Oshkosh Corporation JLG 3394RT, Operation And Safety Manual

Page 1: ...Operation and Safety Manual Original Instructions keep this manual with the machine at all times ANSI Model 3394RT 4394RT P N 3121132 November 30 2010...

Page 2: ...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 improve...

Page 3: ...AVE AN ORANGE BACKGROUND INDICATES A POTENTIALITY HAZARDOUS SITUATION IF NOT AVOIDED MAY RESULT IN MINOR OR MODERATE INJURY IT MAY ALSO ALERT AGAINST UNSAFE PRACTICES THIS DECAL WILL HAVE A YELLOW BAC...

Page 4: ...CES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROPERTY OR THE JLG PRODUCT Contact Product S...

Page 5: ...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 M...

Page 6: ...azards 1 10 SECTION 2 USER RESPONSIBILITIES MACHINE PREPA RATION AND INSPECTION 2 1 PERSONNEL TRAINING 2 1 Operator Training 2 1 Training Supervision 2 1 Operator Responsibility 2 1 2 2 PREPARATION IN...

Page 7: ...7 4 6 PLATFORM EXTENSION 4 7 4 7 STEERING 4 7 4 8 TRAVELING 4 8 Traveling Forward 4 8 Traveling in Reverse 4 8 4 9 PARKING AND STOWING 4 10 4 10 PLATFORM LOADING 4 10 4 11 SAFETY PROP 4 11 4 12 TIE DO...

Page 8: ...gines 6 4 Critical Stability Weights 6 6 Lubrication 6 6 6 4 OPERATOR MAINTENANCE 6 15 6 5 TIRES AND WHEELS 6 20 Tire Damage 6 20 Tire Replacement 6 21 Wheel Replacement 6 21 Wheel Installation 6 21 6...

Page 9: ...eet 2 of 2 6 9 6 3 Engine Operating Temperature Specifications Ford Sheet 1 of 2 6 10 6 4 Engine Operating Temperature Specifications Ford Sheet 2 of 2 6 11 6 5 Engine Operating Temperature Specificat...

Page 10: ...s been read training is accomplished and operation of the machine has been completed under the supervision of an experienced and qualified operator These sections contain the responsibilities of the o...

Page 11: ...Workplace Inspection Precautions to avoid all hazards in the work area must be taken by the user before operation of the machine Do not operate or raise the platform from a position on trucks trailers...

Page 12: ...atform deck Keep mud oil grease and other slippery substances from foot wear and platform deck 1 3 OPERATION General Do not use the machine for any purpose other than posi tioning personnel their tool...

Page 13: ...d machine by pushing or pulling except by pulling at the chassis tie down lugs Stow scissor arm assembly and shut off all power before leaving machine Trip and Fall Hazards JLG Industries Inc recommen...

Page 14: ...eme caution when entering or leaving platform Ensure that the scissor arm assembly is fully lowered Face the machine when entering or leaving the platform Always maintain three point contact with the...

Page 15: ...hine and its occupants their tools and their equipment from any electrical line or apparatus car rying up to 50 000 volts One foot additional clearance is required for every additional 30 000 volts or...

Page 16: ...PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN OTHERWISE Tipping Hazards Ensure that the ground conditions are adequate to sup port the maximum tire load indicated on the tire load decals located on the...

Page 17: ...ust be removed before attempting to free the machine Use cranes forklift trucks or other appropriate equipment to stabilize machine and remove personnel Crushing and Collision Hazards Approved head ge...

Page 18: ...e should not be towed except in the event of emergency malfunction power failure or loading unload ing Refer to Emergency Procedures section of this man ual for emergency towing procedures Ensure plat...

Page 19: ...he aid of a mechanical device Do not allow heavy objects to rest in an unstable position Ensure adequate support is pro vided when raising components of the machine Remove all rings watches and jewelr...

Page 20: ...contact with skin or clothing BATTERY FLUID IS HIGHLY CORROSIVE AVOID CONTACT WITH SKIN AND CLOTHING AT ALL TIMES IMMEDIATELY RINSE ANY CONTACTED AREA WITH CLEAN WATER AND SEEK MEDICAL ATTENTION Charg...

Page 21: ...SECTION 1 SAFETY PRECAUTIONS 1 12 JLG Lift 3121132 NOTES...

