JLG 4394RT Manuals

Manuals and User Guides for JLG 4394RT. We have 4 JLG 4394RT manuals available for free PDF download: Service And Maintenance Manual, Service Maintenance Manual, Operation And Safety Manual, Quick Start Manual

JLG 4394RT Service And Maintenance Manual (240 pages)

Brand: JLG | Category: Lifting Systems | Size: 22 MB

Table of Contents
5
Subject - Section, Paragraph

15
Specifications

15
General

33
- Machine Preparation, Inspection, and Maintenance
  33
- Service and Guidelines
  34
  - General
    34
  - Safety and Workmanship
    34
  - Cleanliness
    34
  - Components Removal and Installation
    34
  - Component Disassembly and Reassembly
    35
  - Pressure-Fit Parts
    35
  - Bearings
    35
  - Gaskets
    35
  - Bolt Usage and Torque Application
    35
  - Hydraulic Lines and Electrical Wiring
    35
  - Hydraulic System
    35
  - Lubrication
    35
  - Battery
    35
  - Lubrication and Servicing
    35
- Lubrication and Information
  36
  - Hydraulic System
    36
  - Hydraulic Oil
    36
  - Changing Hydraulic Oil
    36
  - Lubrication Specifications
    36
- Cylinder Drift Test
  37
  - Platform Drift
    37
  - Cylinder Drift
    37
- Pins and Composite Bearing Repair Guidelines
  37
- Preventive Maintenance and Inspection Schedule
  38
- Preventive Maintenance and Safety Inspection
  39
Chassis, Platform & Scissor Arms

41
- Operating Characteristics
  41
  - Leveling Jacks
    41
  - Power Deck
    41
  - Generator
    41
  - Lift
    41
  - Drive
    41
- Tires, Wheels & Drive Assembly
  41
  - Tire Inflation
    41
  - Tire Damage
    41
  - Tire Replacement
    42
  - Wheel Replacement
    42
  - Wheel Installation
    42
  - Drive Assembly
    43
- Drive Assembly (Bosch Rexroth )
  43
- Drive Assembly - (Fairfield/Sauer)
  44
  - Drive Hub (Fairfield)
    45
    
    Roll and Leak Testing
    45
    
    Tightening and Torquing Bolts
    45
    
    Oil Information
    45
- Drive Hub
  45
- Drive Hub
  46
- Drive Hub Part Description
  47
- Drive Hub (Cross-Section)
  48
  - Main Disassembly for Drive Hub
    49
  - Hub-Spindle Disassembly
    49
  - Cover Disassembly
    50
  - Carrier Disassembly
    50
  - Assembly of the Carrier
    50
  - Cover Sub-Assembly
    52
  - Hub-Spindle Sub-Assembly
    53
  - Main Assembly
    55
- Cluster Gear Punch Marks
  57
  - Tool List
    60
  - Re-Aligning Torque Hub Input Coupling
    60
  - Drive Motor (Sauer)
    61
    
    Description
    61
    
    Shaft Seal Replacement
    61
- Drive Motor Cross Section
  61
- Servo Piston
  61
  - Loop Flushing Valve
    62
  - Troubleshooting
    63
  - Disassembly
    64
- 31. Cylinder Kit Assembly
  66
  - Swash Plate & Servo Piston
    67
  - Inspection
    68
  - Assembly
    70
- Swash Plate and Journal Bearing
  71
- Cylinder Kit Assembly
  71
- Shaft and Front Bearing
  72
- Cylinder Kit Installation
  72
- Servo Spring and Minimum Angle Stop
  72
- Valve Plate and Rear Bearing
  73
- 25. End Cap
  73
- 27. Shaft Seal
  74
  - Initial Start-Up Procedures
    75
  - Front Axle
    76
    
    Steering Assembly
    76
    
    Axle Assembly
    77
    
    Front Axle - Tow Bar Installation (if Equipped)
    78
- Tow Bar Installation (if Equipped)
  78
  - Axle Lockout Cylinder
    79
  - Leveling Jacks (if Equipped)
    80
    
    Cylinder Removal
    80
    
    Assembly Removal
    81
- Leveling Jacks Assembly
  81
  - Platform
    82
    
    Deck Extension Cylinders (if Equipped)
    83
    
    Platform Control Station
    84
    
    Joystick Controller
    85
  - Scissor Arms
    86
    
    Lift Cylinder Removal
    86
    
    Scissor Arms Removal
    87
    
    Scissor Arm Assembly Removal
    87
  - Side Compartment Covers
    88
  - 3.10 Ground Control Station
    89
    
