JLG M4069 Service Manual

Service & Maintenance Manual

Models

3369LE

4069LE

M3369

M4069

3121824

July 23, 2012

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

SECTION A. INTRODUCTION - MAINTENANCE SAFETY

PRECAUTIONS

A GENERAL

This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others, or damage to the equipment. A maintenance program must be followed to ensure that the machine is safe to operate.

MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST AS SAFE AS ORIGINALLY MANUFACTURED, IS A SAFETY VIOLATION.

The specific precautions to be observed during maintenance are inserted at the appropriate point in the manual. These precautions are, for the most part, those that apply when servicing 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.

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

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.

C MAINTENANCE

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

•NO SMOKING IS MANDATORY. NEVER REFUEL DURING ELECTRICAL STORMS. ENSURE THAT FUEL CAP IS CLOSED AND SECURE AT ALL OTHER TIMES.

•REMOVE ALL RINGS, WATCHES AND JEWELRY WHEN PERFORMING ANY MAINTENANCE.

•DO NOT WEAR LONG HAIR UNRESTRAINED, OR LOOSE-FITTING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME CAUGHT ON OR ENTANGLED IN EQUIPMENT.

•OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS ON MACHINE AND IN SERVICE MANUAL.

•KEEP OIL, GREASE, WATER, ETC. WIPED FROM STANDING SURFACES AND HAND HOLDS.

•USE CAUTION WHEN CHECKING A HOT, PRESSURIZED COOLANT SYSTEM.

•NEVER WORK UNDER AN ELEVATED 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.

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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

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TABLE OF CONTENTS

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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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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15 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

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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

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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)		10.6 - 12 sec
Elevated Drive Fwd/Rev (sec/50 ft)		40 - 44 sec
Lifting Speed:
No Load	36 - 40 sec			52 - 60 sec
Rated Load	38 - 44 sec			54 - 62 sec
Lowering Speed (no load)	43 - 48 sec			49 - 51 sec
Gradeability (platform stowed)		35%
Maximum Operating Windspeed		12.5 m/sec (28 mph)
Turning Radius:
Inside		2.3 m (7.5 ft)
Outside		4.9 m (16 ft)
Maximum Platform Capacity
-Platform	ANSI/CSA/Brazil:	1000 lbs (454kg)		ANSI/CSA/Brazil:	800 lbs (363kg)
	CE/AUS:	1000 lbs (450kg)		CE/AUS:	800 lbs (360kg)
-Platform Extension	ANSI/CSA/Brazil:	250 lbs (113kg)		ANSI/CSA/Brazil:	250 lbs (113kg)
	CE/AUS:	250 lbs (120kg)		CE/AUS:	250 lbs (120kg)
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			3°
Fore and Aft			5°
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)

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SECTION 1 - SPECIFICATIONS

1.2 CAPACITIES

Table 1-2. Capacities

	Description	3369LE/M3369	4069LE/M4069
	Hydraulic Tank	31.2 liters (8.25 gal)
		20.4 liters (5.4 gal) @ full mark
	Hydraulic System	approx. 32.1 liters (8.5 gal)
	Torque Hubs (2)	0.5 liters (17 ounces)

1.3 PRESSURE SETTINGS

Table 1-3. Pressure Settings

	Description	3369LE/M3369	4069LE/M4069
	Main Relief (±3.5 bar)	207 bar
		(3000 psi)
	Steer Relief	172 bar
		(2500 psi)
	Lift Relief	179 bar	193 bar
		(2600 psi)	(2800 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

JLG MACHINES EQUIPPED WITH DELTA Q BATTERY CHARGERS

ARE DESIGNED FOR THE BEST PERFORMANCE WITH OEM FAC-

TORY APPROVED BATTERIES.

APPROVED JLG REPLACEMENT BATTERIES ARE AVAILABLE THROUGH JLG' S AFTERMARKET PARTS DISTRIBUTION 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 BATTER-

IES IN YOUR JLG EQUIPMENT MAY RESULT IN PERFORMANCE ISSUES OR BATTERY CHARGER FAULT CODES. JLG ASSUMES

NO RESPONSIBILITY FOR SERVICE OR PERFORMANCE ISSUES ARISING FROM THE USE OF NON APPROVED BATTERIES.

