JLG Scissor Lift RT4069 ERT4069 RT4769 ERT4769 Service & Maintenance Manual 3122567000 2025

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JLG Scissor Lift RT4069 ERT4069 RT4769 ERT4769 Service & Maintenance Manual 3122567000 2025
Size: 108.98 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Scissor Lift
Type of Manual: Service & Maintenance Manual, Electrical and Hydraulic Diagrams
Model: JLG RT4069, ERT4069, RT4769, ERT4769 Scissor Lift
Part Number: 3122567000
Publication Date: 2025
Number of Pages: 604 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 Specification​

2.1.2 Machine Specifications - For ERT​

2.1.3 Dimensional Data​

2.1.4 Tires​

2.1.5 Batteries (For ERT)​

2.1.6 Battery Charger (ERT Machines)​

2.1.7 Elevation/Tilt Limit Settings​

2.1.8 Hydraulic Pressure Settings​

2.1.9 Hydraulic Cylinder Specifications​

2.1.10 Critical Stability Weights​

2.1.11 Generator Specifications (If Equipped)​

2.1.12 Drive Information​

2.1.13 Steering Information​

2.1.14 Quicklevel Information​

2.1.15 Engine Specifications​

Serial Number Location​

Fluids and Lubrication​

2.3.1 Hydraulic System​

2.3.2 Hydraulic Oil​

2.3.3 Changing Hydraulic Oil​

2.3.4 Lubrication Specifications​

2.3.5 Fluid Capacities - For RT​

2.3.6 Fluid Capacities - For ERT​

2.3.7 Oil Information​

2.3.8 Fluids​

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​

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 Preventive Maintenance​

Service and Guidelines​

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​

3.3.1 Maintenance and Inspection Schedule Codes​

Pins and Composite Bearing Repair Guidelines​

Tires & Wheels​

3.5.1 Tire Damage​

3.5.2 Tire Replacement​

3.5.3 Wheel Replacement​

Battery Charger​

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​

3.6.5 IC650 DC Wiring Instructions​

3.6.6 IC900 & IC1200 DC Wiring Instructions​

3.6.7 Signals and Control Connector​

3.6.8 IC-Series Charger Interface​

3.6.9 State-of-Charge Indicators​

Service Maintenance Components​

3.7.1 Setting Scissor Arm Safety Prop​

3.7.2 General Maintenance Tips​

3.7.3 Fuel Tank​

3.7.4 Drive Hub​

3.7.5 Hydraulic Oil Tank​

3.7.6 Engine Coolant​

3.7.7 Oil Change with Filter​

3.7.8 Fuel Strainer (Diesel)​

3.7.9 Fuel Filter (Gas)​

3.7.10 Air Filter​

3.7.11 Fuel/Water Separator Filter (Diesel)​

3.7.12 Fan Belt​

Testing, Calibrations and Special Procedures

Special Tools​

4.1.1 Multimeter​

4.1.2 Continuity Measurement Over Long Distances​

4.1.3 Requirements​

4.1.4 Procedure​

4.1.5 Threadlocking Compound​

4.1.6 Tool List (Drive Hub – 2WD For RT)​

4.1.7 Tool List (Drive Hub — For ERT)​

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​

4.3.1 JLG Analyzer​

4.3.2 Calibration Preparation​

4.3.3 Load Sensing System Calibration​

Special Procedures​

4.4.1 Joystick Controller​

4.4.2 Cylinder Checking Procedure​

4.4.3 Cylinder Drift Test​

4.4.4 Initial Start-Up Procedures​

4.4.5 Dual Fuel/LPG System​

4.4.6 Hydraulic Component Start-Up Procedures & Recommendations​

Service Mode Procedures​

4.5.1 Elevation Service​

4.5.2 EEPROM Reset​

4.5.3 Allow Drive​

4.5.4 Allow Leveling Jack Retract​

4.5.5 Set Main Relief​

4.5.6 Hydraulic System Flush​

