JLG 3369LE Service And Maintenance Manual
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JLG 3369LE Service And Maintenance Manual

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Service and Maintenance Manual
AS/NZS
Models
3369LE
4069LE
M3369
M4069
PVC 2004
31217135
March 13, 2020 - Rev A

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Summary of Contents for JLG 3369LE

  • Page 1 Service and Maintenance Manual Models 3369LE 4069LE M3369 M4069 PVC 2004 31217135 March 13, 2020 - Rev A AS/NZS...
  • Page 2 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...
  • Page 3 • USE ONLY REPLACEMENT PARTS OR COMPONENTS THAT ment. A maintenance program must be followed to ARE APPROVED BY JLG. TO BE CONSIDERED APPROVED, ensure that the machine is safe to operate. R EP L AC E M E N T PA R T S O R CO M P O N E N TS M US T BE ID ENTICAL OR EQUIVALENT TO ORIGINAL PAR TS OR COMPONENTS.
  • Page 4 INTRODUCTION REVISION LOG Original Issue A - March 13, 2020 31217135...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SECTION NO. TITLE PAGE NO SECTION 1 - SPECIFICATIONS Specifications ..................1-1 Component Data .
  • Page 6 To Connect the JLG Control System Analyzer to the Generator .......
  • Page 7 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO Hub-Spindle Disassembly ..............3-34 Cover Disassembly .
  • Page 8 SECTION 5 - JLG CONTROL SYSTEM Hand Held Analyzer ................5-1 To Connect the Hand Held Analyzer.
  • Page 9 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO 31217135...
  • Page 10 Joystick Controller - (JLG PN 1600403)........
  • Page 11 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 6-7. Connector Assembly Figure 2 ..............6-8 6-8.
  • Page 12 LIST OF TABLES TABLE NO. TITLE PAGE NO. Engine Specifications (Generator - If equipped)............1-3 Engine Battery Specifications .
  • Page 13 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 14: Specifications

    SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 SPECIFICATIONS Description 3369LE/M3369 4069LE/M4069 ANSI CE/AUS ANSI CE/AUS Max. Number of Persons Max. Workload (Capacity) ANSI/CSA/Brazil: 1000 lb (454kg) ANSI/CSA/Brazil: 800 lb (363kg) CE/AUS: 1000 lb (450kg) CE/AUS: 800 lb (360kg) ANSI/CSA/Brazil:...

  • Page 15: Component Data

    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.

  • Page 16: Tires

    SECTION 1 - SPECIFICATIONS Tires 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 lb @ 105 psi 8550 lb @ 105 psi 7960 lb @ 95 psi (3878kg @ 724kPa) 4019 lb @ 42 psi (3878kg @ 724kPa)

  • Page 17: Capacities

    STROKE ROD DIA. Fuel Tank (M Models only) Approx. 0.9 gal (3.3 L) Lift Cylinder 4.00 in 63.69 in 2.75 in (M3369/3369LE) (10.16 cm) (161.77 cm) (6.98 cm) Hydraulic Tank 8.25 gal (31.2 L) Upper Lift Cylinder 3.00 in 58.13 in 2.75 in...

  • Page 18: Lubrication

    40° C 15 cSt at 100° C 4.1 cSt Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not contain at 100° F 80 SUS the same required additives or be of comparable viscosi- at 210°...
  • Page 19 SECTION 1 - SPECIFICATIONS Note: 500 Hrs. = 3 months 1000 Hrs. = 6 months 2000 Hrs. = 1 year 4000 Hrs. = 2 years Figure 1-1. Lubrication Chart Table 1-5. Lubrication Chart INDEX NO/TYPE LUBE COMPONENT LUBE/METHOD INTERVAL HOURS COMMENTS NUMBER POINTS...

  • Page 20: Serial Number Locations

    SECTION 1 - SPECIFICATIONS 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.

  • Page 21: Thread Locking Compound

    SECTION 1 - SPECIFICATIONS 1.11 THREAD LOCKING COMPOUND JLG PN Loctite® ND Industries Description 0100011 242™ Vibra-TITE™ 121 Medium Strength (Blue) 1001095650 243™ Vibra-TITE™ 122 Medium Strength (Blue) 0100019 271™ High Strength (Red) Vibra-TITE™ 140 0100071 262™ Vibra-TITE™ 131 Medium - High Strength (Red) NOTE: Loctite®...

  • Page 22: Torque Charts

    SECTION 1 - SPECIFICATIONS 1.12 TORQUE CHARTS SAE Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque Torque Tensile Clamp Torque Torque Size Bolt Dia (Loctite® 242™ or 271™ or (Loctite®...

  • Page 23: Sae Fastener Torque Chart (Continued)

    SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Torque Torque Torque (Loctite® 242™ or 271™ or Tensile Stress (Loctite® 262™ or Size Bolt Dia Clamp Load...
  • Page 24 SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque Torque Torque (Loctite® 242™ or 271™ or Tensile Stress (Loctite® 262™ or Size Bolt Dia Clamp Load (Dry) Area...

  • Page 25: Sae Fastener Torque Chart (Continued)

    SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Torque Torque Torque (Loctite® 242™ or 271™ or Tensile Stress (Loctite® 262™ or Size Bolt Dia Clamp Load (Dry or Loctite®...
  • Page 26 SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SOCKET HEAD CAPSCREWS Torque Torque (Loctite® 242™ or 271™ or Tensile Stress Clamp Load Torque (Loctite® 262™ or Size Bolt Dia Area See Note 4 (Dry) K=0.17 Vibra-TITE™...

