JLG RT3669 Manuals

Manuals and User Guides for JLG RT3669. We have 1 JLG RT3669 manual available for free PDF download: Service And Maintenance Manual

JLG RT3669 Service And Maintenance Manual (376 pages)

Brand: JLG | Category: Lifting Systems | Size: 66 MB

Section A. Introduction - Maintenance Safety Precautions
3
Ageneral
3
Bhydraulic System Safety
3
Cmaintenance
3
Table of Contents
5
Section 1 - Specifications
19
Specifications
19
Machine Specifications - for RT
19
Machine Specifications - for ERT
19
Generator Specifications (if Equipped)
20
Dimensional Data
20
Fluid Capacities - for RT
20
Fluid Capacities - for ERT
20
Drive Information
20
Steering Information
20
Batteries (for ERT)
21
Tires
21
Critical Stability Weights
21
1.2 Serial Number Location
21
1.3 Lubrication
22
Hydraulic Oil Specification
22
1.4 Hydraulic Pressure Settings
24
1.5 Hydraulic Cylinder Specifications
24
1.6 Engine Specifications
24
Battery Charger (ERT Machines)
25
1.8 Elevation/Tilt Limit Settings
26
Threadlocking Compound
29
1.10 Torque Charts
30
SAE Fastener Torque Chart
30
Metric Fastener Torque Chart
36
Section 2 - General
41
Machine Preparation, Inspection, and Maintenance
41
General
41
Preparation, Inspection, and Maintenance
41
Pre-Start Inspection
41
Pre-Delivery Inspection and Frequent Inspection
41
Annual Machine Inspection
41
Preventative Maintenance
41
Preventive Maintenance and Inspection Schedule
42
Maintenance and Inspection Schedule Codes
42
Footnotes
45
Footnotes
48
Service and Guidelines
49
General
49
Safety and Workmanship
49
Cleanliness
49
Components Removal and Installation
49
Component Disassembly and Reassembly
49
Pressure-Fit Parts
49
Bearings
49
Gaskets
49
Bolt Usage and Torque Application
49
Hydraulic Lines and Electrical Wiring
50
Hydraulic System
50
Lubrication
50
Battery
50
Lubrication and Servicing
50
Lubrication and Information
50
Hydraulic Oil
50
Changing Hydraulic Oil
51
Lubrication Specifications
51
Service Maintenance Components
51
Setting Scissor Arm Safety Prop
51
General Maintenance Tips
52
Fuel Tank
54
Drive Hub
54
Scissor Arms - Sliding Wear Pads
54
Hydraulic Oil Tank
54
Engine Coolant
54
Oil Change with Filter
55
Fuel Strainer (Diesel)
55
Fuel Filter (Gas)
55
Air Filter
56
Fuel/Water Separator Filter (Diesel)
56
Fan Belt
56
Cylinder Drift Test
57
Platform Drift
57
Cylinder Drift
57
Pins and Composite Bearing Repair Guidelines
57
Operating Characteristics
59
Leveling Jacks (if Equipped)
59
Quiklevel Advanced (Dual Oscillating Axles) (if Equipped)
60
Lift
60
Drive
60
Tires, Wheels & Drive Assembly
61
Tire Damage
61
Tire Replacement
61
Wheel Replacement
61
Wheel Installation
61
Drive Assembly
62
Drive Hub - 2WD (for RT)
69
Roll and Leak Testing
69
Tightening and Torquing Bolts
69
Oil Information
69
Main Disassembly for Drive Hub
73
Hub-Spindle Disassembly
73
Cover Disassembly
74
Carrier Disassembly
74
Carrier Assembly
74
Cover Sub-Assembly
76
Hub-Spindle Sub-Assembly
77
Main Assembly
79
Tool List
84
Re-Aligning Torque Hub Input Coupling
84
Drive Hub - 4WD (for RT)
85
Drive Hub (for ERT)
86
Tightening and Torquing Bolts
86
Main Disassembly
87
Output Carrier Disassembly
89
Input Carrier Disassembly
91
Hub-Spindle Disassembly
92
Cover Disassembly
93
Input Carrier Sub-Assembly
94
Output Planet Gear Sub-Assembly
94
Output Carrier Sub-Assembly
94
Hub-Spindle Sub-Assembly
95
7HB0 Cover Sub-Assembly
95
Main Assembly
95
Tool List
96
Drive Motor (Sauer)
98
Description
98
Shaft Seal Replacement
98
Loop Flushing Valve
99
Troubleshooting
100
Disassembly
101
Inspection
104
Assembly
107
Initial Start-Up Procedures
112
Axle Installation
113
Removal
114
Assembly
114
Steer Installation
115
Steer Cylinder Removal
118
Spindle Removal
118
Assembly
118
Oscillating Axle Cylinder
119
Leveling Jacks (if Equipped)
120
Cylinder Removal
120
Assembly Removal
121
3.10 Platform
122
Platform Control Station
123
Joystick Controller
124
3.11 Scissor Arms
125
Lift Cylinder Removal
125
Scissor Arms Removal
125
Scissor Arm Assembly Removal
125
3.12 Side Compartment Covers
130
Cover Removal
133
Cover Installation
133
3.13 Ground Control Station
133
Control Station Removal
133
Ground Control Station Components
135
3.14 Battery
137
3.15 Tank
139
Removal
139
Installation
139
Battery Charger
141
Delta-Q - Battery Charger
141
Battery Charging
141
