to rod end (7) and jack pad (1) before installing jack pad.

15. O-Ring

16. Spacer

17. Piston

18. O-Ring

19. Wiper Seal

20. Piston Seal (4 Piece)

21. Wiper Seal

22. Piston Retaining Ring

23. Cylinder Barrel

24. Cylinder Port Block

25. P/O Check Valve

26. Counter Balance Valve

Figure 4-11. Leveling Jack Cylinder (1001140600)

4-14 – JLG Lift – 3121824

101111

12131415161718

1. Cylinder Barrel

2. Jack Pad

3. Special Screw, 1/2" - 13NC x 1 1/4

4. Cylinder Rod

5. Retaining Ring

6. Plate

7. End Cap

8. Locknut

9. Piston

10. Flatwasher, 1 1/4"

11. Wear Ring

12. Piston Seal

13. O-Ring

14. Head

15. Wear Ring

16. O-Ring

17. Polyseal

18. Wiper Seal

19. Plug

20. Counter Balance Valve (see note)

21. Check Valve (see note)

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

SECTION 4 - HYDRAULICS

NOTE: Torque Locknut (8) to 542.3 Nm (400 ft-lbs).

Torque Counter Balance Valve (20) and Check Valve (21) to 40-47 Nm. (30-35 ft. lb.)

When servicing, apply a light coat of grease the to the Jack Pad (2) before installing.

3121824 – JLG Lift – 4-15

SECTION 4 - HYDRAULICS

1. Cylinder Barrel

2. Jack Pad

3. Special Screw, 1/2" - 13NC x 1 1/4

4. Cylinder Rod

5. Retaining Ring

6. Plate

7. End Cap

8. Head

9. Hydrolock

10. 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 note)

21. Check Valve (see note)

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

Machines)

NOTE: Torque Locknut (8) to 542.3 Nm (400 ft-lbs).

Torque Counter Balance Valve (20) and Check Valve (21) to 40-47 Nm. (30-35 ft. lb.)

When servicing, apply a light coat of grease the to the Jack Pad (2) before installing.

4-16 – JLG Lift – 3121824

SECTION 4 - HYDRAULICS

(1 - 3 not used)

4. Trailer Ball

5. Bolt, 3/8" - 16NC Grade 8

6. Cap

7. Head

8. Rod

9. Barrel

10. Plug

11. (not used)

12. Nut

13. Jack Pad

14. Piston

15. Plate

16. Retainer Ring

17. Locking Screw

18. Wear Ring

19. Guidelock

20. O-Ring

21. O-Ring

22. Wiper Seal

23. Polyseal

24. Hydrolock

25. Spacer Tube

26. Counter Balance Valve (see note)

27. Check Valve (see note)

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

NOTE: Torque Nut (12) to 542.3 Nm (400 ft-lbs). Torque

Locking Screw (17) to 11.3 Nm (100 in-lbs). Torque Counter Balance Valve (20) and Check Valve (21) to 40-47 Nm. (30-35 ft. lb.)

3121824 – JLG Lift – 4-17

SECTION 4 - HYDRAULICS

Figure 4-16. Steer Cylinder

1. Barrel

2. Rod

3. Guide

4. Locknut

5. Piston

6. Piston Seal

7. O-Ring

8. Back-Up Ring

9. Seal

10. Wiper

11. Retainer Ring

12. O-Ring

4-18 – JLG Lift – 3121824

SECTION 4 - HYDRAULICS

1415161718

1. Barrel Weldment

2. Washer Ring

3. Capscrews, 5/16" - 18NC x 1"

4. Cylinder Rod

5. Jam Nut, 3/4" - 16NF

6. Rollpin

7. Rod End

8. Composite Bearing

9. Head

10. Piston

11. Wear Ring

12. T-Seal

13. Wear Ring

14. O-Ring

15. Back-Up Ring

16. Rod Seal

17. Wiper Seal

18. O-Ring Plug #6

19. O-Ring Plug #4

20. Bleeder Valve

21. Bushing

22. Thermal Relief Valve

Figure 4-17. Axle Lockout Cylinder

NOTE: Torque Capscrews (3) to 41 Nm (30 ft-lbs). Torque

Thermal Relief Valve (22) to 27 - 34 Nm (20 - 25 ftlbs).

