Service and Maintenance Manual: Models 3369LE 4069LE M3369 M4069

Service and Maintenance Manual
Models
3369LE
4069LE
M3369
M4069
S/N-0200230092 to Present
S/N-M200000100 to Present
3121639
July 23, 2018 - Rev C

INTRODUCTION
SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

GENERAL MAINTENANCE
This section contains the general safety precautions
which must be observed during maintenance of the
aerial platform. It is of utmost importance that mainte- FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SEC-
nance personnel pay strict attention to these warnings TION COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR
and precautions to avoid possible injury to themselves DEATH AND IS A SAFETY VIOLATION.
or others, or damage to the equipment. A maintenance • ENSURE REPLACEMENT PARTS OR COMPONENTS ARE
program must be followed to ensure that the machine is IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS OR
safe to operate. COMPONENTS.
• NO SMOKING IS MANDATORY. NEVER REFUEL DURING
ELECTRICAL STORMS. ENSURE THAT FUEL CAP IS
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM CLOSED AND SECURE AT ALL OTHER TIMES.
SHALL BE MADE ONLY WITH WRITTEN PERMISSION FROM THE MANU- • REMOVE ALL RINGS, WATCHES AND JEWELRY WHEN
FACTURER. PERFORMING ANY MAINTENANCE.
The specific precautions to be observed during mainte- • DO NOT WEAR LONG HAIR UNRESTRAINED, OR
nance are inserted at the appropriate point in the man- LOOSE-FITTING CLOTHING AND NECKTIES WHICH ARE
ual. These precautions are, for the most part, those that APT TO BECOME CAUGHT ON OR ENTANGLED IN
apply when servicing hydraulic and larger machine EQUIPMENT.
component parts. • OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS
Your safety, and that of others, is the first consideration ON MACHINE AND IN SERVICE MANUAL.
when engaging in the maintenance of equipment. • KEEP OIL, GREASE, WATER, ETC. WIPED FROM STAND-
Always be conscious of weight. Never attempt to move ING SURFACES AND HAND HOLDS.
heavy parts without the aid of a mechanical device. Do
not allow heavy objects to rest in an unstable position. • USE CAUTION WHEN CHECKING A HOT, PRESSURIZED
When raising a portion of the equipment, ensure that COOLANT SYSTEM.
adequate support is provided. • NEVER WORK UNDER AN ELEVATED SCISSOR UNTIL
PLATFORM HAS BEEN SAFELY RESTRAINED FROM ANY
MOVEMENT BY BLOCKING OR OVERHEAD SLING, OR
SAFETY PROP HAS BEEN ENGAGED.
SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER
THE FIELD INSPECTION AND MAINTENANCE, SAFETY IN THIS AREA • BEFORE MAKING ADJUSTMENTS, LUBRICATING OR
RESPONSIBILITY OF THE OWNER/OPERATOR. PERFORMING ANY OTHER MAINTENANCE, SHUT OFF
ALL POWER CONTROLS.
HYDRAULIC SYSTEM SAFETY • BATTERY SHOULD ALWAYS BE DISCONNECTED DUR-

ING REPLACEMENT OF ELECTRICAL COMPONENTS.
It should be noted that the machines hydraulic systems • KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS
operate at extremely high potentially dangerous pres- STOWED IN THEIR PROPER PLACE.
sures. Every effort should be made to relieve any system
• USE ONLY APPROVED, NONFLAMMABLE CLEANING
pressure prior to disconnecting or removing any por-
SOLVENTS.
tion of the system.
3121639 A-1
INTRODUCTION
REVISION LOG
Original Issue A - June 10, 2014
Revised B - June 17, 2015
Revised C - July 23, 2018
A-2 3121639
TABLE OF CONTENTS
TABLE OF CONTENTS
SECTION 1 - SPECIFICATIONS
1.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Component Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Drive System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Steer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Hydraulic Pump/Electric Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Engine (Generator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.4 Pressure Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.5 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.6 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.7 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.8 Critical Stability Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.9 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.10 Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.11 Torque Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
SECTION 2 - GENERAL
2.1 Machine Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-Delivery Inspection and Frequent Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Annual Machine Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preventative Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Service and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Components Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Pressure-Fit Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic Lines and Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3 Lubrication and Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Changing Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.4 Cylinder Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Platform Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.5 Pins and Composite Bearing Repair Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.6 Preventive Maintenance and Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
3121639 i
TABLE OF CONTENTS
SECTION 3 - CHASSIS & SCISSOR ARMS

3.1 Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Elevation Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Speed Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tilt Sensor Calibration: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Joystick Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2 Tilt Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Tilt Sensor, JLG P/N 4000021: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.3 Battery Maintenance and Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Battery Maintenance, Quarterly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Optional On-Board Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Battery Charging (On Board Charger) (MAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Charging Sequence of Remote LED Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Battery Charger (Delta-Q) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Battery Charger Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Battery Charger Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Battery Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Removing the Battery Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.4 Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Timing Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
To Connect the JLG Control System Analyzer to the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Alarms and Fault Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Output Current and Voltage Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Priming the Fuel Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3.5 Supplementary Fuse For APU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Tools And Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.6 Joystick Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Power Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3.7 Towing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Disengaging for Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Engaging after Towing is Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3.8 Drive Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Disassembly of Cover Unit (8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Disassembly of First Stage Planetary Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Disassembly of the Second Stage Planet Gears (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3.9 Drive Brake - MICO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
3.10 Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Roll Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Leak Test (Main Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Tightening and Torquing Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Main Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Output Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Input Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Hub-Spindle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Cover Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Input Carrier Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Output Carrier Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Hub-Spindle Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Cover Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
SECTION 4 - HYDRAULICS
ii 3121639
TABLE OF CONTENTS
4.1 Servicing and Maintenance Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Component Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Pressure Fit Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Hydraulic Lines and Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 Lubrication Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Changing Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3 Cylinders - Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.4 Valves - Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.5 Component Functional Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Manual Descent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.6 Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.7 Motor Controller - Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Traction Motor (Drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Pump Motor (LIft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.8 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Traction Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.9 Cylinder Checking Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Cylinder Without Counterbalance Valves (Steer). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Cylinders With Single Counterbalance Valve (Lift Cylinder) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Cylinders with Duel Counterbalance Valves (Oscillating Cylinders) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.10 Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Lift Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Lift Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.11 Cylinder Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.12 Steer Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.13 Oscillation Cylinder Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Bleeding Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Checking Oscillation Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.14 Oscillating AXLE - Lockout Cylinder Test (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Left Side Wheel Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Right Side Wheel Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
3121639 iii
TABLE OF CONTENTS
4.15 Cylinder Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4.16 Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Main Relief at Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Lift Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Steer Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4.17 Drive Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4.18 Drive Assist Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
SECTION 5 - JLG CONTROL SYSTEM
5.1 Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
To Connect the Hand Held Analyzer: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Using the Analyzer: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Changing the Access Level of the Hand Held Analyzer:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Adjusting Parameters Using the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.2 PC Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.3 Flash Codes/DTC’s and Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.4 Ground Control Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Software Version P1.X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Multimeter Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Backprobing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Min/Max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Voltage Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Current Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Continuity Measurement Over Long Distances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Requirements:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.3 Applying Silicone Dielectric Compound To Amp Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Wedge Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Service - Voltage Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6.4 Working With Deutsch Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
DT/DTP Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
DT/DTP Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
HD30/HDP20 Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
HD30/HDP20 Series Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
6.5 Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
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LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.
1-1. Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1-2. Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1-3. Torque Chart - Sheet 1 of 5 - (SAE Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1-6. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1-7. Torque Chart - Sheet 5 of 5 - (METRIC Fasteners). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
3-1. Tilt Sensor Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-2. Tilt Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-3. Remote LED Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3-4. Battery Charger Location(M model shown). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-5. Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-6. Batteries and Battery Charger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3-7. Generator Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3-8. Generator System Analyzer Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3-9. Joystick Controller - (JLG P/N 1600403) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3-10. Drive Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3-11. Power Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3-12. Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3-13. Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3-14. Torque Hub Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3-15. Bolt Torquing Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
3-16. Hub Main Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3-17. Output Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
3-18. Input Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
3-19. Hub-Spindle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
3-20. Cover Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
3-21. Input Carrier Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
3-22. Output Carrier Sub-Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
3-23. Hub-Spindle Sub-Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
3-24. Cover Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
3-25. Hub Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
4-1. Barrel Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4-2. Cap Screw Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4-3. Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4-4. Oil-lite Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4-5. Rod Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4-6. Wiper Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4-7. Installation of Head Seal Kit (Typical). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4-8. Piston Seal Kit Installation (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4-9. Poly-Pak Piston Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4-10. Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4-11. Lift Cylinder - 3369LE & M3369 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4-12. Lift Cylinder - 4069LE & M4069 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4-13. Leveling Jack Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4-14. Steer Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4-15. Oscillating Axle Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4-16. Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4-17. Drive Assist Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
5-1. Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5-2. PC Boards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5-2. Analyzer Flow Chart - Software P1.X - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
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TABLE OF CONTENTS
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
6-10. 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
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
6-22. Electrical Schematic (All except AUS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6-23. Electrical Schematic (AUS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
6-24. Hydraulic Schematic (All except CE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
6-25. Hydraulic Schematic (CE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
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LIST OF TABLES
TABLE NO. TITLE PAGE NO.
1-1 Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-2 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-3 Tire Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-4 Engine Specifications (Generator - If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-5 Engine Battery Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-6 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-7 Pressure Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-8 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-9 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-10 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-11 Critical Stability Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-12 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1-13 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1-14 Mobil DTE 11M Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1-15 Synthetic Biodegradable Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1-16 Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
2-1 Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-2 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2-3 Preventive Maintenance and Safety Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
3-1 Tilt Sensor Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-2 Delta-Q - Battery Charger Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-3 Battery Algorithms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3-4 RBS Pre start Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3-5 RBS Startup Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3-6 RBS Shutdown Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3-7 Generator System Flash Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3-8 Joystick Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3-9 Joystick Plug Loading Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3-10 Power Controller Cable Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
5-1 Flash Codes/DTC’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5-2 Power Module Diagnostic LED Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5-3 Machine Model Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5-4 Machine Configuration Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5-5 J1 Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5-6 J2 Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5-7 J3 Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5-8 J4 Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
5-9 J5 Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
5-10 J6 Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
3121639 vii
TABLE OF CONTENTS
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viii 3121639
SECTION 1. SPECIFICATIONS
1.1 SPECIFICATIONS
Table 1-1. Operating Specifications
Description 3369LE/M3369 4069LE/M4069

ANSI CE/AUS CSA ANSI CE/AUS CSA
Max. Number of Persons 2 2
Max. Workload (Capacity) ANSI/CSA/Brazil: 1000 lbs (454kg) ANSI/CSA/Brazil: 800 lbs (363kg)
CE/AUS: 1000 lbs (450kg) CE/AUS: 800 lbs (360kg)
Extension Only: ANSI/CSA/Brazil: 250 lbs (113kg) ANSI/CSA/Brazil: 250 lbs (113kg)
CE/AUS: 250 lbs (120kg) CE/AUS: 250 lbs (120kg)
Max. Platform Height 33 ft (10.1m) 40 ft (12.2 m)
Max. Gradeability 35% 35%
Max. Slope (Left - Right) 5° Up to 25 ft (7.6 m) 5° Up to 30 ft (9.1 m)
3° Up to 33 ft 3° Up to 40 ft
4° Up to 30 ft (9.1 m) 4° Up to 36 ft (11 m)
(10 m) (12.2 m)
3° Up to 33 ft (10 m) 3° Up to 40 ft (12.2 m)
Max. Slope (Front - Back) 3° Up to 33 ft 3° Up to 40 ft
5° Up to 33 ft (10 m) 5° Up to 40 ft (12.2 m)
(10 m) (12.2 m)
Max. Slope (Left - Right) 4° Up to 25 ft
(optional for CE machines with 37 (7.6 m)
NA NA NA NA NA
mph (16.7 m/s) windspeed rating 2° Up to 33 ft
only) (10 m)
Max. Slope (Front - Back) 5° Up to 25 ft

(optional forCE machines with 37 (7.6 m)
NA NA NA NA NA
mph (16.7 m/s) windspeed rating 4° Up to 33 ft
only) (10 m)
Max. Tire Load 3200 lbs 3700 lbs

(1452 kg) (1680 kg)
Max. Ground Bearing 57 psi 61 psi
Pressure (4 kg/cm2) (4.3 kg/cm2)
Max. Allowable Wind Speed 28 mph 28 mph
(Standard rating) (12.5 m/s) (12.5 m/s)
Maximum Horizontal Manual Side 667 N 400 N 534 N 400N
Force (150 lb force)) (90 lb force) (120 lb force) (90 lb force)
Max. Allowable Wind Speed (16.7
m/s machines only) 16.7m/s
NA NA NA NA NA
(Optional rating for CE Specification (37 mph)
only)
Turning Radius:
Inside 7.5 ft (2.3 m) 7.5 ft (2.3 m)
Outside 16 ft (4.9 m) 16 ft (4.9 m)
Wheelbase 91.5 in (2.3m) 91.5 in (2.3 m)

Gross Machine Weight 9,760 lbs 10,060 lbs 10,560 lbs 11,500 lbs
(Approximate) (4,427 kg) (4563 kg) (4,790 kg) (5216.3 kg)
Maximum Drive Speed 3 mph (4.8 kmh) 3 mph (4.8 kmh)
3121639 1-1
Table 1-1. Operating Specifications

ANSI CE AUS ANSI CE AUS
Drive Speed - (reduced) 16 - 24 sec/50 ft (15 m) 16 - 24 sec/50 ft (15 m)
Drive Speed - (high) 10.6 - 12 sec/50 ft (15 m) 10.6 - 12 sec/50 ft (15 m)
Drive Speed - (creep) 142 -146 sec/25 ft
NA NA
(AUS Full drive height model) (7.6 m)
Platform Lift Up Speed
36 - 40 sec 52 - 60 sec
(platform empty)
Platform Lowering Speed (platform
41 - 48 sec 49 - 51 sec
empty)
Max Operating Hydraulic Pressure 3000 psi (207 bar) 3000 psi (207 bar)
Electrical System Voltage 48 volt 48 volt
Ground Clearance 8 in (20 cm) 8 in (20 cm)
NOTE: If function speeds are slow on a fully charged machine a clogged hydraulic filter may be indicated. Change filter.
1.2 COMPONENT DATA

JLG MACHINES EQUIPPED WITH DELTA Q BATTERY CHARGERS ARE DESIGNED
Dimensional Data FOR THE BEST PERFORMANCE WITH OEM FACTORY APPROVED BATTERIES.
APPROVED JLG REPLACEMENT BATTERIES ARE AVAILABLE THROUGH JLG' S
Table 1-2. Dimensional Data AFTERMARKET PARTS DISTRIBUTION CENTERS OR JLG' S AFTERMARKET PRO-
GRAMS. FOR ASSISTANCE WITH PROPER BATTERY REPLACEMENT, PLEASE
3369LE/M3369 4069LE/M4069 CONTACT YOUR LOCAL JLG SUPPORT OFFICE.
Transport Height (rails down) 76.5 in (1.9 m) 79 in (2 m) BATTERIES APPROVED BY JLG HAVE BEEN TESTED FOR COMPATIBILITY WITH
THE ALGORITHM PROGRAMMING OF THE DELTA Q BATTERY CHARGER TO
Machine Length 121 in (3.1 m)
OPTIMIZE BATTERY LIFE AND MACHINE C YCLE TIMES. THE USE OF NON
Machine Width 69 in (1.75 m) APPROVED BATTERIES IN YOUR JLG EQUIPMENT MAY RESULT IN PERFOR-
MANCE ISSUES OR BATTERY CHARGER FAULT CODES. JLG ASSUMES NO
RESPONSIBILITY FOR SERVICE OR PERFORMANCE ISSUES ARISING FROM THE
Battery Charger USE OF NON APPROVED BATTERIES.
Input 220 VAC, 50 HZ Input, (110 VAC,60 HZ)
Drive System
Output, 48 VDC @ 23 Amp
Drive Motor - 48 VDC, 11.8 H.P. peak 5.5 H.P. continuous,
Batteries rotation - reversible
6 Volt, 375 Amp-hour - Quantity (8) - US Battery Drive Brake - 24 VDC, spring-applied, hydraulically
6 Volt, 390 Amp-Hour - Quantity (8) - Harris Battery released
Steer System
Tires - IN240/55-17.5 FF
IN240/55-17.5 FF non marking
27.2/10.5LL-15.0 FF TURF - SLR - 4020 lb.@42 PSI
Toe-In - 1/4 inch (6.4 mm) overall
Hydraulic Pump/Electric Motor Assembly

Pump Output - 3.86 gpm (14.6 lpm) @ 2175 psi (150 bar)
1-2 3121639
Tires
Table 1-3. Tire Specifications
Size 240/55 D17.5 R4 Tread IN240/55-17.5

IN240/55-17.5 FF 27.2/10.5-15 FF Turf
(Fill tire with high durometer polyurethane at 90 psi) Non Marking
Load Rating 8550 lbs @ 105 psi 8550 lbs @ 105 psi
7960 lbs @ 95 psi (3878kg @ 724kPa) 4019 lbs @ 42 psi (3878kg @ 724kPa)
(3611kg @ 655kPa) 7960 lbs @ 95 psi (1823kg @ 290 kPa) 7960 lbs @ 95 psi
7730 lbs @ 90 psi (3611kg @ 655kPa) 2180 lbs @ 32 psi (3611kg @ 655kPa)
(3506kg @ 621 kPa) 7730 lbs @ 90 psi (989kg @ 221 kPa) 7730 lbs @ 90 psi
(3506kg @ 621 kPa) (3506kg @ 621 kPa)
Ply Rating 12 Ply 10 Ply 6 Ply 10 Ply
Wheel Nut Torque 170 ft lbs

(230 Nm)
Engine (Generator)
Table 1-4. Engine Specifications (Generator - If equipped)
Air Cooled, 4 Cycle, Kubota Diesel OC60-D

TYPE
(T4F)
Displacement 16.85 cu. in. (0.276L)
Bore x Stroke 2.83 in x 2.68 in (72mm x 68mm)
Number of cylinders 1
Horsepower 5.6HP/3600 rpm (4.5 kw/3600rpm)
Fuel Type Diesel (SAE No. 2-D)
Glow Plug Preheater on @ 40° F (5° C)
Weight 38 lb. (17.24 kg)
Air Cleaner Paper Element Type
Table 1-5. Engine Battery Specifications
BCI Group Size 51R - 675

Cranking Performance 550 Amps @ 32° F (0° C)
450 Amps @ 0° F (-18° C)
Reserve Capacity 80 minutes @ 80° F(27° C) Kubota OC60-D Engine - Oil Dip Stick and Drain Location
Weight 29 lb. (13.15 kg)
3121639 1-3
1.3 CAPACITIES 1.6 CYLINDER SPECIFICATIONS

Table 1-6. Capacities Table 1-9. Cylinder Specifications
Description 3369LE/M3369 4069LE/M4069 DESCRIPTION BORE STROKE ROD DIA.

Hydraulic Tank 8.25 gal (31.2 liters) Lift Cylinder (M3369/ 4.00 in 63.69 in 2.75 in
5.4 gal (20.4 liters) @ full mark 3369LE) (10.16 cm) (161.77 cm) (6.98 cm)
Hydraulic System approx. 8.5 gal (32.1 liters) Upper Lift Cylinder 3.00 in 58.13 in 2.75 in
(M4069/4069LE) (7.62 cm) (147.65 cm) (6.98 cm)
Fuel Tank - (M Models only) Approx. 0.9 gal (3.3 l)
Lower Lift Cylinder 4.00 in 58.13 in 2.25 in
Generator Crankcase 1.37 qts(1.3 l)
(M4069/4069LE) (10.16 cm) (147.65 cm) (5.71 cm)
2.00 in 6.5 in 1.125 in
1.4 PRESSURE SETTINGS Steer Cylinder
(5.08 cm) (16.51 cm) (2.86 cm)
Table 1-7. Pressure Settings

1.7 MAJOR COMPONENT WEIGHTS
Main Relief (±50 psi) 3000 psi Table 1-10. Major Component Weights
(207 bar)
Steer Relief 2500 psi
Platform 780 lbs (354 kg)
(172 bar)
Platform Extension 360 lbs (163 kg)
Lift Relief 2600 psi 2800 psi
(179 bar) (193 bar) Arm Assembly 3200 lbs 3900 lbs
(Includes Lift Cylinders) (1451 kg) (1769 kg)
1.5 TORQUE SPECIFICATIONS Chassis (Includes Battery Box and 5420 lbs 5517 lbs
Foam filled Tires) (2458 kg) (2502 kg)
Table 1-8. Torque Specifications
Foam Filled Tire and Wheel Assembly
180 lb. (81.6 kg)
DESCRIPTION TORQUE VALUE (DRY) INTERVAL HOURS (each)
240 ft lbs
Torque Hub 500
(336 Nm)
1.8 CRITICAL STABILITY WEIGHTS
170 ft lbs
Wheel Nuts 50
(238 Nm) Table 1-11. Critical Stability Weights
220 ft lbs
Fixed Axle Bolts 500
(308 Nm) Description 3369LE/M3369 4069LE/M4069
35 ft lbs
Drive Motor N/A Platform 780 lbs (354 kg)
(49 Nm)
Pump Motor 12-14 ft lbs Platform Extension 360 lbs (163 kg)
N/A
Terminals (14-19 Nm)
Foam Filled Tires 207 lbs (94 kg)
NOTE: When maintenance becomes necessary or a fastener has
loosened, refer to Section 1.11, Torque Charts to determine Battery (Each) 122 lbs (55 kg)
proper torque value.
1-4 3121639
1.9 LUBRICATION
Table 1-12. Hydraulic Oil Table 1-14. Mobil DTE 11M Specs
Hydraulic System Operating ISO Viscosity Grade #15

SAE Viscosity Grade
Temperature Range Gravity API 31.9
0° F to 23° F (-18°C to -5°C) 10W Pour Point, Max -40°F (-40°C)
0° F to 210° F (-18°C to +99°C) 10W-20, 10W- 0
Flash Point, Min. 330°F (166°C)
50° F to 210° F (+10°C to +99°C) 20W-20
Viscosity
NOTE: Hydraulic oils must have anti-wear qualities at least to API
Service Classification GL-3, and sufficient chemical stability at 40° C 15 cSt
for mobile hydraulic system service. JLG Industries recom- at 100° C 4.1 cSt
mends Mobil DTE 11M hydraulic oil, which has an SAE vis-
cosity index of 140. at 100° F 80 SUS
Aside from JLG recommendations, it is not advisable to mix at 210° F 43 SUS
oils of different brands or types, as they may not contain
cp at -30° F 3.200
the same required additives or be of comparable viscosi-
ties. Viscosity Index 140
Lubrication Specifications Table 1-15. Synthetic Biodegradable Hydraulic Fluid

Table 1-13. Lubrication Specifications
Mobil EAL Mobil SHC Hydraulic
Specification
KEY SPECIFICATIONS Envirosyn H 46 EAL 46
Extreme Pressure Gear Lube (oil) meeting API service classification ISO Viscosity Grade 46
EPGL
GL-5 or MIL-Spec MIL-L-2105
Density @ 59°F (15°C) 0.874 kg/l 0.93 kg/l
HO Hydraulic Oil. API service classification Gl-3, BP Energol SHS46.
Pour Point, Max -49°F (-45°C) -29°F (-33°C)
LL Synthetic Lithium Lubricant, Gredag 741 Grease.
Flash Point, Min. 500°F (260°C) 568°F (298°C)
* MPG may be substituted for these lubricants, if Operating Temperature -20 to 200°F -20 to 200°F
(-29 to 93°C) (-27 to 93°C)
necessary, but service intervals will be reduced.
Viscosity Specifications
NOTE: Refer to Lubrication Chart - Table 1-16 for specific lubrica-
tion procedures. at 40°C 48.8 cSt 43.3 cSt
at 100°C 7.8 cSt 7.7cSt
Viscosity Index 145 149
3121639 1-5
Note:
500 Hrs. = 3 months
1000 Hrs. = 6 months
2000 Hrs. = 1 year
4000 Hrs. = 2 years
Figure 1-1. Lubrication Chart
Table 1-16. Lubrication Chart
INDEX NO/TYPE LUBE

COMPONENT LUBE/METHOD INTERVAL HOURS COMMENTS
NUMBER POINTS
1 Sliding Wear Pads 8 Wear Pads MPG/Brush 50 --
HO - Check HO Level Check oil every 10 hours of operation
2 Hydraulic Oil Fill Level/Drain Plug 10/500
HO - Change HO Change oil after every 1000 hours of operation
3 Wheel Bearings Front Wheels MPG - Repack 1200 --
Spindles/Bushing At Spindle Bushing
4 N/A LL --
(not shown) Replacement
Check oil level at side plug daily.
5 Wheel Drive Hub Fill Plug/Half Full EPGL 1200 Change after first 150 hours of operation then every 1000 hours
thereafter
*High Pressure Filter Replaceable Replace filter element after first 50 hours of operation and every
6 N/A 50/250
(not shown) Element 1000 hours thereafter.
KEY TO LUBRICANTS:
HO - Hydraulic Oil - Mobil DTE - 11M
EPGL - Extreme Pressure Gear Lube
MPG - Multi Purpose Grease
NOTE: Be sure to lubricate like items on each side of the machine.
TO AVOID PERSONAL INJURY, USE SAFETY PROP FOR ALL MAINTENANCE NOTE: Recommended lubricating intervals are based on machine
REQUIRING PLATFORM TO BE ELEVATED operations under normal conditions. For machines used in
multi-shift operations and/or exposed to hostile environ-
ments or conditions, lubricating frequencies must be
increased accordingly.
*The high pressure filter is located in the main control
valve. See figure title control valve in section 2.
1-6 3121639
1.10 SERIAL NUMBER LOCATIONS

