JLG 3394RT / 4394RT Rough Terrain Scissor Lift Service & Maintenance Manual (Global)

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This service manual PDF download for the 3394RT / 4394RT JLG Rough Terrain Scissor Lift has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

JLG Lift 3394RT
JLG Lift 4394RT

Prior to S/N 0200191606
excluding S/N’s: 0200186972, 0200187002, 0200187013


TABLE OF CONTENTS :

    Section 1. Specifications
        1.1 Specifications
        1.2 Capacities
        1.3 Engines
        1.4 Tires
        1.5 Machine Dimensions
        1.6 Pressure Settings
        1.7 Serial Number Locations
        1.8 Sensors
        1.9 Cylinder Specifications
        1.10 Major Component Weights
        1.11 Critical Stability Weights
        1.12 Lubrication Specifications
        1.13 Operator Maintenance
        1.14 Torque Charts
        
    Section 2. General
        2.1 Machine Preparation, Inspection, and Maintenance
        2.2 Service and Guidelines
        2.3 Lubrication and Information
        2.4 Cylinder Drift Test
        2.5 Pins and Composite Bearing Repair Guidelines
        2.6 Preventive Maintenance and Inspection Schedule
        
    Section 3. Chassis & Scissor Arms
        3.1 Operating Characteristics
        3.2 Calibrations
        3.3 Level Sensor and Analyzer Connections
        3.4 Integrated Torque/drive hub
        3.5 Dual Fuel/LPG System
        3.6 Ford EFI Engine
        3.7 Generator - Ford Engine
        3.8 Deutz EMR 2 (S/N 0200138634 to Present)
        3.9 Generator - Duetz Engine
        3.10 GM Engine General Maintenance
        3.11 Generator - GM Engine
        3.12 GM Engine Dual Fuel System
        3.13 GM Engine Fuel System Repair
        3.14 GM Engine LPG Fuel System Diagnosis
        3.15 Joystick Controller
        
    Section 4. Hydraulics
        4.1 Cylinders - Theory of Operation
        4.2 Valves - Theory of Operation
        4.3 Component Functional Description
        4.4 Cylinder Checking Procedure
        4.5 Cylinder Repair
        4.6 Drive Pump Start-up Procedure
        4.7 Hydraulic Component Start-Up Procedures and Recommendations
        4.8 Hydraulic Gear Pump
        4.9 Main Valve
        4.10 Drive Header Valve (2WD)
        4.11 Drive Header Valve (4WD)
        4.12 Header Valves (4WD)
        4.13 dIRECTIONAL vALVE
        4.14 pOWER dECK sANDWICH vALVE
        4.15 Power Deck Manifold Valve
        4.16 Hydraulic Pump
        4.17 Cylinder Assemblies
            
    Section 5. JLG Control System
        5.1 Hand Held Analyzer
        5.2 Flash Codes and Descriptions
        
    Section 6. General Electrical Information & Schematics
        6.1 General
        6.2 Multimeter Basics
        6.3 Applying Silicone Dielectric Compound To Amp Connectors
        6.4 Working With Deutsch Connectors
        6.5 Switches
        6.6 Schematics


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : 3121133
Total Pages : 228


This service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!! 

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Service & Maintenance Manual
    Section A. Introduction - Maintenance Safety Precautions
        A.A General
        A.B Hydraulic System Safety
        A.C Maintenance
        
    Section 1. Specifications
        1.1 Specifications
        1.2 Capacities
        1.3 Engines
        1.4 Tires
        1.5 Machine Dimensions
        1.6 Pressure Settings
        1.7 Serial Number Locations
        1.8 Sensors
        1.9 Cylinder Specifications
        1.10 Major Component Weights
        1.11 Critical Stability Weights
        1.12 Lubrication Specifications
        1.13 Operator Maintenance
            Draining Oil Build Up From The Propane Regulator
            Propane Fuel Filter Replacement
            Propane Fuel System Pressure Relief
        1.14 Torque Charts
        
    Section 2. General
        2.1 Machine Preparation, Inspection, and Maintenance
            General
            Preparation, Inspection, and Maintenance
            Pre-Start Inspection
            Pre-Delivery Inspection and Frequent Inspection
            Annual Machine Inspection
            Preventative Maintenance
        2.2 Service and Guidelines
            General
            Safety and Workmanship
            Cleanliness
            Components Removal and Installation
            Component Disassembly and Reassembly
            Pressure-Fit Parts
            Bearings
            Gaskets
            Bolt Usage and Torque Application
            Hydraulic Lines and Electrical Wiring
            Hydraulic System
            Lubrication
            Battery
            Lubrication and Servicing
        2.3 Lubrication and Information
            Hydraulic System
            Hydraulic Oil
            Changing Hydraulic Oil
            Lubrication Specifications
        2.4 Cylinder Drift Test
            Platform Drift
            Cylinder Drift
        2.5 Pins and Composite Bearing Repair Guidelines
        2.6 Preventive Maintenance and Inspection Schedule
        