    Control Station Removal
    89
- Ground Control Station Removal
  89
  - 3.11 Fuel Tank
    90
  - 3.12 Hydraulic Tank
    91
  - 3.13 Battery
    92
  - 3.14 Dual Fuel/Lpg System
    93
    
    Changing from Gasoline to LP Gas
    93
    
    Changing from LP Gas to Gasoline
    93
    
    Using Liquid Petroleum (LP) Gas
    93
  - 3.15 Deutz Engine
    94
    
    Engine Tray
    94
    
    Deutz EMR 4
    94
    
    Generator (if Equipped)
    95
    
    Exhaust System
    96
- Exhaust System (Deutz Engine)
  96
  - Air Cleaner System
    97
- Air Cleaner System (Deutz Engine)
  97
  - Relays
    98
- Relays (Deutz Engine)
  98
  - Pumps
    99
- Pump Coupling (Deutz Engine)
  99
  - Pump Coupling
    100
  - Engine Removal
    101
- Engine Removal (Deutz Engine)
  101
  - Radiator
    102
- Radiator (Deutz Engine)
  102
  - 3.16 Gm Engine
    103
    
    Maintenance of the Drive Belt
    103
    
    Engine Electrical System Maintenance
    103
    
    Checking/Filling Engine Oil Level
    103
- Engine Oil Dip Stick
  103
  - Changing the Engine Oil
    104
  - Engine Tray
    104
- Engine Tray Swing
  104
  - Generator
    105
- Generator (GM Engine)
  105
  - Exhaust System
    106
  - Air Cleaner System
    107
- Air Cleaner System (GM Engine)
  107
  - Radiator
    108
- Radiator (GM Engine)
  108
  - Fuel Components
    109
- Fuel Components (GM Engine)
  109
  - Pumps
    110
  - Pump Coupling
    111
- Pump Coupling (GM Engine)
  111
  - Engine Removal
    112
- Engine Removal (GM Engine)
  112
  - 3.17 Gm Engine Dual Fuel System
    113
    
    Fuel Filter
    113
    
    Electric Lock off
    113
    
    Electronic Pressure Regulator Assembly
    113
    
    Low Pressure Regulator (LPR)
    114
    
    Air Fuel Mixer
    114
    
    Electronic Throttle Control (ETC)
    115
    
    Engine Control Module (ECM)
    115
    
    Heated Exhaust Gas Oxygen Sensor (HEGO)
    116
    
    Gasoline Multi Point Fuel Injection System (MPFI)
    116
    
    Gasoline Fuel Pump
    116
    
    Gasoline Pressure and Temperature Sensor Manifold
    116
    
    Fuel Filter
    116
- Gasoline Fuel Pressure and Temperature Manifold Assembly
  116
  - Fuel Injector Rail
    117
  - Fuel Injector
    117
  - 3.18 Gm Engine Fuel System Repair
    117
    
    Propane Fuel System Pressure Relief
    117
    
    Propane Fuel System Leak Test
    117
    
    Propane Fuel Filter Replacement
    118
    
    Electronic Pressure Regulator (EPR) Assembly Replacement
    118
- EPR Assembly
  118
  - Temperature Manifold Absolute Pressure (TMAP) Sensor
    119
- Pressure Regulator Section
  119
  - Electronic Throttle Control Replacement
    120
  - Mixer Replacement
    121
  - Coolant Hose Replacement
    122
  - Vapor Hose Replacement
    122
  - Engine Control Module Replacement
    122
  - Heated Exhaust Gas Oxygen Sensor Replacement
    122
  - 3.19 Gm Engine Lpg Fuel System Diagnosis
    123
    
    Fuel System Description
    123
    
    Diagnostic Aids
    123
- LPF Fuel System Diagnosis
  124
- Symptom Diagnosis
  126
- DTC to SPN/FMI Cross Reference Chart
  134
Hydraulics

137
- Cylinders - Theory of Operation
  137
- Valves - Theory of Operation
  137
  - Solenoid Control Valves (Bang-Bang)
    137
  - Relief Valves
    137
  - Crossover Relief Valves
    137
- Cylinder Checking Procedure
  137
  - Cylinders Without Counterbalance Valves
    137
  - Cylinders with Single Counterbalance Valve
    138
- Oscillating AXLE - Lockout Cylinder Test (if Equipped)
  138
  - Left Side Wheel Test
    138
  - Right Side Wheel Test
    139
- Cylinder Repair
  139
  - Disassembly
    139
- Cylinder Barrel Support
  140
- Cylinder Rod Support
  140
  - Cleaning and Inspection
    141
  - Assembly
    141
- Bushing Installation
  141
- Rod Seal Installation
  142
- Piston Seal Kit Installation
  143
- Rod Assembly Installation
  144
  - Drive Pump Start-Up Procedure
    145
  - Hydraulic Component Start-Up Procedures & Recommendations
    146
  - Hydraulic Gear Pump
    147
    