For machine identification, a serial number plate is affixed to the left front of the frame. If the serial number plate is damaged or miss-
ing, the machine serial number is stamped on the left front of the machine frame.
Figure 1-2. Serial Number Location
3121639 1-7
1.11 TORQUE CHARTS
Figure 1-3. Torque Chart - Sheet 1 of 5 (SAE Fasteners)
1-8 3121639
3121639 1-9
1-10 3121639
Figure 1-6. Torque Chart - Sheet 4 of 5 (METRIC Fasteners)
3121639 1-11
Figure 1-7. Torque Chart - Sheet 5 of 5 (METRIC Fasteners)
1-12 3121639
SECTION 2 - GENERAL
SECTION 2. GENERAL
2.1 MACHINE PREPARATION, INSPECTION, AND Reference the JLG Pre-Delivery and Frequent Inspection Form
and the Inspection and Preventative Maintenance Schedule
MAINTENANCE for items requiring inspection during the performance of
these inspections. Reference the appropriate areas of this
General manual for servicing and maintenance procedures.
This section provides the necessary information needed by Annual Machine Inspection
those personnel that are responsible to place the machine in
operation readiness and maintain its safe operating condition. JLG recommends that an annual machine inspection be per-
For maximum service life and safe operation, ensure that all formed by a Factory-Certified Service Technician on an annual
the necessary inspections and maintenance have been com- basis, no later than thirteen (13) months from the date of the
pleted before placing the machine into service. With proper prior Annual Machine Inspection. JLG Industries, Inc. recog-
care, maintenance and inspections performed per JLG's rec- nizes a Factory-Trained Service Technician as a person who has
ommendations with any and all discrepancies corrected, this successfully completed the JLG Service Training School for the
product will be fit for continued use. subject JLG product model. Reference the machine Service
and Maintenance Manual and appropriate JLG inspection
form for performance of this inspection.
Preparation, Inspection, and Maintenance
Reference the JLG Annual Machine Inspection Form and the
It is important to establish and conform to a comprehensive Inspection and Preventative Maintenance Schedule for items
inspection and preventive maintenance program. The follow- requiring inspection during the performance of this inspec-
ing table outlines the periodic machine inspections and main- tion. Reference the appropriate areas of this manual for servic-
tenance recommended by JLG Industries, Inc. Consult your ing and maintenance procedures.
national, regional, or local regulations for further requirements
for aerial work platforms. The frequency of inspections and For the purpose of receiving safety-related bulletins, it is
maintenance must be increased as environment, severity and important that JLG Industries, Inc. has updated ownership
frequency of usage requires. information for each machine. When performing each Annual
Machine Inspection, notify JLG Industries, Inc. of the current
Pre-Start Inspection machine ownership.
It is the User’s or Operator’s primary responsibility to perform a Preventative Maintenance

Pre-Start Inspection of the machine prior to use daily or at In conjunction with the specified inspections, maintenance
each change of operator. Reference the Operator’s and Safety
shall be performed by a qualified JLG equipment mechanic.
Manual for completion procedures for the Pre-Start Inspec-
JLG Industries, Inc. recognizes a qualified JLG equipment
tion. The Operator and Safety Manual must be read in its mechanic as a person who, by possession of a recognized
entirety and understood prior to performing the Pre-Start
degree, certificate, extensive knowledge, training, or experi-
Inspection. ence, has successfully demonstrated the ability and profi-
ciency to service, repair, and maintain the subject JLG product
Pre-Delivery Inspection and Frequent Inspection model.
The Pre-Delivery Inspection and Frequent Inspection shall be Reference the Preventative Maintenance Schedule and the
performed by a qualified JLG equipment mechanic. JLG Indus- appropriate areas of this manual for servicing and mainte-
tries, Inc. recognizes a qualified JLG equipment mechanic as a nance procedures. The frequency of service and maintenance
person who, by possession of a recognized degree, certificate, must be increased as environment, severity and frequency of
extensive knowledge, training, or experience, has successfully usage requires.
demonstrated the ability and proficiency to service, repair, and
maintain the subject JLG product model.
The Pre-Delivery Inspection and Frequent Inspection proce-

dures 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 environ-
ment, severity and frequency of usage requires.
3121639 2-1
SECTION 2 - GENERAL
Table 2-1. Inspection and Maintenance
Primary Service
Type Frequency Reference
Responsibility Qualification
Prior to use each day; or
Pre-Start Inspection User or Operator User or Operator Operator and Safety Manual
At each Operator change.
Pre-Delivery Prior to each sale, lease, or Service and Maintenance Manual
Owner, Dealer, or User Qualified JLG Mechanic
Inspection rental delivery. and applicable JLG inspection form.
In service for 3 months or 150 hours, whichever
comes first; or
Service and Maintenance Manual
Frequent Inspection Out of service for a period of more than 3 months; Owner, Dealer, or User Qualified JLG Mechanic
and applicable JLG inspection form.
or
Purchased used.
Factory-Trained
Annual Machine Annually, no later than 13 months from the date Service and Maintenance Manual
Owner, Dealer, or User Service Technician
Inspection of the prior inspection. and applicable JLG inspection form.
(recommended)
Preventative At intervals as specified in the Service and
Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
Maintenance Maintenance Manual.
2.2 SERVICE AND GUIDELINES 1. The most important single item in preserving the long
service life of a machine is to keep dirt and foreign mate-
rials out of the vital components. Precautions have been
General taken to safeguard against this. Shields, covers, seals,
The following information is provided to assist you in the use and filters are provided to keep air, fuel, and oil supplies
and application of servicing and maintenance procedures clean; however, these items must be maintained on a
contained in this book. scheduled basis in order to function properly.
Safety and Workmanship 2. At any time when air, fuel, or oil lines are disconnected,
clear adjacent areas as well as the openings and fittings
Your safety, and that of others, is the first consideration when themselves. As soon as a line or component is discon-
engaging in the maintenance of equipment. Always be connected, cap or cover all openings to prevent entry of for-
scious of weight. Never attempt to move heavy parts without eign matter.
the aid of a mechanical device. Do not allow heavy objects to
rest in an unstable position. When raising a portion of the 3. Clean and inspect all parts during servicing or mainte-
equipment, ensure that adequate support is provided. nance, and assure that all passages and openings are
unobstructed. Cover all parts to keep them clean. Be
Cleanliness sure all parts are clean before they are installed. New
parts should remain in their containers until they are
ready to be used.
IT IS GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELEC-

TRONIC COMPONENTS. IN THE EVENT PRESSURE-WASHING THE MACHINE IS
Components Removal and Installation
NEEDED, ENSURE THE MACHINE IS SHUT DOWN BEFORE PRESSURE-WASH-
1. Use adjustable lifting devices, whenever possible, if
ING. SHOULD PRESSURE WASHING BE UTILIZED TO WASH AREAS CONTAINING
mechanical assistance is required. All slings (chains,
ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC. RECOMMENDS
cables, etc.) should be parallel to each other and as near
A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A MINIMUM DISTANCE OF 12
perpendicular as possible to top of part being lifted.
INCHES (30.5 CM) AWAY FROM THESE COMPONENTS. IF ELECTRICAL/ELEC-
TRONIC COMPONENTS ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND BE
2. Should it be necessary to remove a component on an
FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION.
angle, keep in mind that the capacity of an eyebolt or
similar bracket lessens, as the angle between the sup-
porting 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 3121639
SECTION 2 - GENERAL
Component Disassembly and Reassembly Hydraulic Lines and Electrical Wiring

When disassembling or reassembling a component, complete Clearly mark or tag hydraulic lines and electrical wiring, as well
the procedural steps in sequence. Do not partially disassemble as their receptacles, when disconnecting or removing them
or assemble one part, then start on another. Always recheck from the unit. This will assure that they are correctly rein-
your work to assure that nothing has been overlooked. Do not stalled.
make any adjustments, other than those recommended, with-
out obtaining proper approval. Hydraulic System
Pressure-Fit Parts 1. Keep the system clean. If evidence of metal or rubber
particles are found in the hydraulic system, drain and
When assembling pressure-fit parts, use an anti-seize or flush the entire system.
molybdenum disulfide base compound to lubricate the mat-
ing surface. 2. Disassemble and reassemble parts on clean work sur-
face. Clean all metal parts with non-flammable cleaning
Bearings solvent. Lubricate components, as required, to aid
assembly.
1. When a bearing is removed, cover it to keep out dirt and
abrasives. Clean bearings in nonflammable cleaning sol- Lubrication
vent and allow to drip dry. Compressed air can be used
but do not spin the bearing. Service applicable components with the amount, type, and
grade of lubricant recommended in this manual, at the speci-
2. Discard bearings if the races and balls (or rollers) are pit- fied intervals. When recommended lubricants are not avail-
ted, scored, or burned. able, consult your local supplier for an equivalent that meets
3. If bearing is found to be serviceable, apply a light coat of or exceeds the specifications listed.
oil and wrap it in clean (waxed) paper. Do not unwrap
reusable or new bearings until they are ready to install. Battery
4. Lubricate new or used serviceable bearings before Clean battery, using a non-metallic brush and a solution of
installation. When pressing a bearing into a retainer or baking soda and water. Rinse with clean water. After cleaning,
bore, apply pressure to the outer race. If the bearing is to thoroughly dry battery and coat terminals with an anti corro-
be installed on a shaft, apply pressure to the inner race. sion compound.
Gaskets Lubrication and Servicing

Check that holes in gaskets align with openings in the mating Components and assemblies requiring lubrication and servic-
parts. If it becomes necessary to hand-fabricate a gasket, use ing are shown in the Lubrication Chart in Section 1.
gasket material or stock of equivalent material and thickness.
Be sure to cut holes in the right location, as blank gaskets can 2.3 LUBRICATION AND INFORMATION
cause serious system damage.
Bolt Usage and Torque Application Hydraulic System

1. The primary enemy of a hydraulic system is contamina-
1. Self locking fasteners, such as nylon insert and thread
tion. Contaminants enter the system by various means,
deforming locknuts, are not intended to be reinstalled
e.g., using inadequate hydraulic oil, allowing moisture,
after removal. Always use new replacement hardware
grease, filings, sealing components, sand, etc., to enter
when installing locking fasteners.
when performing maintenance, or by permitting the
2. Use bolts of proper length. A bolt which is too long will pump to cavitate due to insufficient system warm-up or
bottom before the head is tight against its related part. If leaks in the pump supply (suction) lines.
a bolt is too short, there will not be enough thread area
to engage and hold the part properly. When replacing 2. The design and manufacturing tolerances of the compo-
bolts, use only those having the same specifications of nent working parts are very close, therefore, even the
the original, or one which is equivalent. smallest amount of dirt or foreign matter entering a sys-
tem can cause wear or damage to the components and
3. Unless specific torque requirements are given within the generally results in faulty operation. Every precaution
text, standard torque values should be used on heat- must be taken to keep hydraulic oil clean, including
treated bolts, studs, and steel nuts, in accordance with reserve oil in storage. Hydraulic system filters should be
recommended shop practices. (See Torque Chart Sec- checked, cleaned, and/or replaced as necessary, at the
tion 1.) specified intervals required in the Lubrication Chart in
3121639 2-3
SECTION 2 - GENERAL
Section 1. Always examine filters for evidence of metal 3. While the unit is shut down, a good preventive mainte-
particles. nance measure is to make a thorough inspection of all
hydraulic components, lines, fittings, etc., as well as a
3. Cloudy oils indicate a high moisture content which per-
functional check of each system, before placing the
mits organic growth, resulting in oxidation or corrosion.
machine back in service.
If this condition occurs, the system must be drained,
flushed, and refilled with clean oil.
Lubrication Specifications
4. It is not advisable to mix oils of different brands or types,
as they may not contain the same required additives or Specified lubricants, as recommended by the component
be of comparable viscosities. Good grade mineral oils, manufacturers, are always the best choice, however, multi-pur-
with viscosities suited to the ambient temperatures in pose greases usually have the qualities which meet a variety of
which the machine is operating, are recommended for single purpose grease requirements. Should any question
use. arise, regarding the use of greases in maintenance stock, con-
sult your local supplier for evaluation. Refer to Section 1 for an
NOTE: Metal particles may appear in the oil or filters of new
explanation of the lubricant key designations appearing in the
machines due to the wear-in of meshing components.
Lubrication Chart.
Hydraulic Oil
2.4 CYLINDER DRIFT TEST
1. Refer to Section 1 for recommendations for viscosity
ranges. Maximum acceptable cylinder drift is to be measured using
the following methods.
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 -

Platform Drift
15°F (-26°C) is not recommended. If it is necessary to start
Measure the drift of the platform to the ground. Fully elevate
the system in a sub-zero environment, it will be necessary
the platform. Maximum allowable drift is 2 in. (5 cm) in 10 min-
to heat the oil with a low density, 100VAC heater to a mini-
utes. If the machine does not pass this test, proceed with the
mum temperature of -15°F (-26°C).
following.
3. The only exception to the above is to drain and fill the
system with Mobil DTE 13 oil or its equivalent. This will Cylinder Drift
allow start up at temperatures down to -20° F (-29° C).
Table 2-2. Cylinder Drift
However, use of this oil will give poor performance at
temperatures above 120°F (49°C). Systems using DTE 13 Max. Acceptable Drift
oil should not be operated at temperatures above 200°F Cylinder Bore Diameter
in 10 Minutes
(94°C) under any condition.
inches mm inches mm
Changing Hydraulic Oil 3 76.2 0.026 0.66
3.5 89 0.019 0.48
1. Use of any of the recommended hydraulic oils elimi- 4 101.6 0.015 0.38
nates the need for changing the oil on a regular basis.
5 127 0.009 0.22
However, filter elements must be changed after the first
50 hours of operation and every 300 hours thereafter. If 6 152.4 0.006 0.15
it is necessary to change the oil, use only those oils 7 177.8 0.005 0.13
meeting or exceeding the specifications appearing in
this manual. If unable to obtain the same type of oil sup-
Drift is to be measured at the cylinder rod with a calibrated
plied with the machine, consult local supplier for assis-
dial indicator. The cylinder oil must be at ambient temperature
tance in selecting the proper equivalent. Avoid mixing
and temperature stabilized.
petroleum and synthetic base oils. JLG Industries recom-
mends changing the hydraulic oil annually.
The cylinder must have the normal load, which is the normal
2. Use every precaution to keep the hydraulic oil clean. If platform load applied.
the oil must be poured from the original container into
another, be sure to clean all possible contaminants from If the cylinder passes this test, it is acceptable.
the service container. Always clean the mesh element of
the filter and replace the cartridge any time the system NOTE: This information is based on 6 drops per minute cylinder
oil is changed. leakage.
2-4 3121639
SECTION 2 - GENERAL
2.5 PINS AND COMPOSITE BEARING REPAIR 2.6 PREVENTIVE MAINTENANCE AND INSPECTION
GUIDELINES SCHEDULE
Filament wound bearings. The preventive maintenance and inspection checks are listed
and defined in Table 2-3, Preventive Maintenance and Safety
1. Pinned joints should be disassembled and inspected if
Inspection. This table is divided into two basic parts, the
the following occurs:
“AREA” to be inspected, and the “INTERVAL” at which the
a. Excessive sloppiness in joints. inspection is to take place. Under the “AREA” of the table, the
b. Noise originating from the joint during operation. various systems along with components that make up that
system are listed. The “INTERVAL” portion of the table is
2. Filament wound bearings should be replaced if any of divided into two columns representing the various inspection
the following is observed: time periods. The numbers listed within the interval column
represent the applicable inspection code for which that com-
a. Frayed or separated fibers on the liner surface.
ponent is to be checked.
b. Cracked or damaged liner backing.
The checks and services listed in this schedule are not
c. Bearings that have moved or spun in their housing.
intended to replace any local or regional regulations that may
d. Debris embedded in liner surface. pertain to this type of equipment nor should the lists be con-
3. Pins should be replaced if any of the following is sidered as all inclusive. Variances in interval times may occur
observed (pin should be properly cleaned prior to due to climate and/or conditions and depending on the loca-
inspection): tion and use of the machine.
a. Detectable wear in the bearing area. JLG Industries requires that a complete annual inspection be
performed in accordance with the “Annual Machine Inspec-
b. Flaking, pealing, scoring, or scratches on the pin sur-
tion Report” form. Forms are supplied with each new machine
face.
and are also available from JLG Customer Service. Forms must
c. Rusting of the pin in the bearing area. be completed and returned to JLG Industries.
4. Re-assembly of pinned joints using filament wound
bearings.
JLG INDUSTRIES REQUIRES THAT A COMPLETE ANNUAL INSPECTION BE PER-
a. Housing should be blown out to remove all dirt and
FORMED IN ACCORDANCE WITH THE “ANNUAL MACHINE INSPECTION
debris...bearings and bearing housings must be free
REPORT” FORM.
of all contamination.
b. Bearing / pins should be cleaned with a solvent to NOTE: This machine requires periodic safety and maintenance
remove all grease and oil...filament wound bearing inspections by a JLG Dealer. A decal located on the frame
are a dry joint and should not be lubricated. affords a place to record (stamp) inspection dates. Notify
c. Pins should be inspected to ensure it is free of burrs, dealer if inspection is overdue.
nicks, and scratches which would damage the bear-
ing during installation and operation.
3121639 2-5
SECTION 2 - GENERAL
Table 2-3. Preventive Maintenance and Safety Inspection
AREA Inspections
1
Pre-Delivery Annual3
or Frequent2 (Yearly)
Inspection (Quarterly) Inspection
Scissor Arms
Scissor Arms 1,2 1,2
Safety Prop 1,2 1,2
Nuts, Bolts, Shafts, Shields, Bearings and Locking Devices 1,2 1,2
Cylinder/Pivot Pins and Attaching Hardware 1,2 1,2
Arm Pads and Sliding Block 1,2 1,2
Platform Assembly
Platform 1 1
Mandrill Chain/gate, Bar and Latches 1,3 1,3
Extend Deck and Locks 1,3 1,3
Guard Rails and Floor 1,2 1,2
Platform Roll Pins and Fold Down Rails 1,2 1,2
Lanyard Anchorage Point 1,2,6 1,2,6
Chassis Assembly
Wheel Rim Nuts 150 150
Tires 1 1,2
Oscillating Axle and Lock Nut 3 3
Steer, Drive and Axle Components 1 1,2,5
Levelling Jacks and Stabilizers 3 3
Hydraulic Tray, Battery, Engine Compartment Covers 1,3 1,3
Outriggers/Stabilizers 3 3
Side-Compartment Door Installation 1,3,5 1,3,5
Drive Motors 1,4,5
Platform Ladder 1,5 1,5
Drive Brakes 1,5
Drive Hubs 1,4,5
Engine Mounts 1 1
Engine Oil 3 3
Exhaust System 1,3,4 1,3,4
Sliding Wear Pads** 1,2,5,7 1,2,5,7
Front Wheel Spindle Nuts/Bolts 150 150
2-6 3121639
SECTION 2 - GENERAL
AREA Inspections
Pre-Delivery1 Annual3
Function/Controls
Control Levers, Switches, Gauges and Instruments 1,3 1,3
Detents Properly Lock, Control Enclosure and Protective Boots/guards 1,3 1,3
Emergency Stop Switches at Ground and Platform 1,3 1,3
Lift, Drive and Speed Cut-outs 3 3
Auxiliary Power System 3 3
Function Enable System 3 3
Brakes 1,5
Machine Functions 3 3
Joystick/toggle Return To Neutral/off When Released 1,3 1,3
Power System
Batteries 4 4
Battery Fluid 4 4
Battery Charger 3
Hydraulic/Electric System
Hydraulic Cylinders 1,7 1,2,4,5,7
Pumps, Oil Lines and Reservoir 1 1,4
Hydraulic Filter -
Hydraulic Tank, Cap, Breather and Vent 1 1,4
Hydraulic Fitting 1 1,4
Electrical Connections 1,3 1,3
Switches, Gauges, Horn and Lights 1,3 1,3
Switches and Controls 1,3 1,3
All Hydraulic Pressures 3 3
Hydraulic Fluid 8 8
General
No Unauthorized Modification or Additions 9 9
Paint and Overall Appearance 5 5
Operation and Safety Manual 9 9
General Structural Condition and Welds 2 2
Grease and Lubrication Specification 9 9
Function Test of All Systems 9 9
Notify JLG of Change in Machine Ownership 9
ANSI and AEM Handbook 9 9
Capacity Decals 9 9
All Decals/Placards 9 9
Annual Machine Inspection 9
Safety Publication 9 9
All Fasteners, Pins, Shields and Covers 1,2 1,2
3121639 2-7
SECTION 2 - GENERAL
AREA Inspections
Pre-Delivery1 Annual3
Footnotes:
1
Prior to each sale, lease, or delivery
2
In service for 3 months; Out of service for 3 months or more; Purchased used
3
Annually, no later than 13 months from the date of the prior inspection, Includes all daily and quarterly inspections, mandated by regulating body
50
Indicates a 50 hour interval required to perform task after initial use of machine. This only occurs once in machine life.
** Refer to Operators Manual for machine specific instructions.
Performance Codes:
1 - Check for proper and secure: installation, adjustment, or torque
2 - Visual inspection for damage: (cracks, corrosion, abrasions, distortion, excessive wear, broken welds, gouges, chafing and threads showing)
3 - Proper operation
4 - Check for proper sealing, signs of leakage and fluid level
5 - Clean and free of debris
6 - Decals installed and legible
7 - Check for proper tolerances, routing, and lubrication
8 - Fully Charged
9 - Verify/Perform
2-8 3121639
SECTION 3. CHASSIS & SCISSOR ARMS
3.1 CALIBRATIONS 4. Tighten up the packing nut.
Refer “Changing the Access Level of the Hand Held Analyzer:” Tilt Sensor Calibration:
to go to access level 1.
Using the Analyzer, in Access Level 1, go to MENU: CALIBRA-
Elevation Sensor Calibration TION:
1. Drive the machine onto a measured level surface (±0.5°
for both x and y axis).
TION:
2. Using the Analyzer, go to MENU: CALIBRATION; TILT SEN-
1. SET STOW ELEV;
SOR. Press Enter. LEVEL VEHICLE will display. Press Enter
a. Completely lower platform to stowed position. again to calibrate.
b. Enter YES on the Analyzer. 3. Both axis’ raw angles need to be within ±5.0°, otherwise
c. COMPLETE will show on the analyzer when cali- the machine is to unlevel and the software will prohibit
brated. calibration. Should this occur, attempt to dissect the
three areas of error to find the primary contributor:
2. SET 25FT ELEV (3369LE) or SET 30FT ELEV (4069LE);
a. Machine mounting and/or grade:
a. Raise platform to a height of 25 feet for the 3369LE With a digital level, measure the top of the Ground
or 30 feet for the 4069LE (measured deck to Control box for levelness. If unable to get a good
ground). reading, check the box’s mounting surface for level-
b. Enter YES on the Analyzer. ness.
c. COMPLETE will show on the analyzer when cali-

brated.
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 cali-
brated.
NOTE: Elevation Proximity Switch must be mounted and func-

tioning properly to calibrate the Elevation Sensor.
Speed Sensor
The speed sensor is located at the lower side of the left, front 1. Ground Control Box
drive motor. If removing the speed sensor for any reason use 2. Digital Level
the following procedure.
1. Using an 18mm wrench, remove the speed sensor from b. Tilt sensor mounting on machine or wedged
the left, front drive motor. crooked in control box:
If the machine mounting/grade appears acceptable,
2. If reusing the speed sensor note the location of the brass open the Ground Control box carefully. Observe
feral on the sensor. Do not remove, this will be the depth whether the tilt sensor is properly seated.
gauge when you replace the sensor. c. Tilt sensor has developed an offset shift:
3. When replacing, seat the sensor so that it fits snug in the Remove the tilt sensor from the Ground Control
motor on the brass feral. box, but keep both the tilt sensor and Ground Con-
trol box electrically connected. Level one axis of the
NOTE: If replacing the speed sensor, the new sensor will have a tilt sensor and observe the raw reading (should be
wax pill on the end of the sensor. Tighten down until you within ±2.0°). Do the same for the other axis. If either
feel the wax pill bottom out inside the motor. axis is greater than ±2.0°, replace the tilt sensor.
3121639 3-1
2. If the Analyzer displays angles other than +20.0°,

attempt to calibrate. If machine will not calibrate, note
2 the reason displayed on Analyzer:
a. SENSOR FAILURE – tilt sensor internal frequency is
out of range (replace sensor).
b. NOT LEVEL - tilt sensor has either developed an off-
set or it is to unlevel as mounted on the machine.
Joystick Calibration
TION: JOYSTICK and press ENTER.
1. Following the analyzer screen prompts:
1 a. Move the Joystick FORWARD and press ENTER.
b. Allow Joystick to be in CENTER position and press
ENTER.
c. Move the Joytstick REVERSE and press ENTER.
2. CAL COMPLETE or CAL FAILED will display on the
analyzer.
1. Ground Control Box
2. Tilt Sensor 3. Possible reasons if calibration failed:
a. The forward position must be a lower voltage than
Some possible reasons that the tilt sensor will not calibrate reverse position.
are:
b. The difference between center and forward & center
a. The surface the machine is sitting on is off level by a and reverse must be atleast 1V.
few degrees (flat doesn’t imply level; parking lots are
often not level).
b. The tilt sensor has failed one or both of the channels
(X axis and Y axis).
c. Tilt sensor has moisture intrusion that has shifted its
output.
d. Water and/or corrosion in the box has corrupted
electrical connections or caused a tilt sensor or
ground control board failure (observe any cracks in
the box).
e. The Ground Control Box, as mounted on the
machine, does not allow the tilt sensor to be level.
For the following troubleshooting steps, a bubble level
(smaller is better) will be needed and the machine must be on
a level surface:
1. On the Analyzer, go to Diagnostics/System and read the

tilt angle. If either angle reports +20.0°, there is an elec-
trical/electronic failure (tilt sensor, control board, electri-
cal connections).
a. Open the Ground Control Box.