  • Page 27: Sae Fastener Torque Chart (Continued)

    SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* SOCKET HEAD CAPSCREWS Torque Torque (Loctite® 242™ or 271™ or Tensile Stress Clamp Load Torque (Loctite® 262™ or Size Bolt Dia Area See Note 4 (Dry) K=0.17 Vibra-TITE™...

  • Page 28: Metric Fastener Torque Chart

    SECTION 1 - SPECIFICATIONS Metric Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS Torque Torque Tensile Stress Clamp Load Torque (Loctite® 262™ or 271™ or Size Pitch Torque (Lube) (Loctite®...

  • Page 29: Metric Fastener Torque Chart (Continued)

    SECTION 1 - SPECIFICATIONS Metric Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* CLASS 10.9 METRIC (HEX HEAD) BOLTS, CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAPSCREWS M3 - M5* Torque Torque Torque (Lube or Loctite® 242™ or 271™ Tensile Clamp Load (Loctite®...
  • Page 30 SECTION 1 - SPECIFICATIONS Metric Fastener Torque Chart (Continued) Values for Magni Coated Fasteners (Ref 4150701)* CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS Torque Torque Torque (Loctite® 262™ or Tensile Clamp Load (Lube or Loctite® 242™ or 271™ Size Pitch (Dry or Loctite®...

  • Page 31: Metric Fastener Torque Chart (Continued)

    SECTION 1 - SPECIFICATIONS Metric Fastener Torque Chart (Continued) Values for Magni Coated Fasteners (Ref 4150701)* CLASS 10.9 METRIC (HEX HEAD) BOLTS CLASS 10 METRIC NUTS, CLASS 12.9 SOCKET HEAD CAPSCREWS M6 AND ABOVE* Torque Torque Torque (Lube or Loctite® 242™ or 271™ Tensile Clamp (Loctite®...

  • Page 32: General

    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. Reference the Preventative Maintenance Schedule and the...

  • Page 33: Service And Guidelines

    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.

  • Page 34: Component Disassembly And Reassembly

    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.

  • Page 35: Hydraulic Oil

    Refer to Section 1 for recommendations for viscosity ranges. Maximum acceptable cylinder drift is to be measured using JLG recommends standard UTTO fluid, which has an SAE the following methods. viscosity of 10W-30 and a viscosity index of 152. Platform Drift NOTE: Start-up of hydraulic system with oil temperatures below - 15°F (-26°C) is not recommended.

  • Page 36: Pins And Composite Bearing Repair Guidelines

    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.
  • Page 37 SECTION 2 - GENERAL Table 2-2. Preventive Maintenance and Safety Inspection AREA Inspections Pre-Delivery Annual (Yearly) or Frequent Inspection Inspection (Quarterly) Scissor Arms Scissor Arms Safety Prop Nuts, Bolts, Shafts, Shields, Bearings and Locking Devices Cylinder/Pivot Pins and Attaching Hardware Arm Pads and Sliding Block Platform Assembly Platform...
  • Page 38 Operation and Safety Manual General Structural Condition and Welds Grease and Lubrication Specification Function Test of All Systems Notify JLG of Change in Machine Ownership ANSI Manual of Responsibilities and AEM Safety Manual in Storage Box (ANSI and ANSI Export Only) Capacity Decals...
  • Page 39 SECTION 2 - GENERAL Table 2-2. Preventive Maintenance and Safety Inspection AREA Inspections Pre-Delivery Annual (Yearly) or Frequent Inspection Inspection (Quarterly) Footnotes: Prior to each sale, lease, or delivery In service for 3 months; Out of service for 3 months or more; Purchased used Annually, no later than 13 months from the date of the prior inspection, Includes all daily and quarterly inspections, mandated by regulating body Indicates a 50 hour interval required to perform task after initial use of machine.
  • Page 40 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 41: Chassis & Scissor Arms

    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 platform to Control box for levelness.

  • Page 42: Joystick Calibration

    SECTION 3 - CHASSIS & SCISSOR ARMS If the Analyzer displays angles other than +20.0°, attempt to calibrate. If machine will not calibrate, note the reason displayed on Analyzer: a. SENSOR FAILURE – tilt sensor internal frequency is out of range (replace sensor). b.

  • Page 43: Tilt Sensor

    SECTION 3 - CHASSIS & SCISSOR ARMS 3.2 TILT SENSOR Tilt Sensor, JLG PN 4000021: 1. Ground Control Box 2. Tilt Sensor Assembly (JLG PN 1810140) Figure 3-1. Tilt Sensor Location 1. Tilt Sensor (JLG PN 4000021) 2. Sensor Mount NOTE: Refer to Figure 3-1., Tilt Sensor Location for numbers in...

  • Page 44: Battery Maintenance And Charging

    OUS INJURY OR DEATH. erly. Optional On-Board Generator JLG MACHINES EQUIPPED WITH DELTA Q BATTERY CHARGERS ARE DESIGNED FOR THE BEST PERFORMANCE WITH OEM FACTORY APPROVED BATTERIES. EXHAUST GAS HAZARD. RUN THE GENERATOR IN A WELL VENTILATED AREA APPROVED JLG REPLACEMENT BATTERIES ARE AVAILABLE THROUGH JLG' S ONLY.