Drive System

Drive Motor - 48 VDC, 11.8 H.P. peak 5.5 H.P. continuous, rotation - reversible

Drive Brake24 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	TORQUE VALUE	INTERVAL HOURS
		(DRY)
	Torque Hub	240 ft lbs	500
		(336 Nm)
	Wheel Nuts	170 ft lbs	50
		(238 Nm)
	Fixed Axle Bolts	220 ft lbs	500
		(308 Nm)
	Drive Motor	35 ft lbs	N/A
		(49 Nm)
	Pump Motor Terminals	12-14 ft lbs	N/A
		(14-19 Nm)

NOTE: When maintenance becomes necessary or a fastener has loosened, refer to the Section 1.12, Torque Charts to determine proper torque value.

1-2

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3121824

SECTION 1 - SPECIFICATIONS

1.6 LUBRICATION

Table 1-5. Hydraulic Oil

	Hydraulic System Operating	SAE Viscosity Grade
	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.

Lubrication Specifications

	Table 1-6. Lubrication Specifications
KEY		SPECIFICATIONS
EPGL		Extreme Pressure Gear Lube (oil) meeting API service
		classification GL-5 or MIL-Spec MIL-L-2105
HO		Hydraulic Oil. API service classification Gl-3, BP Ener-
		gol SHS46.
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 procedures..

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)
	Viscosity
at 40° C		15 cSt
at 100° C		4.1 cSt
at 100° F		80 SUS
at 210° F		43 SUS

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

10.16 cm

161.77 cm

6.98 cm

(M3369/3369LE)

(4.00 in)

(63.69 in)

(2.75 in)

Upper Lift Cylinder

7.62 cm

147.65 cm

6.98 cm

(M4069/4069LE)

(3.00 in)

(58.13 in)

(2.75 in)

Lower Lift Cylinder

10.16 cm

147.65 cm

5.71 cm

(M4069/4069LE)

(4.00 in)

(58.13 in)

(2.25 in)

Steer Cylinder

5.08 cm

16.51 cm

2.86 cm

(2.00 in)

(6.5 in)

(1.125 in)

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

1451 kg

1769 kg

(Includes Lift Cylinders)

(3200 lbs)

(3900 lbs)

Chassis (Includes Battery Box

2458 kg

2502 kg

and Foam filled Tires)

(5420 lbs)

(5517 lbs)

Foam Filled Tire and Wheel

81.6 kg (180 lb.)

Assembly (each)

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)

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1-3

SECTION 1 - SPECIFICATIONS

1.10 LUBRICATION

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

3,4

2

5

Figure 1-1. Lubrication Chart

Table 1-11. Lubrication Chart

	INDEX	COMPONENT		NO/TYPE LUBE				LUBE/METHOD	INTERVAL	COMMENTS
	NUMBER			POINTS					HOURS
	1	Sliding Wear Pads		8 Wear Pads				MPG/Brush	50	--
	2	Hydraulic Oil		Fill Level/Drain Plug				HO - Check HO Level	10/500	Check oil every 10 hours of operation
								HO - Change HO		Change oil after every 1000 hours of operation
	3	Wheel Bearings		Front Wheels				MPG - Repack	1200	--
	4	Spindles/Bushing				N/A		LL	At Spindle Bushing	--
		(not shown)							Replacement
		Wheel Drive Hub								Check oiul level at side plug daily.
	5			Fill Plug/Half Full				EPGL	1200	Change after first 150 hours of operation then every
		(not shown)
										1000 hours thereafter
	6	*High Pressure				N/A		Replaceable	50/250	Replace filter element after first 50 hours of operation
		Filter (not shown)						Element		and every 1000 hours thereafter.
	KEY TO LUBRICANTS:
	HO - Hydraulic Oil - Mobil DTE - 11M
	EPGL - Extreme Pressure Gear Lube
	MPG - Multi Purpose Grease
									NOTE: Recommended lubricating intervals are based on
									machine operations under normal conditions. For
TO AVOID PERSONAL INJURY, USE SAFETY PROP FOR ALL									machines used in multi-shift operations and/or
MAINTENANCE REQUIRING PLATFORM TO BE ELEVATED									exposed to hostile environments or conditions, lubri-
									cating frequencies must be increased accordingly.
NOTE: Be sure to lubricate like items on each side of the									*The high pressure filter is located in the main con-
	machine.								trol valve. See figure title control valve in section 2.