Page 22: ...f the employer and government regulations 4 Use of approved fall protection device 5 Enough knowledge of the mechanical operation of the machine to recognize a malfunction or potential mal function 6...

Page 23: ...for further requirements for aerial work platforms The frequency of inspections and mainte nance must be increased as necessary when the machine is used in a harsh or hostile environment if the machin...

Page 24: ...n service for 3 months or 150 hours whichever comes first or Out of service for a period of more than 3 months or Purchased used Owner Dealer or User Qualified JLG Mechanic Service and Mainte nance Ma...

Page 25: ...Manuals Make sure a copy of the Operator and Safety Manual AEM Safety Manual ANSI markets only and ANSI Manual of Responsibili ties ANSI markets only is enclosed in the weather resistant storage cont...

Page 26: ...ECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 3121132 JLG Lift 2 5 4 5 6 20 19 17 15 5 4 4 5 12 11 10 9 8 7 6 5 4 3 2 1 22 21 3 13 14 16 18 Figure 2 1 Walk Around Inspection Diagra...

Page 27: ...securely fastened and that no visible damage exists in addition to any other criteria men tioned NOTE All wheel lugs are to be torqued at 170 ft lbs 240 Nm 1 Oscillating Header Valve 2WD only If appl...

Page 28: ...4WD only If applicable See Note 15 Engine and Hydraulic Pump Assembly See Note 16 Battery Cables Routing Installation See Note 17 Drive Header Valve 4WD only If applicable See Note 18 Rotary Switch S...

Page 29: ...ontrol console a Ensure that the control console is firmly secured in the proper location b Check that all switch guards are in place c Operate all functions and check all limiting and cut out switche...

Page 30: ...or 10 ft 3 1 m on the 4394RT 5 Place DRIVE control switch to REVERSE position and carefully drive the machine off the block and ramp 6 Have an assistant check to see that the left front wheel remains...

Page 31: ...ne from the ground control station 2 Open the hand valve on the LP Gas supply tank by turn ing counterclockwise 3 While the engine is operating place the LPG GAS SELECT switch at the platform control...

Page 32: ...cards Important points to remember during operation are provided at the control stations by DANGER WARNING CAUTION IMPORTANT and INSTRUCTION placards This information is placed at various locations fo...

Page 33: ...gure 3 1 Ground Control Station 1 Platform Ground Control Switch 2 Glow Plug Diesel Only 3 Circuit Breaker 4 Power Deck Front If equipped 5 Emergency Stop Switch 6 Power Deck Rear If equipped 7 Auxili...

Page 34: ...and the key can be removed to disable the machine 2 Glow Plug Switch Diesel Engine Only A momentary contact push button type switch that supplies electrical power to the engine s glow plugs when depr...

Page 35: ...ours the machine has been operated 10 Oil Pressure Illuminates when the engine oil pressure drops too low 11 Lift Switch A three position momentary contact lift con trol switch provides raising and lo...

Page 36: ...tform Control Station 1 Leveling Jack Select If equipped 2 Front Deck Extension Select If equipped 3 Dual Fuel Select Glow Plug If equipped 4 Rear Deck Extension Select 5 Generator On Off 6 Overload I...

Page 37: ...eveling jack selection switch and squeeze the trigger switch on the controller b To adjust the leveling jacks to the left activate the switch on top of the controller to the left To adjust to the righ...

Page 38: ...ward will extend the power deck extension and moving the control handle backward will retract the power deck extension After selecting the leveling jack function moving the control handle forward will...

Page 39: ...rol station and also to turn off power to the platform function controls in the event of an emergency With the power select switch positioned to platform power is turned on by pulling the switch out o...

Page 40: ...NE CONTROL 3121132 JLG Lift 3 9 1705390A 1705189A 1 2 3 4 5 6 7 8 9 Figure 3 3 Indicator Panel 1 Power Deck 2 Drive 3 Lift 4 Fuel Gauge 5 Tilt 6 System Fault 7 Leveling Jacks Fully Retracted 8 Levelin...

Page 41: ...reater than the allowable amount IF TILT ALARM IS ON WHEN PLATFORM IS RAISED LOWER PLATFORM COMPLETELY THEN REPOSITION MACHINE SO THAT IT IS LEVEL BEFORE RAISING PLATFORM 6 System Fault Indicator This...