  • Page 45: Charging Sequence Of Remote Led Card

    SECTION 3 - CHASSIS & SCISSOR ARMS 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 Plug in charger. All three LED’s (light emitting diode) flash three times. In sequence: a.

  • Page 46: Battery Charger (Delta-Q)

    SECTION 3 - CHASSIS & SCISSOR ARMS 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 OUTPUT on the (M) model machines.

  • Page 47: Battery Charger Maintenance

    SECTION 3 - CHASSIS & SCISSOR ARMS Battery Charger Maintenance Battery Charger Troubleshooting No Lights at all No lights at all indicate that AC power to the charger is not USE CHARGER ONLY ON BATTERY SYSTEMS WITH AN ALGORITHM SELECTED connected or that the AC voltage is too low.
  • Page 48 SECTION 3 - CHASSIS & SCISSOR ARMS [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.
  • Page 49 Table 3-3, Battery Algorithms. These symptoms indicate over-charging or high battery tem- Contact JLG if your specific battery model is not listed. perature. These symptoms are unlikely to be caused by too Each time AC power is applied with the battery pack not con-...

  • Page 50: Battery Temperature Sensor

    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. JLG PN 0400242 Douglas Flooded (JLG default) GES Battery A1055 Trojan T105 East Penn GC-110-WNL Trojan T105 PLUS...

  • Page 51: Removing The Battery Box

    SECTION 3 - CHASSIS & SCISSOR ARMS Removing the Battery Box Figure 3-6. Batteries and Battery Charger To remove the battery box, perform the following steps. Using a forklift, lift the battery box up enough to clear the brackets on the back of the battery box and remove Pull the handle on the battery disconnect to disconnect the battery box from the machine.

  • Page 52: Generator

    SECTION 3 - CHASSIS & SCISSOR ARMS 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.
  • Page 53 SECTION 3 - CHASSIS & SCISSOR ARMS Figure 3-7. Generator Components 3-13 31217135...

  • Page 54: Timing Sequences

    SECTION 3 - CHASSIS & SCISSOR ARMS Timing Sequences Time Delay Bypass (TDBP) Once the engine starts, TDBP must elapse before low oil NOTE: Throughout the Generator section, the abbreviations RBS pressure and underspeed shutdowns are activated. This and CTS are used. RBS stands for Rotary Battery System, allows the engine to come up to normal operating con- which is the generator system.
  • Page 55 SECTION 3 - CHASSIS & SCISSOR ARMS 3-15 31217135...

  • Page 56: Alarms And Fault Flash Codes

    In the event of an RBS alarm, a flash code will be issued and an alarm indicated on the analyzer. The JLG Control System Analyzer can be used to monitor gen- erator settings and conditions. Connect the analyzer as fol- NOTE: Alarms must be reset once the fault has been corrected.

  • Page 57: Output Current And Voltage Settings

    SECTION 3 - CHASSIS & SCISSOR ARMS Priming the Fuel Line • No Speed Signal 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.

  • Page 58: Supplementary Fuse For Apu

    • - AGC1, 1 Amp fuse - JLG PN 2400080 • - 45cm of #16 AWG wire - JLG PN 4920019 • - 2 X insulated butt splice connectors - JLG PN 4460035 • - 6 X medium length wire ties - JLG PN 4240033 •...
  • Page 59 SECTION 3 - CHASSIS & SCISSOR ARMS Cut and remove the Wire Ties holding the Harness label 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.

  • Page 60: Joystick Controller

    SECTION 3 - CHASSIS & SCISSOR ARMS 3.6 JOYSTICK CONTROLLER Figure 3-9. Joystick Controller - (JLG PN 1600403) Table 3-8. Joystick Specifications Table 3-9. Joystick Plug Loading Chart Input Voltage Terminal Color Function Centered Output Voltage 4.25V to 2.60V Yellow...
  • Page 61 SECTION 3 - CHASSIS & SCISSOR ARMS Figure 3-10. Drive Components 3-21 31217135...

  • Page 62: Power Controller

    SECTION 3 - CHASSIS & SCISSOR ARMS 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.

  • Page 63: Engaging After Towing Is Complete

    SECTION 3 - CHASSIS & SCISSOR ARMS Engaging after Towing is Complete Remove the cover. 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.
  • Page 64 SECTION 3 - CHASSIS & SCISSOR ARMS Figure 3-12. Torque Hub 3-24 31217135...

  • Page 65: Drive Hub

    SECTION 3 - CHASSIS & SCISSOR ARMS 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 Disassembly of Cover Unit (8) disconnect mechanism.
  • Page 66 SECTION 3 - CHASSIS & SCISSOR ARMS 1. Retaining Screws 9. Backup Ring 17. Retaining Ring 10. Shaft 18. Bearing 2. Washers 3. Pressure Plate 11. Stator Disc 19. Retaining Ring 4. Case Seal 12. Sensor Ring 20. Dowel Pins 5.

  • Page 67: Drive Brake - Mico

    SECTION 3 - CHASSIS & SCISSOR ARMS 3.9 DRIVE BRAKE - MICO Install shaft assembly and retaining ring (17) in cover (21). Disassembly Install dowel pins (20), spring retainer (16) and springs (15) in cover (21). 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.