1-4

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SECTION 1 - SPECIFICATIONS

1.11 SERIAL NUMBER LOCATIONS

For machine identification, a serial number plate is affixed to the front of the frame. If the serial number plate is damaged or missing, the machine serial number is stamped on the left front of the machine frame.

SERIAL NUMBER

PLATE

SERIAL NUMBER

STAMPED

Figure 1-2. Serial Number Location

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1-5

SECTION 1 - SPECIFICATIONS

1.12 TORQUE CHARTS

				Values for Zinc Yellow Chromate Fasteners (Ref 4150707)
						SAE GRADE 5 BOLTS & GRADE 2 NUTS
											Torque				Torque
			Tensile		Torque			Torque			(Loctite® 242TM or 271TM
Size	TPI	Bolt Dia		Clamp Load												TM	or Vibra-
			Stress Area			(Dry)		Lubricated			OR Vibra-TITE		TM	111 or	(Loctite® 262
															TITETM 131)
											140)
		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
NOTES:	1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS														NO. 5000059		REV. J

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

3.* ASSEMBLY USES HARDENED WASHER

	REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND
JLG P/N	Loctite® P/N		ND Industries P/N	Description
0100011	242TM		Vibra-TITETM 121	Medium Strength (Blue)
0100019	271TM		Vibra-TITETM 140	High Strength (Red)
0100071	262TM		Vibra-TITETM 131	Medium - High Strength (Red)

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

1-6

– JLG Lift –

3121824

SECTION 1 - SPECIFICATIONS

				SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*
						Torque			Torque			Torque
			Tensile						(Loctite® 242TM or 271TM			(Loctite® 262TM or Vibra-
Size	TPI	Bolt Dia	Stress Area	Clamp Load		(Dry or Loctite® 263)			OR Vibra-TITETM 111 or			TITETM 131)
						K= 0.20			140)		K=.18	K=0.15
		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	1320		43		5
10	24	0.1900	0.01750	1580		60		7
	32	0.1900	0.02000	1800		68		8
1/4	20	0.2500	0.0318	2860		143		16	129		15
	28	0.2500	0.0364	3280		164		19	148		17
		In	Sq In	LB		FT-LB		[N.m]	FT-LB		[N.m]	FT-LB		[N.m
5/16	18	0.3125	0.0524	4720		25		35	20		25	20		25
	24	0.3125	0.0580	5220		25		35	25		35	20		25
3/8	16	0.3750	0.0775	7000		45		60	40		55	35		50
	24	0.3750	0.0878	7900		50		70	45		60	35		50
7/16	14	0.4375	0.1063	9550		70		95	65		90	50		70
	20	0.4375	0.1187	10700		80		110	70		95	60		80
1/2	13	0.5000	0.1419	12750		105		145	95		130	80		110
	20	0.5000	0.1599	14400		120		165	110		150	90		120
9/16	12	0.5625	0.1820	16400		155		210	140		190	115		155
	18	0.5625	0.2030	18250		170		230	155		210	130		175
5/8	11	0.6250	0.2260	20350		210		285	190		260	160		220
	18	0.6250	0.2560	23000		240		325	215		290	180		245
3/4	10	0.7500	0.3340	30100		375		510	340		460	280		380
	16	0.7500	0.3730	33600		420		570	380		515	315		430
7/8	9	0.8750	0.4620	41600		605		825	545		740	455		620
	14	0.8750	0.5090	45800		670		910	600		815	500		680
1	8	1.0000	0.6060	51500		860		1170	770		1045	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
NOTES:	1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS											NO. 5000059		REV. J

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

3.* ASSEMBLY USES HARDENED WASHER

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

3121824

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1-7

NO. 5000059 REV. J

SECTION 1 - SPECIFICATIONS

					SOCKET HEAD CAP SCREWS
					Magni Coating (Ref 4150701)*
							Torque			Torque
							(Loctite® 242TM or 271TM
Size	TPI	Bolt Dia	Tensile	Clamp Load	Torque					(Loctite® 262TM
			Stress Area	See Note 4	(Dry)	K = .17	OR Vibra-TITETM 111 or			or Vibra-TITE		TM	131)
							140 OR Precoat 85®
										K=0.15
							K=0.16
		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

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

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% *3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM

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

CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

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

1-8

– JLG Lift –

3121824

NO. 5000059 REV. J

SECTION 1 - SPECIFICATIONS

					SOCKET HEAD CAP SCREWS
				Zinc Yellow Chromate Fasteners (Ref 4150707)*
								Torque			Torque
					Torque			(Loctite® 242TM or 271TM
Size	TPI	Bolt Dia	Tensile	Clamp Load							(Loctite® 262TM
			Stress Area	See Note 4	(Dry)			OR Vibra-TITETM 111 or			or Vibra-TITE		TM	131)
					K = .20			140 OR Precoat 85®
											K=0.15
								K=0.18
		In	Sq In	LB	IN-LB		[N.m]	IN-LB		[N.m]	IN-LB		[N.m]
4	40	0.1120	0.00604
	48	0.1120	0.00661
6	32	0.1380	0.00909
	40	0.1380	0.01015
8	32	0.1640	0.01400
	36	0.1640	0.01474
10	24	0.1900	0.01750
	32	0.1900	0.02000
1/4	20	0.2500	0.0318	2860	143		16	129		15
	28	0.2500	0.0364	3280	164		19	148		17
		In	Sq In	LB	FT-LB		[N.m]	FT-LB		[N.m]	FT-LB		[N.m]
5/16	18	0.3125	0.0524	4720	25		35	20		25	20		25
	24	0.3125	0.0580	5220	25		35	25		35	20		25
3/8	16	0.3750	0.0775	7000	45		60	40		55	35		50
	24	0.3750	0.0878	7900	50		70	45		60	35		50
7/16	14	0.4375	0.1063	9550	70		95	65		90	50		70
	20	0.4375	0.1187	10700	80		110	70		95	60		80
1/2	13	0.5000	0.1419	12750	105		145	95		130	80		110
	20	0.5000	0.1599	14400	120		165	110		150	90		120
9/16	12	0.5625	0.1820	16400	155		210	140		190	115		155
	18	0.5625	0.2030	18250	170		230	155		210	130		175
5/8	11	0.6250	0.2260	20350	210		285	190		260	160		220
	18	0.6250	0.2560	23000	240		325	215		290	180		245
3/4	10	0.7500	0.3340	30100	375		510	340		460	280		380
	16	0.7500	0.3730	33600	420		570	380		515	315		430
7/8	9	0.8750	0.4620	41600	605		825	545		740	455		620
	14	0.8750	0.5090	45800	670		910	600		815	500		680
1	8	1.0000	0.6060	51500	860		1170	775		1055	645		875
	12	1.0000	0.6630	59700	995		1355	895		1215	745		1015
1 1/8	7	1.1250	0.7630	68700	1290		1755	1160		1580	965		1310
	12	1.1250	0.8560	77000	1445		1965	1300		1770	1085		1475
1 1/4	7	1.2500	0.9690	87200	1815		2470	1635		2225	1365		1855
	12	1.2500	1.0730	96600	2015		2740	1810		2460	1510		2055
1 3/8	6	1.3750	1.1550	104000	2385		3245	2145		2915	1785		2430
	12	1.3750	1.3150	118100	2705		3680	2435		3310	2030		2760
1 1/2	6	1.5000	1.4050	126500	3165		4305	2845		3870	2370		3225
	12	1.5000	1.5800	142200	3555		4835	3200		4350	2665		3625

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

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% *3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM

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

CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

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

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SECTION 1 - SPECIFICATIONS

					CLASS 8.8 METRIC BOLTS
					CLASS 8 METRIC NUTS
								Torque	Torque
		Tensile			Torque				(Loctite®
Size	PITCH		Clamp				Torque	(Loctite® 262TM	242TM or 271TM
		Stress	Load		(Dry or Loctite®		(Lub)	OR Vibra-	OR Vibra-
		Area			TM
					263 )			TITETM 131)	TITETM 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
								NO. 5000059 REV. J

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

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

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

4.CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

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

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SECTION 1 - SPECIFICATIONS

					CLASS 10.9 METRIC BOLTS
					CLASS 10 METRIC NUTS
			CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*
							Torque	Torque
		Tensile			Torque		(Lub OR Loctite®
Size	PITCH		Clamp		(Dry or Loctite®		242TM or 271TM OR	(Loctite® 262TM OR
		Stress	Load		263TM)		Vibra-TITETM 111 or	Vibra-TITETM 131)
		Area
					K = 0.20		140)	K=0.15
							K= 0.18
		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
							NO. 5000059 REV. J

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

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

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

4.CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,

ADDITIONAL TESTING IS REQUIRED.