3121824 – JLG Lift – 4-19

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 207 bar (3000 psi).

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 172 bar (2500 psi) on the M3369/ 3369LE and 193 bar (2800 psi) 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 172 bar (2500 psi).

3. Repeat step one activating Steer Right.

4. Shut down hydraulic system and remove pressure gauge.

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 lb 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

4-20 – JLG Lift – 3121824

SECTION 4 - HYDRAULICS

BRAKE

PRESSURE

SWITCH

MAIN RELIEF

STEER RELIEF

LIFT RELIEF

LIFT

FLOW

CONTROL

STEER

HIGH PRESSURE

FILTER

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 the output shaft. The lip seal will be automatically removed during this procedure.

NOTE: If bearing replacement is necessary, the bearing

cups can be removed with a slide hammer puller or driven out with a punch.

11. 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.

12. The needle bearings and thrust spacer are now removed from cluster gear.

NOTE: When rebuilding or repairing the unit, the retaining

ring, o-rings, and seal should always be replaced.

3121824 – JLG Lift – 4-21

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.

2. 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.

3. 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.

4. 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.

5. 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 (straight up) from each planet pin.

6. 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.

8. 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.

9. Thrust washer is installed onto the sun gear and should locate on the gear teeth shoulder.

10. Thrust washer is installed into the counterbore of the carrier.

11. Place o-ring into input cover counterbore. Use petroleum jelly to hold o-ring in place.

12. 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 be necessary to align shoulder bolt with hub counterbore.

13. Install bolts into remaining holes.

14. Pipe plugs are to be installed into input cover using a lubricant seal.

15. Torque bolts to 31- 36 NM (23 - 27 ft. lbs.).

16. Fill unit one-half full with EP90 lubricant.

7. 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 counterbored holes in hub.

NOTE: If gears do not mesh easily or carrier assembly does

not rotate freely, then remove the carrier and ring gear and check the cluster gear timing.

4-22 – JLG Lift – 3121824

4.17 DRIVE ASSIST VALVE

1L 2L

MPL

MPR

T1 T

VALVE SCHEMATIC

MPL

MPR

Figure 4-19. Drive Assist Valve

SECTION 4 - HYDRAULICS

3121824 – JLG Lift – 4-23

SECTION 4 - HYDRAULICS

NOTES:

4-24 – JLG Lift – 3121824

5.1 HAND HELD ANALYZER

me n u :

PRESS ENTERHELP:

Analyzer Display

Escape Key

To return home or access

previous menu

Enter Key

Stores and selects Top Level, Sub

Level, and item menus

Left & Right Arrow Keys

Used to move between Top Level,

Sub Level, and item menus

Up & Down Arrow Keys

Value Selector

Figure 5-1. Hand Held Analyzer

SECTION 5 - JLG CONTROL SYSTEM

SECTION 5. JLG CONTROL SYSTEM

To Connect the Hand Held Analyzer:

1. Connect the four pin end of the cable supplied with 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 connected backwards.

2. Power up the Control System by turning the lower key to the platform position and pulling both emergency stop buttons on.

3121824 – JLG Lift – 5-1

SECTION 5 - JLG CONTROL SYSTEM

MENU: HELP:PRESS ENTER

HELP: 1: STARTUP ( 2 / 1)

Using the Analyzer:

With the machine power on and the analyzer connected properly, the analyzer will display the following:

In platform mode:

HELP: EVERYTHING OK,

In ground mode:

HELP: GROUND MODE OK

If ENTER is pressed again, the display moves to the following display:

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:

LOGGED HELP

1: STARTUP (2/1): (Or last recorded fault)

At this point, 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 Personalities:

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 while in access level 2. Remember, you may always cancel a selected menu item by pressing the ESC key.

