JLG Scissor Lift RT2669, ERT2669, RT3369, ERT3369 Service & Maintenance Manual 3122566600 2025

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JLG Scissor Lift RT2669, ERT2669, RT3369, ERT3369 Service & Maintenance Manual 3122566600 2025
Size: 86.48 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Scissor Lift
Type of Manual: Service & Maintenance Manual, Electrical and Hydraulic Diagrams
Model: JLG RT2669, ERT2669, RT3369, ERT3369 Scissor Lift
Part Number: 3122566600
Publication Date: 2025
Number of Pages: 570 Pages

Contents:
Coverpage
Effectivity Page
Safety

General​

1.1.1 Disclaimer​

1.1.2 Operation & Safety Manual​

Safety Information​

1.2.1 Safety Alert System and Signal Words​

Safety Hazards​

1.3.1 Personal Hazards​

1.3.2 Equipment Hazards​

1.3.3 General Hazards​

1.3.4 Operational Hazards​

Safety Decals​

Machine Verification​

General Machine Information and Specifications

Specifications​

2.1.1 Machine Specifications​

2.1.2 Generator Specifications (If Equipped)​

2.1.3 Machine Dimensional Data​

2.1.4 Fluid Capacities​

2.1.5 Drive Information​

2.1.6 Steering Information​

2.1.7 Quicklevel Information​

2.1.8 Batteries (For ERT)​

2.1.9 Tires​

2.1.10 Critical Stability Weights​

2.1.11 Hydraulic Pressure Settings​

2.1.12 Hydraulic Cylinder Specifications​

2.1.13 Engine Specifications​

2.1.14 Battery Charger (ERT Machines)​

2.1.15 Elevation/Tilt Limit Settings​

Serial Number Location (concept)​

Fluids and Lubrication (task)​

2.3.1 Hydraulic System​

2.3.2 Hydraulic Oil​

2.3.3 Changing Hydraulic Oil​

2.3.4 Lubrication Specifications​

2.3.5 Hydraulic Oil Specification​

Clearsky Smart Fleet (If Equipped)​

2.4.1 General​

2.4.2 ClearSky Smart Fleet™ — Access Control​

Maintenance and Inspection Schedules

Machine Preparation, Inspection, and Maintenance (task)​

3.1.1 General​

3.1.2 Preparation, Inspection, and Maintenance​

3.1.3 Pre-Start Inspection​

3.1.4 Pre-Delivery Inspection and Frequent Inspection​

3.1.5 Annual Machine Inspection​

3.1.6 Preventative Maintenance​

Service and Guidelines (task)​

3.2.1 General​

3.2.2 Safety and Workmanship​

3.2.3 Cleanliness​

3.2.4 Components Removal and Installation​

3.2.5 Component Disassembly and Reassembly​

3.2.6 Pressure-Fit Parts​

3.2.7 Bearings​

3.2.8 Gaskets​

3.2.9 Bolt Usage and Torque Application​

3.2.10 Hydraulic Lines and Electrical Wiring​

3.2.11 Hydraulic System​

3.2.12 Lubrication​

3.2.13 Battery​

3.2.14 Lubrication and Servicing​

Preventive Maintenance and Inspection Schedule (task)​

3.3.1 Maintenance and Inspection Schedule Codes​

Pins and Composite Bearing Repair Guidelines (task)​

Tires and Wheels (concept)​

3.5.1 Tire Damage​

3.5.2 Tire Replacement​

3.5.3 Wheel Replacement​

Battery Charger (task)​

3.6.1 Delta-Q - Battery Charger​

3.6.2 Battery Charging​

3.6.3 Battery Charger Maintenance​

3.6.4 IC Series Setup and Troubleshooting Guide​

Operating Characteristics (task)​

3.7.1 Leveling Jacks (If Equipped)​

3.7.2 Quiklevel Advanced (Dual Oscillating Axles) (If Equipped)​

3.7.3 Lift​

3.7.4 Drive​

Service Maintenance Components (task)​

3.8.1 Fuel Tank​

3.8.2 Drive Hub​

3.8.3 Scissor Arms - Sliding Wear Pads​

3.8.4 Hydraulic Oil Tank​

3.8.5 Engine Coolant​

3.8.6 Oil Change with Filter​

3.8.7 Fuel Strainer (Diesel)​

3.8.8 Fuel Filter (Gas)​

3.8.9 Air Filter​

3.8.10 Fuel/Water Separator Filter (Diesel)​

3.8.11 Fan Belt​

Testing, Calibrations and Special Procedures

Special Tools (concept)​

4.1.1 Multimeter​

4.1.2 Threadlocking Compound​

4.1.3 Tools Catalog​

Testing Procedures​

4.2.1 Preparation​

4.2.2 Testing LSS Control System Warnings and Interlocks:​

4.2.3 Testing LSS Platform Load Performance with Calibrated Weights:​

