Jlg 3394rt & 4394rt Operation And Safety Manual

Full download: http://manualplace.com/download/jlg-3394rt-4394rt-operation-and-safety-manual/

Operation and Safety Manual

Original Instructions, keep this manual with the machine at all times.

Model
3394RT
4394RT

P/N - 3121132
ANSI ®
May 16, 2014

This is the cut pages sample. Download all 104 page(s) at: ManualPlace.com
 FOREWORD

FOREWORD

This manual is a very important tool! Keep it with the machine at all times.
The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and
operating procedures essential for the safe and proper machine operation for its intended purpose.
Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes
without prior notification. Contact JLG Industries, Inc. for updated information.

3121132 – JLG Lift – a

 FOREWORD

SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

This is the Safety Alert Symbol. It is used to alert you to the potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid possi-
ble injury or death.

INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT AVOIDED, INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOT AVOIDED, MAY
WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE A RED RESULT IN MINOR OR MODERATE INJURY. IT MAY ALSO ALERT AGAINST
BACKGROUND. UNSAFE PRACTICES. THIS DECAL WILL HAVE A YELLOW BACKGROUND.

NOTICE
INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOT AVOIDED, INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES DIRECTLY
COULD RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE AN OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROP-
ORANGE BACKGROUND. ERTY.

b – JLG Lift – 3121132

 FOREWORD

For:
THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CON- • Accident Reporting • Standards and Regula-
TACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTA- tions Compliance Infor-
• Product Safety Publi-
TIVE FOR INFORMATION REGARDING SAFETY-RELATED BULLETINS WHICH mation
cations
MAY HAVE BEEN ISSUED FOR THIS PRODUCT. • Questions Regarding Spe-
• Current Owner
cial Product Applications
Updates
NOTICE • Questions Regarding
• Questions Regarding
JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER Product Modifications
Product Safety
OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES, INC. TO ENSURE
THAT THE CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE. Contact:
Product Safety and Reliability Department
NOTICE JLG Industries, Inc.
JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL INSTANCES 13224 Fountainhead Plaza
WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING Hagerstown, MD 21742
BODILY INJURY OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE
HAS OCCURRED TO PERSONAL PROPERTY OR THE JLG PRODUCT. or Your Local JLG Office
(See addresses on manual rear cover)
In USA:
Toll Free: 877-JLG-SAFE (877-554-7233)
Outside USA:
Phone: 240-420-2661
E-mail: [email protected]

3121132 – JLG Lift – c

 FOREWORD

REVISION LOG
Original Issue - April 11, 2002
Revised - July 12, 2002
Revised - July 18, 2003
Revised - February 18, 2004
Revised - August 6, 2004
Revised - December 21, 2004
Revised - July 15, 2005
Revised - February 28, 2006
Revised - March 29, 2007
Revised - May 22, 2008
Revised - September 30, 2008
Revised - November 30, 2010
Revised - May 16, 2014

d – JLG Lift – 3121132

 TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

SECTION - 1 - SAFETY PRECAUTIONS MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