Page 42: ...TION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3121132 JLG Lift 3 11 33 34 18 20 32 32 19 9 20 18 37 17 36 31 12 37 4 5 7 48 43 44 47 43 46 45 44 42 43 51 Figure 3 4 Decal Location Sheet 1 of 2 ANSI...

Page 43: ...CTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3 12 JLG Lift 3121132 11 33 34 8 39 23 33 21 38 21 21 22 40 41 49 50 49 49 49 50 Figure 3 5 Decal Location Sheet 2 of 2 ANSI Leveling Jacks if equippe...

Page 44: ...03816 1705195 1704684 1704691 1704699 8 1703687 1703687 1703687 1703687 1703687 9 1704412 1704412 1704412 1704412 1704412 10 11 3251813 3251813 3251813 3251813 3251813 12 1001092250 1001092251 1001092...

Page 45: ...694 1704702 39 1705019 1705019 1705019 1705019 1705019 40 1704432 1705943 1705311 1705316 1705318 41 1703823 1705944 1705040 1705041 1705043 42 3394RT 4394RT 1705038 1705039 1705038 1705039 1705038 17...

Page 46: ...1701542 1701505 1701542 1701505 1701542 1701505 1701542 1701505 47 1702788 1704174 1702788 1704174 48 1702962 1702961 1702962 1702961 49 1701214 1701214 1704690 1701214 1704697 1704698 50 1705042 170...

Page 47: ...SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3 16 JLG Lift 3121132 6 18 16 36 17 8 16 18 34 31 32 40 41 42 43 41 44 45 38 15 36 4 10 Figure 3 6 Decal Installation Sheet 1 of 2 CE AUS...

Page 48: ...SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3121132 JLG Lift 3 17 6 33 7 37 21 39 36 19 19 19 20 46 47 46 46 46 47 Figure 3 7 Decal Installation Sheet 2 of 2 CE AUS Leveling Jacks if equipped...

Page 49: ...8 1704412 9 10 CE AUS 3252533 3252534 11 14 15 1701509 16 1703811 17 1703812 18 1703814 19 1704277 20 1703819 21 1703822 22 30 31 1702773 32 1704885 33 3251813 34 1703162 35 36 1706338 37 1705019 38 1...

Page 50: ...SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3121132 JLG Lift 3 19 45 3394RT 4394RT 1705034 1705035 1705036 1705037 46 1701785 47 1705042 Table 3 2 Decal Legend CE AUS Item CE AUS 0275086 2...

Page 51: ...SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3 20 JLG Lift 3121132 NOTES...

Page 52: ...OPERATION Platform Ground Select Switch The power selector switch functions to direct electrical power to the desired control station With the switch in the ground position power is supplied to the e...

Page 53: ...lve on the LPG supply tank is opened prior to attempting to start the engine NOTICE IF ENGINE FAILS TO START PROMPTLY DO NOT CRANK FOR AN EXTENDED PERIOD SHOULD ENGINE FAIL TO START ONCE AGAIN ALLOW S...

Page 54: ...d 4 Continue to engage the leveling jacks until the tilt light stops blinking and is no longer lit NOTE If you receive a 2 5 flash code through the system fault light at the platform control station t...

Page 55: ...of level At this time the machine will no longer lift but the machine can be low ered NOTE The machine must be in the stowed position before the trim function is operable NOTE You can not adjust the...

Page 56: ...hut off Lift There is a flow control valve which controls both the lift up and lift down speeds Anytime you abruptly change lift directions there is a three second delay between lift up and lift down...

Page 57: ...ON A SMOOTH FIRM AND LEVEL SURFACE FREE OF OBSTRUCTIONS AND HOLES Raising 1 With the engine running place the power select switch to desired position platform or ground 2 Position the applicable emerg...

Page 58: ...better access to worksites To extend the deck select either the front or rear deck exten sion select switch depress the switch in conjunction with the controller Moving the controller forward extends...

Page 59: ...d move the control grip forward and hold for the duration of travel Drive speed is determined by the distance the control handle is moved from the center off position For additional drive speed positi...

Page 60: ...SECTION 4 MACHINE OPERATION 3121132 JLG Lift 4 9 SIDESLOPE GRADE LEVEL Figure 4 1 Grade and Sideslope...