4.2.4 Testing LSS Platform Load Reading with a Known Weight:​

Calibration Procedures (task)​

4.3.1 JLG Analyzer​

4.3.2 Calibration Preparation​

4.3.3 Load Sensing System Calibration​

4.3.4 Chassis Tilt Sensor - Non QuikLevel Equipped Machine​

4.3.5 Chassis Tilt Sensor - QuikLevel Equipped Machine​

4.3.6 Troubleshooting Steps :​

4.3.7 Front Oscillating Axle Tilt Sensor (CE, UKCA or Quiklevel Equipped Machines Only)​

4.3.8 Elevation Sensor​

4.3.9 Rear Axle Tilt Sensor (Quiklevel Equipped Machines Only)​

4.3.10 Joystick​

4.3.11 Steer Sensor (ERT Family Only)​

4.3.12 Set Charger (ERT Family Only)​

4.3.13 Pressure Relief Valve - Setting Procedures (For RT)​

4.3.14 Pressure Relief Valve - Setting Procedures (For ERT)​

4.3.15 Quick Level Advanced (QLA) Pressure Setting (If Equipped)​

4.3.16 QLA Function Speed Setting (If Equipped)​

Special Procedures (task)​

4.4.1 Setting Scissor Arm Safety Prop​

4.4.2 General Maintenance Tips​

4.4.3 Joystick Controller​

4.4.4 Cylinder Drift Test​

4.4.5 Dual Fuel/LPG System​

4.4.6 Service Mode Procedures​

4.4.7 Initial Start-Up Procedures​

System Software

Load Sensing System (LSS) (reference)​

5.1.1 Theory of Operation​

5.1.2 Service​

5.1.3 Connecting the JLG control system Analyzer​

5.1.4 Machine setup menu​

JLG Analyzer (task)​

5.2.1 Hand Held Analyzer​

5.2.2 Analyzer Menu Flow Chart (Software Version P1.11) (For RT)​

5.2.3 Analyzer Menu Flow Chart (Software Version P1.10) (For ERT)​

Analyzer Software Accessibility (reference)​

5.3.1 Machine Configuration and Programming Settings (Software Version P1.11 For RT)​

5.3.2 Machine Configuration and Programming Settings (Software Version P1.10 For ERT)​

ClearSky (CS550) Configuration and Troubleshooting​

5.4.1 ClearSky Smart FleetTM CS550 Configuration​

5.4.2 Troubleshooting​

Fault Codes

Introduction​

6.1.1 System Fault/DTC Indication​

Diagnostic Trouble Codes (DTC)​

DTC Check Tables (concept)​

6.3.1 DTC and Flash Codes​

6.3.2 ClearSky CSV3 Smart Fleet DTC Fault Codes​

6.3.3 Help Menu and Fault Codes​

6.3.4 Troubleshooting​

ClearSky CS550 Troubleshooting Procedures​

Hydraulics

Theories of Operation (concept)​

7.1.1 Cylinders​

7.1.2 Valves​

7.1.3 Cylinder Checking Procedure​

7.1.4 Oscillating Axle- Lockout Cylinder Test​

7.1.5 Hydraulic Component Start-Up Procedures and Recommendations​

Torque Values​

7.2.1 Main Hydraulic Valve​

7.2.2 Junction Manifold Valve​

7.2.3 Electric Option Valve​

7.2.4 Leveling Jack Valves (If Equipped)​

7.2.5 Dual Axle Option Valve​

7.2.6 Traction Valve (2WD)​

7.2.7 Traction Valve (4WD)​

Gear Pump (task)​

7.3.1 General Repair Instructions​

7.3.2 Gear Pump Priming​

Electricals

General Information​

8.1.1 Applying Silicone Dielectric Compound to Amp Connectors​

8.1.2 Dielectric Grease Application​

8.1.3 Installation​

8.1.4 AMP Mate-N-Lok​

8.1.5 AMP Faston​

8.1.6 AMP Micro-Fit​

8.1.7 AMP Mini Fit Jr​

8.1.8 Mini Fit Sr​

8.1.9 DIN Connectors​

8.1.10 Exceptions​

8.1.11 Exceptions​

8.1.12 Enclosures​

8.1.13 Carling Switch Connectors​

8.1.14 Scissor Platform Cable at the Platform Control​

Electrical Connectors​

8.2.1 Deutsch Connectors​

Electrical Harness Layouts​

8.3.1 Electrical Layout For RT2669, RT3369​

8.3.2 Electrical Layout For ERT2669, ERT3369​

Board Layouts​

8.4.1 Ground Control Module (For RT)​

8.4.2 Ground Control Module (For ERT)​

AMP Connector​

8.5.1 Assembly​

8.5.2 Disassembly​

8.5.3 Wedge Lock​

8.5.4 Service - Voltage Reading​

Switches​

8.6.1 Basic check​

8.6.2 Limit Switches​

8.6.3 Automatic Switches​

8.6.4 Switch Wiring - Low Side, High Side​

Removal and Installation

Battery (task)​

9.1.1 Battery Removal - RT​

9.1.2 Battery Removal -ERT​

Tilt Sensor (task)​

Ground Control Station (task)​