b. Disconnect the sensor and clean any corrosion off of
the tilt sensor and control board connections.
c. Reassemble and test. If fault persists, replace tilt
sensor.
3-2 3121639
3.2 TILT SENSOR

1
Tilt Sensor, JLG P/N 4000021: 6
7
2 1 2
5
4
3
1. Ground Control Box

2. Tilt Sensor Assembly (JLG P/N 1810140)
Figure 3-1. Tilt Sensor Location

1. Tilt Sensor (JLG P/N 4000021)
NOTE: Refer to Figure 3-1., Tilt Sensor Location for numbers in 2. Sensor Mount
parenthesis. 3. Screw, 6-32 x 1
4. Lockwasher
1. Disconnect the batteries. 5. Standoff Insulator
6. Washer, 0.313 x 0.250 Nylon
2. Open the Ground Control Box to gain access to the Tilt 7. Screw, M3.5 x 0.6 x 10
Sensor Assembly.
Figure 3-2. Tilt Sensor Removal
3. Remove the four Screws (3), Lockwashers (4), Standoff
Insulators (5), and Washers (6) to remove the Tilt Sensor
(1) and Sensor Mount (2) from the Ground Control Box.
Table 3-1. Tilt Sensor Harness
4. The Tilt Sensor (1) can be removed from the Sensor
Mount (2) by removing the three Screws (7). Wire Color Function Connector Pin
Red VCC 1
NOTE: Follow the above procedures in reverse order when install-
ing the tilt sensor assembly. After installing, be sure to cali- Green PWMX 2
brate the tilt sensor (refer to Section 3.1, Calibrations). White PWMY 3
Black Ground 4
3121639 3-3
3.3 BATTERY MAINTENANCE AND CHARGING 4. Clean battery post with wire brush then re-connect
cable to post. Coat non-contact surfaces with mineral
grease or petroleum jelly.
5. When all cables and terminal posts have been cleaned,
IF REPLACING A BATTERY, EACH NEW BATTERY MUST WEIGH AT LEAST 52 KG ensure all cables are properly positioned and do not get
(115 LB). FAILURE TO REPLACE THE BATTERY WITH ONE OF THE CORRECT pinched. Close battery compartment cover.
WEIGHT WILL RESULT IN A TIPOVER HAZARD WHICH COULD RESULT IN SERI-
OUS INJURY OR DEATH. 6. Start hydraulic system and ensure that it functions prop-
erly.
Optional On-Board Generator

JLG MACHINES EQUIPPED WITH DELTA Q BATTERY CHARGERS ARE DESIGNED
FOR THE BEST PERFORMANCE WITH OEM FACTORY APPROVED BATTERIES.
APPROVED JLG REPLACEMENT BATTERIES ARE AVAILABLE THROUGH JLG' S EXHAUST GAS HAZARD. RUN THE GENERATOR IN A WELL VENTILATED AREA
AFTERMARKET PARTS DISTRIBUTION CENTERS OR JLG' S AFTERMARKET PRO- ONLY.
GRAMS. FOR ASSISTANCE WITH PROPER BATTERY REPLACEMENT, PLEASE
CONTACT YOUR LOCAL JLG SUPPORT OFFICE.
BATTERIES APPROVED BY JLG HAVE BEEN TESTED FOR COMPATIBILITY WITH
WHEN THE GENERATOR ENABLE CONTROL LOCATED IN THE PLATFORM CON-
THE ALGORITHM PROGRAMMING OF THE DELTA Q BATTERY CHARGER TO TROL BOX IS IN THE ON POSITION AND THE GROUND EMERGENCY STOP
OPTIMIZE BATTERY LIFE AND MACHINE C YCLE TIMES. THE USE OF NON SWITCH IN ON (PULLED OUT), THE GENERATOR WILL START AUTOMATICALLY
APPROVED BATTERIES IN YOUR JLG EQUIPMENT MAY RESULT IN PERFOR- WHEN THE BATTERIES REACH A LOW-CHARGE STATE AUTOMATICALLY CHARG-
MANCE ISSUES OR BATTERY CHARGER FAULT CODES. JLG ASSUMES NO ING THE BATTERIES.
RESPONSIBILITY FOR SERVICE OR PERFORMANCE ISSUES ARISING FROM THE
USE OF NON APPROVED BATTERIES.SEE TABLE 3-3, BATTERY ALGORITHMS. NOTE: The generator engine will automatically shut down under
the following conditions:
Battery Maintenance, Quarterly Fully Charged Batteries
High Engine Oil Temperature
1. Open battery compartment cover to allow access to bat- Low Engine Oil Pressure
tery terminals and (vent caps-wet batteries only). Engine Overspeed
Generator Overvoltage
WHEN ADDING WATER TO (WET) BATTERIES, ADD WATER UNTIL ELECTROLYTE

COVERS PLATES. DO NOT CHARGE BATTERIES UNLESS ELECTROLYTE COVERS TO AVOID INJURY FROM AN EXPLOSION, DO NOT SMOKE OR ALLOW SPARKS
THE PLATES. OR A FLAME NEAR BATTERY DURING SERVICING. ALWAYS WEAR EYE AND
HAND PROTECTION WHEN SERVICING BATTERIES.
NOTE: When adding distilled water to (wet) batteries, non-metal-
lic containers and/or funnels must be used. Battery Charging (On Board Charger) (MAC)
To avoid electrolyte overflow, add distilled water to batter-
1. For maximum battery life:
ies after charging.
When adding water to the battery, fill only to level indi- a. Avoid completely discharging the batteries.
cated or 3/8" above separators. b. Fully charge the batteries each day the machine is
used.
2. Remove all vent caps (wet batteries only) and inspect c. Charge the batteries at available times between
electrolyte level of each cell. Electrolyte level should be charging.
to the ring approximately one inch from top of battery. d. Be sure the battery fluid covers the battery plates
Fill batteries with distilled water only. Replace and before charging, but to avoid overflow, do not top
secure all vent caps. off the fluid level until charging.
3. Remove battery cables from each battery post one at a 2. To charge the batteries, connect the charger to a 230
time, negative first. Clean cables with acid neutralizing volt source with a 15 amp minimum capacity.
solution (e.g. baking soda and water or ammonia) and 3. The charge cycle is complete when the 100% LED is lit.
wire brush. Replace cables and/or cable clamp bolts as Any other reading indicates the charge cycle is not com-
required. plete.
3-4 3121639
4. The Charger will shut off automatically when the batter-

ies are fully charged.
Depleted batteries will take approximately 17 hours to charge.
Charging Sequence of Remote LED Card

1. Plug in charger.
2. All three LED’s (light emitting diode) flash three times.
3. In sequence:
a. Green LED flashes once
b. Yellow LED flashes once
c. Red LED flashes once
4. All Three LED flash three times.
5. Yellow LED comes on indicates charger is charging.
6. Yellow LED will stay on until fully charged and green LED
will illuminate. Figure 3-3. Remote LED Card
7. If Red LED remains on, this indicates a fault.
3121639 3-5
Battery Charger (Delta-Q) Table 3-2. Delta-Q - Battery Charger Specs
The battery charger is located on a tray behind the hinged JLG BATTERY CHARGER SPECIFICATION
cover at the front of the machine, or on the sliding engine tray
on the (M) model machines. OUTPUT
Nominal DC Output Voltage 48V
Maximum DC Output Voltage 52V
Maximum DC Output Current 20A
Maximum Interlock Current 1A
INPUT
AC Input Voltage 85-265VAC
Nominal AC Input Voltage 120VAC - 230VAC RMS
AC Input Frequency 45-65 HZ
Maximum AC Input Current 12A RMS@108VAC
OPERATION
Charging Indicator Yellow LED
100% Charge Indicator Green LED
Fault Indicator Red LED
External Temp Sensor Automatic - Input wire/Output Connector
PROTECTION
Figure 3-4. Battery Charger Location Output Reverse Polarity Electronic Protection - Automatic Reset
(M model shown) Output Short Circuit Electronic Protection - Automatic Reset
AC Overload Current Limited
DC Overload Current Limited
MECHANICAL
1
–22°F to +122°F
Operating Temperature
(–30°C to +50°C)
Housing Shock and Water Resistant Aluminum
4
3
1. AC Voltage - Input Cable 3. DC Power Cable to Batteries

2. Charger Interlock Cable 4. LED Indicator Cable
Figure 3-5. Battery Charger
3-6 3121639
Battery Charger Maintenance Battery Charger Troubleshooting

No Lights at all
USE CHARGER ONLY ON BATTERY SYSTEMS WITH AN ALGORITHM SELECTED No lights at all indicate that AC power to the charger is not
THAT IS APPROPRIATE TO THE SPECIFIC BATTERY TYPE. OTHER USAGE MAY connected or that the AC voltage is too low. It could also indi-
CAUSE PERSONAL INJURY AND DAMAGE. cate an internal failure in the charger.
1. Check the connections to AC power. Check for AC volt-
LEAD ACID BATTERIES MAY GENERATE EXPLOSIVE HYDROGEN GAS DURING age between 90 and 260 VAC at the charger.
NORMAL OPERATION. KEEP SPARKS, FLAMES, AND SMOKING MATERIALS
AWAY FROM BATTERIES. PROVIDE ADEQUATE VENTILATION DURING CHARG- 2. If the AC voltage is verified to be correct at the connec-
ING. tion to the charger, and the charger still displays no
NEVER CHARGE A FROZEN BATTERY. lights at all, return the charger for service.
FAULT LED Flashing
STUDY ALL BATTERY MANUFACTURERS’ SPECIFIC PRECAUTIONS SUCH AS
RECOMMENDED RATES OF CHARGE AND REMOVING OR NOT REMOVING CELL The Fault LED flashes to indicate the micro-controller inside
CAPS WHILE CHARGING. the battery charger has detected a fault. The fault detected is
indicated by the number of flashes. Count the number of
flashes to determine the fault.
RISK OF ELECTRIC SHOCK. CONNECT CHARGER POWER CORD TO AN OUTLET With any battery system, the most common problem will be a
THAT HAS BEEN PROPERLY INSTALLED AND GROUNDED IN ACCORDANCE faulty battery connection. Because of the high likelihood of a
WITH ALL LOCAL CODES AND ORDINANCES. A GROUNDED OUTLET IS battery connection problem, it is always worthwhile to con-
REQUIRED TO REDUCE RISK OF ELECTRIC SHOCK - DO NOT USE GROUND firm that all connections are good before checking for any
ADAPTERS OR MODIFY PLUG. DO NOT TOUCH UN-INSULATED PORTION OF other problems.
OUTPUT CONNECTOR OR UN-INSULATED BATTERY TERMINAL. DISCONNECT [1 Flash] - High Battery Voltage
THE AC SUPPLY BEFORE MAKING OR BREAKING THE CONNECTIONS TO THE
BATTERY WHILE CHARGING. DO NOT OPEN OR DISASSEMBLE CHARGER. DO 1. Indicates a high battery voltage. Check that the battery
NOT OPERATE CHARGER IF THE AC SUPPLY CORD IS DAMAGED OR IF THE charger voltage is consistent with the battery pack volt-
CHARGER HAS RECEIVED A SHARP BLOW, BEEN DROPPED, OR OTHERWISE age. The first two digits of the four digit model name
DAMAGED IN ANY WAY - REFER ALL REPAIR WORK TO QUALIFIED PERSONNEL. indicate the battery voltage the charger supports.
NOT FOR USE BY CHILDREN.
2. Check for wiring errors.
1. For flooded lead-acid batteries, regularly check water 3. This fault will automatically clear and the charger will
levels of each battery cell after charging and add dis- restart charging when this problem is removed.
tilled water as required to level specified by battery
manufacturer. Follow the safety instructions recom- 4. High battery voltage could also occur if there is another
mended by the battery manufacturer. source charging the battery. Disconnect any other
sources during charging.
2. Make sure charger connections to battery terminals are
tight and clean. 5. If this problem does not clear after the battery voltage is
confirmed to be less than 2.4V per cell, return the char-
3. Do not expose charger to oil or to direct heavy water ger for service.
spraying when cleaning vehicle.
[2 Flashes] - Low Battery Voltage
1. Indicates either a battery failure, no battery connected,
or a lower than expected battery voltage. Check the bat-
tery and battery connections.
2. Check the nominal battery voltage. The first two digits
of the four digit model name indicate the battery volt-
age the charger supports. Confirm that a nominal bat-
tery voltage is the same as the charger voltage.
3. This fault will clear automatically when the low battery
voltage problem is rectified.
4. If this problem does not clear after the battery voltage is
confirmed to be higher than 1.0V per cell and all con-
nections are good, return the charger for service.
3121639 3-7
[3 Flashes] - Charge Time-out [5 Flashes] - Over Temperature

Indicates the battery failed to charge within the allowed time. This fault indicates the charger has become too hot during
This could occur if the battery is of larger capacity than the operation. Though not damaging to the charger, charge time
algorithm is intended for. In unusual cases it could mean char- will be extended significantly.
ger output is reduced due to high ambient temperature. It can
1. This fault indication will not clear automatically, but the
also occur if the battery is damaged, old, or in poor condition.
charger will restart charging automatically when the
1. Check the battery for damage such as shorted cells and temperature drops. The fault indication must be cleared
insufficient water. Try the charger on a good battery. manually by unplugging the AC, waiting 30 seconds and
reconnecting the AC power.
2. If the same fault occurs on a good battery, check the
connections on the battery and connection to AC, and 2. If possible, move the machine to a cooler location.
the AC voltage itself.
3. Confirm that dirt or mud is not blocking the cooling fins
3. Confirm that the nominal battery pack voltage is the of the charger. Clean the charger. Rinse the charger with
same as the battery charger voltage. a low pressure hose if required. Do not use high pres-
sure. Do not use a pressure washer.
4. This fault must be cleared manually by unplugging the
AC, waiting 30 seconds and reconnecting the AC power. [6 Flashes] - Over Load/Over Temperature
5. If a charger displays this fault on a battery pack, and the This fault indicates that the batteries will not accept charge
pack is of questionable status, reset the charger by dis- current, or an internal fault has been detected in the charger.
connecting AC for 30 seconds, and then reconnect the This fault will nearly always be set within the first 30 seconds
AC to start a new charge cycle. After a few charge cycles, of operation. If it occurs after the charger has started charging
this problem could stop occurring as the pack "recovers." normally, be sure to make a note of it.
[4 Flashes] - Check Battery 1. Remove excessive AC loads from inverter if installed.
This fault indicates the battery pack could not be trickle 2. Try to clear the fault by unplugging the AC, waiting 30
charged up to the minimum level required for the normal seconds and reconnecting the ac power.
charge cycle to be started.
3. Check all battery connections. Look for a high resistance
1. Check that none of the battery pack connections connection.The most likely reason for this fault is a fault
between modules are reversed or incorrectly connected. in the battery such as a bad battery connection, an open
cell, or insufficient water.
2. Check that one or more cells in the battery are no
shorted. 4. This fault will occur if an internal fuse inside the charger
blows. If the green wire is shorted to ground even
3. Confirm that the nominal battery pack voltage is the
momentarily, this fuse will blow. To check the fuse, mea-
same as the battery charger voltage.
sure with an ohmmeter between the green and red
4. Try the charger on a good battery. wires with the AC disconnected. If a short circuit is not
measured, the fuse has blown. Return unit to a service
5. If this fault occurs, the battery is likely in poor condition. depot to have this fuse replaced.
Try to recover the pack with a charger that can charge
the individual cells - such as an automotive charger. Be 5. If this fault occurs after battery charging has started,
sure to set this charger to the appropriate voltage - 6V confirm that AC power was not interrupted and that all
per 6V battery, 12V per 12V string/battery. battery connections are good.
6. If all battery connections are good, an internal fault has
been detected and the charger must be brought to a
qualified service depot.
3-8 3121639
Excessive Battery Watering Requirements or Strong Checking - Changing the Battery Charger Algorithm
Sulphur (Rotten Egg) Smell
The charger is pre-loaded with programming algorithms for
These symptoms indicate over-charging or high battery tem- the specific batteries detailed in Table 3-3, Battery Algorithms.
perature. These symptoms are unlikely to be caused by too Contact JLG if your specific battery model is not listed.
high a charge current since the maximum charge current of Each time AC power is applied with the battery pack not con-
the charger will be small compared to even a moderately sized nected, the charger enters an algorithm select/display mode
battery pack. The most likely cause for this problem is incor- for approximately 11 seconds. During this time, the current
rect charge algorithm setting and/or high ambient tempera- Algorithm # is indicated on the Yellow Charging LED. A single
tures. digit Algorithm # is indicated by the number of blinks sepa-
rated by a pause. A two digit Algorithm # is indicated by the
1. Confirm that the battery pack is not too small - usually > number of blinks for the first digit followed by a short pause,
50Ah. then the number of blinks for the second digit followed by a
2. Confirm that the nominal battery voltage matches the longer pause.
charger output voltage. To check / change the charging algorithm:
3. Confirm the correct battery charge algorithm. If the bat- 1. Disconnect the charger positive connector from the bat-
tery pack is new, the algorithm will need to be changed tery pack. Apply AC power and after the LED test, the
if the pack is not the same as the old one. for instruc- Algorithm # will display for 11 seconds.
tions on how to determine and change the battery
charge algorithm see the following sub-section. 2. To change the algorithm, touch the connector to the
battery’s positive terminal for 3 seconds during the 11
4. If the output voltage of the charger seems excessive, second display period and then remove. The Algorithm
return the charger for service. Contact JLG to get the # will advance after 3 seconds. Repeat this procedure
expected battery voltage settings for the charger in until the desired Algorithm # is displayed. A 30 second
question. Be sure to have the charger’s serial number time-out is extended for every increment. Incrementing
and charge algorithm setting available when calling. beyond the last Algorithm will recycle back to the first
Algorithm. When the desired Algorithm is displayed,
touch the charger connector to the battery positive ter-
minal until the output relay makes a clicking noise
(approx. 10 seconds). The algorithm is now in the per-
manent memory.
3. Remove the AC power from the charger and reconnect
the charger’s positive connector to the battery.
NOTE: It is recommended to check a newly changed algorithm by

repeating the above steps 1 and 3.
3121639 3-9
Table 3-3. Battery Algorithms Battery Temperature Sensor

Algorithm # Battery Type Machines equipped with the Delta-Q battery charger include a
143 DISCOVER EVL1GA-A battery temperature sensor. The sensor is mounted to the neg-
ative terminal post of the inboard, front battery on the
43 Harris Battery - Discover EVGGC6A-A
machine’s left side mounted battery pack. (See Figure 3-6.) The
Discover EV 305A-A
sensor is wired directly to the battery charger.
35 JLG P/N 0400242
23 Douglas Flooded (JLG default)
GES Battery A1055
Trojan T105
East Penn GC-110-WNL
Trojan T105 PLUS
Champion CHGC2 GC2
US BATT EV-145-WNL
US BATT 2200 XC
8 Concorde 10xAh AGM
7 J305 DV/DT CP
6 DEKA 8G31 Gel
5 Trojan 30/31XHS
4 US Battery USB2200
3 T105 DV/DT CP
2 Trojan T105 tapped
1 Trojan T105
3-10 3121639
Removing the Battery Box
Figure 3-6. Batteries and Battery Charger
To remove the battery box, perform the following steps. 3. Using a forklift, lift the battery box up enough to clear
the brackets on the back of the battery box and remove
1. Pull the handle on the battery disconnect to disconnect
the battery box from the machine.
the batteries.
NOTE: To make battery box removal easier, when possible, raise
2. Remove the two attachment bolts that secure the bat-
the arms of the machine and install the safety prop.
tery box to the frame.
NOTE: The battery box and batteries complete weigh approxi-

mately 670 lbs (304 kg).
3121639 3-11
3.4 GENERATOR • Start Control Relay

The start control relay energizes the solenoid of the engine
NOTE: Throughout the Generator section, the abbreviations RBS starter and the pull coil of the engine fuel solenoid. The
and CTS are used. RBS stands for Rotary Battery System, start control relay is located on the fuel solenoid bracket on
which is the generator system. CTS stands for Call To Start, the right side of the engine. The start control relay is ener-
which is the electronic inputs which signal the generator to gized by the engine/generator controller.
start and charge the batteries.
• Fuel Control Relay
The generator consists of a drive engine, controller, and The fuel control relay energizes the hold coil of the fuel
related components. solenoid. The fuel control relay is energized by the engine/
generator controller.
• Alternator
• Fuel Solenoid
The alternator is a brushless, DC output alternator. The 3
phase output of the alternator is full wave rectified and The fuel solenoid actuates the run/stop lever of the engine.
directed to the output terminator. This solenoid has a pull and hold coil. The pull coil is ener-
gized by the start control relay and the hold coil is ener-
The output rating is 58 volts DC at 45 amps. Voltage regula- gized by the fuel control relay.
tion and current limiting is provided by the Engine/Genera-
tor Controller. • Engine Oil Temperature Sensor
The rectifier diodes and output current sensor are located The engine oil temperature sensor is used to sense the
in the alternator end. temperature of the oil in the sump of the engine. This sen-
sor provides a signal to the engine/generator controller for
• Dynamo and Dynamo Voltage Regulator high engine temperature shutdown.
For machines equipped with a YANMAR engine: • Alternator Output Current Sensor
12 Volt, 15 Amp DC output dynamo.
For machines equipped with a KUBOTA engine: The alternator output current sensor provides a signal pro-
12 Volt, 5 to 7 Amp DC output dyamo. portional to the output current of the alternator to the
engine/generator controller. This signal is used by the con-
• Dynamo Output Fuse troller to regulate the current output of the alternator. The
The dynamo output fuse is used to protect the output of output current is regulated at 55 Amps DC. The alternator
the dynamo. This fuse is rated at 20 Amps DC, slow blow output current sensor is located inside the rear cover of the
and is located on the left side of the engine. alternator.
• Engine Speed Sensor
• Control Fuse
The engine speed sensor provides a signal proportional to
This fuse provides power to the engine/generator and the
the rotational speed of the engine to the engine/generator
relays for start control, fuel control, and pre-heater. This
controller. This signal is used by the controller to determine
fuse is rated at 15 Amps DC and is located on the right side
starter cut-out, overspeed fault, and underspeed fault. This
of the engine.
signal has failsafe protection, if it is not present at the con-
• Start Battery troller, the unit will fault with a loss of speed signal indica-
tion. The engine speed sensor is located inside the recoil
A 12 volt lead-acid battery is utilized to provide starting
starter cover at the front of the engine.
power for the generator and power for the generator con-
trols. This battery is charged by the engine dynamo and • Engine Low Oil Pressure Switch
dynamo regulator when the engine is running. The engine is equipped with a low oil pressure switch. The
• Engine Starter switch is closed when the oil pressure is below
14.2 psi (1 Bar).
The engine is equipped with a 12 Volt DC starter. This
starter provides mechanical power to crank the engine.
Electrical power for the starter is provided by the start bat-
tery. The starter is energized by the start control relay.
3-12 3121639
Figure 3-7. Generator Components
3121639 3-13
Timing Sequences 6. Time Delay Bypass (TDBP)
NOTE: Throughout the Generator section, the abbreviations RBS Once the engine starts, TDBP must elapse before low oil
and CTS are used. RBS stands for Rotary Battery System, pressure and underspeed shutdowns are activated. This
which is the generator system. CTS stands for Call To Start, allows the engine to come up to normal operating con-
which is the electronic inputs which signal the generator to ditions before enabling these shutdowns are monitored.
start and charge the batteries.
Table 3-5. RBS Startup Sequence
• RBS Pre start Sequence
Crank Time -> Rest Time
1. Time Delay Engine Start (TDES) (Until Engine Start or # of Crank Cycles)
TDBP Bypass
TDES is the period which the RBS waits to verify that the
Normal Running Operation
CTS is valid rather than a transient condition.
2. Time Delay Pre-Heat (TDPH) • RBS Shutdown Sequence
TDPH, if enabled, occurs after TDES has elapsed and the Once all CTS conditions have been removed, the RBS will
engine temperature is below the factory set engine pre- begin the shutdown sequence. If a CTS condition is initiated
heat temperature setting. The engine pre heater will be during the shutdown sequence, the RBS will return to normal
energized for the factory set preheat delay period. running operation until the CTS is removed.
1. Time Delay Engine Run (TDER)
Table 3-4. RBS Pre start Sequence
CTS (Call to Start) Once the CTS condition is removed, the TDER period
begins. This period ensures that no further CTS condi-
TDES (Engine Start) tions occur prior to the cool down period.
Preheat Delay
2. Time Delay Cool down (TDC)
RBS Startup Sequence
Once the TDER period ends, the alternator output is
• RBS Startup Sequence reduced to a minimal level in order to allow the engine
to cool down for the TDC period. If a CTS is received dur-
3. Crank Time
ing the TDC period, the CTS must last for at least the
TDES period for the RBS to return to normal running
The RBS will crank for a period up to the crank time or
operation.
until the engine starts.
4. Rest Time Table 3-6. RBS Shutdown Sequence
Remove CTS
If the engine does not successfully start, the RBS will
wait for the rest time before attempting to crank the TDER Engine Run
engine again. TDC Cool down
5. Crank Cycles Engine Stop
The RBS will attempt to start the engine up until the

number of crank cycles is reached. If the RBS does not
start, an Overcrank fault is indicated.
3-14 3121639
3121639
Figure 3-8. Generator System Analyzer Flow Chart
3-15
To Connect the JLG Control System Analyzer to the Alarms and Fault Flash Codes
Generator In the event of an RBS alarm, a flash code will be issued and an
The JLG Control System Analyzer can be used to monitor gen- alarm indicated on the analyzer.
erator settings and conditions. Connect the analyzer as fol-
NOTE: Alarms must be reset once the fault has been corrected.
lows:
Connect the four pin end of the cable supplied with the ana- Table 3-7. Generator System Flash Codes
lyzer, to the connector behind the ground control module
Code Alarm Description
located on the right side of the machine next to the ground
control station and connect the remaining end of the cable to 1-1 Low Oil Pressure Shutdown due to low engine oil pres-
the analyzer. sure
1-2 High Engine Shutdown due to high engine oil tem-
1. The ground control module contains the settings for the Temperature perature
generator.
1-3 Engine Overspeed Shutdown due to high engine speed
1-4 Engine Underspeed/ Shutdown due to engine overcrank or
ANALYZER
Overcrank underspeed
CONNECTION 1-5 No Speed Signal Shutdown due to loss of speed signal
2-1 Overvoltage Shutdown due to high output voltage
2-2 Engine Starting Alarm not a shutdown; Indicates prob-
System fault lem with the engine starting system
2-3 Not Used Not Used
2-4 Loss of Voltage Sense Shutdown due to loss of voltage sens-
ing
Continuous Unit Disabled No Faults. RBS enabled and can
respond to any CTS
GROUND Off Unit Disabled RBS off or disabled; Will not respond to
CONTROL
any CTS
• Low Oil Pressure