    Pump Disassembly
    147
    
    Parts Inspection
    147
    
    Pump Reassembly
    148
  - Valves
    150
    
    Main Valve
    151
- Main Valve Schematic
  152
  - Flow Divider Valve
    153
  - Leveling Jacks Directional Valve
    154
  - Powerdeck Valves
    155
  - Leveling Jack Valves
    156
  - Pressure Setting Procedures
    157
  - 4.10 Gear Pump
    158
    
    Gear Pump Priming
    158
  - 4.11 Axial Hi 45 Pump
    159
- Axial HI 45 Pump - Cross Section View
  160
  - General Repair Instructions
    161
  - Start-Up Procedure
    161
  - Removing the Pump
    162
  - Electric Control Module
    163
  - Control Solenoids
    163
  - Shaft Seal, Roller Bearing & Shaft Replacement
    164
  - Charge Pump
    164
  - Charge Check/Hprv
    166
  - Charge Pressure Relief Valve
    166
  - Pressure Limiter Valve Replacement
    167
  - 4.12 Charge Pump Filter
    167
  - 4.13 Auxiliary Pump Motor
    168
  - 4.14 Cylinder Assemblies
    169
- Lift Cylinder
  170
- Lift Cylinder Valve Cartridge Torque Values
  171
- Oscillating Axle Cylinder
  172
- Leveling Jack Cylinder
  173
- Leveling Jack Torques
  174
- Deck Extension Cylinder
  175
  - Oscillating Axle Cylinder Bleeding Procedure
    176
Jlg Control System

177
- Hand Held Analyzer
  177
- Calibrations
  182
  - Elevation Sensor Calibration
    182
  - Joystick Calibration
    183
  - Tilt Sensor Calibration
    183
  - Tilt Sensor
    184
- 5.3 Flash Codes and Descriptions
  185
- Machine Configuration Programming Information
  195
- Machine Tilt Configuration
  196
- Machine Model Adjustment
  201
General Electrical Information & Schematics

203
- 6.1 General
  203
- 6.2 Multimeter Basics
  203
  - Grounding
    203
  - Backprobing
    203
  - Min/Max
    203
  - Polarity
    203
  - Scale
    203
- Voltage Measurement (DC)
  204
  - Continuity Measurement
    205
  - Continuity Measurement over Long Distances
    206
  - Procedure
    206
  - Requirements
    206
  - Applying Silicone Dielectric Compound to Amp Connectors
    207
    
    Assembly
    208
    
    Disassembly
    209
    
    Wedge Lock
    209
    
    Service - Voltage Reading
    210
  - 6.4 Working with Deutsch Connectors
    211
    
    DT/DTP Series Assembly
    211
    
    DT/DTP Series Disassembly
    211
    
    HD30/HDP20 Series Assembly
    211
    
    HD30/HDP20 Series Disassembly
    211
  - 6.5 Switches
    212
    
    Basic Check
    212
    
    Limit Switches
    212
    
    Automatic Switches
    213
    
    Switch Wiring - Low Side, High Side
    213
- Electrical Components Installation
  214
  - Schematics
    216
- Electrical Schematic - Dual Fuel
  222
- Hydraulic Schematic
  230
- Hydraulic Schematic (CE)
  234

JLG 4394RT Service Maintenance Manual (228 pages)