Battery Charger Maintenance
142
IC Series Setup and Troubleshooting Guide
143
Engine Removal
153
Dual Fuel/Lpg System
154
Changing from Gasoline to LP Gas
154
Changing from LP Gas to Gasoline
154
Using Liquid Petroleum (LP) Gas
154
Propane Fuel System Pressure Relief
154
Propane Fuel System Leak Test
154
Generator (if Equipped)
155
Belt Routing
157
Exhaust System
158
Dual Fuel - Gas/Lpg
159
Diesel
159
Air Cleaner System
160
Radiator
162
Engine Electrical Component Locations
163
Hydraulic Pump Installation
175
Pump Coupling Assembly
176
Section 4 - Basic Hydraulic Information & Schematics
177
Cylinders - Theory of Operation
177
Valves - Theory of Operation
177
Solenoid Control Valves (Bang-Bang)
177
Relief Valves
177
Crossover Relief Valves
177
Cylinder Checking Procedure
177
Cylinders Without Counterbalance Valves
177
Cylinders with Single Counterbalance Valve
178
Oscillating Axle - Lockout Cylinder Test
178
Left Side Wheel Test (CE Market Only)
178
Right Side Wheel Test (CE Market Only)
179
Front Oscillating Axle Test (Non-CE Market Only)
179
Gear Pump Priming
180
Hydraulic Component Start-Up Procedures & Recommendations
180
Hydraulic Valves
182
Junction Manifold Valve
182
Electric Option Valve
183
Leveling Jack Valves (if Equipped)
190
Traction Valve (2WD)
191
Traction Valve (4WD)
193
Ground Control Panel Installation
195
Pressure Relief Valve - Setting Procedures (for RT)
207
Pressure Relief Valve - Setting Procedures (for ERT)
211
Gear Pump
216
General Repair Instructions
218
Cylinder Repair
219
4.10 Cylinder Assemblies
220
Oscillating Axle Cylinder Bleeding Procedure
224
Hydraulic Schematics (for RT)
226
Hydraulic Schematics (for ERT)
236
Section 5 - Jlg Control System
243
Analyzer
243
Connecting the Analyzer
243
Using the Analyzer
244
Changing the Access Level
245
Adjusting Parameters
246
Machine Setup
246
System Fault/Dtc Indication
247
Analyzer Menu Flow Chart (for RT)
248
Analyzer Menu Flow Chart (for ERT)
254
Diagnostic Troubleshooting Codes (Dtc's) and Flash Codes Description (for RT)
260
Diagnostic Troubleshooting Codes (Dtc's) and Flash Codes Description (for ERT)
277
Chassis Tilt Sensor Installation
305
Location of Additional Sensors
306
Calibration Procedures
308
Chassis Tilt Sensor - Non Quiklevel Equipped Machine
308
Chassis Tilt Sensor - Quiklevel Equipped Machine
309
Troubleshooting Steps
310
Front Oscillating Axle Tilt Sensor (CE or Quiklevel Equipped Machines Only)
310
Elevation Sensor
310
Rear Axle Tilt Sensor (Quiklevel Equipped Machines Only)
311
Joystick
312
Steer Sensor (ERT Family Only)
312
Set Charger (ERT Family Only)
312
Service Mode Procedures
313
Elevation Service
313
EEPROM Reset
313
Allow Drive
313
Allow Leveling Jack Retract
313
Set Main Relief
313
Hydraulic System Flush
313
QLA Pressure Set
314
Machine Configuration and Programming Settings (for RT)
315
Machine Configuration and Programming Settings (for ERT)
316
Machine Orientation When Setting Speeds
320
Section 6 - Lss Setup/Calibration/Service
323
Connecting the JLG Control System Analyzer
323
Help Menu & Fault Codes
323
Machine Setup Menu
324
Service
325
Description
325
6.5 Calibration
326
Procedure
326
Troubleshooting Steps
326
Testing & Evaluation
328
6.6 Troubleshooting
329
Multimeter Basics
335
Grounding
335
Backprobing
335
Min/Max
335
Polarity
335
Scale
335
Voltage Measurement
336
Resistance Measurement
336
Continuity Measurement
337
Current Measurement
337
Continuity Measurement over Long Distances
338
Requirements
338
Procedure
338
Applying Silicone Dielectric Compound to Electrical Connections
338
Dielectric Grease Application
339
AMP Mate-N-Lok
339
AMP Faston
339
AMP Micro-Fit
339
AMP Mini Fit Jr
339
Mini Fit Sr
340
DIN Connectors
340
Exceptions
340
AMP Connector
341
Assembly
341
Disassembly
343
Wedge Lock
343
Service - Voltage Reading
344
7.6 Working with Deutsch Connectors
345
DT/DTP Series Assembly
345
DT/DTP Series Disassembly
345
HD30/HDP20 Series Assembly
346
HD30/HDP20 Series Disassembly
346
Switches
347
Basic Check
347
Limit Switches
347
Automatic Switches
348
Switch Wiring - Low Side, High Side
348
Electrical Schematics (for RT)
349
Electrical Schematics (for ERT)
363

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JLG RT3669 Service And Maintenance Manual (376 pages)

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