NOTE: The cable has a four pin connector at each end of the cable; Enabled once TDBP (time delay bypass) period has elapsed
the cable cannot be connected backwards. after engine startup. If the low engine oil pressure switch
closes, the engine will stop immediately and a low oil pres-
2. Power up the Analyzer by pulling out the ground station sure alarm will be indicated.
EMS and positioning the Generator Enable switch on the
platform control box to the "on" position. Refer to Figure • High Engine Temperature
3-8., Generator System Analyzer Flow Chart. If the engine oil temperature exceeds the high engine tem-
perature setting, the engine will stop immediately and a
low oil pressure alarm will be indicated.
• Overspeed
If the engine speed exceeds the overspeed limit, the
engine will stop immediately and an overspeed alarm will
be indicated.
• Underspeed
Enabled once TDBP (time delay bypass) period has elapsed
after engine startup. If the engine speed drops below the
underspeed limit, the engine will stop immediately and an
engine underspeed alarm will be indicated.
• Overcrank
If the engine fails to start after a set number of start
attempts, the RBS will cease attempts to restart and an
engine overcrank alarm will be indicated.
3-16 3121639
• No Speed Signal Priming the Fuel Line

In the event of a loss of speed signal, the RBS will shutdown The following procedure is for re-priming the fuel line on the
and an engine no speed signal alarm will be indicated. This generator engine in the event fuel system components have
shutdown is delayed by a factory set period to ensure the been replaced or the unit has been run dry of fuel.
fault was not momentary.
1. Make sure the fuel line isn’t blocked or kinked.
• Overvoltage
2. Make sure fuel tank has fuel.
If the voltage measured at the alternator output exceeds
the high voltage setting, the RBS will stop immediately and 3. Disconnect the rubber fuel line at the fuel injector
an RBS high output alarm will be indicated. This shutdown pump.
is delayed by a factory set period to ensure the fault was
not caused by a transient condition. This feature protects
the batteries and load from high DC voltages.
• Engine Starting System Fault
Indicates a problem with either the engine start battery,

engine magneto, or magneto voltage regulator.
• Loss Of Voltage Sense
If the voltage measured at the alternator output is less than

half of the system nominal voltage, the RBS will stop imme-
diately and an RBS loss of voltage sense alarm will be indi-
cated. This feature protects the batteries and load from
high DC voltages due to a loss of output control.
• Run Inhibited
4. When fuel starts to flow out of the rubber line, recon-
The RBS unit is disabled by the run inhibited input. nect the fuel line to the fuel injector pump.
5. Clean up any spilled fuel and try to start the generator
Output Current and Voltage Settings again.
• Normal/Extended Output Voltage 6. If the engine still doesn’t start, remove the steel line
from the fuel injector pump.
The normal/extended output voltage setting is the voltage
at which the alternator changes under normal operating 7. Once fuel starts to flow, reconnect the fuel line to the
conditions. fuel injector pump.
• Current Limit 8. Clean up any spilled fuel and try to start the generator
again.
The current limit setting determines the maximum alterna-
tor output current. 9. If no fuel flows there are some possibilities:
• High Voltage Shutdown Level a. There is no fuel getting to the injector pump. No
fuel in tank, or obstruction in fuel line, or clogged in
This setting determines the alternator output voltage at line fuel filter.
which the high voltage shutdown occurs. This protects the b. The engine/camshaft rotation is not opening the
load from abnormally high voltages. injection fuel pump. Using the recoil starter, rotate
• Finish Charging Current the engine 1/3 of a turn and fuel should spill from
the fuel injector pump.
The finish charging current determines the level of the cur-
10. Engine might run rough for 20 seconds or so, but it will
rent alternator output must drop below for a low battery
clean out.
voltage CTS to be removed. This ensures that the batteries
have accepted sufficient charge prior to shutting down the
RBS. This level is used along with the low battery voltage
remove CTS level to determine when the RBS removes the
CTS after a low battery voltage CTS. If the charging current
falls below the finish charging current while another CTS is
active, the RBS will continue to operate at the normal/
extended output voltage until all CTS’s are removed.
3121639 3-17
3.5 SUPPLEMENTARY FUSE FOR APU 2. Find where the harness attaches to the rear cover of the
generator and the connection point for the new inline
The purpose of this section is to describe the procedure to add fuse.
a supplementary fuse for the Engine Generator Controller for
the APU.
Tools And Material

• - Weather proof fuse holder - JLG P/N 2400081
• - AGC1, 1 Amp fuse - JLG P/N 2400080
• - 45cm of #16 AWG wire - JLG P/N 4920019
• - 2 X insulated butt splice connectors - JLG P/N 4460035
• - 6 X medium length wire ties - JLG P/N 4240033
• - Wire/Side cutters
• - 5/32” Allen Key
• - Crimping tool
Procedure
3. Remove the socket head drive screw with a 5/32” Allen
key. Next remove the cable clamp from the harness.
BEFORE BEGINNING THIS PROCEDURE, ENSURE THAT ALL SOURCES OF
POWER ARE DISCONNECTED FROM THE APU!
This procedure is common for all applications of the APU. The

photos contained in this document illustrate the modification
performed to an APU supplied in a JLG M450 lift.
1. Locate the harness at the rear of the APU.
3-18 3121639
4. Cut and remove the Wire Ties holding the Harness label 5. Cut wire 106 going to the Engine/Generator Controller
to the harness. Next, remove the Wire Ties so that the after the existing connection point and install the con-
cable sleeve can be moved, exposing the conductors of ductors that lead to the new in-line fuse holder. Use
the harness. insulated butt splice connectors for these conductors.
6. Re-install the harness with the new fuse in place.
7. Reconnect the lift and APU start battery. The APU is now
ready for use.
3121639 3-19
3.6 JOYSTICK CONTROLLER
Figure 3-9. Joystick Controller - (JLG P/N 1600403)
Table 3-8. Joystick Specifications Table 3-9. Joystick Plug Loading Chart
Input Voltage 5V Terminal Color Function

Centered Output Voltage 4.25V to 2.60V 1 Yellow Steer Right
Reverse Voltage 4.60V to 4.80V 2 Green Steer Left
Forward Voltage 0.40V to 0.60V 3 Brown Pot Wiper
4 Red Handle Common
5 N/A Not Connected
6 White/Red Pot (+)
7 Violet Trigger Switch
8 Blue Trigger Supply
9 White/Black Pot (-)
3-20 3121639
Figure 3-10. Drive Components
3121639 3-21
Power Controller 3.7 TOWING

Disengaging for Towing
PRIOR TO OPERATING THE DISCONNECT THE MACHINE HAS TO BE ON LEVEL

GROUND AND COMPLETELY SECURED FROM ANY MOVEMENT, I.E. VIA TOW
BAR TO PULLING VEHICLE. THE MACHINE SHOULD NOT BE MOVED UNLESS IT
IS SECURED TO THE TOWING VEHICLE TO PREVENT RUNAWAY.
ENSURE THE DISCONNECT MECHANISM IS ONLY OPERATED WITH THE

MACHINE AT A STANDSTILL.
THE GEAR DRIVE TEMPERATURE SHOULD BE CHECKED PRIOR TO ANY WORK

BEING DONE. THIS IS IMPORTANT IF THE GEAR DRIVE HAS RECENTLY BEEN
OPERATED SINCE IT MAY BE HOT AND CAUSE INJURY.
Figure 3-11. Power Controller
Table 3-10. Power Controller Cable Descriptions ENSURE THE AREA SURROUNDING THE DISCONNECT IS CLEANED PRIOR TO
OPERATION. ENSURE THAT DIRT OR OTHER CONTAMINANTS DO NOT ENTER
From To THE GEAR DRIVE.
Power Controller F2 Right Side Drive Motor F1
1. Remove the two hex head bolts from the cover.
Right Side Drive Motor F2 Left Side Drive Motor F2
Power Controller F1 Left Side Drive Motor F1
Power Controller S Left Side Drive Motor A2
Right Side Drive Motor A1 Left Side Drive Motor A1
Power Controller A Right Side Drive Motor A1
Left Side Drive Motor A2 Right Side Drive Motor A2
Power Controller B+ Contactor ++
3-22 3121639
2. Remove the cover. Engaging after Towing is Complete
PRIOR TO OPERATING THE DISCONNECT THE MACHINE HAS TO BE ON LEVEL

GROUND AND COMPLETELY SECURED FROM ANY MOVEMENT, I.E. VIA TOW
BAR TO PULLING VEHICLE. THE MACHINE SHOULD NOT BE MOVED UNLESS IT
IS SECURED TO THE TOWING VEHICLE TO PREVENT RUNAWAY.
ENSURE THE DISCONNECT MECHANISM IS ONLY OPERATED WITH THE

MACHINE AT A STAND STILL.
THE GEAR DRIVE TEMPERATURE SHOULD BE CHECKED PRIOR TO ANY WORK

BEING DONE. THIS IS IMPORTANT IF THE GEAR DRIVE HAS RECENTLY BEEN
OPERATED SINCE IT MAY BE HOT AND CAUSE INJURY.
3. Rotate the cover to show the inside diameter.
ENSURE THE AREA SURROUNDING THE DISCONNECT IS CLEANED PRIOR TO

OPERATION. ENSURE THAT DIRT OR OTHER CONTAMINANTS DO NOT ENTER
THE GEAR DRIVE.
THE COVER IS UNDER SPRING FORCE
1. Remove the 2 hex head bolts securing the cover evenly

and remove the cover.
2. Rotate the cover 180° and secure with the two hex head
bolts.
3. Torque the hex head bolts 6.3 ft lbs (8.8 Nm).
PULL VERY SLOWLY WITH THE TOWING VEHICLE CONNECTED TO THE

4. Press the cover sufficiently against the shift rod to insert MACHINE TO ALLOW THE SPLINE OF THE SUN GEAR SHAFT TO ENGAGE WITH
the bolts at least 2 to 3 threads into the cover. This will
THE SPLINE OF THE INPUT SHAFT.
subject the shift rod to spring force.
5. Install the bolts and torque 6.3 ft lbs (8.8 Nm) until they
are flush with the cover.
DO NOT OPERATE THE MOTOR TO MAKE THE SUN GEAR SHAFT TO ENGAGE
6. The sun gear shaft and input shaft are now discon- WITH THE SPLINE OF THE INPUT SHAFT.
nected and the machine is ready to be towed.
4. Check to ensure all bolts are tight and all components

are returned to their original positions.
BEFORE THE MACHINE IS SEPARATED FROM THE TOWING VEHICLE, EITHER
THE GEAR DRIVE HAS TO BE REENGAGED OR SUITABLE MEASURES MUST BE 5. The gear drive should now be reengaged and the
TAKEN TO SECURE THE MACHINE FROM MOVEMENT. machine can be disconnected from the towing vehicle.
3121639 3-23
Figure 3-12. Torque Hub
3-24 3121639
3.8 DRIVE HUB NOTE: The second stage planetary bearings (11) must be
replaced in sets of four pieces.
The final drive consists of two stages with an integrated
disconnect mechanism. Each stage incorporates a set of Disassembly of Cover Unit (8)
matched planetary gears, which provide an equal load of
distribution. All torque transmitting components are made of 1. Loosen and remove hex-head bolts (53) and remove
forged, quenched and tempered high-alloy steels. External cover (51).
gears are carborized. Precision roller bearings are used 2. Remove Shaft rod (56), O-ring (54), and sleeve (52).
exclusively. Two large, tapered roller bearings support the
sprocket or wheel loads. A shaft seal protects the unit against
contamination. Disassembly of First Stage Planetary Assembly
1. Push the sun gear shaft (43) out of the first stage.
Disassembly
2. Remove snap rings (14) and press planet pins (5) out of
1. Position drive so that one of the fill holes is at the bot- planet carrier (7) and planet gears (2).
tom of the end cover and drain the gear oil.
3. Pull cylindrical roller bearing (10) out of planet gears (2).
2. Remove all bolts holding motor and remove motor from
4. Remove snap ring (16) from sun gear (3) and remove the
drive.
thrust washer (49).
3. Compress the disc (59) using a simple fixture or other
suitable device. Disassembly of the Second Stage Planet Gears (1)
4. Remove snap ring (66) and release pressure on disc until Press cylindrical roller bearings out of planet gears (1).
loose. Remove tool and disc (59).
5. Remove the spring (55) from the input shaft (44) and
turn the unit so that cover (8) is in the up position.
6. Remove screw plugs (22) and seal rings (21).
7. Remove snap ring (34), cover unit (8) from drive and O-
ring (33).
8. Remove first stage planetary assembly (7).
9. Remove hex-head bolts (23) to remove gear (33) and O-

ring (19).
10. Remove Snap rings (15) to pull off planet gears (1)
together with cylindrical roller bearings (11) from spin-
dle (60).
NOTE: Further disassembly of the hub is discouraged. Re-installa-

tion of the shaft nut (4) requires a special tool and a torque
of 626 ft lbs (876 Nm) for proper reassembly. These compo-
nents WILL fail if not properly reassembled.
11. Inspect the planetary stage assemblies as complete

units. Thoroughly clean and check both the gearing and
the bearings for damage and apply new oil. If gears or
bearings need replacing, they must be replaced as com-
plete units.
NOTE: The first stage planetary bearings (10) must be replaced in

sets of three pieces.
The first stage planetary gears (11) must be changed as a

complete set of four and the manufacturer recommends
changing the sun gear shaft (43) along with this set of
planets.
3121639 3-25
1. Retaining Screws 9. Back-up Ring 17. Retaining Ring

2. Washers 10. Shaft 18. Bearing
3. Pressure Plate 11. Stator Disc 19. Retaining Ring
4. Case Seal 12. Sensor Ring 20. Dowel Pins
5. O-ring 13. Rotor Disc 21. Cover
6. Back-up Ring 14. Plate 22. Rotary Oil Seal
7. Piston 15. Springs 23. Brake to Hub Gasket
8. O-ring 16. Spring Retainer 24. Brake to Motor Gasket
Figure 3-13. Brake Assembly
3-26 3121639
3.9 DRIVE BRAKE - MICO 4. Install shaft assembly and retaining ring (17) in cover
(21).
Disassembly 5. Install dowel pins (20), spring retainer (16) and
springs (15) in cover (21).
1. After removing the brake from its installation, place
brake on a clean dry work bench with mounting plate NOTE: Be sure to use the same number of springs and spring pat-
uppermost. tern as recorded during disassembly.
2. Remove pressure plate (3) from cover (21) by removing
cap screws (1) and washers (2). 6. Position plate (14) on springs (15). Hole in plate (14)
must line up with hole in cover (21).
NOTE: Discs (13, 11) and plate (14) must remain dry during instal-
PRESSURE PLATE IS UNDER SPRING TENSION OF APPROXIMATELY 680 KG lation. No oil residue must be allowed to contaminate disc
(1500 LB). THE FOUR CAP SCREWS SHOULD BE LOOSENED EVENLY TO RELIEVE surfaces.
THE FORCE. IF A HYDRAULIC PRESS IS AVAILABLE, 3000 LBS (1361KGF) MINI-
MUM, THE PRESSURE PLATE CAN BE HELD IN POSITION WHILE REMOVING 7. Press sensor ring (12) on rotor disc (13). Place a new
THE CAP SCREWS AND WASHERS. rotor disc (13) on shaft (10) until it contacts plate (14).
Install stator disc (11).
3. Remove case seal (4) from cover (21).
8. Install new o-rings (5, 8) and new back-up rings (6, 9) on
4. Remove piston (7) from pressure plate (3). piston (7). Note order of o-rings and back-up rings.
5. Remove o-rings (5, 8) and back-up rings (6, 9) from pis- Insert piston (7) into pressure plate (3). Be careful not to
ton (7). shear o-rings or back-up rings.
IF THE SENSOR RING (12) IS DAMAGED OR NEEDS REPLACED, THE ENTIRE 9. Install new case seal (4) in cover (21).
BRAKE MUST BE REPLACED AS A UNIT. THE SENSOR RING IS NOT AVAILABLE
10. Position pressure plate (3) on cover (21) aligning dowel
AS A SERVICE PART.
pins (20) with holes in pressure plate.
6. Remove stack assembly, consisting of stator disc (11),
11. Install cap screws (1) and washers (2) and tighten evenly
sensor ring (12), rotor disc (13), and plate (14) from cover
to draw pressure plate (3) to cover (21). Torque cap
(21).
screws to 55 lb ft (74.6 NM).
7. Remove dowel pins (20), springs (15), and spring
retainer (16) from cover (21). NOTE: A hydraulic press will simplify the installation of the pres-
sure plate. Clamp pressure plate in position while tighten-
NOTE: Not all models use the same number of springs or spring ing the cap screws.
pattern. Record this information for reassembly purposes.
8. Remove retaining ring (17) from cover (21).

IF HYDROSTATIC BENCH TESTING IS PERFORMED ON THE BRAKE ASSEMBLY,
9. Remove shaft (10) by pressing or using a soft mallet on
RELEASE PRESSURE SHOULD NOT EXCEED 2000 PSI (137.9 BAR) UNLESS TWO
male end of shaft (10).
ADDITIONAL BOLTS ARE USED FOR SUPPLEMENTAL CLAMPING.
10. Remove retaining ring (19) and bearing (18) from shaft
(10). Bleeding
11. Press rotary oil seal (22) from cover (21). I
1. Install brake in system and connect pressure lines.

Assembly
2. Bleed pressure release section of brake by pressurizing
NOTE: Lubricate all rubber type components from repair kit with side inlet port and allowing air to escape from top port.
clean type fluid used in the system. Pressure should not exceed 100 psi (6.9 bar) during
bleeding.
1. Clean all parts thoroughly before assembly.
3. Apply sufficient pressure to release brake and check for
2. Press new rotary oil seal (22) into cover (21) taking note proper operation in system.
to direction of seal.
NOTE: If damaged, replace the input and output gaskets before
3. Install new bearing (18) and retaining ring (19) on assembling the brake to the hub and motor.
shaft (10). (See Figure 3-10. and Figure 3-13.)
3121639 3-27
3.10 TORQUE HUB
1. Spindle 12. Thrust Washer 23. Needle Bearing 34. O-ring

2. Lip Seal 13. Spacer 24. Thrust Spacer 35. Retaining Ring, Int.
3. Tapered Bearing Cone 14. Seal Boot 25. Planet Shaft 36. Coupling
4. Tapered Bearing Cup 15. Thrust Spacer 26. Planet Gear 37. Input Shaft
5. Tapered Bearing cone 16. Input Carrier 27. Roll Pin 38. Input Sun Gear
6. Ring Gear 17. Thrust Washer 28. Thrust Washer 39. Output Sun Gear
7. Hub (Housing) 18. Needle Bearing 29. Retaining Ring, Ext. 40. O-ring
8. Stud 19. Planet Shaft 30. Cover 41. O-ring
9. Retaining Ring, Ext. 20. Planet Gear 31. Disengage Cap 42. Retaining Ring, Ext.
10. Retaining Ring, Int. 21. Output Carrier 32. Hex Bolt
11. Spring (1.460, 1.500) 22. Thrust Washer 33. Dowel Pin
Figure 3-14. Torque Hub Assembly
3-28 3121639
Roll Test
The purpose of the roll test is to determine if the unit’s gears
are rotating freely and properly. You should be able to rotate
the gears in your unit by applying constant force to the roll
checker. If you feel more drag in the gears only at certain
points, then the gears are not rolling freely and should be
examined for improper installation or defects. Some gear
packages roll with more difficulty than others. Do not be con-
cerned if the gears in your unit seem to roll hard as long as
they roll with consistency.
Leak Test (Main Unit)

The purpose of a leak test is to make sure the unit is air tight.
You can tell if your unit has a leak if the pressure gauge read-
ing on your leak checking fitting starts to fall after the unit has
been pressurized and allowed to equalize. Leaks will most
likely occur at the pipe plugs, the main seal or wherever o-
rings or gaskets are located. The exact location of a leak can
usually be detected by brushing a soap and water solution
around the main seal and where the o-rings or gaskets meet
on the exterior of the unit, then checking for air bubbles. If a
leak is detected in a seal, o-ring or gasket, the part must be
replaced, and the unit rechecked. Leak test at 10 psi for 20 Figure 3-15. Bolt Torquing Sequence
minutes.
Tightening and Torquing Bolts

If an air impact wrench is used to tighten bolts, extreme care
should be taken to ensure theat the bolts are not tightened
beyond their specified torque.
The following steps describe how to tighten and torque bolts
or socket head cap screws in a bolt circle.
1. Tighten (but do not torque) bolt "A" until snug.
2. Go to the opposite side of the bolt circle and tighten
bolt "B" until equally snug.
3. Crisscross around the bolt circle and tighten remaining
bolts.
4. Now use a torque wrench to apply a specified torque to
bolt "A".
5. Using the same sequence, crisscross around the bolt cir-
cle and apply an equal torque to the remaining bolts.
3121639 3-29
Main Disassembly
1. Coupling 7. Input Shaft 13. Housing

2. Retaining Ring 8. Carrier Subassembly 14. O-Ring
3. Ring Gear 9. Second Stage Sun Gear 15. O-Ring
4. Cover Subassembly 10. Output Stage Carrier Subassembly 16. Retaining Ring, Ext.
5. Washer 11. Flat Head Bolts 17. Retaining Ring, Ext.
6. First Stage Sun Gear 12. Ring Gear 18. ID Plate
Figure 3-16. Hub Main Disassembly
3-30 3121639
Disassembly Instructions: NOTE: On units with ratios greater than 36:1 numerically, there
will not be a separate First Stage Sun Gear (6), as the gear
1. Perform the Roll Check and Leak Check, if applicable
teeth will be integral to the Input Shaft (7).
prior to disassembling the unit.
2. Drain oil from the unit. 7. Remove the Input Carrier Subassembly (8).
3. Remove the Coupling (1) from Spindle End first. 8. Remove the Second Stage Sun Gear (9).
4. Remove the Retaining Ring (2) by prying the open end 9. Remove the Input Shaft (7).
of the Retaining Ring out of the groove in the Ring Gear
NOTE: On units with a ratio 48:1, the Sun Gear (9) and the Input
(3) with a screwdriver, then grasp the loose end with pli-
Shaft (7) will need to be removed together.
ers and pull the Retaining Ring completely out of the
groove.
10. Remove the Output Stage Carrier Subassembly (10).
5. Remove the Cover Subassembly (4) from the unit. The
11. Loosen and remove the three Flat Head Bolts (11) that
unit can be carefully pressurized with air to pop the
retain the Ring Gear (12) to the Housing (13).
cover out of the unit. The Washer (5) may have to be
removed separately because of the loose attachment. 12. Lift the Ring Gear (12) off of the Housing (13).
6. Remove the First Stage Sun Gear (6) if applicable. 13. Remove the O-ring (14) from between the Housing (13)
and the Ring Gear (12).
3121639 3-31
Output Carrier Disassembly
1. Roll Pin 5. Thrust Washers

