JLG Scissor Lift 3394RT 4394RT Service & Maintenance Manual 3121249 2025

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JLG Scissor Lift 3394RT 4394RT Service & Maintenance Manual 3121249 2025
Size: 39.52 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Scissor Lift
Type of Manual: Service & Maintenance Manual, Electrical and Hydraulic Diagrams
Model: JLG 3394RT, 4394RT Scissor Lift
Part Number: 3121249
Publication Date: 2025
Number of Pages: 268 Pages

Contents:
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​