Related Manuals for JLG 3369electric
Summary of Contents for JLG 3369electric
- Page 1 Service and Maintenance Manual Models 3369electric 3969electric 3120768 March 10, 2004 ANSI...
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Page 3: Hydraulic System Safety
• USE ONLY APPROVED, NONFLAMMABLE CLEANING ous pressures. Every effort should be made to SOLVENTS. relieve any system pressure prior to disconnecting or removing any portion of the system. – JLG Sizzor – 3120768... - Page 4 March 25, 1999 - Original Issue (This man- ual was part of complete manual 3120597) Updated November 24, 1999 - page 1-2 Updated November 24, 1999 - page 2-11 Updated March 10, 2004 - page 2-11 – JLG Sizzor – 3120768...
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Page 5: Table Of Contents
Hydraulic Circuit Checks............3-1 3120768 – JLG Sizzor –... - Page 6 Flash Code Troubleshooting Messages ..........3-8 – JLG Sizzor –...
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Page 7: Section 1. Specifications
3969 electric - 79 in (2.01 m) Pump Output - 1.09 gpm (4.13 lpm) @ 2000 psi (137.9 Machine Length (stowed) Bar) 3369 electric - 109 in (2.77 m) 3969 electric - 109 in (2.77 m) 3120768 – JLG Sizzor –... -
Page 8: Torque Specifications
When temperatures remain consistently below 2° F 3369 electric - 77 in (1.98 m) (-7 ° C), JLG recommends the use of Mobil DTE 11. 3969 electric - 77 in (1.98 m) NOTE: Aside from JLG recommendations, it is not advisable... -
Page 9: Lubrication Chart
Recommended lubricating intervals are based on machine operations under normal conditions. For EPGL - Extreme Pressure Gear Lube machines used in multi-shift operations and/or exposed to hostile environments or conditions, lubri- cating frequencies must be increased accordingly 3120768 – JLG Sizzor –... -
Page 10: Cylinder Specifications
Arm Assembly (Includes Lift 3393 1539 3903 1770 Cylinders) Chassis (Includes Battery 3662 1661 3662 1661 Box and Foam filled Tires) Machine Complete (GVW) 8000 3629 8800 3992 – JLG Sizzor – 3120768... -
Page 11: Serial Number Location
SECTION 1 - SPECIFICATIONS Figure 1-2. Serial Number Location 3120768 – JLG Sizzor –... - Page 12 SECTION 1 - SPECIFICATIONS – JLG Sizzor – 3120768...
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Page 13: Section 2. Procedures
2. Discard bearings if the races and balls (or rollers) be maintained on a scheduled basis in order to func- are pitted, scored or burned. tion properly. 3120768 – JLG Sizzor –... -
Page 14: Lubrication Information
When recommended lubricants are 2. JLG recommends Kendall Hyken 052 Hydraulic Oil, not available, consult your local supplier for an equivalent which has an SAE viscosity of 10W-20 and a viscos- that meets or exceeds the specifications listed. -
Page 15: Cylinders - Theory Of Operation
The cartridge valves provide for control of proper equivalent. Avoid mixing petroleum and syn- flow, volume of flow and pressure in the hydraulic system. thetic base oils. JLG Industries recommends chang- The directional control valves are solenoid operated, three ing the hydraulic oil annually. -
Page 16: Component Functional Description
If a function switch is activated in neutral, when the vehicle has stopped and the brake is applied, then pump mode will become operational. – JLG Sizzor– 3120768... -
Page 17: Cylinder Checking Procedures
6. Remove lifting device from platform, activate hydrau- After initial discharge, there should be no further lic system and run cylinder through complete cycle leakage from the retract port. to check for leaks and operation. 3120768 – JLG Sizzor –... -
Page 18: Cylinder Removal And Installation
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. Figure 2-2. Capscrew Removal – JLG Sizzor– 3120768... -
Page 19: Rod Support
11. Inspect seal and o-ring grooves in head for burrs rings, guidelock rings and hydrolock seals. and sharp edges. Dress applicable surfaces as nec- 15. If applicable, remove the piston spacer from the rod. essary. 3120768 – JLG Sizzor –... -