Brand: JLG | Category: Boom Lifts | Size: 12 MB

Hydraulic System Safety
3
Maintenance
3
Table of Contents
5
Section 1 - Specifications
11
Specifications
11
Capacities
11
Engines
11
Tires
12
Machine Dimensions
12
Pressure Settings
12
Serial Number Locations
12
Serial Number Location
12
Sensors
13
Cylinder Specifications
13
Major Component Weights
13
Critical Stability Weights
14
Lubrication Specifications
14
Operator Maintenance
15
Filter Lock Assembly
19
Torque Charts
20
Torque Chart (SAE Fasteners - Sheet 1 of 3)
20
Torque Chart (SAE Fasteners - Sheet 2 of 3))
20
Torque Chart (SAE Fasteners - Sheet 3 of 3)
20
Torque Chart (METRIC Fasteners - Sheet 1 of 3)
23
Torque Chart (METRIC Fasteners - Sheet 2 of 3))
23
Torque Chart (METRIC Fasteners - Sheet 3 of 3)
23
Section 2. General
27
Machine Preparation, Inspection, and Maintenance
27
Service and Guidelines
28
Lubrication and Information
30
Cylinder Drift Test
31
Pins and Composite Bearing Repair Guidelines
31
Preventive Maintenance and Inspection Schedule
32
Engine Operating Temperature Specifications - GM
36
Section 3. Chassis & Scissor Arms
37
Operating Characteristics
37
Calibrations
38
Level Sensor and Analyzer Connections
41
Tilt Sensor Removal
42
Integrated Torque/Drive Hub
44
Dual Fuel/Lpg System
66
Ford EFI Engine
67
Generator - Ford Engine
79
Generator (Ford Engine)
79
Generator (Deutz Engine)
79
Deutz EMR 2 (S/N 0200138634 to Present)
80
Generator - Duetz Engine
93
GM Engine General Maintenance
94
Generator - GM Engine
96
Generator (GM Engine)
96
GM Engine Dual Fuel System
97
EPR Assembly
98
Low Pressure Regulators
98
Air Fuel Mixer
99
Heated Exhaust Gas Oxygen Sensor (HEGO)
100
GM Engine Fuel System Repair
102
Pressure Regulator Section
103
GM Engine LPG Fuel System Diagnosis
108
Joystick Controller
112
Section 4 - Hydraulics
125
Cylinders - Theory of Operation
125
Valves - Theory of Operation
125
Component Functional Description
125
Cylinder Checking Procedure
126
Cylinder Repair
127
Drive Pump Start-Up Procedure
133
Hydraulic Component Start-Up Procedures and Recommendations
134
Hydraulic Gear Pump
135
Main Valve
138
Drive Header Valve (2WD)
140
Drive Header Valve (4WD)
140
Header Valves (4WD)
141
Directional Valve
142
Power Deck Sandwich Valve
143
Power Deck Manifold Valve
143
Hydraulic Pump
144
Cylinder Assemblies
146
Section 5. Jlg Control System
155
Hand Held Analyzer
155
Flash Codes and Descriptions
160
Section 6 - General Electrical Information & Schematics
179
General
179
Multimeter Basics
179
Applying Silicone Dielectric Compound to Amp Connectors
183
Working with Deutsch Connectors
188
Switches
190
Schematics
192

JLG 4394RT Operation And Safety Manual (104 pages)

0200239053

Brand: JLG | Category: Lifting Systems | Size: 8 MB

Section - Paragraph, Subject

7
- Table of Contents
  7
Section 1 - Safety Precautions

11
- General
  11
- Pre-Operation
  12
  - Operator Training and Knowledge
    12
  - Workplace Inspection
    12
  - Machine Inspection
    13
- Operation
  13
  - General
    13
  - Trip and Fall Hazards
    15
  - Electrocution Hazards
    16
  - Tipping Hazards
    17
- Minimum Approach Distances (M.A.D.)
  17
- Beaufort Scale (for Reference Only)
  18
  - Crushing and Collision Hazards
    19
  - Towing, Lifting, and Hauling
    21
  - Maintenance
    21
    
    Maintenance Hazards
    21
    
    Battery Hazards
    22
Section 2. User Responsibilities, Machine Preparation and Inspection

23
- 2.1 Personnel Training
  23
  - Operator Training
    23
  - Training Supervision
    23
  - Operator Responsibility
    23
- 2.2 Preparation, Inspection, and
  24
  - Maintenance
    24
- Inspection and Maintenance Table
  25
  - Pre-Start Inspection
    26
  - General
    28
  - Function Check
    30
- Maximum Cutout Height
  30
- Tilt Cutout Settings
  30
  - Lockout Cylinder Test
    31
  - Dual Fuel System (if Equipped)
    33
Section 3 - Machine Controls, Indicators and Operation

35
- 3.1 General
  35
- Description
  35
- Operating Characteristics and Limitations
  36
  - General
    36
  - Placards
    36
  - Capacities
    36
  - Stability
    36
- 3.4 Ground Controls and Indicators
  38
- Emergency Stop Switch
  38
  - Ground Control Station
    39
  - Manual Descent Control
    41
- 3.5 Platform Control Station
  42
  - Platform Controls
    43
  - Indicator Control Panel
    46
- Engine Operation
  48
  - Platform/Ground Select Switch
    48
- Speed Switch
  48
- Starting Procedure
  49
- 3.7 Dual Fuel System
  50
- Operating Characteristics
  50
  - Platform Loading
    50
- Platform Capacities
  50
  - Traveling (Driving)
    51
  - Traveling Forward
    51
  - Traveling in Reverse
    51
  - Traveling on Grade
    51
  - Steering
    51
  - Leveling Jacks
    53
  - Auto Leveling
    53
  - Manual Level Adjustment (Trim)
    54
  - Raising and Lowering Platform
    54
  - Raising
    54
  - Lowering
    55
  - Platform Extension
    55
  - Power Deck
    55
  - Auxiliary Power
    56
  - Generator
    56
- 3.10 Tie Down/Lift Lugs
  57
  - Tie down
    57
  - Lifting
    57
  - 3.11 Towing
    57
- Parking and Stowing
  57
Section 4 - Emergency Procedures

