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

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Service & Maintenance Manual
Models
3369LE
4069LE
M3369
M4069
3121122
January 14, 2011

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Summary of Contents for JLG 3369LE

  • Page 1 Service & Maintenance Manual Models 3369LE 4069LE M3369 M4069 3121122 January 14, 2011...

  • Page 3: Hydraulic System Safety

    • USE ONLY APPROVED, NONFLAMMABLE CLEANING SOLVENTS. Relieve system pressure by cycling the applicable control several times with the engine stopped and 3121122 – JLG Lift –...
  • Page 4 Revision - January 24, 2005 Revision - February 2, 2007 Revision - April 17, 2007 Revision - October 11, 2007 Revision - November 28, 2007 Revision - March 17, 2008 Revision - January 14, 2011 – JLG Lift – 3121122...

  • Page 5: Table Of Contents

    Oscillation Cylinder Bleeding ........... . .4-10 3121122 – JLG Lift –...
  • Page 6 Joystick Controller - (JLG P/N 1600308) ........
  • Page 7 Hydraulic Diagram - 3369LE and M3369 (Fixed Axle) ....... . .
  • Page 8 J6 Connector ..............5-26 – JLG Lift –...

  • Page 9: Section 1 - Specifications

    8 in (20 cm) Wheelbase 91.5 in (2.3 m) Machine Height (w/ rails folded) 76.5 in (1.9 m) 79 in (2.01 m) Machine Length (stowed) 121 in (3.1 m) Machine Width 69 in (1.75 m) 3121122 – JLG Lift –...

  • Page 10: Capacities

    YOUR LOCAL JLG SUPPORT OFFICE. NOTE: Hydraulic oils must have anti-wear qualities at least to API Service Classification GL-3, and sufficient BATTERIES APPROVED BY JLG HAVE BEEN TESTED FOR COM- chemical stability for mobile hydraulic system ser- PATIBILITY WITH THE ALGORITHM PROGRAMMING OF THE vice.

  • Page 11: Cylinder Specifications

    Table 1-10. Critical Stability Weights cp at -30° F 3.200 Description 3369LE/M3369 4069LE/M4069 Viscosity Index Platform 780 lbs (354 kg) Platform Extension 360 lbs (163 kg) Foam Filled Tires 207 lbs (94 kg) Battery (Each) 122 lbs (55 kg) 3121122 – JLG Lift –...

  • Page 12: Lubrication

    NOTE: Be sure to lubricate like items on each side of the *The high pressure filter is located in the main con- machine. trol valve. See figure title control valve in section 2. – JLG Lift – 3121122...

  • Page 13: Serial Number Locations

    For machine identification, a serial number plate is affixed to the front of the frame. If the serial number plate is damaged or missing, the machine serial number is stamped on the left front of the machine frame. SERIAL NUMBER PLATE SERIAL NUMBER STAMPED Figure 1-2. Serial Number Location 3121122 – JLG Lift –...

  • Page 14: Torque Charts

    1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% 3. * ASSEMBLY USES HARDENED WASHER REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND JLG P/N Loctite® P/N...

  • Page 15: Torque Chart (Sae Fasteners - Sheet 2 Of 7))

    1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% 3. * ASSEMBLY USES HARDENED WASHER Figure 1-4. Torque Chart (SAE Fasteners - Sheet 2 of 7)) 3121122 – JLG Lift –...

  • Page 16: Torque Chart (Sae Fasteners - Sheet 3 Of 7)

    4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. Figure 1-5. Torque Chart (SAE Fasteners - Sheet 3 of 7) – JLG Lift – 3121122...

  • Page 17: Torque Chart (Sae Fasteners - Sheet 4 Of 7)

    4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. Figure 1-6. Torque Chart (SAE Fasteners - Sheet 4 of 7) 3121122 – JLG Lift –...

  • Page 18: Torque Chart (Metric Fasteners - Sheet 5 Of 7))

    4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 5 of 7)) 1-10 – JLG Lift – 3121122...

  • Page 19: Torque Chart (Metric Fasteners - Sheet 6 Of 7)

    4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 6 of 7) 3121122 – JLG Lift – 1-11...

  • Page 20: Torque Chart (Metric Fasteners - Sheet 7 Of 7)

    4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. Figure 1-9. Torque Chart (METRIC Fasteners - Sheet 7 of 7) 1-12 – JLG Lift – 3121122...

