Jlg 4394RT Service Manual Bedienungsanleitung Seite 15
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SECTION 1 - SPECIFICATIONS
3121249 – JLG Lift – 1-5
1.12 LUBRICATION SPECIFICATIONS
NOTE: Hydraulic oils must have anti-wear qualities at least
to API Service Classification GL-3, and sufficient
chemical stability for mobile hydraulic system ser-
vice. JLG Industries recommends Mobilfluid 424
hydraulic oil, which has an SAE viscosity index of
152.
Table 1-14. Hydraulic Oil
Hydraulic System Operating
Temperature Range
Sae Viscosity Grade
0°F to +23°F
(-18°C to -5°C)
10W
0°F to +210°F
(-18°C to +100°C)
10W-20,10W-30
+50°F to +210°F
(+10°C to +100°C)
20W-20
Table 1-15. Mobil DTE 13M Specs
ISO Viscosity Grade #32
Specific Gravity 0.877
Pour Point, Max -40°F (-40°C)
Flash Point, Min. 330°F (166°C)
Viscosity
at 40°C 33cSt
at 100°C 6.6 cSt
at 100°F 169 SUS
at 210°F 48 SUS
cp at -20°F 6,200
Viscosity Index 140
Table 1-16. Mobil 424 Specs
Type Synthetic Biodegradable
SAE Grade 10W-30
Gravity, API 29.0
Density 7.35 lb/gal (
Pour Point, Max -46°F (-43°C)
Flash Point, Min. 442°F (228°C)
Viscosity
at 40°C 55 cSt
at 100°C 9.3 cSt
Viscosity Index 152
- May 16, 2014 1
- PRECAUTIONS 3
- REVISION LOG 4
- TABLE OF CONTENTS 5
- 10
- LIST OF TABLES 10
- TABLE NO. TITLE PAGE NO 10
- SECTION 1. SPECIFICATIONS 11
- 1.4 TIRES 12
- 1.5 MACHINE DIMENSIONS 12
- 1.6 PRESSURE SETTINGS 12
- 1.7 SERIAL NUMBER LOCATIONS 13
- 1.8 SENSORS 13
- 1.9 CYLINDER SPECIFICATIONS 14
- 1.10 MAJOR COMPONENT WEIGHTS 14
- SECTION 1 - SPECIFICATIONS 15
- 1.13 OPERATOR MAINTENANCE 16
- Fuel Tank 16
- Drive Hub 17
- Hydraulic Oil 17
- Fuel Filter (Propane) - GM 19
- Regulator 19
- 1.14 TORQUE CHARTS 21
- SECTION 2. GENERAL 27
- 2.2 SERVICE AND GUIDELINES 28
- Safety and Workmanship 28
- Cleanliness 28
- SECTION 2 - GENERAL 29
- Hydraulic System 30
- Changing Hydraulic Oil 30
- Lubrication Specifications 30
- 2.4 CYLINDER DRIFT TEST 31
- Platform Drift 31
- Cylinder Drift 31
- REPAIR GUIDELINES 31
- INSPECTION SCHEDULE 32
- 3121249 – JLG Lift – 3-1 37
- Tire Replacement 38
- Wheel Replacement 38
- Wheel Installation 38
- Drive Assembly 39
- 3-4 – JLG Lift – 3121249 40
- (BOSCH REXROTH) 41
- Roll Test 41
- Leak Test 41
- 3-6 – JLG Lift – 3121249 42
- Disconnect Mechanism 43
- Gearbox Disassembly 44
- 3121249 – JLG Lift – 3-9 45
- Gearbox Assembly 46
- 3121249 – JLG Lift – 3-11 47
- 3-12 – JLG Lift – 3121249 48
- 3121249 – JLG Lift – 3-13 49
- 3-14 – JLG Lift – 3121249 50
- 3121249 – JLG Lift – 3-15 51
- Motor Disassembly 52
- 3121249 – JLG Lift – 3-17 53
- 3-18 – JLG Lift – 3121249 54
- 3121249 – JLG Lift – 3-19 55
- 3-20 – JLG Lift – 3121249 56
- 3121249 – JLG Lift – 3-21 57
- Motor Assembly 58
- 3121249 – JLG Lift – 3-23 59
- 3-24 – JLG Lift – 3121249 60
- 3121249 – JLG Lift – 3-25 61
- 3-26 – JLG Lift – 3121249 62
- 3.4 DRIVE HUB (FAIRFIELD) 63
- Roll and Leak Testing 63
- Oil Information 63
- 3-28 – JLG Lift – 3121249 64