61
- General
  61
- Emergency Towing Procedures
  61
- Emergency Controls and Their Locations
  62
  - Emergency Stop Switch
    62
  - Ground Control Station
    62
  - Manual Descent
    62
- Emergency Operation
  63
  - Use of Ground Controls
    63
  - Operator Unable to Control Machine
    63
  - Platform Caught Overhead
    63
  - Righting of Tipped Machine
    63
  - Post-Incident Inspection
    63
- Incident Notification
  64
Section 5 - General Specifications and Operator Maintenance

65
- Introduction
  65
- Supplemental Information
  65
- Operating Specifications
  66
  - Dimensional Data
    67
  - Capacities
    67
  - Tires
    68
- Tire Specifications
  68
  - Engines
    69
Section - Paragraph, Subject

69
- Deutz - D 2.9 L4 - T4F Engine Specifications
  69
  - Critical Stability Weights
    70
  - Lubrication
    71
- Hydraulic Oil
  71
- Operator Maintenance
  76
  - Safety Prop
    76
- Operator Maintenance Components
  77
  - Fuel Tank
    78
  - Drive Hub
    78
  - Hydraulic Oil
    79
  - Sliding Wear Pads
    79
  - Oil Change W/Filter - Deutz
    79
  - Oil Change W/Filter - Deutz D 2.9 L4 - T4F
    80
  - Oil Change W/Filter - GM
    80
  - Fuel Filter - Deutz
    81
  - Fuel Filter - Deutz D 2.9 L4 - T4F
    81
  - Fuel Filter (Gasoline) - GM
    81
  - Air Filter
    82
  - Electronic Pressure Regulator (LPG Only)
    82
  - Fuel Filter (Propane) - GM
    82
- Draining Oil Build up from the Propane
  83
  - Regulator
    83
- Filter Lock Assembly
  85
  - Propane Fuel System Pressure Relief
    86
  - Propane Fuel System Leak Test
    87
  - Tires and Wheels
    87
    
    Tire Damage
    87
    
    Tire Replacement
    88
    
    Wheel Replacement
    88
    
    Wheel Installation
    88
- Propane Fuel Filter Replacement
  85
  - Removal
    85
  - Installation
    85
- Wheel Torque Chart
  89
  - 5.10 Decal Installation
    90
- Decal Location - Sheet 1 of 2 (ANSI)
  90
- Decal Location - Sheet 2 of 2 (ANSI)
  91
- Decal Location Legend - ANSI
  92
- Decal Installation - Sheet 1 of 2 (CE/AUS)
  95
- Decal Installation - Sheet 2 of 2 (CE/AUS)
  96
- Decal Legend - CE/AUS
  97
- Inspection and Repair Log
  99
Section 6. Inspection and Repair Log

99

JLG 4394RT Quick Start Manual (9 pages)

Scissor Platform Control Measures

Brand: JLG | Category: Lifting Systems | Size: 0 MB

JLG Categories

Boom Lifts Lifting Systems Scissor Lifts Construction Equipment Work Light

More JLG Manuals

JLG 4394RT Manuals

JLG 4394RT Service And Maintenance Manual (240 pages)

Table of Contents

Subject - Section, Paragraph

Specifications

General

Chassis, Platform & Scissor Arms

Hydraulics

Jlg Control System

General Electrical Information & Schematics

JLG 4394RT Service Maintenance Manual (228 pages)

Table of Contents

JLG 4394RT Operation And Safety Manual (104 pages)

Table of Contents

Section - Paragraph, Subject

Section 1 - Safety Precautions

Section 2. User Responsibilities, Machine Preparation and Inspection

Section 3 - Machine Controls, Indicators and Operation

Section 4 - Emergency Procedures

Section 5 - General Specifications and Operator Maintenance

Section - Paragraph, Subject

Section 6. Inspection and Repair Log

JLG 4394RT Quick Start Manual (9 pages)

Table of Contents

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