  • Page 21: Section 2 - General

    Annual Machine Inspection. JLG Indus- tries, Inc. recognizes a Factory-Certified Service Techni- Preparation, Inspection, and Maintenance cian as a person who has successfully completed the JLG Service Training School for the subject JLG product It is important to establish and conform to a comprehen- model.

  • Page 22: Service And Guidelines

    At each Operator change. Service and Maintenance Pre-Delivery Prior to each sale, lease, or Qualified JLG Owner, Dealer, or User Manual and applicable JLG Inspection rental delivery. Mechanic inspection form. In service for 3 months or 150 hours, whichever comes first; or...

  • Page 23: Lubrication And Information

    Hydraulic system filters should be checked, dance with recommended shop practices. (See cleaned, and/or replaced as necessary, at the speci- Torque Chart Section 1.) fied intervals required in the Lubrication Chart in 3121122 – JLG Lift –...

  • Page 24: Cylinder Drift Test

    1. Refer to Section 1 for recommendations for viscosity ranges. 2.4 CYLINDER DRIFT TEST 2. JLG recommends Mobilfluid 424 hydraulic oil, which Maximum acceptable cylinder drift is to be measured has an SAE viscosity of 10W-30 and a viscosity using the following methods.

  • Page 25: Pins And Composite Bearing Repair Guidelines

    Inspection Report” form. Forms are supplied with each b. Noise originating from the joint during operation. new machine and are also available from JLG Customer 2. Filament wound bearings should be replaced if any Service. Forms must be completed and returned to JLG of the following is observed: Industries.

  • Page 26: Preventive Maintenance And Inspection Schedule

    24. Control Tags 25. Hose and Cable 4, 8 * Inspection and Maintenance Code 10 to be performed annually. NOTE: If function speeds are slow on a fully charged machine a clogged filter may be indicated. Change filter. – JLG Lift– 3121122...

  • Page 27: Section 3 - Chassis & Scissor Arms

    M3369/3369LE - 8 ft - 9.5 ft (2.4 - 2.9 m) NOTE: If your machine does not have a motion alarm, the M4069/4069LE - 9.5 ft - 11.7 ft (2.9 - 3.6 m) following procedures will still apply.
  • Page 28 COMPLETE will show on the analyzer when cali- contributor: brated. a. Machine mounting and/or grade: 2. SET 25FT ELEV (3369LE) or SET 30FT ELEV With a digital level, measure the top of the (4069LE); Ground Control box for levelness. If unable to get a good reading, check the box’s mounting...
  • Page 29 (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. 3121122 – JLG Lift –...

  • Page 30: Tilt Sensor

    SECTION 3 - CHASSIS & SCISSOR ARMS TILT SENSOR Tilt Sensor, JLG P/N 4000006: 1. Ground Control Box 2. Tilt Sensor (JLG P/N 4000006) Figure 3-1. Tilt Sensor Location 1. Tilt Sensor (JLG P/N 4000006) Tilt Sensor Removal: 2. Screw, 6-32 x 3/4 3.

  • Page 31: Tilt Sensor Location

    SECTION 3 - CHASSIS & SCISSOR ARMS Tilt Sensor, JLG P/N 4000021: 1. Ground Control Box 2. Tilt Sensor Assembly (JLG P/N 1810140) Figure 3-3. Tilt Sensor Location NOTE: Refer to Figure 3-4., Tilt Sensor Removal for num- 1. Tilt Sensor (JLG P/N 4000021) bers in parenthesis.

  • Page 32: Battery Maintenance And Charging

    TERS OR JLG' S AFTERMARKET PROGRAMS. FOR ASSISTANCE WITH PROPER BATTERY REPLACEMENT, PLEASE CONTACT YOUR LOCAL JLG SUPPORT OFFICE. BATTERIES APPROVED BY JLG HAVE BEEN TESTED FOR COM- WHEN THE GENERATOR ENABLE CONTROL LOCATED IN THE PATIBILITY WITH THE ALGORITHM PROGRAMMING OF THE...

  • Page 33: Remote Led Card

    230 volt source with a 15 amp minimum capacity. The battery charger is located on a tray behind the hinged JLG cover at the front of the machine, or on the sliding 3. The charge cycle is complete when the 100% LED is engine tray on the (M) model machines.