    Section 3. Chassis & Scissor Arms
        3.1 Operating Characteristics
            Leveling Jacks
            Power Deck
            Generator
            Lift
            Drive
        3.2 Calibrations
            Elevation Sensor Calibration (Prior to Software P1.20)
            Elevation Sensor Calibration (Software P1.20 & Higher)
            Joystick Calibration (Software P1.20 & Higher)
            Tilt Sensor Calibration:
        3.3 Level Sensor and Analyzer Connections
            Tilt Sensor, JLG P/N 4000006:
            Tilt Sensor, JLG P/N 4000021:
        3.4 Integrated Torque/drive hub
            Roll Test
            Leak Test
            Disconnect Mechanism
            Gearbox Disassembly
            Gearbox Assembly
            Motor Disassembly
            Motor Assembly
        3.5 Dual Fuel/LPG System
            Changing From Gasoline to LP Gas
            Changing From LP Gas to Gasoline
            Using Liquid Petroleum (LP) Gas
        3.6 Ford EFI Engine
            Performing Diagnostics
            EFI Diagnostics
            ECM and Sensors
            Fuel System
        3.7 Generator - Ford Engine
        3.8 Deutz EMR 2 (S/N 0200138634 to Present)
        3.9 Generator - Duetz Engine
        3.10 GM Engine General Maintenance
            Maintenance of the Drive Belt
            Engine Electrical System Maintenance
            Checking/Filling Engine Oil Level
            Changing The Engine Oil
        3.11 Generator - GM Engine
        3.12 GM Engine Dual Fuel System
            Fuel Filter
            Electric Lock Off
            EPR Assembly
            Low Pressure Regulator (LPR)
            Air Fuel Mixer
            Electronic Throttle Control (ETC)
            Engine Control Module
            Heated Exhaust Gas Oxygen Sensor
            Gasoline Multi Point Fuel Injection System (MPFI)
            Gasoline Fuel Pump
            Gasoline Pressure And Temperature Sensor Manifold
            Fuel Filter
            Fuel Injector Rail
            Fuel Injector
        3.13 GM Engine Fuel System Repair
            Propane Fuel System Pressure Relief
            Propane Fuel System Leak Test
            Propane Fuel Filter Replacement
            Electronic Pressure Regulator (EPR) Assembly Replacement
            Temperature Manifold Absolute Pressure (TMAP) Sensor
            Electronic Throttle Control Replacement
            Mixer Replacement
            Coolant Hose Replacement
            Vapor Hose Replacement
            Engine Control Module Replacement
            Heated Exhaust Gas Oxygen Sensor Replacement
        3.14 GM Engine LPG Fuel System Diagnosis
            Fuel System Description
            Diagnostic Aids
        3.15 Joystick Controller
        
    Section 4. Hydraulics
        4.1 Cylinders - Theory of Operation
        4.2 Valves - Theory of Operation
            Solenoid Control Valves (Bang-Bang)
            Relief Valves
            Crossover Relief Valves
        4.3 Component Functional Description
            Piston Hydraulic Pump
            Gear Hydraulic Pump
            Manual Descent Valve
        4.4 Cylinder Checking Procedure
            Cylinders Without Counterbalance Valves - Steer Cylinder
            Cylinders With Single Counterbalance Valve
            Oscillating Axle Lockout Test
        4.5 Cylinder Repair
            Disassembly
            Cleaning and Inspection
            Assembly
        4.6 Drive Pump Start-up Procedure
        4.7 Hydraulic Component Start-Up Procedures and Recommendations
        4.8 Hydraulic Gear Pump
            Pump Disassembly
            Parts Inspection
            Pump Reassembly
        4.9 Main Valve
            Pressure Setting Procedures
        4.10 Drive Header Valve (2WD)
        4.11 Drive Header Valve (4WD)
        4.12 Header Valves (4WD)
        4.13 dIRECTIONAL vALVE
            Pressure Setting Procedure
        4.14 pOWER dECK sANDWICH vALVE
        4.15 Power Deck Manifold Valve
        4.16 Hydraulic Pump
            Auxiliary Pump Motor
        4.17 Cylinder Assemblies
            Oscillating Axle Bleeding Procedure
            
    Section 5. JLG Control System
        5.1 Hand Held Analyzer
            To Connect the Hand Held Analyzer:
            Using the Analyzer:
            Changing the Access Level of the Hand Held Analyzer:
            Adjusting Parameters Using the Hand Held Analyzer
            Machine Setup
        5.2 Flash Codes and Descriptions
        
    Section 6. General Electrical Information & Schematics
        6.1 General
        6.2 Multimeter Basics
            Grounding
            Backprobing
            Min/Max
            Polarity
            Scale
            Continuity Measurement Over Long Distances
            Requirements:
            Procedure
        6.3 Applying Silicone Dielectric Compound To Amp Connectors
            Assembly
            Disassembly
            Wedge Lock
            Service - Voltage Reading
        6.4 Working With Deutsch Connectors
            DT/DTP Series Assembly
            DT/DTP Series Disassembly
            HD30/HDP20 Series Assembly
            HD30/HDP20 Series Disassembly
        6.5 Switches
            Basic check
            Limit Switches
            Automatic Switches
            Switch Wiring - Low Side, High Side
        6.6 Schematics
        
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