2. Planet Shaft 6. Thrust Spacer
3. Carrier 7. Planet Gears
4. Needle Bearings 8. Thrust Washer
Figure 3-17. Output Carrier Disassembly
1. Using a 1/8" diameter punch, drive the Roll Pin (1) into 4. Slide the Planet Gear Sub-assembly (4 - 7) out of the
the Planet Shaft (2) until it bottoms against the Carrier Output Carrier (3) being careful to not drop the Needle
(refer to Figure 3-14.). Bearings (4) in the process.
2. Using a soft face hammer, tap the Planet Shaft (2) out of 5. Remove the 4 Thrust Washers (5), 28 Needle Rollers (4)
the Carrier (3). and the Thrust Spacer (6) from the Second Stage Planet
Gear (7).
3. Using a 1/8" diameter punch, drive the Roll Pin (1) out of
the Planet Shaft (2). 6. Repeat Steps 1-5 for the remaining two Planet Gears (7).
NOTE: The Roll Pins (1) should not be reused when reassembling 7. Remove the Thrust Washer (8) from the counterbore in
the unit. the Output Carrier (3).
3-32 3121639
Input Carrier Disassembly
1. Roll Pin 4. Planet Gears

2. Planet Shaft 5. Thrust Spacer
3. Carrier 6. Needle Bearings
Figure 3-18. Input Carrier Disassembly
1. Using a 1/8" diameter punch, drive the Roll Pin (1) into NOTE: The Roll Pins (1) should not be reused when reassembling
the Planet Shaft (2) until it bottoms against the Carrier the unit.
(3).
4. Slide the Planet Gear (4) and the two Thrust Washers (5)
2. Using a soft face hammer, tap the Planet Shaft (2) out of
out of the Carrier (3).
the Carrier (3).
5. Remove the 14 Needle Bearings (6) from the bore of the
3. Using a 1/8" diameter punch, drive the Roll Pin (1) out of
Planet Gear (4).
the Planet Shaft (2).
6. Repeat steps 1-5 for each of the two remaining Planet
Gears.
3121639 3-33
Hub-Spindle Disassembly
1. Spindle 4. Bearing Cone 7. Boot Seal

2. Retaining Ring 5. Bearing Cup 8. Studs
3. Spacer 6. Hub 9. Bearing Cone
Figure 3-19. Hub-Spindle Disassembly
1. Place unit on bench with Spindle (1) end down. 6. If necessary, press 9 Studs (8) out of Hub. Locate Hub on
Seal (refer to Figure 3-14.) end.
2. Remove Retaining Ring (2) with appropriate tool.
7. Remove Seal from Hub.
3. Remove Spacer (3).
NOTE: The Seal should NOT be reused when reassembling the
unit.
4. Remove "A" position Bearing Cone (4) from Bearing Cup
(5) in Hub (6).
8. Remove "B" position Bearing Cone (9) from Hub.
5. Lift Hub (6) off of Spindle (1). Remove Boot Seal (7) from 9. Using a soft steel rod, knock both Bearing Cups (5) out of
Hub if applicable. the Hub.
3-34 3121639
Cover Disassembly
1. O-Ring 4. Hex Head Bolts 7. O-ring

2. Cover 5. Disengage Cap 8. O-ring Pipe Plugs
3. Thrust Washer 6. Disengage Rod
Figure 3-20. Cover Disassembly
1. Remove O-ring (1) from the groove in the Cover (2). 4. Pull Disengage Rod (6) out of the Cover.
2. Remove the Thrust Washer (3) from Cover pockets. 5. Use an appropriate tool to remove the O-ring (7) from
the internal groove in the Cover.
3. Unscrew the two Hex Head Bolts (4) and remove the Dis-
engage Cap (5) from the Cover. 6. Remove the two O-ring Pipe Plugs (8) from the Cover.
3121639 3-35
Input Carrier Sub-Assembly
1. Roll Pin
2. Planet Shaft
3. Carrier
4. Planet Gears
5. Thrust Spacer
6. Needle Bearings
Figure 3-21. Input Carrier Sub-Assembly
1. Apply a liberal coat of grease to the bore of one Input 7. Following the Planet Gear, place one more Thrust
Planet Gear (4). Washer onto the Planet Shaft. Align the Thrust Washer in
the same manner described in Step 5.
2. Line the inside of the Planet Gear with 14 Needle Bear-
ings (6). 8. Now insert the Planet Shaft through the opposite planet
shaft hole on the Carrier. Use an alignment punch or
NOTE: The last roller installed must be installed end wise. That is, similar tool to align the roll pin holes on the Carrier and
the end of the last roller must be placed in between the Planet Shaft.
ends of the two rollers which form the space, and then slid,
parallel to the other rollers, into place. NOTE: Be sure not to hit the Planet Gears when driving in the Roll
Pins (1).
3. Set Carrier (3) in an upright position.
9. Drive the Roll Pins down into the aligned roll pin holes.
4. Insert a Planet Shaft (2) into the planet shaft hole in the
Pin should be flush with the flat of the Carrier.
end of the Carrier opposite the splined end. The end of
the Planet Shaft that does NOT have the roll pin hole 10. Repeat Steps 1-9 for the installation of the two remain-
should be inserted into the carrier FIRST. ing Planet Gears.
5. Place one Thrust Washer (5) onto the end of the Planet NOTE: Some grease may need to be applied to the Thrust Washers
Shaft. Make sure the flat faces towards the inside of the to hold them in place while installing the Planet Gears.
carrier and make sure the button fits in the pocket on
the inside of the Carrier towards the OD.
6. Following the Thrust Washer, place the Planet Gear with
Needle Bearings onto the Planet Shaft.
3-36 3121639
Output Carrier Sub-Assembly
1. Roll Pin
2. Planet Shaft
3. Carrier
4. Needle Bearings
5. Thrust Washers
6. Thrust Spacer
7. Planet Gears
8. Thrust Washer
Figure 3-22. Output Carrier Sub-Assembly
1. Apply a liberal coat of grease to the bore of one Output 8. Place the Planet Gear Sub-assembly into the Carrier.
Planet Gear (7). Visually align the planet gear bore with one of the
planet shaft holes on the Carrier.
2. Line the inside of the Planet Gear with 14 Needle Bear-
ings (4).
9. Insert a Planet Shaft (2) into the planet shaft hole
NOTE: The last roller installed must be installed end wise. That is, described in Step 8 on the Carrier. The end of the planet
the end of the last roller must be placed in between the shaft that does NOT have the roll pin hole should be
ends of the two rollers which form the space, and then slid, inserted into the Carrier FIRST.
parallel to the other rollers, into place.
10. Now insert the Planet Shaft through the first set of
3. Place the Spacer (6) into the bore of the Output Planet. Thrust Washers, Planet Gear, then the second set of
Thrust Washers. Use an alignment punch or similar tool
4. Repeat Step 2 to put in second roll of Needle Bearings. to align the roll pin holes on the Carrier and Planet Shaft.
5. Apply grease to hold two Thrust Washers together and
onto Output Planet Gear counterbore. Do the same to NOTE: Be sure not to hit the Planet Gears when driving in the Roll
the other side. Pins (1).
6. Repeat Steps 1-5 to finish the assembly of the two

11. Drive the Roll Pin down into the aligned roll pin holes.
remaining Output Planet Gears.
Pin should be flush with OD of Carrier.
7. Place the Thrust Washer (8) into counterbore of the Car-
rier (3). BE SURE the small diameter side of the Thrust 12. Repeat Steps 7-11 for the installation of the two remain-
Washer is facing the planet gear side. ing Planet Gears.
3121639 3-37
Hub-Spindle Sub-Assembly
1. Spindle
2. Retaining Ring
3. Spacer
4. Bearing Cone
5. Bearing Cup
6. Hub
7. Boot Seal
8. Studs
9. Bearing Cone
Figure 3-23. Hub-Spindle Sub-Assembly
NOTE: Apply a light coat of oil on all component parts during 18. Press Seal Boot (7) onto Hub, if required. Turn Hub over
assembly. and lower onto Spindle (1).
19. Install Bearing Cone (4) into Bearing Cup, position "A".
13. Place the Hub (6) into a pressing base. Press 9 Studs (8)
into the Hub. 20. Place Bearing Spacer (3) on top of Bearing Cone.
21. Using appropriate tool, install Retaining Ring (2) into
NOTE: Use enough pressure to press in studs. Don’t use excessively
Spindle groove. Make sure ring is completely seated in
high pressure to press in Studs as this may crack Hub.
groove.
NOTE: Spray a generous amount of oil on bearings during instal- NOTE: Extra bearing pre-load caused by using tool in Step #9
lation. must be removed. This should be done by placing a tool
(NOT THE SAME TOOL USED IN STEP #9) on the end of the
14. Press Bearing Cup (5), position "A" into Hub using appro- Spindle, and then striking the tool with a piece of barstock.
priate pressing tool. This should be adequate to remove any additional bearing
pre-load.
15. Turn Hub over and press Bearing Cup, position "B" into
Hub using appropriate pressing tool.
16. Place Bearing Cone (9) into Bearing Cup, position "B".
17. Grease Seal (refer to Figure 3-14.) lip and press Seal into
Hub using appropriate tool until seal is flush with end of
Hub.
3-38 3121639
Cover Sub-Assembly
1. O-Ring 4. Hex Head Bolts 7. O-ring

2. Cover 5. Disengage Cap 8. O-ring Pipe Plugs
3. Thrust Washer 6. Disengage Rod
Figure 3-24. Cover Sub-Assembly
1. Grease O-Ring (7) and insert groove in Cover (2). 4. Grease the face of the Thrust Washer (3) and place in the
Cover making sure the tangs on the Washer seat into the
2. Assemble Disengage Cap (5) onto Cover using two Hex
pockets in the Cover.
Head Bolts (4). Torque bolts to 70-80 in-lbs.
5. Install the O-ring Pipe Plugs (8) into the Cover. The plugs
3. Insert Disengage Rod (6) into hole in Cover until it
should be hand tight according to SAE standard.
touches the inside of the Disengage Cap.
NOTE: The Disengage Rod can be inserted either end first.
3121639 3-39
Main Assembly
1
3
8
15 6
4
2
18
5
13
14
12
16
7
9 17
11
1. Coupling 7. Input Shaft 13. Housing

2. Retaining Ring 8. Carrier Subassembly 14. O-Ring
3. Ring Gear 9. Second Stage Sun Gear 15. O-Ring
4. Cover Subassembly 10. Output Stage Carrier Subassembly 16. Retaining ring Ext.
5. Washer 11. Flat Head Bolts 17. Retaining Ring Rxt.
6. First Stage Sun Gear 12. Ring Gear 18. ID Plate
Figure 3-25. Hub Main Assembly
3-40 3121639
NOTE: All components should receive a generous amount of lubri- 8. Place the Input Shaft spline end into mesh with the
cant oil as they are being assembled. Internal Coupling (1) splines.
9. With the modified spline end facing up, place the Out-
1. Place Hub-Spindle Sub-Assembly on a bench.
put Sun Gear into mesh with the Output Planet Gears.
2. Grease O-Ring (14) and place it into the groove of the
10. Place the Input Carrier Sub-Assembly (8) onto the Out-
Housing (13).
put Sun Gear splines. Drop the First Stage Sun Gear (6)
3. Place the Ring Gear (12) onto the Hub. Align the 3 ship- into mesh with the planet gears for specific ratios, if
ping cap screw holes on the Hub and Ring Gear. required. (No timing required).
4. Install the 3 Flat Head Bolts (11) into the Ring Gear and 11. Grease the O-Ring (15) and insert into the groove in the
Hub. Torque the Bolts to 15-20 ft-lbs. Cover Subassembly (4).
5. Place Output Stage Carrier Subassembly (10) into mesh 12. Install the Cover Subassembly into the Ring Gear (3)
with the Spindle splines. counter-bore and install the Retaining Ring (2) into the
groove in the Ring Gear.
6. Place the External Retaining Ring (16) over the 13T
spline to the retaining groove on the Input Shaft (7). 13. Attach the ID Plate (18) onto the unit using the Drive
Screw (not shown).
NOTE: For ratio 48:1, assemble the Second Stage Sun Gear (9) over
the Input Shaft first, then install the External Retaining 14. Check disconnect, roll and air check the unit, leak check
Ring. the brake, and record release pressure.
15. Insert the Plastic Plug (not shown) into place, if applica-
7. Using an appropriate tool, install the Retaining Ring (17)
ble.
into the groove on the Output Sun.
3121639 3-41
NOTES:
3-42 3121639
SECTION 4. HYDRAULICS
4.1 SERVICING AND MAINTENANCE GUIDELINES Component Disassembly and Reassembly

When disassembling or reassembling a component, complete
General
the procedural steps in sequence. Do not partially disassemble
The following information is provided to assist you in the use and or assemble one part, then start on another. Always recheck your
application of servicing and maintenance procedures contained work to assure that nothing has been overlooked. Do not make
in this chapter. any adjustments, other than those recommended, without
obtaining proper approval.
Safety and Workmanship
Pressure Fit Parts
Your safety and that of others is the first consideration when
engaging in the maintenance of equipment. Always be con- When assembling pressure fit parts, use an “anti-seize” or molyb-
scious of weight. Never attempt to move heavy parts without the denum disulfide base compound to lubricate the mating surface.
aid of a mechanical device. Do not allow heavy objects to rest in
an unstable position. When raising a portion of the equipment, Bearings
ensure that adequate support is provided.
1. When a bearing is removed, cover it to keep out dirt and
Cleanliness abrasives. Clean bearings in nonflammable cleaning sol-
vent and allow to drip dry. Compressed air can be used
1. The most important single item in preserving the long but do not spin the bearing.
service life of a machine is to keep dirt and foreign mate-
rials out of the vital components. Precautions have been 2. Discard bearings if the races and balls (or rollers) are pit-
taken to safeguard against this. Shields, covers, seals and ted, scored or burned.
filters are provided to keep oil supplies clean; however,
these items must be maintained on a scheduled basis in 3. If bearing is found to be serviceable, apply a light coat of
order to function properly. oil and wrap it in clean (waxed) paper. Do not unwrap
reusable or new bearings until they are ready to be
2. At any time when hydraulic oil lines are disconnected, installed.
clear adjacent areas as well as the openings and fittings
themselves. As soon as a line or component is discon- 4. Lubricate new or used serviceable bearings before
nected, cap or cover all openings to prevent entry of for- installation. When pressing a bearing into a retainer or
eign matter. bore, apply pressure to the outer race. If the bearing is to
be installed on a shaft, apply pressure to the inner race.
3. Clean and inspect all parts during servicing or mainte-
nance, and assure that all passages and openings are
unobstructed. Cover all parts to keep them clean. Be
Gaskets
sure all parts are clean before they are installed. New Check that holes in gaskets align with openings in the mating
parts should remain in their containers until they are parts. If it becomes necessary to hand fabricate a gasket, use gas-
ready to be used. ket material or stock of equivalent material and thickness. Be
sure to cut holes in the right location as blank gaskets can cause
Component Removal and Installation serious system damage.
1. Use adjustable lifting devices, whenever possible, if
mechanical assistance is required. All slings (chains,
Bolt Usage and Torque Application
cables, etc.) should be parallel to each other and as near
1. Use bolts of proper length. A bolt which is too long will
perpendicular as possible to top of part being lifted.
bottom before the head is tight against its related part. If
2. Should it be necessary to remove a component on an a bolt is too short, there will not be enough thread area
angle, keep in mind that the capacity of an eyebolt or to engage and hold the part properly. When replacing
similar bracket lessens, as the angle between the sup- bolts, use only those having the same specifications of
porting structure and the component becomes less the original, or one which is equivalent.
than 90°.
2. Unless specific torque requirements are given within the
3. If a part resists removal, check to see whether all nuts, text, standard torque values should be used on heat
bolts, cables, brackets, wiring, etc. have been removed treated bolts, studs and steel nuts, in accordance with
and that no adjacent parts are interfering. recommended shop practices.
3121639 4-1
Hydraulic Lines and Electrical Wiring 4.2 LUBRICATION INFORMATION

Clearly mark or tag hydraulic lines and electrical wiring, as well as
their receptacles, when disconnecting or removing them from
Hydraulic System
the unit. This will assure that they are correctly reinstalled. 1. The primary enemy of a hydraulic system is contamina-
tion. Contaminants enter the system by various means,
Hydraulic System e.g.; inadequate hydraulic oil, allowing moisture, grease,
filings, sealing components, sand, etc. to enter when
1. Keep the system clean. If evidence of metal or rubber
performing maintenance, or by permitting the pump to
particles are found in the hydraulic system, drain and
cavitate due to insufficient system warm-up.
flush the entire system.
2. The design and manufacturing tolerances of the compo-
2. Disassemble and reassemble parts on clean work sur-
nent working parts are very close, therefore, even the
face. Clean all metal parts with non-flammable cleaning
smallest amount of dirt or foreign matter entering a sys-
solvent. Lubricate components, as required, to aid
tem can cause wear or damage to the components and
assembly.
generally results in faulty operation. Every precaution
must be taken to keep hydraulic oil clean, including
Lubrication reserve oil in storage. Hydraulic system filters should be
Service applicable components with the amount, type, and checked, cleaned, and/or replaced at the specified inter-
grade of lubricant recommended in this manual, at the specified vals required in Section 1. Always examine filters for evi-
interval. When recommended lubricants are not available, con- dence of metal particles.
sult your local supplier for an equivalent that meets or exceeds
3. Cloudy oils indicate a high moisture content which per-
the specifications listed.
mits organic growth, resulting in oxidation or corrosion.
If this condition occurs, the system must be drained,
Batteries flushed, and refilled with clean oil.
Clean batteries using a non-metallic brush and a solution of bak- 4. It is not advisable to mix oils of different brands or types,
ing soda and water. Rinse with clean water. After cleaning, thor- as they may not contain the same required additives or
oughly dry batteries and coat terminals with an anti-corrosion be of comparable viscosities. Good grade mineral oils,
compound. with viscosities suited to the ambient temperatures in
which the machine is operating, are recommended for
Lubrication and Servicing use.
Components and assemblies requiring lubrication and servicing NOTE: Metal particles may appear in the oil or filters of new
are shown in Section 1. machines due to the wear-in of meshing components.
Hydraulic Oil
1. Refer to Section 1 for recommendations for viscosity
ranges.
2. JLG recommends DTE 11Hydraulic Oil, which has an SAE
viscosity of 10W and a viscosity index of 140.
NOTE: Start-up of hydraulic system, not using DTE 11, with oil
temperatures below -15°F (-26°C) is not recommended. If it
is necessary to start the system in a sub-zero environment,
it will be necessary to heat the oil with a low density,
100VAC heater to a minimum temperature of -15°F (-26°C).
4-2 3121639
Changing Hydraulic Oil 4.4 VALVES - THEORY OF OPERATION

1. Use of any of the recommended hydraulic oils elimi-
Control Valves
nates the need for changing the oil on a regular basis.
However, filter elements must be changed after the first The main control valve consists of cartridge type valves in an alu-
50 hours of operation and every 250 hours thereafter. If minum manifold. The cartridge valves provide for control of flow,
it is necessary to change the oil, use only those oils volume of flow and pressure in the hydraulic system.
meeting or exceeding the specifications appearing in
this manual. If unable to obtain the same type of oil sup- The flow to the lift cylinder(s) is provided by a solenoid operated
plied with the machine, consult local supplier for assis- 3 way spool valve.When flow is required to lift the load the sole-
tance in selecting the proper equivalent. Avoid mixing noid is energized in one direction. When the solenoid is not ener-
petroleum and synthetic base oils. JLG Industries recom- gized the cylinder is held in place by the holding valve mounted
mends changing the hydraulic oil annually. on the cylinder.
2. Use every precaution to keep the hydraulic oil clean. If The directional control valve for steer is a solenoid operated,
the oil must be poured from the original container into three position, 4-way sliding spool type valve. Energizing one of
another, be sure to clean all possible contaminants from the electrical coils on a valve will divert the supply of hydraulic oil
the service container. Always replace the filter cartridge to provide motion of that function in one direction. Energizing
any time the system oil is changed. the other coil will divert the oil for motion in the other direction.
When neither coil is energized, the supply of hydraulic oil is
3. While the unit is shut down, a good preventive mainte- blocked.
nance measure is to make a thorough inspection of all
A solenoid operated three way spool valve controls flow to the
hydraulic components, lines, fittings, etc., as well as a
brakes to release the brakes.When energized it allows flow to the
functional check of each system, before placing the
brake parts until the brake pressure switch is satisfied.
machine back in service.
Pressure relief valves limit the pressure in the steer circuit and the
Lubrication Specifications rod end of each lift cylinder. When the pressure in one of those
circuits reaches the set point of the valve, the valve opens, allow-
Specified lubricants, as recommended by the component manu- ing enough flow to return to the reservoir so that the set pres-
facturers, are always the best choice, however, multi-purpose sure is not exceeded. An adjusting screw on each cartridge relief
greases usually have the qualities which meet a variety of single valve allows the set pressure to be adjusted.
purpose requirements. Should any question arise regarding the
use of greases in maintenance stock, consult your local supplier The aluminum manifold provides the passages through which
for evaluation. Refer to Section 1 for an explanation of the lubri- the hydraulic oil is diverted to provide the desired movement of
cant key designations appearing in the Lubrication Chart. the actuators. No moving parts of the valves slide against the
manifold and so it is not subject to wear.
4.3 CYLINDERS - THEORY OF OPERATION

4.5 COMPONENT FUNCTIONAL DESCRIPTION
1. Cylinders are of the double acting type. The Lift and
Steer systems incorporate double acting cylinders. A Hydraulic Pump
double acting cylinder is one that requires oil flow to
operate the cylinder rod in both directions. Directing oil, The single stage gear pump is attached to the electric motor
by actuating the corresponding control valve to the pis- located in the left side tray of the machine.
ton side of the cylinder, forces the piston to travel
toward the rod end of the barrel, extending the cylinder Manual Descent
rod piston attached to rod. When the oil flow is stopped,
movement of the rod will stop. By directing oil to the rod The manual descent cable handle is located at the rear of the
side of the cylinder, the piston will be forced in the machine frame.
opposite direction and the cylinder rod will retract.
2. Holding valves are used in the lift circuits to prevent 4.6 WEAR PADS
retraction of the cylinder rod should a hydraulic line rup-
ture or leak develop between the cylinder and its related The original thickness of the sliding wear pads is 5 in (12.7 cm).
control valve. Replace sliding pads when worn to 4.7 in (11.9 cm).
3121639 4-3
4.7 MOTOR CONTROLLER - MODES OF OPERATION 4.8 FEATURES

Traction Motor (Drive) Traction Mode
Drive in either forward or reverse will start only if the following
conditions are satisfied: NOTE: The lift up and drive functions are proportional.
1. Function switches off.