  • Page 34: Delta-Q - Battery Charger Specs

    Follow the safety instructions recommended by the battery manufacturer. 2. Make sure charger connections to battery terminals are tight and clean. 3. Do not expose charger to oil or to direct heavy water spraying when cleaning vehicle. – JLG Lift – 3121122...
  • Page 35 Be sure to set this charger to the appropri- 3. This fault will clear automatically when the low bat- ate voltage - 6V per 6V battery, 12V per 12V string/ tery voltage problem is rectified. battery. 3121122 – JLG Lift –...
  • Page 36 4. If the output voltage of the charger seems excessive, started charging normally, be sure to make a note of it. return the charger for service. Contact JLG to get the 1. Remove excessive AC loads from inverter if expected battery voltage settings for the charger in installed.

  • Page 37: Battery Algorithms

    NOTE: It is recommended to check a newly changed algo- for the specific batteries detailed in Table 3-4, Battery rithm by repeating the above steps 1 and 3. Algorithms. Contact JLG if your specific battery model is not listed. Table 3-4. Battery Algorithms...

  • Page 38: Batteries And Battery Charger

    2. Remove the two attachment bolts that secure the NOTE: To make battery box removal easier, when possible, battery box to the frame. raise the arms of the machine and install the safety prop. 3-12 – JLG Lift – 3121122...

  • Page 39: Generator

    The engine is equipped with a low oil pressure switch. The tery. The starter is energized by the start control relay. switch is closed when the oil pressure is below 14.2 psi (1 Bar). 3121122 – JLG Lift – 3-13...

  • Page 40: Generator Components

    SECTION 3 - CHASSIS & SCISSOR ARMS Figure 3-9. Generator Components 3-14 – JLG Lift – 3121122...

  • Page 41: Rbs Pre Start Sequence

    The RBS will crank for a period up to the crank time to the Generator or until the engine starts. The JLG Control System Analyzer can be used to monitor 2. Rest Time generator settings and conditions. Connect the analyzer...
  • Page 42 SECTION 3 - CHASSIS & SCISSOR ARMS 3-16 – JLG Lift – 3121122...

  • Page 43: Generator System Flash Codes

    • Overspeed If the engine speed exceeds the overspeed limit, the engine will stop immediately and an overspeed alarm will be indicated. 3121122 – JLG Lift – 3-17...
  • Page 44 The finish charging current determines the level of the cur- rotate the engine 1/3 of a turn and fuel should rent alternator output must drop below for a low battery spill from the fuel injector pump. 3-18 – JLG Lift – 3121122...

  • Page 45: Supplementary Fuse For Apu

    • - Weather proof fuse holder - JLG P/N 2400081 • - AGC1, 1 Amp fuse - JLG P/N 2400080 • - 45 cm of #16 AWG wire - JLG P/N 4920019 • - 2 X insulated butt splice connectors - JLG P/N 4460035 •...
  • Page 46 Use insulated butt splice connectors for these con- ductors. 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. 3-20 – JLG Lift – 3121122...

  • Page 47: Joystick Controller

    SECTION 3 - CHASSIS & SCISSOR ARMS 3.6 JOYSTICK CONTROLLER Figure 3-11. Joystick Controller - (JLG P/N 1600308) Table 3-9. Joystick Specifications Table 3-10. Joystick Plug Loading Chart Input Voltage 4.3V (±0.1V) Terminal Color Function Centered Output Voltage 2.2V (±0.1V)

  • Page 48: Joystick Controller - (Jlg P/N 1600403)

    SECTION 3 - CHASSIS & SCISSOR ARMS Figure 3-12. Joystick Controller - (JLG P/N 1600403) Table 3-11. Joystick Specifications Table 3-12. Joystick Plug Loading Chart Input Voltage Terminal Color Function Centered Output Voltage 4.25V to 2.60V Yellow Steer Right Reverse Voltage 4.60V to 4.80V...

  • Page 49: Drive Components

    SECTION 3 - CHASSIS & SCISSOR ARMS Figure 3-13. Drive Components 3121122 – JLG Lift – 3-23...

  • Page 50: Towing

    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. 3. Rotate the cover to show the inside diameter. 3-24 – JLG Lift – 3121122...
  • Page 51 MACHINE SHOULD NOT BE MOVED UNLESS IT IS SECURED TO 5. The gear drive should now be reengaged and the THE TOWING VEHICLE TO PREVENT RUNAWAY. machine can be disconnected from the towing vehi- cle. 3121122 – JLG Lift – 3-25...

  • Page 52: Torque Hub

    SECTION 3 - CHASSIS & SCISSOR ARMS Figure 3-15. Torque Hub 3-26 – JLG Lift – 3121122...

  • Page 53: Drive Hub

    The first stage planetary gears (11) must be changed as a complete set of four and the manufac- turer recommends changing the sun gear shaft (43) along with this set of planets. 3121122 – JLG Lift – 3-27...