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

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SECTION 1 - SPECIFICATIONS

			Magni Coating (Ref 4150701)*
			CLASS 12.9 SOCKET HEAD CAP SCREWS
				M6 AND ABOVE*
					Torque	Torque
				Torque	(Lub OR Loctite®
		Tensile				(Loctite® 262TM
Size	PITCH		Clamp Load	(Dry or Loctite®	242TM or 271TM
		Stress	See Note 4	263TM)	OR Vibra-TITETM	OR Vibra-TITE	TM
		Area
				K = .17	111 or 140)	131)
						K = .15
					K = .16
		Sq mm	kN	[N.m]	[N.m]	[N.m]
3	0.5	5.03
3.5	0.6	6.78
4	0.7	8.78
5	0.8	14.20
6	1	20.10	12.5	13	12	11
7	1	28.90	18.0	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
					NO. 5000059 REV. J

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

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

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

4.CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,

ADDITIONAL TESTING IS REQUIRED.

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

1-12

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SECTION 2 - GENERAL

SECTION 2. GENERAL

2.1MACHINE PREPARATION, INSPECTION, AND MAINTENANCE

General

This section provides the necessary information needed by those personnel that are responsible to place the machine in operation readiness and maintain its safe operating condition. For maximum service life and safe operation, ensure that all the necessary inspections and maintenance have been completed before placing the machine into service.

Preparation, Inspection, and Maintenance

It is important to establish and conform to a comprehensive inspection and preventive maintenance program. The following table outlines the periodic machine inspections and maintenance recommended by JLG Industries, Inc. Consult your national, regional, or local regulations for further requirements for aerial work platforms. The frequency of inspections and maintenance must be increased as environment, severity and frequency of usage requires.

Pre-Start Inspection

It is the User’s or Operator’s primary responsibility to perform a Pre-Start Inspection of the machine prior to use daily or at each change of operator. Reference the Operator’s and Safety Manual for completion procedures for the Pre-Start Inspection. The Operator and Safety Manual must be read in its entirety and understood prior to performing the Pre-Start Inspection.

Pre-Delivery Inspection and Frequent Inspection

The Pre-Delivery Inspection and Frequent Inspection shall be performed by a qualified JLG equipment mechanic. JLG Industries, Inc. recognizes a qualified JLG equipment mechanic as a person who, by possession of a recognized degree, certificate, extensive knowledge, training, or experience, has successfully demonstrated the ability and proficiency to service, repair, and maintain the subject JLG product model.

The Pre-Delivery Inspection and Frequent Inspection procedures are performed in the same manner, but at different times. The Pre-Delivery Inspection shall be performed prior to each sale, lease, or rental delivery. The Frequent Inspection shall be accomplished for each machine in service for 3 months or 150 hours (whichever comes first); out of service for a period of more than 3 months; or when purchased used. The frequency of this inspection must be increased as environment, severity and frequency of usage requires.

Reference the JLG Pre-Delivery and Frequent Inspection Form and the Inspection and Preventative Maintenance Schedule for items requiring inspection during the performance of these inspections. Reference the appropriate areas of this manual for servicing and maintenance procedures.

Annual Machine Inspection

JLG recommends that an annual machine inspection be performed by a Factory-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

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.

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SECTION 2 - GENERAL

Table 2-1. Inspection and Maintenance

	Type	Frequency	Primary	Service	Reference
			Responsibility	Qualification
	Pre-Start Inspection	Prior to use each day; or	User or Operator	User or Operator	Operator and Safety Manual
		At each Operator change.
	Pre-Delivery	Prior to each sale, lease, or		Qualified JLG	Service and Maintenance
			Owner, Dealer, or User		Manual and applicable JLG
	Inspection	rental delivery.		Mechanic
					inspection form.
		In service for 3 months or 150 hours,
		whichever comes first; or		Qualified JLG	Service and Maintenance
	Frequent Inspection	Out of service for a period of more than 3	Owner, Dealer, or User		Manual and applicable JLG
				Mechanic
		months; or			inspection form.
		Purchased used.
	Annual Machine	Annually, no later than 13 monthsfrom the		Factory-Trained	Service and Maintenance
			Owner, Dealer, or User	Service Technician	Manual and applicable JLG
	Inspection	date of the prior inspection.
				(recommended)	inspection form.
	Preventative	At intervals as specified in the Service and	Owner, Dealer, or User	Qualified JLG	Service and Maintenance
	Maintenance	Maintenance Manual.		Mechanic	Manual

2.2 SERVICE AND GUIDELINES

General

The following information is provided to assist you in the use and application of servicing and maintenance procedures contained in this book.