Page 20: Oil-Lite Bearing Installation
NOTE: Apply a light film of hydraulic oil to all components prior to assembly. Figure 2-8. Installation of Head Seal Kit 1. Using a special tool, pictured in the following illustra- tion, install a new rod seal into the applicable cylin- – JLG Sizzor– 3120768... -
Page 21: Piston Seal Kit Installation
10. Install the bolts into the bushing using Loctite #242. Refer to Cylinder Component Torque Specifications Table for proper bolt torque values. Figure 2-12. Rod Assembly Installation 11. Remove the cylinder rod from the holding fixture. 3120768 – JLG Sizzor –... - Page 22 THAT THE OUTER END OF THE ROD IS SUPPORTED. USE (102-109 Nm) EITHER A TRAVELING OVERHEAD HOIST, FORKLIFT, OR OTHER Racine - 1-7/8 hex 1-5/8 - 12 thds 100-110 ft lb MEANS TO SUPPORT THE OVERHANGING WEIGHT OF THE (136-149 Nm) EXTENDING ROD. – JLG Sizzor– 3120768 2-10...
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Page 23: Tilt Switch Indicator Leveling Procedure
High drive speed is cut out when platform is raised above stowed (fully lowered) position. NOTE: There is no adjustment to be made to the Platform Ext. limit switch which bolts on the bottom of the plat- form (If Equipped). Updated 11/24/99 3120768 – JLG Sizzor – 2-11... -
Page 24: Drive Torque Hub
After planet 7. While wearing eye protection, remove the retaining shaft has been removed, the roll pin can be driven ring from the output shaft and discard. out. – JLG Sizzor– 3120768 2-12... -
Page 25: Drive Torque Hub Assembly
NOTE: When rebuilding or repairing the unit, the retaining put shaft. Sufficient grease or petroleum jelly should ring (9), o-rings (22), and seal (2) should always be be used to hold thrust washer in place. replaced. 3120768 – JLG Sizzor – 2-13... -
Page 26: Drive Brake Assembly
15. Torque bolts (28 & 29) to 23 - 27 ft. lbs. (31- 36 NM). inches (0.35 - 0.60 mm). 16. Fill unit one-half full with EP90 lubricant. 4. After checking air gap, connect power supply. – JLG Sizzor– 3120768 2-14... -
Page 27: Free Wheeling Procedure
(towards drive motor) and tightening the three nuts on each brake. 3. Connect suitable equipment, remove chocks, and move machine. 4. After moving machine, position on a firm, level sur- face. 5. Chock wheels securely. 3120768 – JLG Sizzor – 2-15... -
Page 28: Preventive Maintenance And Inspection Schedule
SECTION 2 - PROCEDURES NOTE: This machine requires periodic safety and mainte- 2.19 PREVENTIVE MAINTENANCE AND nance inspections by a JLG Dealer. A decal located INSPECTION SCHEDULE on the frame affords a place to record (stamp) inspection dates. Notify dealer if inspection is over- The preventive maintenance and inspection checks are due. - Page 29 21. Wear Pads 22. Pivot Pins/Bolts 1, 4 7, 8 23. Switches, Ground Control 1, 11 24. Control Tags 25. Hose and Cable 4, 8 * Inspection and Maintenance Code 10 to be performed annually. 3120768 – JLG Sizzor – 2-17...
- Page 30 SECTION 2 - PROCEDURES This page intentionally left blank. – JLG Sizzor– 3120768 2-18...
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Page 31: Section 3. Troubleshooting
SECTION 3 - TROUBLESHOOTING SECTION 3. TROUBLESHOOTING 4. It should be recognized that the majority of the prob- 3.1 GENERAL lems arising in the machine will be centered in the hydraulic and electrical systems. For this reason, This section contains troubleshooting information to be every effort has been made to ensure that all likely used for locating and correcting most of the operating problems in these areas are given the fullest possi-... - Page 32 Refer to the electrical schematic and/or electrical valve cartridge system troubleshooting chart Lift down control cartridge not functioning prop- Repair or replace lift down control cartridge erly Lift cylinder not functioning properly Repair or replace lift cylinder – JLG Sizzor – 3120768...