  • Page 54: Brake Assembly

    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 8. O-ring 16. Spring Retainer Figure 3-16. Brake Assembly 3-28 – JLG Lift – 3121122...

  • Page 55: Drive Brake - Mico

    NOTE: If damaged, replace the input and output gaskets 2. Press new rotary oil seal (22) into cover (21) taking before assembling the brake to the hub and motor. note to direction of seal. (See Figure 3-13. and Figure 3-16.) 3121122 – JLG Lift – 3-29...

  • Page 56: Torque Hub

    Stud Planet Shaft Cover O-ring Retaining Ring, Ext. Planet Gear Disengage Cap Retaining Ring, Ext. Retaining Ring, Int. Output Carrier Hex Bolt Spring (1.460, 1.500) Thrust Washer Dowel Pin Figure 3-17. Torque Hub Assembly 3-30 – JLG Lift – 3121122...

  • Page 57: Bolt Torquing Sequence

    4. Now use a torque wrench to apply a specified torque to bolt "A". 5. Using the same sequence, crisscross around the bolt circle and apply an equal torque to the remain- ing bolts. 3121122 – JLG Lift – 3-31...

  • Page 58: Hub Main Disassembly

    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 3-19. Hub Main Disassembly 3-32 – JLG Lift – 3121122...
  • Page 59 First Stage Sun Gear (6), as the gear teeth will be integral to the Input Shaft (7). 7. Remove the Input Carrier Subassembly (8). 8. Remove the Second Stage Sun Gear (9). 9. Remove the Input Shaft (7). 3121122 – JLG Lift – 3-33...

  • Page 60: Output Carrier Disassembly

    Planet Shaft (2). (7). 7. Remove the Thrust Washer (8) from the counterbore NOTE: The Roll Pins (1) should not be reused when reas- in the Output Carrier (3). sembling the unit. 3-34 – JLG Lift – 3121122...

  • Page 61: Input Carrier Disassembly

    6. Repeat steps 1-5 for each of the two remaining 3. Using a 1/8" diameter punch, drive the Roll Pin (1) Planet Gears. out of the Planet Shaft (2). NOTE: The Roll Pins (1) should not be reused when reas- sembling the unit. 3121122 – JLG Lift – 3-35...

  • Page 62: Hub-Spindle Disassembly

    5. Lift Hub (6) off of Spindle (1). Remove Boot Seal (7) out of the Hub. from Hub if applicable. 6. If necessary, press 9 Studs (8) out of Hub. Locate Hub on Seal (refer to Figure 3-17.) end. 3-36 – JLG Lift – 3121122...

  • Page 63: Cover Disassembly

    Cover. 3. Unscrew the two Hex Head Bolts (4) and remove the Disengage Cap (5) from the Cover. 6. Remove the two O-ring Pipe Plugs (8) from the Cover. 3121122 – JLG Lift – 3-37...

  • Page 64: Input Carrier Sub-Assembly

    NOTE: Some grease may need to be applied tothe Thrust the pocket on the inside of the Carrier towards the Washers to hold them in place while installing the Planet Gears. 3-38 – JLG Lift – 3121122...

  • Page 65: Output Carrier Sub-Assembly

    Pin should be flush with OD of Carrier. 6. Repeat Steps 1-5 to finish the assembly of the two 12. Repeat Steps 7-11 for the installation of the two remaining Output Planet Gears. remaining Planet Gears. 3121122 – JLG Lift – 3-39...

  • Page 66: Hub-Spindle Sub-Assembly

    4. Place Bearing Cone (9) into Bearing Cup, position "B". 5. Grease Seal (refer to Figure 3-17.) lip and press Seal into Hub using appropriate tool until seal is flush with end of Hub. 3-40 – JLG Lift – 3121122...

  • Page 67: Cover Sub-Assembly

    3. Insert Disengage Rod (6) into hole in Cover until it plugs should be hand tight according to SAE stan- touches the inside of the Disengage Cap. dard. NOTE: The Disengage Rod can be inserted either end first. 3121122 – JLG Lift – 3-41...

  • Page 68: Hub Main Assembly

    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 3-26. Hub Main Assembly 3-42 – JLG Lift – 3121122...
  • Page 69 External Retaining Ring. 15. Insert the Plastic Plug (not shown) into place, if 7. Using an appropriate tool, install the Retaining Ring applicable. (17) into the groove on the Output Sun. 3121122 – JLG Lift – 3-43...
  • Page 70 SECTION 3 - CHASSIS & SCISSOR ARMS NOTES: 3-44 – JLG Lift – 3121122...