Safety and Workmanship

Your safety, and that of others, is the first consideration when engaging in the maintenance of equipment. Always be conscious of weight. Never attempt to move heavy parts without the aid of a mechanical device. Do not allow heavy objects to rest in an unstable position. When raising a portion of the equipment, ensure that adequate support is provided.

Cleanliness

IT IS GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS. IN THE EVENT PRES-

SURE-WASHING THE MACHINE IS NEEDED, ENSURE THE

MACHINE IS SHUT DOWN BEFORE PRESSURE-WASHING. SHOULD PRESSURE WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG

INDUSTRIES, INC. RECOMMENDS A MAXIMUM PRESSURE OF

750 PSI (52 BAR) AT A MINIMUM DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM THESE COMPONENTS. IF ELECTRICAL/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-

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.

Components Removal and Installation

1.Use adjustable lifting devices, whenever possible, if mechanical assistance is required. All slings (chains, cables, etc.) should be parallel to each other and as near perpendicular as possible to top of part being lifted.

2.Should it be necessary to remove a component on an angle, keep in mind that the capacity of an eyebolt or similar bracket lessens, as the angle between the supporting structure and the component becomes less than 90°.

3.If a part resists removal, check to see whether all nuts, bolts, cables, brackets, wiring, etc., have been removed and that no adjacent parts are interfering.

2-2

– JLG Lift–

3121824

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.

Gaskets

Check that holes in gaskets align with openings in the mating parts. If it becomes necessary to hand-fabricate a gasket, use gasket material or stock of equivalent material and thickness. Be sure to cut holes in the right location, as blank gaskets can cause serious system damage.

Bolt Usage and Torque Application

1.Use bolts of proper length. A bolt which is too long will bottom before the head is tight against its related part. If a bolt is too short, there will not be enough thread area to engage and hold the part properly. When replacing bolts, use only those having the same specifications of the original, or one which is equivalent.

2.Unless specific torque requirements are given within the text, standard torque values should be used on heat-treated bolts, studs, and steel nuts, in accordance with recommended shop practices. (See Torque Chart Section 1.)

Hydraulic Lines and Electrical Wiring

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

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.

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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.

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).

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.

2-4

– JLG Lift–

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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		Max. Acceptable Drift
			in 10 Minutes
	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 cylinder leakage.

2.5PINS 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 housing.

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.

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2-5

SECTION 2 - GENERAL

2.6PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE

The preventive maintenance and inspection checks are listed and defined in Table 2-3, Preventive Maintenance and Inspection Schedule. This table is divided into two basic parts, the “AREA” to be inspected, and the “INTERVAL” at which the inspection is to take place. Under the “AREA” of the table, the various systems along with components that make up that system are listed. The “INTERVAL” portion of the table is divided into five columns representing the various inspection time periods. The numbers listed within the interval column represent the applicable inspection code for which that component is to be checked.

The checks and services listed in this schedule are not intended to replace any local or regional regulations that may pertain to this type of equipment nor should the lists be considered as all inclusive. Variances in interval times may occur due to climate and/or conditions and depending on the location and use of the machine.

JLG Industries requires that a complete annual inspection be performed in accordance with the “Annual Machine Inspection Report” form. Forms are supplied with each new machine and are also available from JLG Customer Service. Forms must be completed and returned to JLG Industries.

JLG INDUSTRIES REQUIRES THAT A COMPLETE ANNUAL INSPECTION BE PERFORMED IN ACCORDANCE WITH THE

“ANNUAL MACHINE INSPECTION REPORT” FORM.

NOTE: This machine requires periodic safety and maintenance 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.

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.

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SECTION 2 - GENERAL

Table 2-3. Preventive Maintenance and Inspection Schedule

	AREA			INTERVAL
	PLATFORM	10 HOURS	50 HOURS	200 HOURS	500 HOURS	1000 HOURS
		DAILY	WEEKLY	MONTHLY	3 MONTHS	6 MONTHS
	1. Controller	1, 11
	2. Switches	1, 11
	3. Placards and Decals	1, 2
	4. Control Tags	1, 2
	5. Hoses and Cables	1	5, 8
	6. Wear Pads			8
	7. Handrail and Chains	1, 4
	CHASSIS
	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.