- Page 33 SECTION 3 - TROUBLESHOOTING Table 3-1. Platform Assembly Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Platform raises or lowers erratically Enable switch not activated Activate enable switch Function not activated within 3 seconds after Reactivate enable switch enable switch was depressed Enable switch not functioning properly replace enable switch circuit card Hydraulic system low replenish oil as necessary...
- Page 34 Wires loose or broken from Tach Drive system to Check flashcode on Sevcon. Repair or replace wire Sevcon controller as necessary Tach Drive shaft broke off Replace Tach Drive shaft Tach Drive defective Check flashcode – JLG Sizzor – 3120768...
- Page 35 SECTION 3 - TROUBLESHOOTING Table 3-2. Chassis Troubleshooting TROUBLE PROBABLE CAUSE REMEDY STEER SYSTEM No response to control Enable switch not activated Activate enable switch Function not activated within 3 seconds after Reactivate enable switch Enable switch was depressed Enable switch not functioning properly Replace enable switch circuit card Hydraulic system low Replenish oil as necessary...
- Page 36 Defective valve cartridge Replace cartridge Systems operate erratically Sticking or binding valve cartridge, piston rod, Clean, repair or replace components as etc. required Hydraulic oil not at operating temperature Allow oil sufficient time to warm up – JLG Sizzor – 3120768...
- Page 37 SECTION 3 - TROUBLESHOOTING Table 3-4. Electrical System Troubleshooting TROUBLE PROBABLE CAUSE REMEDY ELECTRICAL SYSTEM Hand controller No electric power to hand controller Check electrical input to hand controller Control valve will not function when thumb- No electric power to valve Check electric output and electrical signal at the switch is moved in either direction valve...
- Page 38 * If speed switch is turned 25% - 50% toward full speed, Sevcon controller will give a 2 flash fault indicating a procedure fault. If, while 2 flash fault is being indicated, the speed control knob is turned to less then 25% the 2 flash fault will stop and LED will come on steady, indicating controller operational. – JLG Sizzor – 3120768...
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Page 39: Hydraulic Schematic
SECTION 3 - TROUBLESHOOTING Figure 3-1. Hydraulic Schematic 3120768 – JLGSizzor –... -
Page 40: Platform Wiring Diagram (Sheet 1 Of 2)
SECTION 3 - TROUBLESHOOTING Figure 3-2. Platform Wiring Diagram (Sheet 1 of 2) – JLG Sizzor – 3120768 3-10... -
Page 41: Platform Wiring Diagram (Sheet 2 Of 2)
SECTION 3 - TROUBLESHOOTING Figure 3-2. Platform wiring Diagram (Sheet 2 of 2) 3120768 – JLGSizzor – 3-11... -
Page 42: Ground Control Wiring Diagram (Sheet 1 Of 2)
SECTION 3 - TROUBLESHOOTING Figure 3-3. Ground Control Wiring Diagram (Sheet 1 of 2) – JLG Sizzor – 3120768 3-12... -
Page 43: Ground Control Wiring Diagram (Sheet 2 Of 2)
SECTION 3 - TROUBLESHOOTING Figure 3-3. Ground Control Wiring Diagram (Sheet 2 of 2) 3120768 – JLGSizzor – 3-13... - Page 44 SECTION 3 - TROUBLESHOOTING This page intentionally left blank. – JLG Sizzor – 3120768 3-14...
- Page 46 England Fax: (49) 421 693 5035 Fax: (61) 2 65 810122 Phone: (44) 870 200 7700 Fax: (44) 870 200 7711 JLG Latino Americana Ltda. JLG Europe B.V. JLG Industries (Norge AS) JLG Polska Rua Eng. Carlos Stevenson, Jupiterstraat 234 Sofeimyrveien 12 UI.