  • Page 71: Section 4 - Hydraulics

    When replacing bolts, use only those having the bolt or similar bracket lessens, as the angle between same specifications of the original, or one which is the supporting structure and the component equivalent. becomes less than 90°. 3121122 – JLG Lift –...

  • Page 72: Lubrication Information

    When recommended lubricants are 2. JLG recommends DTE 11Hydraulic Oil, which has not available, consult your local supplier for an equivalent an SAE viscosity of 10W and a viscosity index of that meets or exceeds the specifications listed.

  • Page 73: Cylinders - Theory Of Operation

    When neither coil is ener- tion position. If a function switch is selected during gized, the supply of hydraulic oil is blocked. traction, a procedure fault will occur when neutral is 3121122 – JLG Lift –...

  • Page 74: Features

    1 in (2.5 cm) below the platform. 3. After completing the above, shut down hydraulic system and allow machine to sit for 10-15 minutes. This is done to relieve pressure in the hydraulic – JLG Lift – 3121122...

  • Page 75: Cylinder Removal And Installation

    If leakage occurs at a rate of 6-8 drops per minute or more, the piston seals are defective and NOTE: Always check hydraulic fluid level after completely must be replaced. elevating and lowering machine. 3121122 – JLG Lift –...

  • Page 76: Cylinder Repair

    14. If applicable, remove the piston spacer from the rod. 4. To aid in realignment, mark cylinder head and barrel 15. Remove the rod from the holding fixture. Remove with a center punch. the cylinder head and retainer plate from the rod. – JLG Lift – 3121122...

  • Page 77: Oil-Lite Bearing Installation

    NOTE: Install the cylinder pin into the Garmax bearing dry. FOR CORRECT SEAL ORIENTATION. IMPROPER SEAL INSTALLA- Lubrication is not required with chrome pins and TION COULD RESULT IN CYLINDER LEAKAGE AND IMPROPER bearings. CYLINDER OPERATION. 3121122 – JLG Lift –...

  • Page 78: Wiper Seal Installation

    9. Thread the piston onto the rod until it abuts the spacer end and install the tapered bushing. NOTE: When installing the tapered bushing, the piston and mating end of the rod must be free of oil. – JLG Lift – 3121122...

  • Page 79: Rod Assembly Installation

    (1575 - 1925 Nm) 26. After the cylinder has been reassembled, the rod 150 ft lbs should be pushed all the way in (fully retracted) prior Steer Cylinder (210 Nm) to the reinstallation of any holding valves. 3121122 – JLG Lift –...

  • Page 80: Steer Cylinder Removal

    3. Repeat this procedure for the other side. If the lock- out cylinders do not hold, repeat the bleeding proce- dure or check for the following: a. Air in lockout system b. Bad cylinder seals c. Bad holding valves 4-10 – JLG Lift – 3121122...
  • Page 81 11. Raise machine platform approximately 7 ft (2.1 m) lockout cylinder test. on the 3369LE or 9 ft (2.7 m) on the 4069LE. 1. Place a 6 inch (15.2 cm) high block with ascension 12. Place DRIVE control switch to REVERSE position ramp in front of left front wheel.

  • Page 82: 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 lbs (99.8 kg) •...

  • Page 83: Lift Cylinder - 4069Le & M4069

    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) 3121122 – JLG Lift – 4-13...
  • Page 84 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 – JLG Lift – 3121122...
  • Page 85 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. 3121122 – JLG Lift – 4-15...

  • Page 86: Leveling Jack Cylinder - Usa Built Machines Prior To S/N 0200104829

    NOTE: Torque Nut (12) to 400 ft lbs (542.3 Nm). Torque Locking Screw (17) to 100 in lbs (11.3 Nm). Torque Counter Balance Valve (26) and Check Valve (27) to 30-35 ft. lb. (40-47 Nm). 4-16 – JLG Lift – 3121122...

  • Page 87: Steer Cylinder

    SECTION 4 - HYDRAULICS 1. Barrel 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 Figure 4-16. Steer Cylinder 3121122 – JLG Lift – 4-17...

  • Page 88: Axle Lockout Cylinder

    22. Thermal Relief Valve Figure 4-17. Axle Lockout Cylinder NOTE: Torque Capscrews (3) to 30 ft lbs (41 Nm). Torque Thermal Relief Valve (22) to 20 - 25 ft lbs (27 - 34 Nm). 4-18 – JLG Lift – 3121122...