The drive function is fully proportional with automatic speed
2. No procedure or diagnostic faults present. cutback above elevation. The system is designed for maximum
traction to be delivered to both wheels at all times.
3. Depress drive select. Lights indicating drive at the plat-
form control will flash. The controller must be moved Machines equipped with oscillating axle will have oscillation
within 3 seconds after the drive select illuminates. below elevation cutback speed only.
4. FWD or REV selected as appropriate.
Table 4-1. Cutout Heights
Once in “drive” mode, activating a function switch shall not cause
drive mode to be exited, the pump/traction contactor drive shall Function M3369/3369LE M4069/4069LE
not be energized it will be left at the traction position. If a func-
tion switch is selected during traction, a procedure fault will 8 ft - 9 ft 6 in 9 ft 6 in - 11 ft 8 in
Elevated Cutback Height
occur when neutral is selected, remaining until a function switch (2.4 m - 2.9 m) (2.9m - 3.6m)
and both directions are no longer selected.
28 ft - 30 ft
When the controller is returned to neutral, the controller will con- Drive Cutout Height N/A
(8.5 m - 9.1m)
trol smooth stopping of the machine, using plug braking, before
the brake is allowed to operate.
NOTE: Depressing the lift function switch while driving will not 4.9 CYLINDER CHECKING PROCEDURES
interrupt drive function.
NOTE: Cylinder checks must be performed any time a cylinder
Pump Motor (LIft) component is replaced or when improper system opera-
tion is suspected.
Pump motor drive will start only if the following conditions are
satisfied:
Cylinder Without Counterbalance Valves (Steer)
1. Accelerator in neutral position.
2. Traction mode off (brake applied). 1. Using all applicable safety precautions, activate hydrau-
lic system and fully extend cylinder to be checked. Shut
3. Depress lift select. the lights indicating lift select at the down hydraulic system.
platform control will flash. The accelerator must be
moved within 3 seconds after the lift light illuminates. 2. Carefully disconnect hydraulic hose from retract port of
NOTE: Depressing the drive function switch while lifting will not cylinder. There will be initial weeping of hydraulic fluid
interrupt lift function. which can be caught in a suitable container. After initial
discharge, there should be no further leakage from the
Any time brushes are being replaced in a drive motor or retract port.
pump motor, all brushes in the motor should be replaced.
3. Activate hydraulic system, and activate cylinder extend
function.
4. If cylinder retract port leakage is less than 6-8 drops per

minute, carefully reconnect hose to retract port and
retract cylinder. If leakage continues at a rate of 6-8
drops per minute or more, cylinder repairs must be
made.
5. With cylinder fully retracted, shut down motor and care-

fully disconnect hydraulic hose from cylinder extend
port.
6. Activate hydraulic system and activate cylinder retract

function. Check extend port for leakage.
4-4 3121639
7. If extend port leakage is less than 6-8 drops per minute, 4. There will be initial weeping of hydraulic fluid, which
carefully reconnect hose to extend port, then activate can be caught in a suitable container. After the initial
cylinder through one complete cycle and check for discharge, there should not be any further leakage from
leaks. If leakage continues at a rate of 6-8 drops per min- the ports. If leakage continues at a rate of 6-8 drops per
ute or more, cylinder repairs must be made. minute or more, the following cylinder repairs must be
made. If the retract port is leaking, the piston is leaking,
Cylinders With Single Counterbalance Valve (Lift the piston seals are defective and must be replaced. If
the extend port is leaking, the counterbalance is defec-
Cylinder) tive and must be replaced.
5. To check piston seals, carefully remove the counterbal-
ance valve from the retract port. After initial discharge
OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY.
there should not be any further leakage from the ports.
If leakage occurs at a rate of 6-8 drops per minute or
1. Using all applicable safety precautions, activate hydrau- more, the piston seals are defective and must be
lic system. replaced.
2. Raise platform completely and place a suitable over- 6. If no repairs are necessary or when repairs have been
head lifting device approximately 1 in (2.5 cm) below made, carefully reconnect hydraulic hoses to the appro-
the platform. priate ports.
3. After completing the above, shut down hydraulic sys- 7. Activate hydraulic system and run cylinder through
tem and allow machine to sit for 10-15 minutes. This is complete cycle to check for leaks and operation.
done to relieve pressure in the hydraulic lines. Carefully
remove hydraulic hoses from appropriate cylinder port
block. 4.10 CYLINDER REMOVAL AND INSTALLATION
4. There will be initial weeping of hydraulic fluid, which
can be caught in a suitable container. After the initial Lift Cylinder Removal
discharge, there should not be any further leakage from
the ports. If leakage continues at a rate of 6-8 drops per 1. Place the machine on a flat and level surface. Turn
minute or more, the following cylinder repairs must be power on and raise the platform. Turn power off and
made. If the retract port is leaking, the piston is leaking, attach a suitable lifting device to the platform.
the piston seals are defective and must be replaced. If 2. Remove the bolt, locknut and keeper shaft securing the
the extend port is leaking, the counterbalance is defec- cylinder rod attach pin to the upper inner arm assembly.
tive and must be replaced. Using a suitable brass drift, drive out the rod end attach
pin from the arm assembly.
5. If no repairs are necessary or when repairs have been
made, carefully reconnect hydraulic hoses to the appro- 3. Retract the cylinder rod completely.
priate ports.
4. Tag and disconnect, then cap the lift cylinder hydraulic
6. Remove lifting device from platform, activate hydraulic lines and ports.
system and run cylinder through complete cycle to
check for leaks and operation. 5. Remove the bolt, locknut and keeper shaft securing the
cylinder barrel attach pin to the upper inner arm assem-
Cylinders with Duel Counterbalance Valves bly. Using a suitable brass drift, drive out the rod end
attach pin from the arm assembly.
(Oscillating Cylinders)
6. Carefully remove the cylinder from the scissor lift and
place in a suitable work area.
OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY.
1. When working on oscillating axle cylinder, place

machine on firm level surface.
2. Using all applicable safety precautions, activate hydrau-
lic system.
3. Shut down hydraulic system and allow machine to sit for
10-15 minutes. This is done to relieve pressure in the
hydraulic lines. Carefully remove hydraulic hoses from
appropriate cylinder port block.
3121639 4-5
Lift Cylinder Installation

1. Install lift cylinder in place using a suitable slings, align-
ing barrel end attaching pin mounting holes on lower
arm assembly.
2. Using a suitable drift, drive the barrel end attach pin

through the mounting holes in the lift cylinder and the
lower arm assembly. Secure in place with bolt, locknut
and keeper shaft.
3. Remove cylinder port plugs and hydraulic line caps and

correctly attach lines to cylinder ports.
4. Extend the cylinder rod until the attach pin hole aligns
with those in the upper arm assembly. Using a suitable
drift, drive the cylinder rod attach pin through the
Figure 4-1. Barrel Support
aligned holes, taking care to align the pin retaining
holes with the hole on the arm assembly. Secure the pin
in place with bolt, locknut and keeper shaft.
5. Lower platform to stowed position and shut down

motor. Check hydraulic fluid level and adjust accord-
ingly.
NOTE: Always check hydraulic fluid level after completely elevat-

ing and lowering machine.
4.11 CYLINDER REPAIR

NOTE: The following are general procedures that apply to all of
the cylinders on this machine. Procedures that apply to a
specific cylinder will be so noted.
Figure 4-2. Cap Screw Removal
Disassembly
6. Attach a suitable pulling device to the cylinder rod port
block or cylinder rod end, as applicable.
DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK

SURFACE IN A DIRT FREE WORK AREA.
EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD,
1. Operate the hydraulic power source and extend the cyl- HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD
inder. Shut down and disconnect the power source. CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.
Adequately support the cylinder rod, if necessary.
2. If applicable, remove the cartridge-type holding valve 7. With the barrel clamped securely, apply pressure to the
and fittings from the cylinder port block. Discard o- rod pulling device and carefully withdraw the complete
rings. rod assembly from the cylinder barrel.
3. Place the cylinder barrel into a suitable holding fixture. 8. Using suitable protection, clamp the cylinder rod in a
vise or similar holding fixture as close to the piston as
4. To aid in realignment, mark cylinder head and barrel
with a center punch. possible.
5. Using a suitable spanner wrench, loosen the spanner 9. If applicable, loosen and remove the nut which attaches
nut retainer and remove the spanner nut from the cylin- the piston to the rod, then remove the piston from the
der barrel. rod.
10. If applicable, loosen and remove the cap screw(s) secur-

ing the tapered bushing to the piston.
4-6 3121639
9. Inspect cylinder head inside diameter for scoring or

other damage and for ovality and tapering. Replace as
necessary.
10. Inspect threaded portion of head for damage. Dress

threads as necessary.
11. Inspect seal and o-ring grooves in head for burrs and
sharp edges. Dress applicable surfaces as necessary.
12. Inspect cylinder head outside diameter for scoring or

other damage and ovality and tapering. Replace as nec-
essary.
13. If applicable, inspect rod and barrel bearings for signs of

Figure 4-3. Rod Support
correct lubrication and excessive wear. If necessary,
11. Insert the capscrew(s) in the threaded holes in the outer replace bearings as follows:
piece of the tapered bushing. Progressively tighten the
cap screw(s) until the bushing is loose on the piston, a. Thoroughly clean steel bushing hole of burrs, dirt,
then remove the bushing from the piston. etc. to facilitate bearing installation.
12. Screw the piston counter-clockwise, by hand, and b. Inspect steel bushing for wear or other damage. If
remove the piston from the cylinder rod. steel bushing is worn or damaged, rod or barrel (as
applicable) must be replaced.
13. Remove and discard the piston o-rings, back-up rings,
guidelock rings and hydrolock seals. c. Using arbor of the correct size, carefully press the
bearing into the steel bushing.
14. If applicable, remove the piston spacer from the rod.
15. Remove the rod from the holding fixture. Remove the
cylinder head and retainer plate from the rod. NOTE: Install the cylinder pin into the Garmax bearing dry. Lubri-
cation is not required with chrome pins and bearings.
Cleaning and Inspection
1. Clean all parts thoroughly in an approved cleaning sol-
GARMAX
vent. BUSHING
2. Inspect the cylinder rod for scoring, tapering, ovality, or
other damage. If necessary, dress rod with Scotch Brite
or equivalent. Replace rod if necessary.
3. Inspect threaded portion of rod for damage. Dress

threads as necessary.
4. Inspect inner surface of cylinder barrel tube for scoring Figure 4-4. Oil-lite Bearing Installation
or other damage. Check inside diameter for tapering or
ovality. Replace if necessary.
14. Inspect travel limiting collar or spacer for burrs and
5. Inspect threaded portion of barrel for damage. Dress sharp edges. If necessary, dress inside diameter surface
threads as necessary. with Scotch Brite or equivalent.
6. Inspect piston surface for damage and scoring and for 15. If applicable, inspect port block fittings and holding
distortion. Dress piston surface or replace piston as nec-
valve. Replace as necessary.
essary.
7. Inspect threaded portion of piston for damage. dress 16. Inspect the oil ports for blockage or the presence of dirt
threads as necessary. or other foreign material. Repair as necessary.
8. Inspect seal and o-ring grooves in piston for burrs and 17. If applicable, inspect piston rings for cracks or other
sharp edges. Dress applicable surfaces as necessary. damage. Replace as necessary.
3121639 4-7
Assembly
NOTE: Prior to cylinder assembly, ensure that the proper cylinder
seal kit is used.
Apply a light film of hydraulic oil to all components prior to

assembly.
1. Using a special tool, pictured in the following illustra-

tion, install a new rod seal into the applicable cylinder
head gland groove. Refer to the following illustration for
the proper tool size.
Figure 4-7. Installation of Head Seal Kit (Typical)
5. Carefully slide the piston spacer onto the rod.
6. If applicable, correctly place a new o-ring and back-up

rings in the inner piston diameter groove.
7. Using suitable protection, clamp the cylinder rod in a

vise or similar holding fixture as close to the piston as
possible.
8. Carefully thread the piston on the cylinder rod hand

Figure 4-5. Rod Seal Installation tight, ensuring that the o-ring and back-up rings are not
damaged or dislodged.
9. Thread the piston onto the rod until it abuts the spacer
WHEN INSTALLING NEW “POLY-PAK” TYPE PISTON SEALS, ENSURE SEALS ARE end and install the tapered bushing.
INSTALLED PROPERLY. (SEE FIGURE 4-9.) FOR CORRECT SEAL ORIENTATION.
IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND NOTE: When installing the tapered bushing, the piston and mat-
IMPROPER CYLINDER OPERATION. ing end of the rod must be free of oil.
2. Using a soft mallet, tap a new wiper seal into the appli-
cable cylinder head gland groove. Install a new wear
ring into the applicable head gland groove.
Figure 4-8. Piston Seal Kit Installation (Typical)

Figure 4-6. Wiper Seal Installation
3. Place a new o-ring and back-up seal in the applicable

outside diameter groove of the cylinder head.
4. Install a washer ring onto the rod, then carefully install WHEN REBUILDING THE LIFT CYLINDER, APPLY LOCTITE #242 TO TAPERED
the head gland on the rod, ensuring that the wiper and BUSHING BOLTS, THEN TIGHTEN BOLTS SECURELY. REFER TO TABLE 4-2, CYL-
rod seals are not damaged or dislodged. Push the head INDER PISTON NUT TORQUE SPECIFICATIONS AND TABLE 4-3, HOLDING VALVE
along the rod to the rod end, as applicable. TORQUE SPECIFICATIONS FOR PROPER BOLT TORQUE VALUES.
4-8 3121639
10. Install the bolts into the bushing using Loctite #242. 17. After the cylinder has been reassembled, the rod should
Refer to Cylinder Component Torque Specifications be pushed all the way in (fully retracted) prior to the
Table for proper bolt torque values. reinstallation of any holding valve or valves.
11. Remove the cylinder rod from the holding fixture. 18. If applicable, install the cartridge-type holding valve and
fittings in the port block using new o-rings as applica-
12. Place new guidelock and hydrolock seals in the applicable.
ble outside diameter grooves of both the piston and the
cylinder head.
13. Position the cylinder barrel in a suitable holding fixture. WHEN REBUILDING THE LIFT CYLINDERS, APPLY LOCTITE 242 TO PISTON NUT
AND SETSCREWS.
Table 4-2. Cylinder Piston Nut Torque Specifications
Nut Torque Value

Description
(Wet)
Lift Cylinder 800 - 1000 ft lbs

(3369) (1120 - 1400 Nm)
LIft Cylinder 1125 - 1375 ft lbs

(4069) (1575 - 1925 Nm)
Steer Cylinder See Applicable Figure

Figure 4-9. Poly-Pak Piston Seal Installation
Table 4-3. Holding Valve Torque Specifications
Description Torque Value

EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD,
30 - 35 ft lbs
HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD Sun - 7/8 hex M20 x1.5 thds
(41 - 48 Nm)
CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.
45 - 50 ft lbs
Sun - 1-1/8 hex 1 - 14 UNS thds
(61 - 68 Nm)
150 - 160 ft lbs

Sun - 1-1/4 hex M36 x 2 thds
(204 - 207 Nm)
50 - 55 ft lbs
Racine - 1-1/8 hex 1-1/16 - 12 thds
(68 - 75 Nm)
75 - 80 ft lbs
Racine - 1-3/8 hex 1-3/16 - 12 thds
(102 - 109 Nm)
100 - 110 ft lbs

Racine - 1-7/8 hex 1-5/8 - 12 thds
(136 - 149 Nm)
Figure 4-10. Rod Assembly Installation
NOTE: These cylinders use setscrews which should be discarded
and replaced whenever they are removed.
14. With the barrel clamped securely, and while adequately
supporting the rod, insert the piston end into the cylin- 19. Remove cylinder rod from the holding fixture.
der barrel. Ensure that the piston loading o-ring and seal
ring are not damaged or dislodged. 20. Place new o-rings and seals in the applicable outside
diameter grooves of both the piston and the cylinder
15. Continue pushing the rod into the barrel until the cylin- head.
der head gland can be inserted into the cylinder barrel.
16. Secure the cylinder head gland using the washer ring
and socket head bolts.
3121639 4-9
21. Position the cylinder barrel in a suitable holding fixture. 4.13 OSCILLATION CYLINDER BLEEDING
Bleeding Procedure
EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD,
HEAD AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD 1. Run one side wheel onto a ramp or block of wood. On
CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES. the other side, the lockout cylinder should be extended.
2. Block the rear wheels and disconnect the drive hubs.
22. With barrel clamped securely, and while adequately sup-
porting the rod, insert the piston end into the cylinder 3. Open up the bleeder screw on the bottom of the
barrel. Ensure that the piston loading o-ring and seal extended side lockout cylinder. Disconnect coil on the
ring are not damaged or dislodged. flow control valve. Have an assistant hold lift up switch
(causing pump to run continually) for approx. 10 sec-
23. Continue pushing the rod into the barrel until the cylin- onds or until all the air bubbles are no longer visible.
der head gland can be inserted into the barrel cylinder Then close the bleeder screw while pump is running.
or if applicable until the cylinder head threads engage
the barrel threads. 4. Open bleeder on the top of the retracted lockout cylin-
der. Let hydraulic oil run for approx. 10 seconds or until
24. If applicable, apply loctite #222 and secure the cylinder air bubbles are no longer visible. Then close the bleeder
head retainer using a suitable chain wrench. screw.
25. Insert the other cylinder head gland into the barrel cyl- 5. Fully oscillate the axle in the opposite direction and
inder. Secure the cylinder head retainer using a suitable repeat step three.
chain wrench.
Checking Oscillation Cylinders
26. After the cylinder has been reassembled, the rod should
be pushed all the way in (fully retracted) prior to the After bleeding the lockout cylinders, check to see that they are
reinstallation of any holding valves. holding their position when oscillated.
27. If applicable, install the cartridge type holding valve and 1. Run one wheel onto a ramp or a block of wood, mark the
fittings in the rod port block using new o-rings as appli- retracted cylinder with a marker, elevate platform above
cable. Refer to Table 4-3, Holding Valve Torque Specifica- high speed cutout.
tions for proper torque.
2. Back the unit off of the ramp, check the retracted cylin-
der for drive no more than ½".
IF THE CYLINDER IS TO BE TESTED PRIOR TO INSTALLATION ON THE MACHINE, 3. Repeat this procedure for the other side. If the lockout
EXTREME CARE SHOULD BE USED TO INSURE THAT THE OUTER END OF THE cylinders do not hold, repeat the bleeding procedure or
ROD IS SUPPORTED. USE EITHER A TRAVELING OVERHEAD HOIST, FORKLIFT, check for the following:
OR OTHER MEANS TO SUPPORT THE OVERHANGING WEIGHT OF THE EXTEND- a. Air in lockout system
ING ROD.
b. Bad cylinder seals
c. Bad holding valves
4.12 STEER CYLINDER REMOVAL
1. Park the machine on a firm and level surface.
2. Using proper lifting devices raise the machine to access
the steer cylinder form underneath.
NOTE: Be sure and use proper equipment to stabilize the machine

while performing maintenance underneath.
3. Remove both hydraulic lines from the steer cylinder and

allow excess oil in lines to drain into a suitable container.
4. Remove the nut and bolt from the barrel end of the cyl-
inder from underneath the machine.
5. Remove the nut and bolt from the rod end of the cylin-
der from out at the spindle.
6. Remove cylinder from machine.
4-10 3121639
4.14 OSCILLATING AXLE - LOCKOUT CYLINDER TEST Right Side Wheel Test
(IF EQUIPPED) 1. Place a 4 inch (10.16 cm) high block with ascension
ramp in front of right wheel of the oscillating axle.
2. From platform control station, select LOW drive speed.
LOCKOUT CYLINDER SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY
3. Set the DRIVE control switch and carefully drive the
TIME A SYSTEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM
machine up ascension ramp until right oscillating axle
OPERATION IS SUSPECTED.
wheel is on top of block.
NOTE: Ensure platform is fully lowered prior to beginning lockout 4. Verify the axle oscillates to maintain contact with the
cylinder test, and that the surface used to approach the ground/ramp. (All four wheels on the ground).
ramp is flat and level. 5. Raise machine platform above stowed position approxi-
mately 7 ft (2.1 m) on the 3369LE or 9 ft (2.7 m) on the
Left Side Wheel Test 4069LE.
6. Carefully drive the machine back off the block and ramp.
1. Place a 4 inch (10.16 cm) high block with ascension
ramp in front of left wheel of the oscillating axle. 7. Have an assistant check to see that the right oscillating
axle wheel that was on the block is in position on the
2. From platform control station, select LOW drive speed. ground. The axle should oscillate so that all four wheels
maintain contact with the ground.
3. Set the DRIVE control switch and carefully drive the
machine up ascension ramp until left oscillating axle 8. In the current position (platform raised and all four tires
wheel is on top of block. on flat and level surface), carefully drive machine up the
ramp block again.
4. Verify the axle oscillates to maintain contact with the
ground/ramp. (All four wheels on the ground). 9. Have an assistant check to verify that the axle did not
oscillate and remained locked (one wheel is off of the
5. Raise machine platform above stowed position approxi- ground).
mately 7 ft (2.1 m) on the 3369LE or 9 ft (2.7 m) on the
4069LE.
11. Lower the machine platform; the lockout cylinder
6. Carefully drive the machine back off the block and ramp. should then release and allow wheel to rest on the
ground. It may be necessary to activate DRIVE to release
7. Have an assistant check to see that the left oscillating
cylinders.
axle wheel that was on the block is in position on the
ground. The axle should oscillate so that all four wheels 12. If the lockout cylinders do not function properly, have
maintain contact with the ground. qualified personnel correct the malfunction prior to any
further operation.
8. In the current position (platform raised and all four tires
on flat and level surface), carefully drive machine up the
ramp block again.
9. Have an assistant check to verify that the axle did not

oscillate and remained locked (one wheel is off of the
ground).
11. Lower the machine platform; the lockout cylinder

should then release and allow wheel to rest on the
ground. It may be necessary to activate DRIVE to release
cylinders.
12. If the lockout cylinders do not function properly, have

qualified personnel correct the malfunction prior to any
further operation.
3121639 4-11
4.15 CYLINDER ASSEMBLIES
18
20
19 22 1. Barrel Weldment
21
3 2. Rod Weldment
3. Garmax Bushings
23 4. Locknut
24 5. Piston
25 6. O-Ring
7. Wear Ring
8. Seal
1 9. Spacer
10. Head
11. Wear Ring
17
4 12. Back-Up Ring
7
13. O-Ring
8 14. O-Ring
5
15. Seal
6 16. Wiper
9
12 17. Check/Restrictor Valve
13 18. Manual Descent Cable
19. Jam Nut, 1/4" - 28F
11
20. Flatwasher, 1/4"
14 21. Bracket
10 22. Bolt, 5/16" - 18NC x 3/4"
23. Cotter Pin, 1/8" x 1 1/4"
15
24. Adapter
16 25. Solenoid Valve
2
Figure 4-11. Lift Cylinder - 3369LE & M3369
NOTE: Torque Locknut (4) to 1125 - 1375 ft lbs (1525.3 - 1864 Nm).
• Approximate cylinder dry weight = 220 lbs (99.8 kg)

• Operating Pressure = 2100 psi (145 bar)
4-12 3121639
18
20
19 22
21 1. Barrel Weldment
3 LOWERLIFT 26 2. Rod Weldment
CYLINDER 3. Garmax Bushings
23 4. Locnut
24
OR
5. Piston
25 UPPERLIFT 6. O-Ring
CYLINDER
7. Wear Ring
17 8. Seal
9. Spacer
10. Head
1
11. Wear Ring
4 12. Back-Up Ring
7 13. O-Ring
8 14. O-Ring
5 15. Seal
6 16. Wiper
9 17. Relief Valve
12 18. Manual Descent Cable
13 19. Flatwasher, 1/4"
20. Jam Nut, 1/4" - 28NF
11
21. Bracket
14 22. Bolt, 5/16" - 18NC x 3/4"
10 23. Cotter Pin, 1/8" x 1 1/4"
24. Adapter
15 25. Solenoid Valve (Lower Cylinder)
16
26. Solenoid Valve (Upper Cylinder)
2
Figure 4-12. Lift Cylinder - 4069LE & M4069
NOTE: Torque Locknut (4) to 1125 - 1375 ft lbs (1525.3 - 1864 Nm).
• Approximate cylinder dry weight = 224 lbs (101.6 kg)

• Operating Pressure = 2100 psi (145 bar)
3121639 4-13
20 8
1. Cylinder Barrel
19 2. Jack Pad
10
3. Special Screw, 1/2" - 13NC x 1-1/4
11 4. Cylinder Rod
9 5. Retaining Ring
6. Plate
19 7. End Cap
12 8. Locknut
9. Piston
13 11 10. Flatwasher, 1-1/4"
11. Wear Ring
15 12. Piston Seal
4
13. O-Ring
21 14. Head
15. Wear Ring
16. O-Ring
14 16 17. Polyseal
18. Wiper Seal
17 19. Plug
20. Counter Balance Valve (see note)
18 21. Check Valve (see note)
1 5
5
3
2 3
Figure 4-13. Leveling Jack Cylinder
NOTE: Torque Locknut (8) to 400 ft lbs (542.3 Nm).