  • Page 68: Torque Hub

    SECTION 3 - CHASSIS & SCISSOR ARMS 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.

  • Page 69: Roll Test

    SECTION 3 - CHASSIS & SCISSOR ARMS Roll Test The purpose of the roll test is to determine if the unit’s gears are rotating freely and properly. You should be able to rotate the gears in your unit by applying constant force to the roll checker.

  • Page 70: Main Disassembly

    SECTION 3 - CHASSIS & SCISSOR ARMS Main Disassembly 1. Coupling 7. Input Shaft 13. Housing 2. Retaining Ring 8. Carrier Subassembly 14. O-Ring 15. O-Ring 3. Ring Gear 9. Second Stage Sun Gear 4. Cover Subassembly 10. Output Stage Carrier Subassembly 16.
  • Page 71 SECTION 3 - CHASSIS & SCISSOR ARMS 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 Perform the Roll Check and Leak Check, if applicable teeth will be integral to the Input Shaft (7).

  • Page 72: Output Carrier Disassembly

    SECTION 3 - CHASSIS & SCISSOR ARMS Output Carrier Disassembly 1. Roll Pin 5. Thrust Washers 2. Planet Shaft 6. Thrust Spacer 3. Carrier 7. Planet Gears 8. Thrust Washer 4. Needle Bearings Figure 3-17. Output Carrier Disassembly Using a 1/8" diameter punch, drive the Roll Pin (1) into 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...

  • Page 73: Input Carrier Disassembly

    SECTION 3 - CHASSIS & SCISSOR ARMS 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 NOTE: The Roll Pins (1) should not be reused when reassembling Using a 1/8"...

  • Page 74: Hub-Spindle Disassembly

    SECTION 3 - CHASSIS & SCISSOR ARMS 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 Place unit on bench with Spindle (1) end down. If necessary, press 9 Studs (8) out of Hub.

  • Page 75: Cover Disassembly

    SECTION 3 - CHASSIS & SCISSOR ARMS 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 Remove O-ring (1) from the groove in the Cover (2). Pull Disengage Rod (6) out of the Cover.

  • Page 76: Input Carrier Sub-Assembly

    SECTION 3 - CHASSIS & SCISSOR ARMS 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 Following the Planet Gear, place one more Thrust Apply a liberal coat of grease to the bore of one Input Planet Gear (4).

  • Page 77: Output Carrier Sub-Assembly

    SECTION 3 - CHASSIS & SCISSOR ARMS 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 Apply a liberal coat of grease to the bore of one Output Place the Planet Gear Sub-assembly into the Carrier.

  • Page 78: Hub-Spindle Sub-Assembly

    SECTION 3 - CHASSIS & SCISSOR ARMS 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 Press Seal Boot (7) onto Hub, if required.

  • Page 79: Cover Sub-Assembly

    SECTION 3 - CHASSIS & SCISSOR ARMS 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 Grease O-Ring (7) and insert groove in Cover (2). Grease the face of the Thrust Washer (3) and place in the Cover making sure the tangs on the Washer seat into the Assemble Disengage Cap (5) onto Cover using two Hex...

  • Page 80: Main Assembly

    SECTION 3 - CHASSIS & SCISSOR ARMS Main Assembly 7. Input Shaft 13. Housing 1. Coupling 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.
  • Page 81 SECTION 3 - CHASSIS & SCISSOR ARMS NOTE: All components should receive a generous amount of lubri- Place the Input Shaft spline end into mesh with the cant oil as they are being assembled. Internal Coupling (1) splines. With the modified spline end facing up, place the Out- Place Hub-Spindle Sub-Assembly on a bench.

  • Page 82: Hydraulics

    SECTION 4 - HYDRAULICS 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 or assemble one part, then start on another. Always recheck your The following information is provided to assist you in the use and work to assure that nothing has been overlooked.

  • Page 83: Hydraulic Lines And Electrical Wiring

    Hydraulic Oil Refer to Section 1 for recommendations for viscosity ranges. 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.

  • Page 84: Changing Hydraulic Oil

    When the solenoid is not ener- tance in selecting the proper equivalent. Avoid mixing gized the cylinder is held in place by the holding valve mounted petroleum and synthetic base oils. JLG Industries recom- on the cylinder. mends changing the hydraulic oil annually.

  • Page 85: Motor Controller - Modes Of Operation

    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...

  • Page 86: Cylinders With Single Counterbalance Valve (Lift Cylinder)

    SECTION 4 - HYDRAULICS If extend port leakage is less than 6-8 drops per minute, 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.

  • Page 87: Lift Cylinder Installation

    SECTION 4 - HYDRAULICS Lift Cylinder Installation Install lift cylinder in place using a suitable slings, align- ing barrel end attaching pin mounting holes on lower arm assembly. Using a suitable drift, drive the barrel end attach pin through the mounting holes in the lift cylinder and the lower arm assembly.

  • Page 88: Cleaning And Inspection

    SECTION 4 - HYDRAULICS Inspect cylinder head inside diameter for scoring or other damage and for ovality and tapering. Replace as necessary. Inspect threaded portion of head for damage. Dress threads as necessary. Inspect seal and o-ring grooves in head for burrs and sharp edges.