  • Page 89: Pressure Setting Procedures

    1. With pressure gauge at “MP” port on control valve, Brake activate and bottom out Lift Up. High Pressure Filter 2. Adjust Lift Relief to 2500 psi (172 bar) on the M3369/ 3369LE and 2800 psi (193 bar) on the M4069/ Steer 4069LE. Lift Steer Relief Flow Control 1.

  • Page 90: Drive Torque Hub

    8. Remove thrust washer from the output shaft. 9. The output shaft may now be pressed out of the housing. 10. The bearing cups will remain in hub as will the inner bearing cone. The outer bearing cone will remain on 4-20 – JLG Lift – 3121122...
  • Page 91 “X” over one of the marked coun- terbored 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. 3121122 – JLG Lift – 4-21...

  • Page 92: Drive Assist Valve

    SECTION 4 - HYDRAULICS 4.17 DRIVE ASSIST VALVE PR MPR T1 T VALVE SCHEMATIC Figure 4-19. Drive Assist Valve 4-22 – JLG Lift – 3121122...

  • Page 93: Hand Held Analyzer

    SECTION 5 - JLG CONTROL SYSTEM SECTION 5. JLG CONTROL SYSTEM 5.1 HAND HELD ANALYZER m en u: Analyzer Display HELP: PRESS ENTER Enter Key Escape Key Stores and selects Top Level, Sub To return home or access Level, and item menus previous menu Left &...
  • Page 94 SECTION 5 - JLG CONTROL SYSTEM Using the Analyzer: In platform mode: HELP: With the machine power on and the analyzer connected EVERYTHING OK, properly, the analyzer will display the following: In ground mode: HELP: GROUND MODE OK If ENTER is pressed again, the display moves to the fol-...
  • Page 95 SECTION 5 - JLG CONTROL SYSTEM while in access level 2. Remember, you may always can- Once the correct password is displayed, press ENTER. The access level should display the following, if the pass- cel a selected menu item by pressing the ESC key.
  • Page 96 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...

  • Page 97: Pc Boards

    SECTION 5 - JLG CONTROL SYSTEM 5.2 PC BOARDS NOTE: Refer to Table 5-3, Machine Model Adjustment, and Table 5-4, Machine Configuration Programming Information for the default settings. PCB - JLG P/N 0610143 Password 33271 will give you access to level 1, which will permit you to change all machine person- ality and/or machine setup settings.

  • Page 98: 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. – JLG Lift– 3121122...
  • Page 99 SECTION 5 - JLG CONTROL SYSTEM Table 5-1. Flash Codes/DTC’s FLASH CODE HELP MESSAGE AND DESCRIPTION POWER UP POWER CYCLE A new system power up has occurred since the last help message. KEYSWITCH FAULTY Both Platform and Ground modes are selected simultaneously.
  • Page 100 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 101 SECTION 5 - JLG CONTROL SYSTEM Table 5-1. Flash Codes/DTC’s FLASH CODE HELP MESSAGE AND DESCRIPTION BATTERY SUPPLY BATTERY VOLTAGE TOO LOW - SYSTEM SHUTDOWN Recharge batteries or check for damaged batteries. BATTERY VOLTAGE TOO HIGH - SYSTEM SHUTDOWN Disconnect battery charger. Check that the correct voltage batteries are being used.

  • Page 102: Power Module Diagnostic Led Flash Codes

    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 103 SECTION 5 - JLG CONTROL SYSTEM 3121122 – JLG Lift – 5-11...
  • Page 104 SECTION 5 - JLG CONTROL SYSTEM 5-12 – JLG Lift– 3121122...
  • Page 105 SECTION 5 - JLG CONTROL SYSTEM 3121122 – JLG Lift – 5-13...
  • Page 106 SECTION 5 - JLG CONTROL SYSTEM 5-14 – JLG Lift– 3121122...
  • Page 107 SECTION 5 - JLG CONTROL SYSTEM 3121122 – JLG Lift – 5-15...
  • Page 108 SECTION 5 - JLG CONTROL SYSTEM 5-16 – JLG Lift– 3121122...

  • Page 109: Machine Model Adjustment

    SECTION 5 - JLG CONTROL SYSTEM Table 5-3. Machine Model Adjustment 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% MAXIMUM 30 - 100%...

  • Page 110: Machine Configuration Programming Information

    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 con- figured for the CE Market. The selection will default to STANDARD otherwise.

