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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