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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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JLG 3394RT / 4394RT Rough Terrain Scissor Lift Service & Maintenance Manual (Global).pdf
Source : Sitelux.com