  • Page 89: Assembly

    SECTION 4 - HYDRAULICS 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. Using a special tool, pictured in the following illustra- tion, install a new rod seal into the applicable cylinder head gland groove.
  • Page 90 SECTION 4 - HYDRAULICS Install the bolts into the bushing using medium strength After the cylinder has been reassembled, the rod should threadlocking compound. Refer to Cylinder Component be pushed all the way in (fully retracted) prior to the Torque Specifications Table for proper bolt torque val- reinstallation of any holding valve or valves.

  • Page 91: Steer Cylinder Removal

    SECTION 4 - HYDRAULICS 4.13 OSCILLATION CYLINDER BLEEDING Position the cylinder barrel in a suitable holding fixture. Bleeding Procedure EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, Run one side wheel onto a ramp or block of wood. On HEAD AND PISTON.

  • Page 92: Oscillating Axle - Lockout Cylinder Test (If Equipped)

    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.

  • Page 93: Cylinder Assemblies

    23. Cotter Pin, 1/8" x 1 1/4" 24. Adapter 25. Solenoid Valve 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 lb (99.8 kg) •...
  • Page 94 SECTION 4 - HYDRAULICS 1. Barrel Weldment 2. Rod Weldment L O W ER LIFT C Y LIN D E R 3. Garmax Bushings 4. Locnut 5. Piston 6. O-Ring U P P E R LIFT C Y LIN D ER 7.
  • Page 95 SECTION 4 - HYDRAULICS 1. Cylinder Barrel 2. Jack Pad 3. Special Screw, 1/2" - 13NC x 1-1/4 4. Cylinder Rod 5. Retaining Ring 6. Plate 7. End Cap 8. Locknut 9. Piston 10. Flatwasher, 1-1/4" 11. Wear Ring 12. Piston Seal 13.
  • Page 96 SECTION 4 - HYDRAULICS 1. Barrel 2. Rod 3. Guide 4. Locknut 5. Piston 6. Piston Seal 7. O-Ring 8. Backup Ring 9. Seal 10. Wiper 11. Retainer Ring 12. O-Ring Figure 4-14. Steer Cylinder 4-15 31217135...
  • Page 97 SECTION 4 - HYDRAULICS 1. Barrel 2. Rod 3. Wiper 4. Wear Ring 5. Rod Seal 6. Plug 7. Piston Pilot 8. Check Valve 9. Bleeder Valve 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.

  • Page 98: Pressure Setting Procedures

    With pressure gauge at “MP” port on control valve, acti- Brake vate and bottom out Lift Up. High Pressure Filter Adjust Lift Relief to 2500 psi (172 bar) on the M3369/ 3369LE and 2800 psi (193 bar) on the M4069/4069LE. Steer Steer Relief Lift Flow Control With pressure gauge at “MP”...

  • Page 99: Drive Torque Hub

    SECTION 4 - HYDRAULICS Figure 4-16. Control Valve 4.17 DRIVE TORQUE HUB 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 Disassembly during this procedure.

  • Page 100: Assembly

    SECTION 4 - HYDRAULICS Assembly Sun gear is installed, meshing with the teeth of the large diameter cluster gear. The counterbore on the sun gear 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.

  • Page 101: Drive Assist Valve

    SECTION 4 - HYDRAULICS 4.18 DRIVE ASSIST VALVE M P R 2R M P L M P L P L P R M P R T 1 T V A L V E S C HE M A T IC Figure 4-17.
  • Page 102 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 103: Jlg Control System

    SECTION 5 - JLG CONTROL SYSTEM SECTION 5. JLG CONTROL SYSTEM 5.1 HAND HELD ANALYZER Analyzer Display Menu: HELP: PRESS ENTER Enter Key Escape Key Stores and selects Top Level, To return home or Sub Level, and item menus access previous menu Left &...

  • Page 104: Using The Analyzer

    SECTION 5 - JLG CONTROL SYSTEM Using the Analyzer In platform mode: HELP: EVERYTHING OK, With the machine power on and the analyzer connected prop- In ground mode: erly, the analyzer will display the following: HELP: GROUND MODE OK If ENTER is pressed again, the display moves to the following...

  • Page 105: Changing The Access Level Of The Hand Held Analyzer

    SECTION 5 - JLG CONTROL SYSTEM 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...

  • Page 106: Adjusting Parameters Using The Hand Held Analyzer

    SECTION 5 - JLG CONTROL SYSTEM 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...

  • Page 107: Pc Boards

    SECTION 5 - JLG CONTROL SYSTEM 5.2 PC BOARDS NOTE: Refer to Table 5-3, Machine Model Adjustment - Version P1.6, and Table 5-4, Machine Configuration Programming Information - Version P1.6 for the default settings. PCB - JLG PN 1001099428 Password 33271 will give you access to level 1, which will permit you to change all machine personality and/or machine setup settings.