4.5.7 QLA Pressure Set​

Operating Characteristics​

4.6.1 Leveling Jacks (If Equipped)​

4.6.2 Manual Level Adjustment (Trim)​

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

System Software

Load Sensing System (LSS)​

5.1.1 Theory of Operation​

5.1.2 Description​

5.1.3 Connecting The Jlg Control System Analyzer​

5.1.4 Machine Setup Menu​

5.1.5 Load Sensing Calibration​

JLG Analyzer​

5.2.1 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​

5.3.1 Machine Configuration and Programming Settings (For RT)​

5.3.2 Machine Configuration and Programming Settings (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​

6.3.1 DTC and Flash Codes​

6.3.2 ClearSky CSV3 Smart Fleet DTC Fault Codes​

6.3.3 Troubleshooting​

6.3.4 Help Menu & Fault Codes​

6.3.5 LSS Troubleshooting​

6.3.6 Troubleshooting​

ClearSky CS550 Troubleshooting Procedures​

Hydraulics

Theories of Operation​

7.1.1 Cylinders​

7.1.2 Valves​

Torque Values​

7.2.1 Main Hydraulic Valve​

7.2.2 Junction Manifold Valve​

7.2.3 Lift Down Valve​

7.2.4 Electric Option Valve​

7.2.5 Leveling Jack Valves (If Equipped)​

7.2.6 Dual Axle Option Valve​

7.2.7 Traction Valve (2WD)​

7.2.8 Traction Valve (4WD)​

Gear Pump​

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 AMP Mate-N-Lok​

8.1.4 AMP Faston​

8.1.5 AMP Micro-Fit​

8.1.6 AMP Mini Fit Jr​

8.1.7 Mini Fit Sr​

8.1.8 DIN Connectors​

8.1.9 Exceptions​

Electrical Connectors​

8.2.1 Deutsch Connectors​

Electrical Harness Layout​

8.3.1 Electrical Layout For RT4069, RT4769​

8.3.2 Electrical Layout For ERT4069, ERT4769​

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

Wheels​

9.1.1 Wheel Installation​

Battery​

9.2.1 Battery Removal For RT​

9.2.2 Battery Removal For ERT​

Chassis Tilt Sensor Installation​

Ground Control Station​

9.4.1 Control Station Removal​

9.4.2 Removal​

9.4.3 Installation​

9.4.4 Ground Control Station Components​

Hydraulic Tank​

9.5.1 Tank Installation For RT​

9.5.2 Tank Installation For ERT​

Scissor Arms​

9.6.1 Lift Cylinder Removal​

9.6.2 Scissor Arms Removal​

9.6.3 Scissor Arm Assembly Removal​

Platform​

Drive Assembly​

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

9.8.2 Drive Assembly - For ERT​

Axle Installation​

Steer Installation​

9.10.1 Steering Assembly - For RT​

9.10.2 Steering Assembly - For ERT​

9.10.3 Oscillating Axle Cylinder​

Leveling Jacks​

9.11.1 Cylinder Removal​

9.11.2 Cylinder Removal​

9.11.3 Assembly Removal​

Side Compartment Covers​

Hydraulic Valves​

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

Location of Additional Sensors​

Drive Motor (Sauer)​

9.15.1 Description​

9.15.2 Shaft Seal Replacement​

9.15.3 Loop Flushing Valve​

Engine​

9.16.1 Exhaust System​

9.16.2 Exhaust System (Kubota Engine)​

9.16.3 Air Cleaner System​

9.16.4 Radiator​

9.16.5 Engine Electrical Component Locations​

Generator​

9.17.1 Belt Routing​

Hydraulic Pump Installation​

Pump Coupling Assembly​

Ground Control Panel​

9.20.1 Ground Control Panel Installation​

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​

Hydraulic Cylinders​

10.4.1 Cylinder Repair​

10.4.2 Cylinder Assemblies​

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)​