- 3121249 – JLG Lift – 3-29 65
- 3-30 – JLG Lift – 3121249 66
- Hub-Spindle Disassembly 67
- Cover Disassembly 68
- Carrier Disassembly 68
- Assembly of the Carrier 68
- 3121249 – JLG Lift – 3-33 69
- Cover Sub-Assembly 70
- Hub-Spindle Sub-Assembly 71
- 3-36 – JLG Lift – 3121249 72
- Main Assembly 73
- 3-38 – JLG Lift – 3121249 74
- 3121249 – JLG Lift – 3-39 75
- 3-40 – JLG Lift – 3121249 76
- 3121249 – JLG Lift – 3-41 77
- Tool List 78
- 3.5 DRIVE MOTOR (SAUER) 79
- Description 79
- Shaft Seal Replacement 79
- Loop Flushing Valve 80
- Troubleshooting 81
- 3121249 – JLG Lift – 3-47 83
- 3-48 – JLG Lift – 3121249 84
- 3121249 – JLG Lift – 3-49 85
- Inspection 86
- 3121249 – JLG Lift – 3-53 89
- 3-54 – JLG Lift – 3121249 90
- 3121249 – JLG Lift – 3-55 91
- 3-56 – JLG Lift – 3121249 92
- Initial Start-up Procedures 93
- 3.6 FRONT AXLE 94
- Steering Assembly 94
- Axle Assembly 95
- 3-60 – JLG Lift – 3121249 96
- Axle Lockout Cylinder 97
- Cylinder Removal 98
- Assembly Removal 99
- 3.8 PLATFORM 100
- 3121249 – JLG Lift – 3-65 101
- REMOVAL: 101
- INSTALLATION: 101
- Platform Control Station 102
- Joystick Controller 103
- 3.9 SCISSOR ARMS 104
- Lift Cylinder Removal 104
- Scissor Arms Removal 105
- Scissor Arm Assembly Removal 105
- 3.10 SIDE COMPARTMENT COVERS 106
- 3.11 GROUND CONTROL STATION 107
- Control Station Removal 107
- Ground Control Station 107
- 3.12 FUEL TANK 108
- 3.13 HYDRAULIC TANK 109
- 3.14 BATTERY 110
- 3.15 DUAL FUEL/LPG SYSTEM 111
- 3.16 DEUTZ ENGINE 112
- Engine Tray 112
- Deutz EMR 2 112
- Deutz EMR 4 112
- 3121249 – JLG Lift – 3-77 113
- 3-78 – JLG Lift – 3121249 114
- 3121249 – JLG Lift – 3-79 115
- 3-80 – JLG Lift – 3121249 116
- 3121249 – JLG Lift – 3-81 117
- 3-82 – JLG Lift – 3121249 118
- 3121249 – JLG Lift – 3-83 119
- 3-84 – JLG Lift – 3121249 120
- 3121249 – JLG Lift – 3-85 121
- 3-86 – JLG Lift – 3121249 122
- 3121249 – JLG Lift – 3-87 123
- 3-88 – JLG Lift – 3121249 124
- Generator (if equipped) 125
- Exhaust System 126
- Air Cleaner System 127
- 3-92 – JLG Lift – 3121249 128
- 3121249 – JLG Lift – 3-93 129
- Pump Coupling 130
- Engine Removal 131
- Radiator 132
- 3.17 GM ENGINE 133
- Maintenance of the Drive Belt 133
- Changing The Engine Oil 134
- Generator 135
- Fuel Components 139
- Fuel Filter 143
- Electric Lock Off 143
- Low Pressure Regulator (LPR) 144
- Air Fuel Mixer 144
- Engine Control Module (ECM) 145
- 3-110 – JLG Lift – 3121249 146
- 3121249 – JLG Lift – 3-111 147
- Assembly Replacement 148
- 3121249 – JLG Lift – 3-113 149
- (TMAP) Sensor 150
- Mixer Replacement 151
- Coolant Hose Replacement 152
- Vapor Hose Replacement 152
- Replacement 152
- DIAGNOSIS 153
- Fuel System Description 153
- Diagnostic Aids 153
- 3-118 – JLG Lift – 3121249 154
- 3121249 – JLG Lift – 3-119 155
- 3-120 – JLG Lift – 3121249 156
- 3121249 – JLG Lift – 3-121 157
- 3-122 – JLG Lift – 3121249 158
- 3121249 – JLG Lift – 3-123 159
- 3-124 – JLG Lift – 3121249 160