  • Page 111: Ground Control Circuit Board

    SECTION 5 - JLG CONTROL SYSTEM 5.4 GROUND CONTROL CIRCUIT BOARD Software Version 13.6 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 112: J2 Connector

    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 113: J3 Connector

    SECTION 5 - JLG CONTROL SYSTEM Table 5-6. J2 Connector TAGNAME FUNCTION TYPE 4WAF 4 Wheel Assist Forward Solenoid Valve DIGITAL OUTPUT 4AWR 4 Wheel Assist Reverse Solenoid Valve DIGITAL OUTPUT OSAX Oscillating Axle Solenoid Valves DIGITAL OUTPUT DO22 Spare High-Side Digital Otput 22 (12V, 5A)

  • Page 114: J4 Connector

    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 115: J1 Connector

    SECTION 5 - JLG CONTROL SYSTEM Software Version P1.0 Table 5-11. J1 Connector TAGNAME FUNCTION TYPE PLTS Platform Select POWER OUTPUT PLTE Platform EMS POWER INPUT Ground POWER OUTPUT COL0 Column 0 Output DIGITAL OUTPUT COL1 Column 1 Output DIGITAL...

  • Page 116: J2 Connector

    SECTION 5 - JLG CONTROL SYSTEM Table 5-12. 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 117: J3 Connector

    SECTION 5 - JLG CONTROL SYSTEM Table 5-12. 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 Otput 22 (12V, 5A) DIGITAL OUTPUT Table 5-13. J3 Connector...

  • Page 118: J4 Connector

    SECTION 5 - JLG CONTROL SYSTEM Table 5-14. 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 5-15. J5 Connector TAGNAME...

  • Page 119: General

    ING THE MACHINE IS NEEDED, ENSURE THE MACHINE IS SHUT DOWN BEFORE PRESSURE-WASHING. SHOULD PRESSURE WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC. RECOMMENDS A MAXI- MUM PRESSURE OF 750 PSI (52 BAR) AT A MINIMUM DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM THESE COMPONENTS. IF ELEC- TRICAL/ELECTRONIC COMPONENTS ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION.

  • Page 120: Voltage Measurement (Dc)

    • Circuit power must be turned OFF before testing resistance • 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 – JLG Lift – 3121122...

  • Page 121: Continuity Measurement

    (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 continuity 3121122 – JLG Lift –...

  • Page 122: Continuity Measurement Over Long Distances

    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 third wire is used to troubleshoot the other wires. To find the problem, start at step 1 and use the entire procedure. – JLG Lift – 3121122...

  • Page 123: Applying Silicone Dielectric Compound To Amp Connectors

    2. Pierce one of the unused wire seals to allow the trapped air inside the housing to escape. 3. Install a hole plug into this and/or any unused wire seal that has silicone dielectric compound escaping from it. Figure 6-5. AMP Connector 3121122 – JLG Lift –...

  • Page 124: Connector Assembly (1 Of 4)

    (See Figure 6-8. Connector Assembly (3 of 4)). 4. Slide the wedge lock into the housing until it is flush with the housing (See Figure 6-9. Connector Assembly (4 of 4)). Figure 6-7. Connector Assembly (2 of 4) – JLG Lift – 3121122...

  • Page 125: Connector Assembly (3 Of 4)

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-8. Connector Assembly (3 of 4) Figure 6-9. Connector Assembly (4 of 4) 3121122 – JLG Lift –...

  • Page 126: Connector Disassembly

    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. – JLG Lift – 3121122...

  • Page 127: Connector Installation

    This nullifies the effectiveness of the connector seals and could result in system failure. Figure 6-11. Connector Installation 3121122 – JLG Lift –...

  • Page 128: Working With Deutsch Connectors

    7. Hold the rear seal in place, as removing the contact may displace the seal. HD30/HDP20 Series Assembly Figure 6-14. HD/HDP Contact Installation 8. Grasp contact about 25mm behind the contact crimp barrel. 9. Hold connector with rear grommet facing you. 6-10 – JLG Lift – 3121122...

  • Page 129: Hd/Hdp Locking Contacts Into Position

    12. Slide tool along into the insert cavity until it engages contact and resistance is felt. 13. Pull contact-wire assembly out of connector. Figure 6-17. HD/HDP Unlocking Contacts NOTE: Do Not twist or insert tool at an angle. 3121122 – JLG Lift – 6-11...

