JLG 3369LE / 4069LE / M3369 / M4069 Electric Scissor Lift Service & Maintenance Manual (CE)

This service manual PDF download for the 3369LE / 4069LE / M3369 / M4069 JLG Electric Scissor Lift has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.


APPLICABLE MODELS :

JLG Lift 3369LE
JLG Lift 4069LE
JLG Lift M3369
JLG Lift M4069


TABLE OF CONTENTS :

Section 1. Specifications
1.1 Specifications
1.2 Capacities
1.3 Pressure Settings
1.4 Component Data
1.5 Torque Specifications
1.6 Lubrication
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
2.2 Service and Guidelines
2.3 Lubrication and Information
2.4 Cylinder Drift Test
2.5 Pins and Composite Bearing Repair Guidelines
2.6 Preventive Maintenance and Inspection Schedule

Section 3. Chassis & Scissor Arms
3.1 Calibrations
3.2 Tilt Sensor
3.3 Battery Maintenance and Charging
3.4 Generator
3.5 Supplementary Fuse For APU
3.6 Joystick Controller
3.7 Torque Hub
3.8 Drive Hub
3.9 Drive Brake - MICO
3.10 Torque Hub

Section 4. Hydraulics
4.1 Servicing and Maintenance Guidelines
4.2 Lubrication Information
4.3 Cylinders - Theory of Operation
4.4 Valves - Theory of Operation
4.5 Component Functional Description
4.6 Wear Pads
4.7 Motor Controller - Modes of Operation
4.8 Features
4.9 Cylinder Checking Procedures
4.10 Cylinder Removal and Installation
4.11 Cylinder Repair
4.12 Steer Cylinder Removal
4.13 Oscillation Cylinder Bleeding
4.14 Cylinder Assemblies
4.15 Pressure Setting Procedures
4.16 Drive Torque Hub
4.17 Drive Assist Valve

Section 5. JLG Control System
5.1 Hand Held Analyzer
5.2 PC Boards
5.3 Flash Codes/DTC’s and Descriptions
5.4 Ground Control Circuit Board

Section 6. General Electrical Information & Schematics
6.1 General
6.2 Multimeter Basics
6.3 Applying Silicone Dielectric Compound To Amp Connectors
6.4 Working With Deutsch Connectors


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : 3121824
Total Pages : 152


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Section A. Introduction - Maintenance Safety Precautions
A General
B Hydraulic System Safety
C Maintenance

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
Pre-Delivery Inspection and Frequent Inspection
Annual Machine Inspection
Preventative Maintenance
2.2 Service and Guidelines
General
Safety and Workmanship
Cleanliness
Components Removal and Installation
Component Disassembly and Reassembly
Pressure-Fit Parts
Bearings
Gaskets
Bolt Usage and Torque Application
Hydraulic Lines and Electrical Wiring
Hydraulic System
Lubrication
Battery
Lubrication and Servicing
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)
Speed Sensor
Tilt Sensor Calibration:
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
Timing Sequences
To Connect the JLG Control System Analyzer to the Generator
Alarms and Fault Flash Codes
Output Current and Voltage Settings
Priming the Fuel Line
3.5 Supplementary Fuse For APU
Tools And Material
Procedure
3.6 Joystick Controller
Power Controller
3.7 Torque Hub
Disengaging for Towing
Engaging after Towing is Complete
3.8 Drive Hub
Disassembly
Disassembly of Cover Unit (8)
Disassembly of First Stage Planetary Assembly
Disassembly of the Second Stage Planet Gears (1)
3.9 Drive Brake - MICO
Disassembly
Assembly
Bleeding
3.10 Torque Hub
Roll Test
Leak Test (Main Unit)
Tightening and Torquing Bolts
Main Disassembly
Output Carrier Disassembly
Input Carrier Disassembly
Hub-Spindle Disassembly
Cover Disassembly
Input Carrier Sub-Assembly
Output Carrier Sub-Assembly
Hub-Spindle Sub-Assembly
Cover Sub-Assembly
Main Assembly

Section 4. Hydraulics
4.1 Servicing and Maintenance Guidelines
General
Safety and Workmanship
Cleanliness
Component Removal and Installation
Component Disassembly and Reassembly
Pressure Fit Parts
Bearings
Gaskets
Bolt Usage and Torque Application
Hydraulic Lines and Electrical Wiring
Hydraulic System
Lubrication
Batteries
Lubrication and Servicing
4.2 Lubrication Information
Hydraulic System
Hydraulic Oil
Changing Hydraulic Oil
Lubrication Specifications
4.3 Cylinders - Theory of Operation
4.4 Valves - Theory of Operation
Control Valves
4.5 Component Functional Description
Hydraulic Pump
Manual Descent
4.6 Wear Pads
4.7 Motor Controller - Modes of Operation
Traction Motor (Drive)
Pump Motor (LIft)
4.8 Features
Traction Mode
4.9 Cylinder Checking Procedures
Cylinder Without Counterbalance Valves (Steer)
Cylinders With Single Counterbalance Valve (Lift Cylinder)
Cylinders with Duel Counterbalance Valves (Oscillating Cylinders)
4.10 Cylinder Removal and Installation
Lift Cylinder Removal
Lift Cylinder Installation
4.11 Cylinder Repair
Disassembly
Cleaning and Inspection
Assembly
4.12 Steer Cylinder Removal
4.13 Oscillation Cylinder Bleeding
Bleeding Procedure
Checking Oscillation Cylinders
Oscillating Axle Lockout Test (If Equipped)
4.14 Cylinder Assemblies
4.15 Pressure Setting Procedures
Main Relief at Pump
Lift Relief
Steer Relief
4.16 Drive Torque Hub
Disassembly
Assembly
4.17 Drive Assist Valve

Section 5. JLG Control System
5.1 Hand Held Analyzer
To Connect the Hand Held Analyzer:
Using the Analyzer:
Changing the Access Level of the Hand Held Analyzer:
Adjusting Parameters Using the Hand Held Analyzer
Machine Setup
5.2 PC Boards
5.3 Flash Codes/DTC’s and Descriptions
5.4 Ground Control Circuit Board
Software Version 13.6
Software Version P1.0

Section 6. General Electrical Information & Schematics
6.1 General
6.2 Multimeter Basics
Grounding
Backprobing
Min/Max
Polarity
Scale
Continuity Measurement Over Long Distances
Requirements:
Procedure
6.3 Applying Silicone Dielectric Compound To Amp Connectors
Assembly
Disassembly
Wedge Lock
Service - Voltage Reading
6.4 Working With Deutsch Connectors
DT/DTP Series Assembly
DT/DTP Series Disassembly
HD30/HDP20 Series Assembly
HD30/HDP20 Series Disassembly

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