  • Page 108: Flash Codes/Dtc's And Descriptions

    Machine is exceeding tilt allowance and platform is elevated above allowed height. Applicable when Machine Setup’s TILT CUTOUT is set to 1 = YES. 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. 0022 DIFFERENT FUNCTION SELECTED &...
  • Page 109 SECTION 5 - JLG CONTROL SYSTEM Table 5-1. Flash Codes/DTC’s FLASH CODE HELP MESSAGE AND DESCRIPTION PLATFORM CONTROLS 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.
  • Page 110 SECTION 5 - JLG CONTROL SYSTEM Table 5-1. Flash Codes/DTC’s FLASH CODE HELP MESSAGE AND DESCRIPTION FUNCTION PREVENTED 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.
  • Page 111 SECTION 5 - JLG CONTROL SYSTEM Table 5-1. Flash Codes/DTC’s FLASH CODE HELP MESSAGE AND DESCRIPTION COMMUNICATION CANBUS FAILUR: POWER MODULE Lost communication to power module. Check wiring at ground control and power module. Recycle power to clear fault. ELECTRIC MOTOR CAPACITOR BANK FAULT - CHECK POWER CIRCUITS Check power wiring.
  • Page 112 SECTION 5 - JLG CONTROL SYSTEM 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...
  • Page 113 SECTION 5 - JLG CONTROL SYSTEM JLG ANALYZER INTERFACE HELP: PRESS ENTER DIAGNOSTICS GROUND TRACTION SYSTEM DIAGNOSTICS PLATFORM TEMPERATURE PLATFORM: GROUND: TRACTION: SYSTEM: DRIVE SEL OPEN PLATFORM OPEN MODE->NEUTRAL BATTERY 47.0V PLATFORM: GROUND: TRACTION: SYSTEM: GROUND CLOSED LIFT SEL OPEN...
  • Page 114 SECTION 5 - JLG CONTROL SYSTEM FROM ELEV SENSOR DATALOG VERSIONS DIAGNOSTICS : TEMPERATURE VALVES SYSTEM TEMPERATURE: VALVES: ELEV SENSOR: DATALOG: VERSIONS AMBIENT XXXC READING 0.00V STEER LEFT OPEN DRIVE 0H 0M LE P1.5 VALVES: ELEV SENSOR: DATALOG: VERSIONS TEMPERATURE: CUTOUT INACTIVE READING 0.00V...
  • Page 115 SECTION 5 - JLG CONTROL SYSTEM FROM DIAGNOSTICS : RUN SYSTEM TEST: RUN SYSTEM TEST: RUN SYSTEM TEST: RUN SYSTEM TEST: RUN SYSTEM TEST: TO : SYSTEM TEST YES:ENTER, NO:ESC TEST VALVES TEST GROUND SW TEST PLAT SW TEST LEDS & ALRM...
  • Page 116 SECTION 5 - JLG CONTROL SYSTEM FROM RUN SYSTEM TEST: RUN SYSTEM TEST: RUN SYSTEM TEST: TEST PROP ACCEL? TESTS COMPLETE TEST LEDS & ALRM RUN SYSTEM TEST: ACCEL TO CENTER RUN SYSTEM TEST: ACCEL FW TO MAX RUN SYSTEM TEST:...
  • Page 117 SECTION 5 - JLG CONTROL SYSTEM FROM MACHINE SETUP: MACHINE SETUP: MACHINE SETUP: MACHINE SETUP: MACHINE SETUP: MACHINE SETUP: GROUND ALARM FUNC CUTOUT 4 WHEEL ASSIST LOAD TILT LIMIT CHARGER INTRLOK GROUND ALARM: FUNC CUTOUT: LOAD: 4 WHEEL ASSIST: TILT LIMIT:...
  • Page 118 SECTION 5 - JLG CONTROL SYSTEM Table 5-3. Machine Model Adjustment - Version P1.6 Adjustment Adjustment Range Default Values - 3369LE Default Values - 4069LE DRIVE ACCEL 1.0 - 5.0 (sec) DECEL 0.1 - 5.0 s (sec) MINIMUM 1 - 6%...
  • Page 119 CUTOUT ALL - LSS is fitted. Platform and Ground Controls are prevented in the event of an Overload STANDARD - Normal tilt limits. SPECIAL 1 - Vehicle tilt limits restricted to allow operation of a standard 3369LE in 16.7 m/s wind speeds for the CE Market. (TILT LIMIT)* NOTE: Tilt Limit selection is only visible for the 3369LE configured for the CE Market.
  • Page 120 SECTION 5 - JLG CONTROL SYSTEM Table 5-4. Machine Configuration Programming Information - Version P1.6 NOT INSTALLED - Rail Prox Switches not installed YES - Rail Prox Switches installed, drive and left prevented when rails folded down (RAIL CUTOUT) TRANSPORT - Rail prox switches installed, drive allowed when stowed. Drive and lift prevented when elevated.