  • Page 130: Electrical Components Installation - (Sheet 1 Of 4)

    MOTOR DRIVE CONTROLLER LEFT DRIVE MOTOR MAIN VALVE PLATFORM CONSOLE BATTERY CHARGER TO GROUND CONTROL BOX TERMINAL J1 LIFT CYLINDER PRESSURE TRANSDUCER OVERLOAD CUT-OUT Figure 6-18. Electrical Components Installation - (Sheet 1 of 4) 6-12 – JLG Lift – 3121122...

  • Page 131: Electrical Components Installation - (Sheet 2 Of 4)

    MACHINES PRIOR TO SWITCH OSCILLATING S/N 0200138293 & ALL AXLE BELGIUM BUILT CYLINDERS MACHINES) HORN BEACON LIGHT HARNESS GROUND CONTROL ANALYZER PC BOARD ANALYZER CONTROLLER Figure 6-19. Electrical Components Installation - (Sheet 2 of 4) 3121122 – JLG Lift – 6-13...

  • Page 132: Electrical Components Installation - (Sheet 3 Of 4)

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS LEVEL JACK SWITCHES GENERATOR MODULE (M3369 & M4069) LEVEL JACK VALVES ALARM BEACON LIGHT VALVE HARNESS PLATFORM GROUND CONTROL Figure 6-20. Electrical Components Installation - (Sheet 3 of 4) 6-14 – JLG Lift – 3121122...

  • Page 133: Electrical Components Installation - (Sheet 4 Of 4)

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS DRIVE DRIVE CONTACTOR CONTROLLER CIRCUIT BREAKER RECEPTACLE AT PLATFORM PLATFORM CONSOLE PLATFORM WORKLIGHTS Figure 6-21. Electrical Components Installation - (Sheet 4 of 4) 3121122 – JLG Lift – 6-15...

  • Page 134: Electrical Schematic - Sheet 1 Of 2

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Electrical Schematic - 1870130 RevE GROUND ELECTRONICS Figure 6-22. Electrical Schematic - Sheet 1 of 2 6-16 – JLG Lift – 3121122...

  • Page 135: Electrical Schematic - Sheet 2 Of 2

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS GROUND ELECTRONICS 1870130 F Figure 6-23. Electrical Schematic - Sheet 2 of 2 3121122 – JLG Lift – 6-17...

  • Page 136: Electrical Schematic - Kubota Engine (M3369 & 3369Le Only)

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Electrical Schematic - Kubota Engine - 2000327 RevB Figure 6-24. Electrical Schematic - Kubota Engine (M3369 & 3369LE only) 6-18 – JLG Lift – 3121122...

  • Page 137: Electrical Schematic - Yanmar Engine (M3369 & 3369Le Only)

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Electrical Schematic - Yanmar Engine - 0270787 RevF Figure 6-25. Electrical Schematic - Yanmar Engine (M3369 & 3369LE only) 3121122 – JLG Lift – 6-19...

  • Page 138: Hydraulic Diagram - 3369Le And M3369 (Fixed Axle)

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Hydraulic Diagram - 2792443 RevE 2792443_E Figure 6-26. Hydraulic Diagram - 3369LE and M3369 (Fixed Axle) 6-20 – JLG Lift – 3121122...

  • Page 139: Hydraulic Diagram - 3369Le And M3369 (Oscillating Axle)

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Hydraulic Diagram - 2792444 RevG 2792444_G Figure 6-27. Hydraulic Diagram - 3369LE and M3369 (Oscillating Axle) 3121122 – JLG Lift – 6-21...

  • Page 140: Hydraulic Diagram - 4069Le And M4069 (Fixed Axle)

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Hydraulic Diagram - 2792445 RevF 2792445_F Figure 6-28. Hydraulic Diagram - 4069LE and M4069 (Fixed Axle) 6-22 – JLG Lift – 3121122...

  • Page 141: Hydraulic Diagram - 4069Le And M4069 (Oscillating Axle)

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Hydraulic Diagram - 2792446 RevH 2792446_H Figure 6-29. Hydraulic Diagram - 4069LE and M4069 (Oscillating Axle) 3121122 – JLG Lift – 6-23...

  • Page 142: Hydraulic Schematic

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Hydraulic Schematic - 2792442 RevF 2792442_F Figure 6-30. Hydraulic Schematic 6-24 – JLG Lift – 3121122...
  • Page 144 JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) Ltd JLG France SAS P.O. Box 5119 Rua Eng. Carlos Stevenson, Bentley House Z.I. de Baulieu...

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M33694069leM4069

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