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

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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 Towing
    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 : 3121122
Total Pages : 150


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Section A. Introduction - Maintenance Safety Precautions
    A.A General
    A.B Hydraulic System Safety
    A.C Maintenance
    
Section 1. Specifications
    1.1 Specifications
    1.2 Capacities
    1.3 Pressure Settings
    1.4 Component Data
        Battery Charger
        Batteries
        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 Towing
        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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