  • Page 121: Ground Control Circuit Board

    SECTION 5 - JLG CONTROL SYSTEM 5.4 GROUND CONTROL CIRCUIT BOARD Software Version P1.6 Table 5-5. J1 Connector TAGNAME FUNCTION TYPE PLTS Platform Select POWER OUTPUT PLTE Platform EMS POWER INPUT Ground POWER OUTPUT COL0 Column 0 Output DIGITAL OUTPUT...
  • Page 122 SECTION 5 - JLG CONTROL SYSTEM Table 5-6. J2 Connector TAGNAME FUNCTION TYPE Control System Supply (+48V) POWER INPUT Control System Ground POWER INPUT Steer Left Solenoid Valve DIGITAL OUTPUT Steer Right Solenoid Valve DIGITAL OUTPUT Flow Control Solenoid Valve...
  • Page 123 SECTION 5 - JLG CONTROL SYSTEM Table 5-6. J2 Connector TAGNAME FUNCTION TYPE 4AWR 4 Wheel Assist Reverse Solenoid Valve DIGITAL OUTPUT OSAX Oscillating Axle Solenoid Valves DIGITAL OUTPUT DO22 Spare High-Side Digital Output 22 (12V, 5A) DIGITAL OUTPUT Table 5-7. J3 Connector...
  • Page 124 SECTION 5 - JLG CONTROL SYSTEM Table 5-8. J4 Connector TAGNAME FUNCTION TYPE 12V Sensor Supply POWER OUTPUT TILTX X-Axis Tilt Input (PWM) ANALOG INPUT TILTY Y-Axis Tilt Input (PWM) ANALOG INPUT Ground POWER OUTPUT Table 5-9. J5 Connector TAGNAME...
  • Page 125 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 126: General Electrical Information & Schematics

    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.

  • Page 127: Voltage Measurement

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 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)

  • Page 128: Continuity Measurement

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 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 •...

  • Page 129: Continuity Measurement Over Long Distances

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Continuity Measurement Over Long Distances Jumper from wire under test to wire #1. Measure continuity. If there is continuity, the wire under test is good. Resistance of a wire When trying to determine continuity of a harness or increases as the length increases and as the wire, longer than the reach of standard instrument diameter decreases.

  • Page 130: Dielectric Grease Application

    Dielectric grease helps to prevent corrosion of electrical This connector system is typically used on operator contacts and improper conductivity between contacts switches at JLG. Follow the general guidance for installa- from moisture intrusion. Non-waterproof connectors tion. benefit from the application of dielectric grease.

  • Page 131: Mini Fit Sr

    This connector system is typically used on control mod- discontinuity, due to silicone dielectric grease ingress ules at JLG. Follow the general guidance for installation. when switching inductive loads. Therefore, dielectric grease shall not be applied to Carling switch mating connectors unless specifically noted.

  • Page 132: Amp Connector

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS AMP CONNECTOR Figure 6-5. AMP Connector Assembly To insert a contact, push it straight into the appro- priate circuit cavity as far as it will go Check to be sure the wedge lock is in the open, or as- (See Figure 6-7.) shipped, position (See Figure 6-6.) Proceed as follows: Pull back on the contact wire with a force of 1 or 2...
  • Page 133 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-7. Connector Assembly Figure 2 After all required contacts have been inserted, Slide the wedge lock into the housing until it is the wedge lock must be closed to its locked flush with the housing (See Figure 6-9.) position.
  • Page 134 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-10. Connector Disassembly 31217135...

  • Page 135: Disassembly

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Disassembly Insert a 4.8 mm (3/16 in.) wide screwdriver blade between the mating seal and one of the red wedge lock tabs. Pry open the wedge lock to the open position. While rotating the wire back and forth over a half turn (1/4 turn in each direction), gently pull the wire until the contact is removed.
  • Page 136 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-11. Connector Installation 6-11 31217135...

  • Page 137: Working With Deutsch Connectors

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS WORKING WITH DEUTSCH CONNECTORS DT/DTP Series Disassembly DT/DTP Series Assembly Figure 6-13. DT/DTP Contact Removal Remove wedge lock using needle nose pliers or a hook shaped wire to pull wedge straight out. DT/DTP Contact Installation Figure 6-12.

  • Page 138: Hd30/Hdp20 Series Assembly

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS HD30/HDP20 Series Assembly HD30/HDP20 Series Disassembly Figure 6-16. HD/HDP Contact Removal Figure 6-14. HD/HDP Contact Installation Grasp contact about 25mm behind the contact With rear insert toward you, snap appropriate crimp barrel. size extractor tool over the wire of contact to be removed.
  • Page 139 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS PUMP/MOTOR DRIVE CONTA CTOR TO BA TTERIES RIGHT DRIVE MOTOR DRIVE CONTROLLER LEFT DRIVE MOTOR MAIN VA L VE PLA TFORM CONSOLE BA TTERY CHARGER TO GROUND CONTROL BOX TERMINAL J1 LIFT CY LINDER PRESSURE TRANSDUCER...
  • Page 140 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS GENERATOR MOTOR/ MODULE GENERATOR ANALYZER PROXIMITY SENSOR SWITCH (ALL USA BUILT MACHINE) LEFT SIDE MOTOR ROTARY ANGLE SENSOR PROXIMITY SENSOR SWITCH OSCILLATING AXLE SWITCH (ALL BELGIUM CYLINDERS BUILT MACHINE) HORN BEACON LIGHT HARNESS GROUND CONTROL...
  • Page 141 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS LEVEL JA CK SW ITCHES GENERA TOR MODULE (M3369 & M4069) LEVEL JACK V AL VES A LARM BEACON LIGHT V AL VE HARNESS PLA TFORM GROUND CONTROL Figure 6-20. Electrical Components Installation - (Sheet 3 of 4) 6-16 31217135...
  • Page 142 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS DRIVE DRIVE CONTA CTOR CONTROLLER CIRCUIT BREA KER RECEPT ACLE A T PLA TFORM PLA TFORM CONSOLE PLA TFORM W ORK LIGHTS Figure 6-21. Electrical Components Installation - (Sheet 4 of 4) 6-17 31217135...