1.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Pre-Start Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
1.2 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Operator Training and Knowledge . . . . . . . . . . . 1-2 Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Workplace Inspection . . . . . . . . . . . . . . . . . . . . . . . 1-2 2.3 LOCKOUT CYLINDER TEST . . . . . . . . . . . . . . . . . . . . . . .2-9
Machine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 2.4 DUAL FUEL SYSTEM (IF EQUIPPED) . . . . . . . . . . . . 2-10
1.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 SECTION - 3 - USER RESPONSIBILITIES AND MACHINE CON-
Trip and Fall Hazards . . . . . . . . . . . . . . . . . . . . . . . . 1-5 TROL
Electrocution Hazards . . . . . . . . . . . . . . . . . . . . . . . 1-6 3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Tipping Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 3.2 OPERATING CHARACTERISTICS AND
Crushing and Collision Hazards . . . . . . . . . . . . . . 1-8 LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . . . . 1-9 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
1.5 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10 Placards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Maintenance Hazards . . . . . . . . . . . . . . . . . . . . . . 1-10 Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Battery Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 3.3 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . .3-2
Ground Control Station . . . . . . . . . . . . . . . . . . . . . . 3-3
SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPARA- Platform Control Station . . . . . . . . . . . . . . . . . . . . . 3-6
TION AND INSPECTION Indicator Control Panel . . . . . . . . . . . . . . . . . . . . . 3-10
2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 SECTION - 4 - MACHINE OPERATION
Training Supervision . . . . . . . . . . . . . . . . . . . . . . . . 2-1 4.1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Operator Responsibility . . . . . . . . . . . . . . . . . . . . . 2-1 4.2 ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
2.2 PREPARATION, INSPECTION, AND Platform/Ground Select Switch. . . . . . . . . . . . . . . 4-1

3121132 – JLG Lift – i

TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

Emergency Stop Switch. . . . . . . . . . . . . . . . . . . . . . 4-1 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Speed Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.13 TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.3 OPERATING CHARACTERISTICS . . . . . . . . . . . . . . . . . .4-3 SECTION - 5 - EMERGENCY PROCEDURES
Leveling Jacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 5.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Auto Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 5.2 EMERGENCY TOWING PROCEDURES . . . . . . . . . . . . 5-1
Manual Level Adjustment (Trim) . . . . . . . . . . . . . 4-4 5.3 EMERGENCY CONTROLS AND THEIR LOCATIONS 5-2
Power Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Emergency Stop Switch . . . . . . . . . . . . . . . . . . . . . . 5-2
Auxiliary Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Ground Control Station . . . . . . . . . . . . . . . . . . . . . . 5-2
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Manual Descent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 5.4 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . . . . . . 5-3
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Use of Ground Controls . . . . . . . . . . . . . . . . . . . . . . 5-3
4.4 DUAL FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5 Operator Unable to Control Machine . . . . . . . . . 5-3
4.5 RAISING AND LOWERING PLATFORM . . . . . . . . . . . .4-6 Platform Caught Overhead . . . . . . . . . . . . . . . . . . . 5-3
Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Righting of Tipped Machine . . . . . . . . . . . . . . . . . . 5-3
Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Post-Incident Inspection . . . . . . . . . . . . . . . . . . . . . 5-3
4.6 PLATFORM EXTENSION . . . . . . . . . . . . . . . . . . . . . . . . .4-7 5.5 INCIDENT NOTIFICATION . . . . . . . . . . . . . . . . . . . . . . . 5-4
4.7 STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
4.8 TRAVELING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8 SECTION - 6 - GENERAL SPECIFICATIONS AND OPERATOR
Traveling Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 MAINTENANCE
Traveling in Reverse . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.9 PARKING AND STOWING . . . . . . . . . . . . . . . . . . . . . . 4-10 6.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
4.10 PLATFORM LOADING . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 6.2 SUPPLEMENTAL INFORMATION. . . . . . . . . . . . . . . . . 6-1
4.11 SAFETY PROP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 6.3 OPERATING SPECIFICATIONS . . . . . . . . . . . . . . . . . . . 6-2
4.12 TIE DOWN/LIFT LUGS . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

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 TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 6.7 PROPANE FUEL SYSTEM PRESSURE RELIEF . . . . . 6-25

Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 6.8 PROPANE FUEL SYSTEM LEAK TEST . . . . . . . . . . . . 6-26
Critical Stability Weights. . . . . . . . . . . . . . . . . . . . . 6-7 6.9 TIRES AND WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Tire Damage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
6.4 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . .6-16 Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Drive Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Sliding Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 SECTION - 7 - INSPECTION AND REPAIR LOG
Oil Change w/Filter - Ford . . . . . . . . . . . . . . . . . . 6-18
Oil Change w/Filter - Deutz . . . . . . . . . . . . . . . . . 6-18
Oil Change w/Filter - Deutz D 2.9 L4 - T4F . . . 6-19 LIST OF FIGURES
Oil Change w/Filter - GM. . . . . . . . . . . . . . . . . . . . 6-19
Fuel Filter - Ford. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 2-1. Walk Around Inspection Diagram . . . . . . . . . . . . . . .2-5
Fuel Filter - Deutz . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 2-2. Walk Around Inspection Points - Sheet 1 of 2 . . . .2-6
Fuel Filter - Deutz D 2.9 L4 - T4F. . . . . . . . . . . . . 6-21 2-3. Walk Around Inspection Points - Sheet 2 of 2 . . . .2-7
Fuel Filter (Gasoline) - GM . . . . . . . . . . . . . . . . . . 6-21 3-1. Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 3-2. Platform Control Station . . . . . . . . . . . . . . . . . . . . . . . .3-5
Electronic Pressure Regulator (LPG only) . . . . 6-21 3-3. Indicator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
Fuel Filter (Propane) - GM. . . . . . . . . . . . . . . . . . . 6-22 3-4. Decal Location - Sheet 1 of 2 (ANSI). . . . . . . . . . . . 3-11
6.5 DRAINING OIL BUILD UP FROM THE 3-5. Decal Location - Sheet 2 of 2 (ANSI). . . . . . . . . . . . 3-12
PROPANE REGULATOR. . . . . . . . . . . . . . . . . . . . . . . . .6-22 3-6. Decal Installation - Sheet 1 of 2 (CE/AUS) . . . . . . 3-16
6.6 PROPANE FUEL FILTER REPLACEMENT. . . . . . . . . .6-24 3-7. Decal Installation - Sheet 2 of 2 (CE/AUS) . . . . . . 3-17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25 4-1. Grade and Sideslope . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25 4-2. Lifting and Tie Down Chart (Sheet 1 of 2) . . . . . . 4-12
4-3. Lifting and Tie Down Chart (Sheet 2 of 2) . . . . . . 4-13

3121132 – JLG Lift – iii

Jlg 3394rt & 4394rt Operation And Safety Manual
FullTABLE
download: http://manualplace.com/download/jlg-3394rt-4394rt-operation-and-safety-manual/
OF CONTENTS

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

6-1. Engine Operating Temperature Specifications - LIST OF TABLES
Deutz - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9 1-1 Minimum Approach Distances (M.A.D.) . . . . . . . . . 1-6
6-2. Engine Operating Temperature Specifications -
2-1 Inspection and Maintenance Table . . . . . . . . . . . . . 2-3
Deutz - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 2-2 Maximum Cutout Height . . . . . . . . . . . . . . . . . . . . . . . 2-8
6-3. Engine Operating Temperature Specifications - 2-3 Tilt Cutout Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Ford - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
3-1 Decal Location Legend - ANSI . . . . . . . . . . . . . . . . . 3-13
6-4. Engine Operating Temperature Specifications - 3-2 Decal Legend - CE/AUS . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Ford - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 4-1 Platform Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
6-5. Engine Operating Temperature Specifications -
6-1 Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . 6-2
GM - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 6-2 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6-6. Engine Operating Temperature Specifications - 6-3 Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
GM - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
6-4 Tire Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6-7. Operator Maintenance and 6-5 Ford LRG-425 Specifications . . . . . . . . . . . . . . . . . . . . 6-5
Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 6-6 Deutz F3M2011 Specifications . . . . . . . . . . . . . . . . . . 6-5
6-8. Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
6-7 Deutz - D 2.9 - L4 - T4F Engine Specifications . . . . 6-6
6-8 GM 3.0L Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-9 Critical Stability Weights. . . . . . . . . . . . . . . . . . . . . . . . 6-7
6-10 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6-11 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . 6-8
6-12 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
7-1 Inspection and Repair Log . . . . . . . . . . . . . . . . . . . . . . 7-1

iv – JLG Lift – 3121132

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