Torque Counter Balance Valve (20) and Check Valve (21) to
30-35 ft. lb. (40-47 Nm).
When servicing, apply a light coat of grease to the Jack Pad

(2) before installing.
4-14 3121639
1. Barrel
1 2. Rod
3. Guide
4. Locknut
5. Piston
6. Piston Seal
7. O-Ring
8. Back-Up Ring
9. Seal
10. Wiper
11. Retainer Ring
12. O-Ring
4
6
5
7
8
9
3
10
11
12
Figure 4-14. Steer Cylinder
3121639 4-15
1 1. Barrel
2. Rod
3. Wiper
4. Wear Ring
5. Rod Seal
6. Plug
4 7. Piston Pilot
8. Check Valve
9. Bleeder Valve
5 NOTE: Torque item #8 to 25-27 lb-ft

(34-37 Nm)
THE CYLINDER ROD CAN SLIDE OUT OF THE

CYLINDER IF THE BLEEDER VALVE IS LOOS-
Figure 4-15. Oscillating Axle Cylinder
4-16 3121639
4.16 PRESSURE SETTING PROCEDURES NOTE: On the back of the control valve is a flow control valve. This
valve is used to adjust the lift down speed.
Main Relief at Pump Table 4-4. Valve Component Torque Values
1. Install pressure gauge at port “MP” on control valve.
COMPONENT Ft lb Nm
2. Remove the plug from the lift coil.
Main Relief 25 35
3. Activate and bottom out Lift Up. Adjust Main Relief to
3000 psi (207 bar). Lift Relief 25 35
4. Replace the plug on the lift coil. Steer Relief 20 28
Lift Relief Pressure Switch 12 16.8
1. With pressure gauge at “MP” port on control valve, acti- Brake 20 28

vate and bottom out Lift Up.
High Pressure Filter 50 70
2. Adjust Lift Relief to 2500 psi (172 bar) on the M3369/
3369LE and 2800 psi (193 bar) on the M4069/4069LE. Steer 20 28
Steer Relief Lift 25 35
1. With pressure gauge at “MP” port on control valve, acti- Flow Control 25 35
vate and bottom out Steer Left.
Coil Nuts 7 9.8
2. Adjust Steer Relief to 2500 psi (172 bar).
3. Repeat step one activating Steer Right.
4. Shut down hydraulic system and remove pressure
gauge.
3121639 4-17
Figure 4-16. Control Valve
10. The bearing cups will remain in hub as will the inner
bearing cone. The outer bearing cone will remain on the
output shaft. The lip seal will be automatically removed
4.17 DRIVE TORQUE HUB during this procedure.
NOTE: If bearing replacement is necessary, the bearing cups can

Disassembly be removed with a slide hammer puller or driven out with a
1. Loosen all cover bolts and drain oil from unit. punch.
2. Remove the cover bolts and lift off input cover. Remove 11. To remove the cluster gears from the carrier, drive the
and discard o-ring from counterbore of input cover. roll pin into the planet shaft. The planet shaft may now
3. Remove sun gear and thrust washer. be tapped out of the carrier. After planet shaft has been
removed, the roll pin can be driven out The cluster gear
4. Lift out the carrier and thrust washer. can now be removed from the carrier). The tanged
5. Remove input spacer. thrust washer will be removed from the cluster gear.
6. Lift out internal gear and thrust washer. 12. The needle bearings and thrust spacer are now removed
from cluster gear.
7. While wearing eye protection, remove the retaining ring
from the output shaft and discard. NOTE: When rebuilding or repairing the unit, the retaining ring, o-
rings, and seal should always be replaced.
8. Remove thrust washer from the output shaft.
9. The output shaft may now be pressed out of the hous-
ing.
4-18 3121639
Assembly 8. Sun gear is installed, meshing with the teeth of the large
diameter cluster gear. The counterbore on the sun gear
1. With the hub shaft sub-assembly resting on the shaft locates on the shoulder of the input spacer. This is to be
install internal gear. The spline of the internal gear. bore a slip fit and should operate freely.
will mesh with the spline of the output shaft.
9. Thrust washer is installed onto the sun gear and should
2. Thrust washer is installed on the face of the output shaft. locate on the gear teeth shoulder.
Sufficient grease or petroleum jelly should be used to
10. Thrust washer is installed into the counterbore of the
hold thrust washer in place.
carrier.
3. Place o-ring into hub counterbore. Use petroleum jelly
11. Place o-ring into input cover counterbore. Use petro-
to hold in place. Locate and mark the four counter
leum jelly to hold o-ring in place.
beamed holes in the face of the housing. This is for iden-
tification later in the assembly. 12. The input cover is now installed on this assembly. Taking
care to correctly align pipe plug hole with those in the
4. Thrust spacer is installed into the bore of the output
hub, usually 90° to one another, locate the four counter-
shaft. This should be a slip fit and the thrust spacer
bore holes in housing, marked in step (3) and install four
should rotate in this location.
shoulder bolts. A tap with a hammer may be necessary
5. Place carrier assembly on a flat surface with the gear to align shoulder bolt with hub counterbore.
cluster up. Find the punch marked tooth on each large
13. Install bolts into remaining holes.
gear and locate at 12 o’clock (straight up) from each
planet pin. 14. Pipe plugs are to be installed into input cover using a
lubricant seal.
6. With shoulder side of ring gear facing down, place ring
gear over (into mesh with) cluster gear. Be sure that 15. Torque bolts to 23 - 27 ft lbs (31- 36 NM).
punch marks remain in correct location during installa-
tion. The side of the ring gear with an “X” stamped on it 16. Fill unit one-half full with EP90 lubricant.
should be up.
7. While holding ring gear and cluster gear in mesh, place
small side of cluster gear into mesh with the internal
gear and sun gear. On the ring gear, locate the hole
marked “X” over one of the marked counterbored holes
in hub.
NOTE: If gears do not mesh easily or carrier assembly does not

rotate freely, then remove the carrier and ring gear and
check the cluster gear timing.
3121639 4-19
4.18 DRIVE ASSIST VALVE
2L
1R
T1
PR
T 1L MPR
PL 2R MPL
1L 2L 1R 2R
MPL PL PR MPR T1 T
VALVE SCHEMATIC
Figure 4-17. Drive Assist Valve
4-20 3121639
SECTION 5. JLG CONTROL SYSTEM

5.1 HAND HELD ANALYZER
men u:
Analyzer Dis- HELP:PRESS ENTER
Escape Key Enter Key

To return home or Stores and selects Top Level,
access previous menu Sub Level, and item menus
Left & Right Arrow Keys

Up & Down Arrow
Used to move between Top
Keys
Level, Sub Level, and item
Figure 5-1. Hand Held Analyzer
To Connect the Hand Held Analyzer: 2. Power up the Control System by turning the lower key to
the platform position and pulling both emergency stop
1. Connect the four pin end of the cable supplied with the buttons on.
analyzer, to the four position connector on the PCB and
connect the remaining end of the cable to the analyzer.
NOTE: The cable has a four pin connector at each end of the cable;
the cable cannot be connected backwards.
3121639 5-1
Using the Analyzer: In platform mode:

HELP:
With the machine power on and the analyzer connected prop- EVERYTHING OK,
erly, the analyzer will display the following: In ground mode:
HELP:
GROUND MODE OK
If ENTER is pressed again, the display moves to the following
display:
MENU:
HELP:PRESS ENTER
log:
1:Startup(2/1)
HELP:
PRESS ENTER
At this point, using the RIGHT and LEFT arrow keys, you can LOGGED HELP
move between the top level menu items. To select a displayed
menu item, press ENTER. To cancel a selected menu item, 1: STARTUP (2/1): (Or last recorded fault)
press ESC; then you will be able to scroll using the right and At this point, the analyzer will display the highest priority
left arrow keys to select a different menu item. active fault, if any are present. You may scroll through the fault
logs to view what the last 15 faults were. Use the right and left
The top level menus are as follows: arrow keys to scroll through the fault logs. The active faults, are
listed before the first POWER CYCLE. To return to the top
HELP menu, press ESC two times.
DIAGNOSTICS When a top level menu is selected, a new set of menu items
may be offered; If for example you choose Personalities:
ACTIVATE TESTS
DRIVE
ACCESS LEVEL
LIFT
PERSONALITIES STEER
MACHINE SETUP JOYSTICK
CALIBRATION: (Access level 1 only) Pressing ENTER with any of the above displayed menus, will
display additional sub-menus within the selected menu. In
If you press ENTER, at the HELP:PRESS ENTER display, and a some cases the next level is the parameter or information to
fault is present, the analyzer display will scroll the fault across be changed. Refer to the flow chart for what menus are avail-
the screen. If more than one fault is present only the highest able within the top level menus. You may only view the per-
priority fault will show. The other active faults are viewable in sonality settings for selected menus while in access level 2.
Logged Help. If there was no fault detected, the display will Remember, you may always cancel a selected menu item by
read: pressing the ESC key.
5-2 3121639
Changing the Access Level of the Hand Held Once the correct password is displayed, press ENTER. The
access level should display the following, if the password was
Analyzer: entered correctly:
When the analyzer is first connected, you will be in access level
2 which enables you to only view most configuration settings
which cannot be changed until you enter a password to
advance to a lower level. This ensures that a setting cannot be
accidentally altered. To change the access level, the correct MENU:
password must be entered. To enter the password, scroll to the ACCESS LEVEL 1
ACCESS LEVEL menu. For example:
MENU:
ACCESS LEVEL 2
MENU:
ACCESS LEVEL 1
Repeat the above steps if the correct access level is not dis-
played or you can not adjust the personality settings:
MENU:
ACCESS LEVEL 2
Press ENTER to select the ACCESS LEVEL menu.
Using the UP or DOWN arrow keys, enter the first digit of the
password, 3.
Then using the RIGHT arrow key, position the cursor to the
right one space to enter the second digit of the password.
Use the UP or DOWN arrow key to enter the second digit of
the password which is 3.
Repeat this process until you have entered all five digits of the
password which is 33271.
3121639 5-3
Adjusting Parameters Using the Hand Held Machine Setup

Analyzer When a machine digit item is selected, press the UP or DOWN
arrow keys to adjust its value, for example:
Once you have gained access to level 1, and a personality item
is selected, press the UP or DOWN arrow keys to adjust its
value, for example:
FAILURE TO MAKE THE PROPER SETTINGS FOR THE PAR-
TICULAR MACHINE CAN RESULT IN IMPROPER OPERATION.
PERSONALITIES:
DRIVE ACCEL 1.0s
GROUND ALARM:
1=MOTION
PERSONALITIES:
DRIVE ACCEL 1.0s
GROUND ALARM:
There will be a minimum and maximum for the value to 1=DESCENT
ensure efficient operation. The Value will not increase if the UP
arrow is pressed when at the maximum value nor will the The effect of the machine digit value is displayed along with
value decrease if the DOWN arrow is pressed and the value is its value. The above display would be selected if the machine
at the minimum value for any particular personality. If the was equipped with a ground alarm and you wanted it to
value does not change when pressing the up and down sound when driving. There are certain settings allowed to
arrows, check the access level to ensure you are at access install optional features or select the machine model.
level 1. When selecting the machine model to match the size of the
machine, the personality settings will return to default
settings.
5-4 3121639
NOTE: Refer to Table 5-3, Machine Model Adjustment, and Table 5.2 PC BOARDS
5-4, Machine Configuration Programming Information for
the default settings. PCB - JLG P/N 1001099428
Password 33271 will give you access to level 1, which will
permit you to change all machine personality and/or
machine setup settings.
CHANGING THESE SETTINGS MAY ADVERSELY AFFECT THE

PERFORMANCE OF YOUR MACHINE.
The flash code is indicated on the face of the platform control

box as shown:
SYSTEM
FAULT
Figure 5-2. PC Boards
NOTE: Figure 5-2., PC Boards, is shown for part distinguishing pur-

poses. PC Board (p/n 1001099428) is used on machines
with Software P1.0 and higher.
NOTE: For machines with software prior to P1.0, flash codes are
also displayed on the handheld analyzer. For descriptions
see,Table 5-1, Flash Codes/DTC’s.
IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING

ELECTRICAL/ELECTRONIC COMPONENTS. SHOULD PRES-
SURE-WASHING BE UTILIZED TO WASH AREAS CONTAIN-
I N G E L E C T R I C A L / E L E C T R O N I C CO M P O N E N T S , J LG
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.
3121639 5-5
5.3 FLASH CODES/DTC’S AND DESCRIPTIONS NOTE: Diagnostic Trouble Codes (DTC’s) will only show for
machines with software P1.0 and above. The 3 to 5 digit
DTC will display in parenthesis on the JLG Analyzer in the
NOTE: Machines with software prior to P1.0 will display the Flash
upper right corner of the display screen as shown below.
Code on the JLG Analyzer as shown below. The 2 digit Flash
Refer to Table 5-1 for DTC’s.
Code is scrolled at the end of the Help Message. Refer to
"Flash Code" column of Table 5-1.
hel p: ( 001) DTC

ever y t hi n g ok
hel p:
n g chan ge ( 2/ 2) .
FLASH
CODE
Table 5-1. Flash Codes/DTC’s
FLASH CODE DTC HELP MESSAGE AND DESCRIPTION

No Flash Code 000 HELP COMMENT
001 EVERYTHING OK
The normal help message in Platform Mode.
002 GROUND MODE OK
The normal help message in Ground Mode.
0022 DIFFERENT FUNCTION SELECTED & IGNORED
A function (i.e. Drive, Lift, etc.) is active and the operator has selected another function. The system has ignored the new selection.
0023 FUNCTION SELECTED BUT TRIGGER SWITCH OPEN
A function (i.e. Drive, Lift, etc.) has been selected by the operator, but the trigger switch is not active (closed).
0024 JOYSTICK MOVED BUT NO FUNCTION SELECTED
The joystick was moved out of the center position before a function was selected.
0025 ALARM SOUNDING - PLATFORM OVERLOADED
Load Sensing System indicates that the platform is overloaded. Applicable when Machine Setup’s Load is set to "1 = CUTOUT PLT" and the vehicle is
operating in Ground Mode.
003 ALARM SOUNDING - TILTED & ABOVE ELEVATION
Platform is elevated and the chassis is not level. Applicable when Machine Setup’s TILT CUTOUT is set to 0 = NO.
004 DRIVING AT CUTBACK - ABOVE ELEVATION
Platform is elevated and the machine is in the drive mode of operation.
005 DRIVE & LIFT UP PREVENTED - TILTED & ELEVATED
Machine is exceeding tilt allowance and platform is elevated above allowed height. Applicable when Machine Setup’s TILT CUTOUT is set to 1 = YES.
009 DRIVE PREVENTED - ELEVATED ABOVE DRIVE CUTOUT HEIGHT
Machin is elevated above the drive cutout height. Not applicable when Machine Setup’s MODEL is set to 0 = 3369LE.
2-1 210 POWER UP
211 POWER CYCLE
A new system power up has occurred since the last help message.
212 KEYSWITCH FAULTY
Both Platform and Ground modes are selected simultaneously.
5-6 3121639

2-2 220 PLATFORM CONTROLS
221 FUNCTION PROBLEM - HORN PERMANENTLY SELECTED
Horn switch in platform control box closed at start up. Release switch to clear fault.
2210 TRIGGER CLOSED TOO LONG WHILE IN NEUTRAL
Trigger switch in the platform control box closed for more than ten seconds while the joystick is in the neutral position. Release switch to clear fault.
2234 FUNCTION PROBLEM - DRIVE PERMANENTLY SELECTED
Drive select switch in the platform control box closed at start up or for more than ten seconds. Release switch to clear fault.
2235 FUNCTION PROBLEM - LIFT PERMANENTLY SELECTED
Lift select switch in the platform control box closed at start up or for more than ten seconds. Release switch to clear fault.
2236 FUNCTION PROBLEM - O/R PERMANENTLY SELECTED
An outrigger select switch in the platform control box closed at start up or for more than ten seconds. Release switch to clear fault.
2237 JOYSTICK FAULTY - STEER SWITCHES ACTIVE TOGETHER
Both the steer left and steer right inputs are closed at the same time. A short in the steer switch wiring or a failed steer switch can cause this.
2238 FUNCTIONS LOCKED OUT - SHORT TO PLATFORM ROW INPUT
A short circuit to IGN has been detected in the platform cable wiring.
2239 FUNCTION PROBLEM - JOYSTICK CALIBRATION FAULTY
The Personalities for the Joystick are improperly adjusted or a joystick calibration attempt failed. Re-adjust or recalibrate.
224 FUNCTION PROBLEM - STEER LEFT PERMANENTLY SELECTED
Steer left switch in the platform control box closed at start up. Release switch to clear fault.
225 FUNCTION PROBLEM - STEER RIGHT PERMANENTLY SELECTED
Steer right switch in the platform control box closed at start up. Release switch to clear fault.
226 ACCELERATOR (or JOYSTICK) FAULTY - WIPER OUT OF RANGE
The joystick wiper signal input is outside the acceptable voltage range. The wiper wire being off, the wiper wire shorted to battery power, or the wiper
wire shorted to battery negative could cause this.
228 FUNCTION LOCKED OUT - JOYSTICK NOT CENTERED
Selected function is not allowed because the joystick is not centered. Return joystick to center and reselect function.
229 FUNCTION PROBLEM - TRIGGER PERMANENTLY CLOSED
Trigger switch in the platform control box closed at start up. Release switch to clear fault.
N/A ELEV ANGLE SENSOR NOT DETECTING CHANGE
Platform elevated for 5 sec. and elevation voltage change not detected. Faulty sensor, wire harness, or ground module. Return platform to stowed posi-
tion to clear. Reset model or recalibrate elev angle sensor.
N/A TRIGGER CLOSED TOO LONG WHILE IN NEUTRAL
Trigger switch in the platform control box closed for more than ten seconds while the joystick is in the neutral position. Release switch to clear fault.
2-3 230 GROUND CONTROLS
231 FUNCTION PROBLEM - LIFT PERMANENTLY SELECTED
Lift switch (up or down) in the ground control box closed at start up. Release switch to clear fault.
N/A NO DATA FROM TILT SENSOR - NOT CONNECTED OR FAULTY
No signal from the tilt switch. Check wiring and plug connections at the level sensor and at the ground control board.
3121639 5-7

2-5 250 FUNCTION PREVENTED
251 ELEV ANGLE SESOR FAULTY - VOLTAGE OUT OF RANGE
The sensor signal input voltage is outside acceptable range. This could be a short to IGN, short to B+, short to ground, or sensor not properly mounted.
2512 ELEV ANGLE SENSOR NOT DETECTING CHANGE
Platform elevated for 5 sec. and elevation voltage change not detected. Fault sensor, wire harness, or ground module. Return platform to stowed posi-
tion to clear. Reset Model or recalibrate elev angle sensor
252 ELEV ANGLE SENSOR HAS NOT BEEN CALIBRATED
Calibrate elevation rotary sensor using calibration procedure.
2535 SHORT DETECTED ON IGNITION WIRING - CHECK HARNESS
A short to ground has been detected on one of the following: J2-21, J2-22, J2-23, J2-27, J2-28, J3-7, J3-10, J5-5
2536 ALL FUNCTIONS PREVENTED - FUNCTION CUTOUT ACTIVE
Machine Setup’s FUNCTION CUTOUT is set for "2 = ALL FUNCTIONS" and Ground Module J2-11 is de-energized by an external safety device.
2537 DRIVE & LIFT UP PREVENTED - FUNCTION CUTOUT ACTIVE
Machine Setup’s FUNCTION CUTOUT is set for "1 = DRV & LFT UP" and Ground Module J2-11 is de-energized by an external safety device.
2538 FUNCTION PREVENTED - CHARGER CONNECTED
Disconnect AC line from charger to clear fault.
255 PLATFORM OVERLOADED
Machine Setup’s LOAD is set to "1 = CUTOUT PLT" or "2 = CUTOUT ALL" and the Load Sensing System indicates that the platform is overloaded.
257 ELEV PROX PERMANENTLY CLOSED - CHECK PROX AND ANGLE ADJUSTMENT
Elevation proximity sensor closed. This could be due to a misadjustment of the prox or angle mount sensor or metal debris on the prox.
N/A ELEV PROX PERMANENTLY OPEN - CHECK PROX AND ANGLE ADJUSTMENT
3-1 310 LINE CONTACTOR OPEN CIRCUIT
311 OPEN CIRCUIT LINE CONTACTOR
Line contactor did not close.
313 OPEN CIRCUIT PUMP CONTACTOR
Pump contactor did not close.
3-2 320 LINE CONTACTOR SHORT CIRCUIT
321 LINE CONTACTOR MISWIRED ON OR WELDED
The line contactor is permanently closed or the coil is wired improperly.
323 PUMP CONTACTOR MISWIRED ON OR WELDED
The pump contactor is permanently closed or the auxiliary contacts are wired improperly.
3-3 330 GROUND OUTPUT DRIVER
33330 SHORT CIRCUIT LINE/PUMP CONTACTOR COIL
The line or pump contactor coils are shorted to ground or mis-wired.
4-2 420 THERMAL LIMIT
421 POWER MODULE TOO HOT - PLEASE WAIT
The power module over the rear axle is too hot. Allow to cool by powering down.
425 POWER CONVERTER TOO HOT - PLEASE WAIT
Switching power supply in ground control box too hot. Allow to cool by powering down to clear fault.
4-4 440 BATTERY SUPPLY
441 BATTERY VOLTAGE TOO LOW - SYSTEM SHUTDOWN
Recharge batteries or check for damaged batteries.
442 BATTERY VOLTAGE TOO HIGH - SYSTEM SHUTDOWN
Disconnect battery charger. Check that the correct voltage batteries are being used.
N/A BATTERY CHARGE TOO LOW - SYSTEM SHUTDOWN
5-8 3121639

6-6 660 COMMUNICATION
661 CANBUS FAILUR: POWER MODULE
Lost communication to power module. Check wiring at ground control and power module. Recycle power to clear fault.
7-7 770 ELECTRIC MOTOR
773 CAPACITOR BANK FAULT - CHECK POWER CIRCUITS
Check power wiring. If no error in power wiring, replace power controller.
775 OPEN CIRCUIT FIELD (or TRACTION) WIRING
Open circuit between F1 and F2 terminals on power module and the drive motors. Check wiring.
8-1 810 TILT SENSOR
812 NO DATA FROM TILT SENSOR - NOT CONNECTED OR FAULTY
No signal from the tilt switch. Check wiring and plug connections at the level sensor and at the ground control box.
9-9 990 HARDWARE
995 POWER MODULE FAILURE - PERSONALITY RANGE ERROR
Toggle MODEL then re-configure Machine Setup and Personalities. If this does not resolve issue, replace power controller.
996 POWER MODULE FAILURE - INTERNAL ERROR
997 POWER MODULE FAILURE - CHECK POWER CIRCUITS OR MOSFET SHORT CIRCUIT
Check power wiring. If no error in power wiring module, replace power controller.
9980 POWER MODULE FAILURE - PERSONALITY CRC ERROR
N/A POWER MODULE FAILURE - CAPACITOR BANK FAULT
Replace power module.
3121639 5-9
Table 5-2. Power Module Diagnostic LED Flash Codes
Flash Code Fault
Constant Illumination No Fault, Normal Condition
LED Extinguished Internal Controller Fault
1 Flash Personality Out of Range
2 Flashes Illegal Start Condition or Illegal Steer Switch Input
3 Flashes MOSFET Short Circuit
4 Flashes Contactor Fault or Motor Open Circuit
5 Flashes Not Used
6 Flashes Accelerator, Steer Pot or Speed Probe Wire Default
7 Flashes Low or High Battery Voltage or BDI Cut-Out Operating
8 Flashes Over Temperature
9 Flashes Contactor Coil Short Circuit
12 Flashes CAN Bus Fault
5-10 3121639
3121639
(Press Escape Twice to Return to Help)
- Top Level Menu

- Sub Level Menu
- Item to be Viewed
or Changed
*(Outrigger Option Only)

**(Test in Ground Mode)
***(Test in Platform Mode)
NOTE: IN ORDERTO RUN “SYSTEM TEST”, THE OPERATORMUST ENTERPASSWORD 33271
Figure 5-2. Analyzer Flow Chart - Software P1.X - Sheet 1 of 3
5-11
5-12
BYPRESSING THESE ARROWKEYS ( ) YOU CAN SCROLL THROUGH THE TOP LEVEL MENUS.
- Top Level Menu

- Sub Level Menu
- Item to be Viewed
or Changed
3121639
3121639
BYPRESSING THESE ARROWKEYS ( ) YOU CAN SCROLL THROUGH THE TOP LEVEL MENUS.
*(CE Market Only)

**(All Markets Except Japan) - Top Level Menu
***(All Markets Except ANSI USA and CSA)
****(3369LE Model for CE Market Only) - Sub Level Menu
- Item to be Viewed
or Changed
5-13
Table 5-3. Machine Model Adjustment
Adjustment Adjustment Range Default Values - 3369LE Default Values - 4069LE

DRIVE
ACCEL 1.0 - 5.0 (sec) 3.5 3.5
DECEL 0.1 - 5.0 s (sec) 0.1 0.1
MINIMUM 1 - 6% 4 4
MAXIMUM 30 - 100% 100 100
ELEVATED 1 - 15% 10 10
LOW MAX 35 - 65% 50 50
BRAKE FLOW 15 - 100% 75 75
OSC AXLE 15 - 100% 50 50
OSC AXLE 0.1 - 5.0 (sec) 1.0 1.0
4WA MAX 35 - 65% 40 40
4 WHEEL ASSIST*
ACCEL 1.0 - 5.0 (sec) 2.0 2.0.
DECEL 0.1 - 5.0 (sec) 0.1 0.1
MIN 4WA 0 - 25% 16 16
MAX 4WA 25 - 100% 75 75
ACCELERATOR THRESH 0 - 100% 75 75
DRIVE SPEED 0 -1.5 MPH 0.5 0.5
LIFT
ACCEL 0.2 - 5.0 (sec) 2.0 2.0
DECEL 0.2 - 5.0 (sec) 0.5 0.5
MIN UP 0 - 25% 16 16
MAX UP 25 - 100% 65 65
LOW MAX 35 - 65% 35 35
STEER
STATIC LEFT 15 - 100% 31 31
STATIC RIGHT 15 - 100% 37 37
DRIVE LEFT 15 - 100% 23 23
DRIVE RIGHT 15 - 100% 25 25
JOYSTICK
FWD MAX 0 - 5.0 V 0.65 0.65
FWD MIN 0 - 5.0 V 2.25 2.25
REV MIN 0 - 5.0 V 2.80 2.80
REV MAX 0 - 5.0 V 4.45 4.45
4150351_E
NOTE: These settings may change in order to achieve optimal per-

formance on a machine by machine basis.
* The 4 Wheel Assist Menu will not be available if the option
is not configured.
5-14 3121639
NOTE: When configuring an LE scissors machine, the machine tings first and then changing the model number of the
configuration must be completed before any personality machine configuration will cause the personality settings
settings can be changed. Changing the personality set- to return to default.
Table 5-4. Machine Configuration Programming Information
Default Number
Configuration Digit Number Description
0 1 2 3 4 5
1 0 3369LE
0
(MODEL #) 1 4069LE
0 ANSI USA
1 ANSI EXPORT
2 2 CSA
3 0
(MARKET) CE
4 AUSTRALIA
5 JAPAN
3 0 NO - Drive & Lift Up not prevented when Tilted & Elevated

1 1 1 0 1 1
(TILT CUTOUT) 1 YES - Drive & Lift Up prevented when Tilted & Elevated.
4 0 NO - Leveling Jacks are not installed.