5-2 – JLG Lift– 3121824

SECTION 5 - JLG CONTROL SYSTEM

MENU: ACCESS LEVEL 2

MENU: ACCESS L EVEL 1

Changing the Access Level of the Hand Held Analyzer:

When the analyzer is first connected, you will be in access level 2 which enables you to only view most configuration settings which cannot be changed until you enter a password to advance to a lower level. This ensures that a setting 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:

Once the correct password is displayed, press ENTER. The access level should display the following, if the password was entered correctly:

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 password.

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.

MENU:

ACCESS LEVEL 1

Repeat the above steps if the correct access level is not displayed or you can not adjust the personality settings:

3121824 – JLG Lift – 5-3

SECTION 5 - JLG CONTROL SYSTEM

PERSONALITIES: DRIVE ACCEL 1.0s

GROUND ALARM: 1=MOTI ON

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:

Machine Setup

When a machine digit item is selected, press the UP or DOWN arrow keys to adjust its value, for example:

FAILURE TO MAKE THE PROPER SETTINGS FOR THE PARTICULAR MACHINE CAN RESULT IN IMPROPER OPERATION.

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 maximum value nor will the value decrease if the DOWN arrow is pressed and the value is at the minimum value for any particular personality. 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.

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 settings 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– 3121824

JLG M4069 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

AGENERAL

B HYDRAULIC SYSTEM SAFETY

CMAINTENANCE

SECTION 1. SPECIFICATIONS

1.1 SPECIFICATIONS

1.2 CAPACITIES

1.3 PRESSURE SETTINGS

1.4 COMPONENT DATA

Battery Charger

Batteries (8)

Drive System

Steer System

Hydraulic Pump/Electric Motor Assembly

1.5 TORQUE SPECIFICATIONS

1.6 LUBRICATION

Lubrication Specifications

1.7 CYLINDER SPECIFICATIONS

1.8 MAJOR COMPONENT WEIGHTS

1.9 CRITICAL STABILITY WEIGHTS

1.10 LUBRICATION

1.11 SERIAL NUMBER LOCATIONS

1.12 TORQUE CHARTS

SECTION 2. GENERAL

2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE

General

Preparation, Inspection, and Maintenance

Pre-Start Inspection

Annual Machine Inspection

Preventative Maintenance

Pre-Delivery Inspection and Frequent Inspection

2.2 SERVICE AND GUIDELINES

General

Safety and Workmanship

Cleanliness

Components Removal and Installation

Component Disassembly and Reassembly

Pressure-Fit Parts

Bearings

Hydraulic Lines and Electrical Wiring

Hydraulic System

Lubrication

Battery

Lubrication and Servicing

Gaskets

Bolt Usage and Torque Application

2.3 LUBRICATION AND INFORMATION

Hydraulic System

Hydraulic Oil

Changing Hydraulic Oil

Lubrication Specifications

2.4 CYLINDER DRIFT TEST

Platform Drift

Cylinder Drift

2.5 PINS AND COMPOSITE BEARING REPAIR GUIDELINES

2.6 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE

SECTION 3. CHASSIS & SCISSOR ARMS

3.1 CALIBRATIONS

Elevation Sensor Calibration (Prior to Software V13.6)

Elevation Sensor Calibration (Software V13.6 and Higher)

Tilt Sensor Calibration:

Speed Sensor

Joystick Calibration (SW V13.5 & Higher and P1.0 & Higher)

3.2 TILT SENSOR

Tilt Sensor, JLG P/N 4000006:

Tilt Sensor, JLG P/N 4000021:

3.3 BATTERY MAINTENANCE AND CHARGING

Battery Maintenance, Quarterly

Optional On Board Generator

Battery Charging (On Board Charger) (MAC)

Charging Sequence of Remote LED Card

Battery Charger (Delta-Q)

Battery Charger Maintenance

Battery Charger Troubleshooting

Battery Temperature Sensor

Removing the Battery Box

3.4 GENERATOR