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

S/N 0200191606 to Present
including 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, Platform & Scissor Arms
    3.1 Operating Characteristics
    3.2 Tires, Wheels & Drive Assembly
    3.3 Integrated Torque/drive hub (Bosch Rexroth)
    3.4 Drive Hub (Fairfield)
    3.5 Drive Motor (Sauer)
    3.6 Front Axle
    3.7 Leveling Jacks (If Equipped)
    3.8 Platform
    3.9 Scissor Arms
    3.10 Side Compartment Covers
    3.11 Ground Control Station
    3.12 Fuel Tank
    3.13 Hydraulic Tank
    3.14 Battery
    3.15 Dual Fuel/LPG System
    3.16 Deutz Engine
    3.17 GM Engine
    3.18 GM Engine Dual Fuel System
    3.19 GM Engine Fuel System Repair
    3.20 GM Engine LPG Fuel System Diagnosis
        
Section 4. Hydraulics
    4.1 Cylinders - Theory of Operation
    4.2 Valves - Theory of Operation
    4.3 Cylinder Checking Procedure
    4.4 Cylinder Repair
    4.5 Drive Pump Start-up Procedure
    4.6 Hydraulic Component Start-Up Procedures & Recommendations
    4.7 Hydraulic Gear Pump
    4.8 Valves
    4.9 Gear Pump
    4.10 Axial HI 45 Pump
    4.11 Charge Pump Filter
    4.12 Auxiliary Pump Motor
    4.13 Cylinder Assemblies
        
Section 5. JLG Control System
    5.1 Hand Held Analyzer
    5.2 Calibrations
    5.3 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 : 3121249
Total Pages : 268


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Section A. Introduction - Maintenance Safety Precautions
    A. General
    B. Hydraulic System Safety
    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
        Fuel Tank
        Drive Hub
        Hydraulic Oil
        Engine Oil Change w/Filter - Deutz
        Engine Oil Change w/Filter - Deutz D2.9 L4 - T4F
        Oil Change w/Filter - GM
        Engine Fuel Filter - Deutz
        Engine Fuel Filter - Deutz D 2.9 L4 - T4F
        Engine Fuel Filter (Gasoline) - GM
        Air Filter
        Electronic Pressure Regulator (LP only)
        Fuel Filter (Propane) - GM
        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, Platform & Scissor Arms
    3.1 Operating Characteristics
        Leveling Jacks
        Power Deck
        Generator
        Lift
        Drive
    3.2 Tires, Wheels & Drive Assembly
        Tire Inflation
        Tire Damage
        Tire Replacement
        Wheel Replacement
        Wheel Installation
        Drive Assembly
    3.3 Integrated Torque/drive hub (Bosch Rexroth)
        Roll Test
        Leak Test
        Disconnect Mechanism
        Gearbox Disassembly
        Gearbox Assembly
        Motor Disassembly
        Motor Assembly
    3.4 Drive Hub (Fairfield)
        Roll and Leak Testing
        Tightening and Torquing Bolts
        Oil Information
        Main Disassembly for Drive Hub
        Hub-Spindle Disassembly
        Cover Disassembly
        Carrier Disassembly
        Assembly of the Carrier
        Cover Sub-Assembly
        Hub-Spindle Sub-Assembly
        Main Assembly
        Tool List
        Re-Aligning Torque Hub Input Coupling
    3.5 Drive Motor (Sauer)
        Description
        Shaft Seal Replacement
        Loop Flushing Valve
        Troubleshooting
        Disassembly
        Inspection
        Assembly
        Initial Start-up Procedures
    3.6 Front Axle
        Steering Assembly
        Axle Assembly
        Front Axle - Tow Bar Installation (If Equipped)
        Axle Lockout Cylinder
    3.7 Leveling Jacks (If Equipped)
        Cylinder Removal
        Assembly Removal
    3.8 Platform
        Deck Extension Cylinders (if equipped)
        Platform Control Station
        Joystick Controller
    3.9 Scissor Arms
        Lift Cylinder Removal
        Scissor Arms Removal
        Scissor Arm Assembly Removal
    3.10 Side Compartment Covers
    3.11 Ground Control Station
        Control Station Removal
        Ground Control Station
    3.12 Fuel Tank
    3.13 Hydraulic Tank
    3.14 Battery
    3.15 Dual Fuel/LPG System
        Changing From Gasoline to LP Gas
        Changing From LP Gas to Gasoline
        Using Liquid Petroleum (LP) Gas
    3.16 Deutz Engine
        Engine Tray
        Deutz EMR 2
        Deutz EMR 4
        Generator (if equipped)
        Exhaust System
        Air Cleaner System
        Relays
        Pumps
        Pump Coupling
        Engine Removal
        Radiator
    3.17 GM Engine
        Maintenance of the Drive Belt
        Engine Electrical System Maintenance
        Checking/Filling Engine Oil Level
        Changing The Engine Oil
        Engine Tray
        Generator
        Exhaust System
        Air Cleaner System
        Radiator
        Fuel Components
        Pumps
        Pump Coupling
        Engine Removal
    3.18 GM Engine Dual Fuel System
        Fuel Filter
        Electric Lock Off
        Electronic Pressure Regulator Assembly
        Low Pressure Regulator (LPR)
        Air Fuel Mixer
        Electronic Throttle Control (ETC)
        Engine Control Module (ECM)
        Heated Exhaust Gas Oxygen Sensor (HEGO)
        Gasoline Multi Point Fuel Injection System (MPFI)
        Gasoline Fuel Pump
        Gasoline Pressure And Temperature Sensor Manifold
        Fuel Filter
        Fuel Injector Rail
        Fuel Injector
    3.19 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
    3.20 GM Engine LPG Fuel System Diagnosis
        Fuel System Description
        Diagnostic Aids
        
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 Cylinder Checking Procedure
        Cylinders Without Counterbalance Valves
        Cylinders With Single Counterbalance Valve
        Oscillating Axle Cylinder Test (Lockout)
    4.4 Cylinder Repair
        Disassembly
        Cleaning and Inspection
        Assembly
    4.5 Drive Pump Start-up Procedure
    4.6 Hydraulic Component Start-Up Procedures & Recommendations
    4.7 Hydraulic Gear Pump
        Pump Disassembly
        Parts Inspection
        Pump Reassembly
    4.8 Valves
        Main Valve
        Flow Divider Valve
        Leveling Jacks Directional Valve
        Powerdeck Valves
        Leveling Jack Valves
        Pressure Setting Procedures
    4.9 Gear Pump
        Gear Pump Priming
    4.10 Axial HI 45 Pump
        General Repair Instructions
        Start-Up Procedure
        Removing the pump
        Electric Control Module
        Control Solenoids
        Shaft Seal, Roller Bearing & Shaft Replacement
        Charge Pump
        Charge Check/HPRV
        Charge Pressure Relief Valve
        Pressure Limiter Valve Replacement
    4.11 Charge Pump Filter
    4.12 Auxiliary Pump Motor
    4.13 Cylinder Assemblies
        Oscillating Axle Cylinder 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 Calibrations
        Elevation Sensor Calibration
        Joystick Calibration
        Tilt Sensor Calibration:
        Tilt Sensor
    5.3 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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