1 0
(LEVELING JACKS) YES - Leveling Jacks are installed.
5 0 DRIVE - Drive is prevented when the vehicle is being charged.

0
(CHARGER INTRLOK) 1 DRIVE & LIFT - Drive & Lift Up are prevented when the vehicle is being charged.
0 NOT INSTALLED - The Ground Alarm shall not sound

6 1 DESCENT - The Ground Alarm shall sound during Lift Down 1 1 1 1 1 2
(GROUND ALARM) 2 MOTION - The Ground Alarm shall sound during any vehicle motion.
0 NONE
7 1 DRV & LFT UP - Only allows Lift Down when Function Cutout is active. 0
(FUNCTION CUTOUT) 2 ALL FUNCTIONS - All functions are prevented when Function Cutout is active
8 0 NO - The 4 Wheel Assist option is not installed.

0
(4 WHEEL ASSIST) 1 YES - The 4 Wheel Assist option is installed.
0 NOT INSTALLED - Load Sensing System (LSS) is not fitted to the vehicle.
1 CUTOUT PLT - LSS is fitted, and Platform Controls are prevented in the event of an
9
Overload. Ground Controls remain functional. This is the default setting for CE machines. 0 1 0 1 0 1
(LOAD)
CUTOUT ALL - LSS is fitted. Platform and Ground Controls are prevented in the event of
2 an Overload
0 STANDARD - Normal tilt limits.

1 SPECIAL 1 - Vehicle tilt limits restricted to allow operation of a standard 3369LE in 16.7
10 m/s wind speeds for the CE Market.
0 0 0 0 0 0
(TILT LIMIT)* NOTE: Tilt Limit selection is only visible for the 3369LE configured
for the CE Market. The selection will default to STANDARD
otherwise.
4150352_G
3121639 5-15
5.4 GROUND CONTROL CIRCUIT BOARD

Software Version P1.X
Table 5-5. J1 Connector
PIN TAGNAME FUNCTION TYPE

1 PLTS Platform Select POWER OUTPUT
2 PLTE Platform EMS POWER INPUT
3 GND Ground POWER OUTPUT
4 COL0 Column 0 Output DIGITAL OUTPUT
7 PCTL Joystick Input (0 - 5VDC) ANALOG INPUT
8 ROW0 Row 0 Input DIGITAL INPUT
14 LCLK LED Latch Clock Output DIGITAL OUTPUT
15 ALRM Platform Alarm DIGITAL OUTPUT
16 IGN Ignition Power (+12V; 750mA Limit) POWER OUTPUT
17 GALR Ground Alarm DIGITAL OUTPUT
18 DO9 Spare High-Side Digital Output 9 (12V, 5A) DIGITAL OUTPUT
19 QPRX Trigger Switch POWER INPUT
20 GNDE Ground EMS (from J5-2; 500mA Limit) POWER OUTPUT
21 GINH Generator Inhibit Start Switch POWER I/O
22 CANH1 CANBUS High CH1 SERIAL I/0
24 CANL1 CANBUS High CH1 SERIAL I/0
5-16 3121639

1 B+ Control System Supply (+48V) POWER INPUT
2 GND Control System Ground POWER INPUT
3 LTS Steer Left Solenoid Valve DIGITAL OUTPUT
4 RTS Steer Right Solenoid Valve DIGITAL OUTPUT
5 DPS Flow Control Solenoid Valve FWM OUTPUT
6 BRS Brake Solenoid Valve DIGITAL OUTPUT
7 UPS Lift Up Solenoid Valve DIGITAL OUTPUT
8 DDNS Lift Down Solenoid Valve FWM OUTPUT
9 HORN Horn Relay (+48V) DIGITAL OUTPUT
11 FCU Load Sensing System / Function Cutout Input DIGITAL INPUT
12 BPS Brake Pressure Switch DIGITAL INPUT
13 ELPX Elevation Prox Switch DIGITAL INPUT
14 APWR +5V Analog Excitation for Elevation Angle Sensor POWER OUTPUT
15 ANGL Elevation Angle Sensor Analog Input (0 -5VDC) ANALOG INPUT
16 12V 12V Sensor Supply POWER OUTPUT
17 SPD 4 Wheel Assist Speed Sensor Analog Input (FRBQ) ANALOG INPUT
18 CANH CANbus High to Power Module SERIAL I/O
19 CANL CANbus Low to Power Module SERIAL I/O
20 CANS CANbus Shield (Ground) POWER OUTPUT
21 IGN Ignition Power (+12V) POWER OUTPUT
26 PWRON Power On (GNDS or PLTE Powered; 1.8A Limit) POWER OUTPUT
31 CHGI Charger Interlock Input DIGITAL INPUT
32 DI9 Spare High-Sensing Digital Input 9 DIGITAL INPUT
35 DO17 Spare High-Sensing Digital Output 17 (12V, 5A) DIGITAL OUTPUT
36 DO18 Spare High-Sensing Digital Output 18 (12V, 5A) DIGITAL OUTPUT
37 4WAF 4 Wheel Assist Forward Solenoid Valve DIGITAL OUTPUT
3121639 5-17

38 4AWR 4 Wheel Assist Reverse Solenoid Valve DIGITAL OUTPUT
39 OSAX Oscillating Axle Solenoid Valves DIGITAL OUTPUT
40 DO22 Spare High-Side Digital Output 22 (12V, 5A) DIGITAL OUTPUT

1 DO23 High-Side Digital Output 23 (12V, 5A) DIGITAL OUTPUT
5 DI12 High-Sensing Digital Input 12 DIGITAL INPUT
8 ORSTO Outrigger Set Input DIGITAL INPUT
9 ORSET Outrigger Stow Input DIGITAL INPUT
11 FLU Front-Left O/R Up Solenoid Valve DIGITAL OUTPUT
12 FLD Front-Left O/R Down Solenoid Valve DIGITAL OUTPUT
13 FRU Front-Right O/R Up Solenoid Valve DIGITAL OUTPUT
14 FRD Front-Right O/R Down Solenoid Valve DIGITAL OUTPUT
15 RLU Rear-Left O/R Up Solenoid Valve DIGITAL OUTPUT
16 RLD Rear-Left O/R Down Solenoid Valve DIGITAL OUTPUT
17 RRU Rear-Right O/R Up Solenoid Valve DIGITAL OUTPUT
18 RRD Front-Right O/R Down Solenoid Valve DIGITAL OUTPUT
19 GMST Generator Manual Start (to J5-13) POWER I/O
20 GINH Generator Inhibit Start (to J1-21) POWER I/O
21 GFLT Generator Fault LED (to J5-14) POWER I/O
22 GNDE Ground EMS (from J5-2; 500mA Limit) POWER OUTPUT
5-18 3121639

1 12V 12V Sensor Supply POWER OUTPUT
2 TILTX X-Axis Tilt Input (PWM) ANALOG INPUT
3 TILTY Y-Axis Tilt Input (PWM) ANALOG INPUT

1 B+ Master Supply Connection (from J2-1) POWER OUTPUT
2 GNDE Ground EMS (to J1-20, J3-22) POWER INPUT
3 PLTS Platform Select Input (to J1-1) POWER INPUT
4 GNDS Ground Select Input POWER INPUT
7 UPG Ground Lift Up Switch DIGITAL INPUT
8 DNG Ground Lift Down Switch DIGITAL INPUT
9 FDH Full Drive Height Input DIGITAL INPUT
13 GMST Generator Manual Start (to J3-19) POWER I/O
14 GFLT Generator Fault LED (to J3-21) POWER I/O
15 HRMT Hourmeter DIGITAL OUTPUT

1 12V Ignition Power (+12V) POWER OUTPUT
2 RX RS-232 Serial Receive SERIAL INPUT
3 TX RS-232 Serial Transmit SERIAL OUTPUT
3121639 5-19
NOTES:
5-20 3121639
SECTION 6. GENERAL ELECTRICAL INFORMATION & SCHEMATICS

6.1 GENERAL Backprobing
This section contains schematics to be used for locating and To "backprobe" means to take the measurement by accessing
correcting most of the operating problems which may a connector’s contact on the same side as the wires, the back
develop. If a problem should develop which is not presented of the connector. Readings can be done while maintaining cir-
in this section or which is not corrected by listed corrective cuit continuity this way. If the connector is the sealed type,
actions, technically qualified guidance should be obtained great care must be taken to avoid damaging the seal around
before proceeding with any maintenance. the wire. It is best to use probes or probe tips specifically
designed for this technique, especially on sealed connectors.
Whenever possible insert probes into the side of the connec-
tor such that the test also checks both terminals of the con-
IT IS GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELEC-
nection. It is possible to inspect a connection within a closed
TRONIC COMPONENTS. IN THE EVENT PRESSURE-WASHING THE MACHINE IS
connector by backprobing both sides of a connector terminal
NEEDED, ENSURE THE MACHINE IS SHUT DOWN BEFORE PRESSURE-WASH-
and measuring resistance. Do this after giving each wire a gen-
ING. SHOULD PRESSURE WASHING BE UTILIZED TO WASH AREAS CONTAINING
tle pull to ensure the wires are still attached to the contact and
ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC. RECOMMENDS
contacts are seated in the connector.
A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A MINIMUM DISTANCE OF 12
INCHES (30.5CM) AWAY FROM THESE COMPONENTS. IF ELECTRICAL/ELEC-
TRONIC COMPONENTS ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND BE
Min/Max
FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION. Use of the "Min/Max" recording feature of some meters can
help when taking measurements of intermittent conditions
6.2 MULTIMETER BASICS while alone. For example, you can read the voltage applied to
a solenoid when it is only operational while a switch, far from
A wide variety of multimeters or Volt Ohm Meters (VOM) can the solenoid and meter, is held down.
be used for troubleshooting your equipment. A digital meter
with reasonable accuracy (within 7%) is recommended for the Polarity
measurements in these procedures. This section shows dia-
grams of a common, digital VOM configured for several differ- Finding a negative voltage or current reading when expecting
ent circuit measurements. Instructions for your VOM may vary. a positive reading frequently means the leads are reversed.
Please consult the meter operator’s manual for more informa- Check what reading is expected, the location of the signal and
tion. that the leads are connected to the device under test correctly.
Also check that the lead on the "COM" port goes to the ground
Grounding or negative side of the signal and the lead on the other port
goes to the positive side of the signal.
"Grounding the meter" means to take the black lead (which is
connected to the COM (common) or negative port) and touch Scale
it to a good path to the negative side of the voltage source.
M = Mega = 1,000,000 * (Displayed Number)
k = kilo = 1,000 * (Displayed Number)
m = milli = (Displayed Number) / 1,000
μ = micro = (Displayed Number) / 1,000,000
Example: 1.2 k = 1200 
Example: 50 mA = 0.05 A
3121639 6-1
Voltage Measurement Resistance Measurement
Figure 6-1. Voltage Measurement (DC) Figure 6-2. Resistance Measurement
• If meter is not auto ranging, set it to the correct range • First test meter and leads by touching leads together.
(See multimeter’s operation manual) Resistance should read a short circuit (very low resis-
tance)
• Use firm contact with meter leads
• Circuit power must be turned OFF before testing resis-
tance
• Disconnect component from circuit before testing
• If meter is not auto ranging, set it to the correct range
(See multimeter’s operation manual)
• Use firm contact with meter leads
6-2 3121639
Continuity Measurement Current Measurement
Figure 6-3. Continuity Measurement Figure 6-4. Current Measurement (DC)
• Some meters require a separate button press to enable • Set up the meter for the expected current range
audible continuity testing
• Be sure to connect the meter leads to the correct jacks for
• Circuit power must be turned OFF before testing continu- the current range you have selected
ity
• If meter is not auto ranging, set it to the correct range
• Disconnect component from circuit before testing (See multi meter’s operation manual)
• Use firm contact with meter leads • Use firm contact with meter leads
• First test meter and leads by touching leads together.
Meter should produce an audible alarm, indicating conti-
nuity
3121639 6-3
Continuity Measurement Over Long Distances 1. Disconnect all connections associated with the wire
under test and the two additional wires. If harness is not
When trying to determine continuity of a harness or wire, lon- completely isolated disconnect battery terminals also,
ger than the reach of standard instrument leads, is possible to as a precaution.
perform the check without excessively long leads. Using the
other wires in the harness one can determine the condition of 2. Measure continuity between all three wires, the wire
a particular wire in the harness. under test, wire #1 and wire #2. These should be open. If
not, repair the shorted wires or replace the harness.
Requirements: 3. On one side, jumper from contact of wire #1 and wire #2.
• Harness with at least three separate wires including the wire 4. Measure continuity between wire #1 and wire #2. If
under test. there is continuity, both wires are good and can be used
• These wires must be able to be isolated from other wires, etc. for this test. If there is not continuity, either wire could
be bad. Check connections and measurement setup.
• Jumper or method to connect contacts on one side of har- Redo measurement. If still no continuity, repair wires or
ness. consult schematic for other wires to use for test.
• Meter that can measure resistance or continuity. 5. Jumper from wire under test to wire #1.
Procedure 6. Measure continuity. If there is continuity, the wire under

test is good. Resistance of a wire increases as the length
Test multimeter leads resistance. Subtract this value from the increases and as the diameter decreases.
measured resistance of the wires to get a more accurate mea-
surement. One can find the continuity of two wires, here #1 and #2, at
once by following steps 1 through 4. If there is a problem the
Consult the circuit schematic to determine which wires to use third wire is used to troubleshoot the other wires. To find the
in addition to wire under test, here called wire #1 and wire #2, problem, start at step 1 and use the entire procedure.
and how to isolate these wires. These wires should appear in
the same connectors as the wire under test or are within reach
of the jumper.
6-4 3121639
6.3 APPLYING SILICONE DIELECTRIC male and female pins on the inside of the connector
after the mating of the housing to the header. This is
COMPOUND TO AMP CONNECTORS easily achieved by using a syringe to fill the header with
Silicone Dielectric Compound must be used on the AMP con- silicone dielectric compound, to a point just above the
nections for the following reasons: top of the male pins inside the header. When assem-
bling the housing to the header, it is possible that the
• To prevent oxidation at the mechanical joint between male housing will become air locked, thus preventing the
and female pins. housing latch from engaging.
• To prevent electrical malfunction caused by low level con-
2. Pierce one of the unused wire seals to allow the trapped
ductivity between pins when wet.
air inside the housing to escape.
Use the following procedure to apply Silicone Dielectric Com-
pound to the electrical connectors. 3. Install a hole plug into this and/or any unused wire seal
that has silicone dielectric compound escaping from it.
1. To prevent oxidation and low level conductivity, silicone
dielectric grease must be packed completely around
Figure 6-5. AMP Connector
3121639 6-5
Assembly
Check to be sure the wedge lock is in the open, or as-shipped, position (See Figure 6-6. Connector Assembly (1 of 4)).
Proceed as follows:
Figure 6-6. Connector Assembly (1 of 4)

1. To insert a contact, push it straight into the appropriate 3. After all required contacts have been inserted, the
circuit cavity as far as it will go (See Figure 6-7. Connec- wedge lock must be closed to its locked position.
tor Assembly (2 of 4)). Release the locking latches by squeezing them inward
(See Figure 6-8. Connector Assembly (3 of 4)).
2. Pull back on the contact wire with a force of 1 or 2 lbs. to
be sure the retention fingers are holding the contact 4. Slide the wedge lock into the housing until it is flush
(See Figure 6-7. Connector Assembly (2 of 4)). with the housing (See Figure 6-9. Connector Assembly
(4 of 4)).
6-6 3121639
3121639 6-7
Disassembly 2. Pry open the wedge lock to the open position.

3. While rotating the wire back and forth over a half turn
1. Insert a 4.8 mm (3/16”) wide screwdriver blade between
(1/4 turn in each direction), gently pull the wire until the
the mating seal and one of the red wedge lock tabs.
contact is removed.
Figure 6-10. Connector Disassembly
NOTE: The wedge lock should never be removed from the housing
for insertion or removal of the contacts.
Wedge Lock
The wedge lock has slotted openings in the forward, or mating
end. These slots accommodate circuit testing in the field, by
using a flat probe such as a pocket knife. DO NOT use a sharp
point such as an ice pick.
6-8 3121639
Service - Voltage Reading It has been common practice in electrical troubleshooting to

probe wires by piercing the insulation with a sharp point. This
practice should be discouraged when dealing with the
AMPSEAL plug assembly, or any other sealed connector sys-
DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS. tem. The resulting pinholes in the insulation will allow mois-
ture to invade the system by traveling along the wire strands.
This nullifies the effectiveness of the connector seals and
could result in system failure.
Figure 6-11. Connector Installation
3121639 6-9
6.4 WORKING WITH DEUTSCH CONNECTORS HD30/HDP20 Series Assembly

DT/DTP Series Assembly
Figure 6-12. DT/DTP Contact Installation Figure 6-14. HD/HDP Contact Installation
1. Grasp crimped contact about 25mm behind the contact 1. Grasp contact about 25mm behind the contact crimp
barrel. barrel.
2. Hold connector with rear grommet facing you. 2. Hold connector with rear grommet facing you.
3. Push contact straight into connector grommet until a 3. Push contact straight into connector grommet until a
click is felt. A slight tug will confirm that it is properly positive stop is felt. A slight tug will confirm that it is
locked in place. properly locked in place.
4. Once all contacts are in place, insert wedgelock with
arrow pointing toward exterior locking mechanism. The
wedgelock will snap into place. Rectangular wedges are
not oriented. Thy may go in either way.
NOTE: The receptacle is shown - use the same procedure for plug.
Figure 6-15. HD/HDP Locking Contacts Into Position
DT/DTP Series Disassembly
NOTE: For unused wire cavities, insert sealing plugs for full envi-
ronmental sealing.
Figure 6-13. DT/DTP Contact Removal

1. Remove wedgelock using needlenose pliers or a hook
shaped wire to pull wedge straight out.
2. To remove the contacts, gently pull wire backwards,
while at the same time releasing the locking finger by
moving it away from the contact with a screwdriver.
3. Hold the rear seal in place, as removing the contact may
displace the seal.
6-10 3121639
HD30/HDP20 Series Disassembly
Figure 6-16. HD/HDP Contact Removal

1. With rear insert toward you, snap appropriate size
extractor tool over the wire of contact to be removed.
2. Slide tool along into the insert cavity until it engages
contact and resistance is felt.
3. Pull contact-wire assembly out of connector.
Figure 6-17. HD/HDP Unlocking Contacts
NOTE: Do Not twist or insert tool at an angle.
3121639 6-11
PUMP/MOTOR
DRIVE
CONTACTOR
TO BATTERIES
RIGHT
DRIVE
MOTOR
DRIVE
CONTROLLER
F2
LEFT
DRIVE
MOTOR
MAIN
VALVE
PLATFORM
CONSOLE
BOX
BATTERY
CHARGER
TO GROUND
CONTROL BOX
TERMINAL J1
LIFT
CYLINDER
PRESSURE
TRANSDUCER OR
OVERLOAD
CUT-OUT
Figure 6-18. Electrical Components Installation - (Sheet 1 of 4)
6-12 3121639
TO
MOTOR/ GENERATOR
GENERATOR MODULE
J2
TO
ANALYZER
PROXIMITY SENSOR
SWITCH (USA BUILT
MACHINES S/N
4WD 0200138293 TO PRESENT)
LEFT
SIDE
MOTOR
ROTARY
PROXIMITY SENSOR ANGLE
SWITCH (USA BUILT SENSOR
OSCILLATING MACHINES PRIOR TO SWITCH
AXLE S/N 0200138293 & ALL
CYLINDERS BELGIUM BUILT
MACHINES)
HORN
TO
BEACON
LIGHT
HARNESS
GROUND
CONTROL
BOX
TO
ANALYZER
PC BOARD TO
CONTROLLER ANALYZER
3121639 6-13
LEVEL
JACK
SWITCHES
TO
GENERATOR
MODULE
(M3369 & M4069)
LEVEL
JACK
VALVES
ALARM BEACON
LIGHT
VALVE
HARNESS
TO
PLATFORM
GROUND
CONTROL
BOX
6-14 3121639
DRIVE
DRIVE CONTACTOR
CONTROLLER
CIRCUIT
BREAKER
RECEPTACLE
AT PLATFORM
PLATFORM
CONSOLE
BOX
PLATFORM
WORKLIGHTS
3121639 6-15
6.5 ELECTRICAL SCHEMATICS
Figure 6-22. Electrical Schematic (All except AUS)
6-16 3121639
1001171104_F-Sht. 1 of 3
Figure 6-22., Electrical Schematic (All except AUS)
3121639 6-17
6-18 3121639
1001171104_F-Sht. 2 of 3
3121639 6-19
6-20 3121639
1001171104_F-Sht. 3 of 3
3121639 6-21
Figure 6-23. Electrical Schematic (AUS)
6-22 3121639
1001171105_D-Sht. 1 of 2
Figure 6-23., Electrical Schematic (AUS)
3121639 6-23
6-24 3121639
1001171105_D-Sht. 2 of 2
3121639 6-25
Figure 6-24. Hydraulic Schematic (All except CE)
6-26 3121639
1001167495_C
Figure 6-24., Hydraulic Schematic (All except CE)
3121639 6-27
1001191135_B
Figure 6-25. Hydraulic Schematic (CE)
6-28 3121639
Figure 6-25., Hydraulic Schematic (CE)
3121639 6-29
NOTES:
6-30 3121639
3121639
Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg, PA 17233-9533 USA
(717) 485-5161 (Corporate)
(877) 554-5438 (Customer Support)
(717) 485-6417
Visit our website for JLG Worldwide Locations.

www.jlg.com

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Service and Maintenance Manual

July 23, 2018 - Rev C

SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

HYDRAULIC SYSTEM SAFETY • BATTERY SHOULD ALWAYS BE DISCONNECTED DUR-

SECTION 3 - CHASSIS & SCISSOR ARMS

4.1 Servicing and Maintenance Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.15 Cylinder Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

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

This page left blank intentionally

Description 3369LE/M3369 4069LE/M4069

Max. Slope (Front - Back) 5° Up to 25 ft

Max. Tire Load 3200 lbs 3700 lbs

Wheelbase 91.5 in (2.3m) 91.5 in (2.3 m)

Maximum Drive Speed 3 mph (4.8 kmh) 3 mph (4.8 kmh)

Table 1-1. Operating Specifications

Description 3369LE/M3369 4069LE/M4069

1.2 COMPONENT DATA

IN240/55-17.5 FF non marking

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

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

Hydraulic Pump/Electric Motor Assembly

Size 240/55 D17.5 R4 Tread IN240/55-17.5

Ply Rating 12 Ply 10 Ply 6 Ply 10 Ply

Wheel Nut Torque 170 ft lbs

Air Cooled, 4 Cycle, Kubota Diesel OC60-D

Table 1-5. Engine Battery Specifications

BCI Group Size 51R - 675

1.3 CAPACITIES 1.6 CYLINDER SPECIFICATIONS

Description 3369LE/M3369 4069LE/M4069 DESCRIPTION BORE STROKE ROD DIA.

Table 1-7. Pressure Settings

Hydraulic System Operating ISO Viscosity Grade #15

Lubrication Specifications Table 1-15. Synthetic Biodegradable Hydraulic Fluid

Figure 1-1. Lubrication Chart

Table 1-16. Lubrication Chart

INDEX NO/TYPE LUBE

1.10 SERIAL NUMBER LOCATIONS

Figure 1-2. Serial Number Location

1.11 TORQUE CHARTS

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

Figure 1-4. Torque Chart - Sheet 2 of 5 (SAE Fasteners)

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

Figure 1-6. Torque Chart - Sheet 4 of 5 (METRIC Fasteners)

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

It is the User’s or Operator’s primary responsibility to perform a Preventative Maintenance

The Pre-Delivery Inspection and Frequent Inspection proce-

Table 2-1. Inspection and Maintenance

IT IS GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELEC-

3. If a part resists removal, check to see whether all nuts,

Component Disassembly and Reassembly Hydraulic Lines and Electrical Wiring

Gaskets Lubrication and Servicing

Bolt Usage and Torque Application Hydraulic System

NOTE: Start-up of hydraulic system with oil temperatures below -

Table 2-3. Preventive Maintenance and Safety Inspection

Table 2-3. Preventive Maintenance and Safety Inspection

Table 2-3. Preventive Maintenance and Safety Inspection

SECTION 3. CHASSIS & SCISSOR ARMS

3.1 CALIBRATIONS 4. Tighten up the packing nut.

c. COMPLETE will show on the analyzer when cali-

NOTE: Elevation Proximity Switch must be mounted and func-