NOTE: If function speeds are slow on a fully charged machine a clogged filter may be indicated. Change filter.

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NOTES:

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SECTION 3 - CHASSIS & SCISSOR ARMS

SECTION 3. CHASSIS & SCISSOR ARMS

3.1 CALIBRATIONS

Elevation Sensor Calibration (Prior to Software V13.6)

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

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

Use ELEV SENSOR sub level menu for rotary switch adjustments.

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

NOTE: If the Always set the rotary switch first before the proximity switch because they back each other up in the case of a component failure.

1.When mounting, make sure the rotary switch is aligned with the bladed pin mounted on the scissor arm. There must be a preload when installing the rotary switch on the bladed pin bracket, similar to a throttle actuator.

2.There are (3) 3/8 mounting screws that hold the switch onto the scissor arm mounting lug, make sure they are snug, not loose, so you are able to rotate the rotary switch.

3.Make sure the deck is fully lowered. Plug in the analyzer and scroll through DIAGNOSTICS/ELEV SENSOR to ANGLE SNSR. This should read 0.40v - 0.45v.

NOTE: Anytime the ground control board or if the rotary sensor is replaced the rotary sensor must be reset (zeroed out).

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

5.Loosen the hardware that holds the proximity switch and allow the switch to drop to the bottom of the slide bracket. Using the analyzer, press escape twice and scroll through ACCESS LEVEL 2. enter the password to get into ACCESS LEVEL 1. Scroll to SET ELEV SENSOR and after pressing ENTER you should hear the motion alarm sounding off. This puts the machine in adjustment mode.

NOTE: If your machine does not have a motion alarm, the following procedures will still apply.

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

7.Using the analyzer, press ESCAPE, scroll to DIAGNOSTICS, press ENTER, scroll to ELEV SENSOR and press ENTER. YOu should now see ANGLE SNSR. The setting here should be 0.60v - 0.70v. This is the rotary switch output voltage that is being sent to J2-15 of GEC at the lift cutout mark. A fully elevated platform will read 2.95 volts.

8.Press ESCAPE on the analyzer, scroll to SYSTEM then to ELEV PROX OPEN. Now manually adjust the proximity switch until you see the analyzer read ELEV PROX CLOSED. At this point make sure you have the maximum 5/16 in of clearance between the eye of the proximity switch and the scissor arm. If you don’t, shim it. If everything is okay at this point tighten it down, this setting is required in case the rotary switch fails. The proximity switch is a back up to assure proper lift cut-out.

NOTE: If the gap ever increases beyond 5/16 in., the switch may cause intermittent operation.

9.Completely lower the platform. Using the analyzer press escape and scroll through DIAGNOSTICS and then go to ELEV SENSOR, press ENTER. Check to see that the following items are reading correctly.

ANGLE SNSR 0.40 - 0.45 ZEROED 0.00V SENSOR OK

STOWED? YES ELEVATED? NO DRIVE? YES CALIB 0.40 - 0.45

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

11.Press ESCAPE until you arrive at DIAGNOSTICS, then scroll over to top level menu SET ELV SENSOR, press ENTER, an alarm will sound off if your machine is equipped with one. The analyzer will now ask to SET ELEV SENSOR. At this point press ENTER key. If everything tested properly the analyzer will read COMPLETE.

12.Now lift the machine up until it stops lifting, measure the cutback height;

M3369/3369LE - 8 ft - 9.5 ft (2.4 - 2.9 m) M4069/4069LE - 9.5 ft - 11.7 ft (2.9 - 3.6 m)

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13.Press ESCAPE, remove analyzer and assure all hardware is tight.

Elevation Sensor Calibration

(Software V13.6 and Higher)

Using the Analyzer, in Access Level 1, go to MENU: CALI-

BRATION:

1.SET STOW ELEV;

a.Completely lower platform to stowed position.

b.Enter YES on the Analyzer.

c.COMPLETE will show on the analyzer when calibrated.

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 calibrated.

3.SET 30FT ELEV (3369LE) or SET 36FT ELEV (4069LE);

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 calibrated.

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 the motor on the brass feral.

NOTE: If replacing the speed sensor, the new sensor will have a wax pill on the end of the sensor. Tighten down until you feel the wax pill bottom out inside the motor.

4. Tighten up the packing nut.

Tilt Sensor Calibration:

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

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.

2

1

1. Ground Control Box

2. Digital Level

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