9.3.1 Control Station Removal​

9.3.2 Removal​

9.3.3 Installation​

9.3.4 Ground Control Station Components​

Tank (task)​

9.4.1 Tank Installation - RT​

9.4.2 Tank Installation - For ERT​

Scissor Arms (task)​

9.5.1 Lift Cylinder​

9.5.2 Scissor Arms​

9.5.3 Scissor Arm Assembly​

Platform (task)​

Wheel (task)​

9.7.1 Removal​

9.7.2 Installation​

Axle (task)​

9.8.1 Removal​

9.8.2 Installation​

Steer (task)​

9.9.1 Steer - For RT​

9.9.2 Steer - For ERT​

Leveling Jacks (task)​

9.10.1 Cylinder Removal​

9.10.2 Cylinder Removal (Full Cover)​

9.10.3 Assembly Removal​

Oscillating Axle Cylinder (task)​

9.11.1 Removal​

9.11.2 Installation​

Drive Motor (Sauer) (task)​

9.12.1 Shaft Seal Replacement​

9.12.2 Loop Flushing Valve​

9.12.3 Troubleshooting​

Generator (If Equipped) (task)​

9.13.1 AC Generator​

9.13.2 Belt Routing​

Drive Assembly (task)​

9.14.1 Spindle Assembly Hub - For RT (2WD)​

9.14.2 Drive Assembly - For ERT​

Side Compartment Covers (Task)​

9.15.1 Removal​

9.15.2 Installation​

Engine​

9.16.1 Exhaust System - Dual Fuel - Gas/LPG​

9.16.2 Exhaust System – Diesel​

9.16.3 Air Cleaner System – Dual Fuel - Gas/LPG​

9.16.4 Air Cleaner System – Diesel​

9.16.5 Radiator​

9.16.6 Engine Electrical Component Locations​

Hydraulic Pump (task)​

9.17.1 Pump Coupling Assembly​

Hydraulic Valves (task)​

Ground Control Panel (task)​

Sensor (task)​

9.20.1 Location of Additional Sensors​

ClearSky® LED Motion / Amber Beacon (CS550) (if equipped)​

9.21.1 ClearSky® LED Motion / Amber Beacon (CS550) (if equipped)​

Disassembly and Assembly

Drive Assembly​

10.1.1 DRIVE HUB- 2WD (FOR RT)​

10.1.2 DRIVE HUB - 4WD (FOR RT)​

10.1.3 DRIVE HUB (FOR ERT)​

10.1.4 Drive Motor (Sauer)​

Scissor Arm Assembly​

10.2.1 Scissor Arm Assembly​

Platform Control Station​

10.3.1 Disassembly​

10.3.2 Assembly​

Hydraulic Cylinders​

10.4.1 Disassembly​

10.4.2 Cleaning and Inspection​

10.4.3 Assembly​

Cylinder Assemblies​

10.5.1 Steer Cylinder​

10.5.2 Lift Cylinder​

10.5.3 Oscillating Axle Cylinder​

10.5.4 Leveling Jack Cylinder​

10.5.5 Oscillating Axle Cylinder Bleeding Procedure​

Torque/Connection Information

Hydraulic Fittings​

11.1.1 Tapered Thread Types​

11.1.2 Straight Thread Types, Tube and Hose Connections​

11.1.3 Straight Thread Types, Port Connections​

11.1.4 Flange Connection Types​

11.1.5 Tightening Methods​

11.1.6 Assembly and Torque Specifications​

11.1.7 General Tube Type Fitting Assembly Instructions​

11.1.8 Assembly Instructions for American Standard Pipe Thread Tapered Connections.​

11.1.9 Assembly Instructions for British Standard Pipe Thread Tapered Connections​

11.1.10 Assembly Instructions for 37° (JIC) Flare Fittings​

11.1.11 Assembly Instructions for 45° SAE Flare Fittings​

11.1.12 Assembly Instructions for O-Ring Face Seal (ORFS) Fittings​

11.1.13 Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS)​

11.1.14 Assembly Instructions for Bulkhead (BH) Fittings​

11.1.15 Assembly Instructions for O-Ring Boss (ORB) Fittings​

11.1.16 Assembly Instructions for Adjustable Port End Metric Fittings​

11.1.17 Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends​

11.1.18 Assembly instructions for Adjustable Port End (BSPP) Fittings​

11.1.19 Assembly Instructions for Flange Connections: (FL61 and FL62)​

11.1.20 Double Wrench Method​

11.1.21 FFWR and TFFT Methods​

11.1.22 Adjustable Stud End Assembly​

11.1.23 O-ring Installation (Replacement)​

Torque Charts​

11.2.1 SAE Fastener Torque Chart​

11.2.2 Metric Fastener Torque Chart​

Schematics

Hydraulic Schematics​

12.1.1 Hydraulic Schematics (for RT)​

12.1.2 Hydraulic Schematics (for ERT)​

Electrical Schematics​

12.2.1 Electrical Schematic (For RT)​

12.2.2 Electrical Schematic (For ERT)​