JLG RT2669 - Service And Maintenance Manual

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Service and Maintenance Manual

Models

RT2669

RT3669

ERT2669

ERT3669

PVC 2004

31215923

January 08, 2021 - Rev A

AS/NZS

Main Page

Section A. Introduction - Maintenance Safety Precautions3
Ageneral3
Bhydraulic System Safety3
Cmaintenance3
Table of Contents5
Section 1 - Specifications19
Specifications19
Machine Specifications - for RT19
Machine Specifications - for ERT19
Generator Specifications (if Equipped)20
Dimensional Data20
Fluid Capacities - for RT20
Fluid Capacities - for ERT20
Drive Information20
Steering Information20
Batteries (for ERT)21
Tires21
Critical Stability Weights21
1.2 Serial Number Location21
1.3 Lubrication22
Hydraulic Oil Specification22
1.4 Hydraulic Pressure Settings24
1.5 Hydraulic Cylinder Specifications24
1.6 Engine Specifications24
Battery Charger (ERT Machines)25
1.8 Elevation/Tilt Limit Settings26
Threadlocking Compound29
1.10 Torque Charts30
SAE Fastener Torque Chart30
Metric Fastener Torque Chart36
Section 2 - General41
Machine Preparation, Inspection, and Maintenance41
General41
Preparation, Inspection, and Maintenance41
Pre-Start Inspection41
Pre-Delivery Inspection and Frequent Inspection41
Annual Machine Inspection41
Preventative Maintenance41
Preventive Maintenance and Inspection Schedule42
Maintenance and Inspection Schedule Codes42
Footnotes45
Footnotes48
Service and Guidelines49
General49
Safety and Workmanship49
Cleanliness49
Components Removal and Installation49
Component Disassembly and Reassembly49
Pressure-Fit Parts49
Bearings49
Gaskets49
Bolt Usage and Torque Application49
Hydraulic Lines and Electrical Wiring50
Hydraulic System50
Lubrication50
Battery50
Lubrication and Servicing50
Lubrication and Information50
Hydraulic Oil50
Changing Hydraulic Oil51
Lubrication Specifications51
Service Maintenance Components51
Setting Scissor Arm Safety Prop51
General Maintenance Tips52
Fuel Tank54
Drive Hub54
Scissor Arms - Sliding Wear Pads54
Hydraulic Oil Tank54
Engine Coolant54
Oil Change with Filter55
Fuel Strainer (Diesel)55
Fuel Filter (Gas)55
Air Filter56
Fuel/Water Separator Filter (Diesel)56
Fan Belt56
Cylinder Drift Test57
Platform Drift57
Cylinder Drift57
Pins and Composite Bearing Repair Guidelines57
Operating Characteristics59
Leveling Jacks (if Equipped)59
Quiklevel Advanced (Dual Oscillating Axles) (if Equipped)60
Lift60
Drive60
Tires, Wheels & Drive Assembly61
Tire Damage61
Tire Replacement61
Wheel Replacement61
Wheel Installation61
Drive Assembly62
Drive Hub - 2WD (for RT)69
Roll and Leak Testing69
Tightening and Torquing Bolts69
Oil Information69
Main Disassembly for Drive Hub73
Hub-Spindle Disassembly73
Cover Disassembly74
Carrier Disassembly74
Carrier Assembly74
Cover Sub-Assembly76
Hub-Spindle Sub-Assembly77
Main Assembly79
Tool List84
Re-Aligning Torque Hub Input Coupling84
Drive Hub - 4WD (for RT)85
Drive Hub (for ERT)86
Tightening and Torquing Bolts86
Main Disassembly87
Output Carrier Disassembly89
Input Carrier Disassembly91
Hub-Spindle Disassembly92
Cover Disassembly93
Input Carrier Sub-Assembly94
Output Planet Gear Sub-Assembly94
Output Carrier Sub-Assembly94
Hub-Spindle Sub-Assembly95
7HB0 Cover Sub-Assembly95
Main Assembly95
Tool List96
Drive Motor (Sauer)98
Description98
Shaft Seal Replacement98
Loop Flushing Valve99
Troubleshooting100
Disassembly101
Inspection104
Assembly107
Initial Start-Up Procedures112
Axle Installation113
Removal114
Assembly114
Steer Installation115
Steer Cylinder Removal118
Spindle Removal118
Assembly118
Oscillating Axle Cylinder119
Leveling Jacks (if Equipped)120
Cylinder Removal120
Assembly Removal121
3.10 Platform122
Platform Control Station123
Joystick Controller124
3.11 Scissor Arms125
Lift Cylinder Removal125
Scissor Arms Removal125
Scissor Arm Assembly Removal125
3.12 Side Compartment Covers130
Cover Removal133
Cover Installation133
3.13 Ground Control Station133
Control Station Removal133