  • Page 143: Electrical Schematics

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 6.7 ELECTRICAL SCHEMATICS OPTION PLATFORM CONSOLE LIGHT GROUND PIN TABLE IGNITION PIN TABLE (+12V) ORN/WHT 55-6 FUNCTION FUNCTION ORN/WHT 55-5 J1-3 PLATFORM CONTROL BOX GROUND ORN/WHT 55-4 J1-16 PLAT. CNTL CIRCUIT CARD POWER ORN/WHT 55-3 OPTIONAL J1-22...
  • Page 144 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS ORN/WHT 55-6 ORN/WHT 55-5 ORN/WHT 55-4 ORN/WHT 55-3 ORANGE 55-8 BLU/ORN 52-1 ORANGE 55-10__ TAN 55-2 ORANGE 55-1 1K OHM POT W/ 150 OHM CURRENT LIMITING RESISTORS BLACK 8 J3-5 5V OUTPUT J3-1 2.5V @ CENTER PLATFORM DISPLAY...
  • Page 145 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS TO POWER CONTACTOR B+ BLACK (10 AWG) GENERATOR POSITIVE TO POWER CONTROLLER B- BLACK (10 AWG) GENERATOR NEGATIVE OPTIONAL TRICKLE CHARGER FROM A/C PLUG FOR CHARGER GRN/YEL UA103 48VDC UA131 TO CHARGER 48VDC GRN/YEL BLUE GRN/YEL...
  • Page 146 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS J2 PLUG ASSEMBLY GENERATOR CONTROL MODULE EC104 SYSTEM 48 VDC SYSTEM 0 VDC FUEL SOLENOID STARTER SOLENOLD MANUAL CALL TO START LOW OIL PRESSURE AMBIENT TEMP. ENGINE OIL TEMP. SPEED SENSING INPUT RS232 +12V CONN-2 RS232...
  • Page 147 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS TO VALVE HARNESS CONNECTS TO X401A X402 (SHEET 1- F8) CANH 18_RED X401B CANL 18_BLK LOSAX CONNECTS TO SHEET 1 F7 29-5 BLACK ORANGE 75-1 ORANGE 75-1-2 SHT-1 (B5) RED 1-1-2 MS405-2 CANH 18_RED BLACK 72 CANL 18_BLK...
  • Page 148 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS TO VALVE HARNESS CONVERTER CONNECTS TO X401A XCONVERT (SHEET 1- F8) X402 120 OHM RED 1-1D BAT +48/36V INPUT VOLTAGE CANH 18_RED YEL 2-0 IGN IGNITION X401B CANL 18_BLK BLK 0-0 GND GROUND INPUT RED 1-1E BAT +12V (MEMORY)
  • Page 149 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS ORN/WHT 55-6 ORN/WHT 55-5 ORN/WHT 55-4 ORN/WHT 55-3 GROUND PIN TABLE ORANGE 55-8 IGNITION PIN TABLE (+12V) FUNCTION BLU/ORN 52-1 FUNCTION J1-3 PLATFORM CONTROL BOX GROUND WHT/RED 57-5 ORANGE 55-10__ J1-16 PLAT. CNTL CIRCUIT CARD POWER J1-22 SPARE TAN 55-2...
  • Page 150 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS ORN/WHT 55-6 ORN/WHT 55-5 ORN/WHT 55-4 ORN/WHT 55-3 ORANGE 55-8 BLU/ORN 52-1 ORANGE 55-10__ TAN 55-2 ORANGE 55-1 1K OHM POT W/ 150 OHM CURRENT LIMITING RESISTORS BLACK 8 J3-5 5V OUTPUT J3-1 2.5V @ CENTER...
  • Page 151 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS CONVERTER XCONVERT RED 1-1D BAT +48/36V INPUT VOLTAGE YEL 2-0 IGN IGNITION BLK 0-0 GND GROUND INPUT RED 1-1E BAT +12V (MEMORY) YEL 2-1 IGN +12V (SWITCHED) TO TELEMATICS BLK 0-1 GND GROUND OUTPUT XTELE-B HARNESS, TELEMATICS CONVERTER...
  • Page 152 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 401 18_ORN/RED_GXL XPCU 403 18_YEL/RED_GXL XPCT PLATFORM SOFT TOUCH ACCESORY 402 18_YEL/RED_GXL X135 142 18_YEL/RED_GXL XPCE 232 18_ORN/RED_GXL 401 18_ORN/RED_GXL XPCB 1001171105-E SHEET 2 MAF21090E Figure 6-31. Electrical Schematic (AUS) - Sheet 4 of 4 6-27 31217135...
  • Page 153 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-32. Hydraulic Schematic (All except CE) - Sheet 1 of 2 6-28 31217135...
  • Page 154 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001167495_C Figure 6-33. Hydraulic Schematic (All except CE) - Sheet 2 of 2 6-29 31217135...
  • Page 155 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001191135_B Figure 6-34. Hydraulic Schematic (CE) - Sheet 1 of 2 6-30 31217135...
  • Page 156 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-35. Hydraulic Schematic (CE) - Sheet 2 of 2 6-31 31217135...
  • Page 157 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

This manual is also suitable for:

4069leM3369M4069

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