- 3121249 – JLG Lift – 3-125 161
- 3-126 – JLG Lift – 3121249 162
- 3121249 – JLG Lift – 3-127 163
- 3-128 – JLG Lift – 3121249 164
- 3121249 – JLG Lift – 3-129 165
- 3-130 – JLG Lift – 3121249 166
- SECTION 4. HYDRAULICS 167
- SECTION 4 - HYDRAULICS 168
- 4.4 CYLINDER REPAIR 169
- Disassembly 169
- Cleaning and Inspection 170
- Assembly 171
- 4.7 HYDRAULIC GEAR PUMP 176
- Pump Disassembly 176
- Parts Inspection 177
- Pump Reassembly 177
- 4.8 VALVES 179
- Main Valve 180
- Flow Divider Valve 182
- Powerdeck Valves 184
- Leveling Jack Valves 185
- Pressure Setting Procedures 186
- 4.9 GEAR PUMP 187
- Gear Pump Priming 187
- 4.10 AXIAL HI 45 PUMP 188
- General Repair Instructions 190
- Start-Up Procedure 190
- Removing the pump 191
- Electric Control Module 192
- Control Solenoids 192
- Charge Pump 193
- Charge Check/HPRV 195
- Charge Pressure Relief Valve 195
- 4.11 CHARGE PUMP FILTER 196
- 4.12 AUXILIARY PUMP MOTOR 197
- 4.13 CYLINDER ASSEMBLIES 198
- Hydraulic 203
- Schematic 203
- PRESS ENTERHEL P: 207
- ME N U : 208
- HELP: PRESS ENTER 208
- 1: s t ar t up ( 2/ 1) 208
- ACCESS LEVEL 2 209
- ACCESS LEVEL 1 209
- PERSONALI TI ES: 210
- DRIVE ACCEL 3.0s 210
- GROUND ALARM: 210
- 1=DESCENT 210
- 1705189A 211
- 5.2 CALIBRATIONS 212
- Elevation Sensor Calibration 212
- 3121249 – JLG Lift – 5-7 213
- 5-8 – JLG Lift– 3121249 214
- 3121249 – JLG Lift – 5-9 215
- 5-10 – JLG Lift– 3121249 216
- 3121249 – JLG Lift – 5-11 217
- 5-12 – JLG Lift– 3121249 218
- 3121249 – JLG Lift – 5-13 219
- 5-14 – JLG Lift– 3121249 220
- 4150588 D 221
- 5-16 – JLG Lift– 3121249 222
- 3121249 – JLG Lift – 5-17 223
- 5-18 – JLG Lift– 3121249 224
- 3121249 – JLG Lift – 5-19 225
- 5-20 – JLG Lift– 3121249 226
- 4150390 K 227
- 4150389 D 231
- 5-26 – JLG Lift– 3121249 232
- 3121249 – JLG Lift – 6-1 233
- 6-2 – JLG Lift – 3121249 234
- 3121249 – JLG Lift – 6-3 235
- Requirements: 236
- Procedure 236
- 3121249 – JLG Lift – 6-5 237
- 3121249 – JLG Lift – 6-7 239
- Wedge Lock 240
- Service - Voltage Reading 241
- DT/DTP Series Assembly 242
- DT/DTP Series Disassembly 242
- HD30/HDP20 Series Assembly 242
- HD30/HDP20 Series Disassembly 243
- 6.5 SWITCHES 244
- Basic check 244
- Limit Switches 244
- Automatic Switches 245
- 6.6 SCHEMATICS 246
- 3121249 – JLG Lift – 6-15 247
- 6-16 – JLG Lift – 3121249 248
- 3121249 – JLG Lift – 6-17 249
- 6-18 – JLG Lift – 3121249 250
- 3121249 – JLG Lift – 6-19 251
- 6-20 – JLG Lift – 3121249 252
- 3121249 – JLG Lift – 6-21 253
- 6-22 – JLG Lift – 3121249 254
- 3121249 – JLG Lift – 6-23 255
- 6-24 – JLG Lift – 3121249 256
- 3121249 – JLG Lift – 6-25 257
- 6-26 – JLG Lift – 3121249 258
- 1001103708_B 259
- 6-28 – JLG Lift – 3121249 260
- 3121249 – JLG Lift – 6-29 261
- 6-30 – JLG Lift – 3121249 262
- 3121249 – JLG Lift – 6-31 263
- 6-32 – JLG Lift – 3121249 264
- 3121249 – JLG Lift – 6-33 265
- 6-34 – JLG Lift – 3121249 266
- JLG Worldwide Locations 268
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