Ground Control Station Components135
3.14 Battery137
3.15 Tank139
Removal139
Installation139
Battery Charger141
Delta-Q - Battery Charger141
Battery Charging141
Battery Charger Maintenance142
IC Series Setup and Troubleshooting Guide143
Engine Removal153
Dual Fuel/Lpg System154
Changing from Gasoline to LP Gas154
Changing from LP Gas to Gasoline154
Using Liquid Petroleum (LP) Gas154
Propane Fuel System Pressure Relief154
Propane Fuel System Leak Test154
Generator (if Equipped)155
Belt Routing157
Exhaust System158
Dual Fuel - Gas/Lpg159
Diesel159
Air Cleaner System160
Radiator162
Engine Electrical Component Locations163
Hydraulic Pump Installation175
Pump Coupling Assembly176
Section 4 - Basic Hydraulic Information & Schematics177
Cylinders - Theory of Operation177
Valves - Theory of Operation177
Solenoid Control Valves (Bang-Bang)177
Relief Valves177
Crossover Relief Valves177
Cylinder Checking Procedure177
Cylinders Without Counterbalance Valves177
Cylinders with Single Counterbalance Valve178
Oscillating Axle - Lockout Cylinder Test178
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 Priming180
Hydraulic Component Start-Up Procedures & Recommendations180
Hydraulic Valves182
Junction Manifold Valve182
Electric Option Valve183
Leveling Jack Valves (if Equipped)190
Traction Valve (2WD)191
Traction Valve (4WD)193
Ground Control Panel Installation195
Pressure Relief Valve - Setting Procedures (for RT)207
Pressure Relief Valve - Setting Procedures (for ERT)211
Gear Pump216
General Repair Instructions218
Cylinder Repair219
4.10 Cylinder Assemblies220
Oscillating Axle Cylinder Bleeding Procedure224
Hydraulic Schematics (for RT)226
Hydraulic Schematics (for ERT)236
Section 5 - Jlg Control System243
Analyzer243
Connecting the Analyzer243
Using the Analyzer244
Changing the Access Level245
Adjusting Parameters246
Machine Setup246
System Fault/Dtc Indication247
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 Installation305
Location of Additional Sensors306
Calibration Procedures308
Chassis Tilt Sensor - Non Quiklevel Equipped Machine308
Chassis Tilt Sensor - Quiklevel Equipped Machine309
Troubleshooting Steps310
Front Oscillating Axle Tilt Sensor (CE or Quiklevel Equipped Machines Only)310
Elevation Sensor310
Rear Axle Tilt Sensor (Quiklevel Equipped Machines Only)311
Joystick312
Steer Sensor (ERT Family Only)312
Set Charger (ERT Family Only)312
Service Mode Procedures313
Elevation Service313
EEPROM Reset313
Allow Drive313
Allow Leveling Jack Retract313
Set Main Relief313
Hydraulic System Flush313
QLA Pressure Set314
Machine Configuration and Programming Settings (for RT)315
Machine Configuration and Programming Settings (for ERT)316
Machine Orientation When Setting Speeds320
Section 6 - Lss Setup/Calibration/Service323
Connecting the JLG Control System Analyzer323
Help Menu & Fault Codes323
Machine Setup Menu324
Service325
Description325
6.5 Calibration326
Procedure326
Troubleshooting Steps326
Testing & Evaluation328
6.6 Troubleshooting329
Multimeter Basics335
Grounding335
Backprobing335
Min/Max335
Polarity335
Scale335
Voltage Measurement336
Resistance Measurement336
Continuity Measurement337
Current Measurement337
Continuity Measurement over Long Distances338
Requirements338
Procedure338
Applying Silicone Dielectric Compound to Electrical Connections338
Dielectric Grease Application339
AMP Mate-N-Lok339
AMP Faston339
AMP Micro-Fit339
AMP Mini Fit Jr339
Mini Fit Sr340
DIN Connectors340
Exceptions340
AMP Connector341
Assembly341
Disassembly343
Wedge Lock343
Service - Voltage Reading344
7.6 Working with Deutsch Connectors345
DT/DTP Series Assembly345
DT/DTP Series Disassembly345
HD30/HDP20 Series Assembly346
HD30/HDP20 Series Disassembly346
Switches347
Basic Check347
Limit Switches347
Automatic Switches348
Switch Wiring - Low Side, High Side348
Electrical Schematics (for RT)349
Electrical Schematics (for ERT)363

JLG RT2669 - Service And Maintenance Manual

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