Page 61: ...or switch to off and remove the key to disable the machine and prevent unauthorized use 4 10 PLATFORM LOADING The platform maximum rated load capacity is shown on a placard located on the platform and...

Page 62: ...the platform extensions must be fully retracted and the platform fully lowered in the stowed mode with the machine securely tied down to the truck or trailer deck Refer to the four tie down lift lugs...

Page 63: ...SECTION 4 MACHINE OPERATION 4 12 JLG Lift 3121132 WHEELBASE in cm X in cm Z in cm Z X 116 58 39 295 147 100 Figure 4 2 Lifting and Tie Down Chart Sheet 1 of 2...

Page 64: ...SECTION 4 MACHINE OPERATION 3121132 JLG Lift 4 13 MACHINE WITHOUT LEVELING JACKS MACHINE WITH LEVELING JACKS Figure 4 3 Lifting and Tie Down Chart Sheet 2 of 2...

Page 65: ...SECTION 4 MACHINE OPERATION 4 14 JLG Lift 3121132 NOTES...

Page 66: ...ct with the machine 5 2 EMERGENCY TOWING PROCEDURES Towing this machine is prohibited unless properly equipped However provisions for moving the machine in case of a malfunction or power failure have...

Page 67: ...located on the left side of the machine frame The controls on this panel provide the means for overriding the platform controls and for controlling the platform lift up and down functions from the gro...

Page 68: ...and stabilize motion of the machine in case machine controls are inadequate or malfunction when used Platform Caught Overhead If the platform becomes jammed or snagged in overhead structures or equip...

Page 69: ...Product Safety and Reliability Department at the factory should be contacted by telephone and provided with all necessary details Contact at 1 877 JLG SAFE 554 7223 between the hours of 8 00 AM 4 45...

Page 70: ...2 0200187013 Illustrated Parts Manuals 3121134 Prior to S N 0200191606 excluding S N s 0200186972 0200187002 0200187013 3121250 S N 0200191606 to Present including S N s 0200186972 0200187002 02001870...

Page 71: ...8kph 3 5mph 5 6kph LIftUp Speed Stowed toFullHeight 29 31sec 40 45sec LiftDownSpeed Full Heightto Stowed MaximumWindSpeed 28mph 12 5m s MaximumHorizontal Manual SideForce Single Extension Dual Extensi...

Page 72: ...Extension Note Certainoptionsor coun try standardsincreaseweight 11 910lbs 5 402kg 15 300lbs 6 940kg Table 6 1 Operating Specifications Model 3394RT 4394RT Table 6 2 Dimensional Data 3394RT 4394RT Ma...

Page 73: ...8Nm 33 16LLx16 1 FoamFilled Sand 10 170ftlbs 238Nm 31x15 50 15 10 60psi 4bar 170ftlbs 238Nm IN315 55D20 Pneumatic 12 75psi 5bar 170ftlbs 238Nm IN315 55D20 FoamFilled 12 170ftlbs 238Nm Table 6 5 Ford L...

Page 74: ...hRPM 1 3GPH 4 9lph 1 6GPH 6 0lph Horsepower 48 2800RPM full load Table 6 7 GM 3 0L Specifications Fuel Gasoline orGasoline LP Gas No of Cylinders 4 HorsePower Gasoline LP 83hp 3000rpm 75hp 3000rpm Bor...

Page 75: ...ommends the use of Mobil DTE13 Table 6 8 Critical Stability Weights Component 3394RT 4394RT Wheeland Tire 12x16 5Pneumatic 12x16 5FoamFilled 33 1550 16 5Pneumatic 33 1550 16 5Foam Filled 33 16LLx16 1S...

Page 76: ...contact JLG Industries for proper recommenda tions Table 6 10 Lubrication Specifications KEY SPECIFICATIONS MPG MultipurposeGreasehaving aminimumdrippingpointof350 F Excellentwaterresistanceandadhesiv...

Page 77: ...NDED FLUIDS A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER PACKAGE IE ENGINE BLOCK HEATER ETHER INJECTION OR GLOW PLUGS BATTERY WARMER AND HYDRAULIC OIL TANK HEATER NO OP...

Page 78: ...F 82 C HYD OIL TANK TEMP NO OPERATION BELOW THIS AMBIENT TEMPERATURE DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS AND COLD WEATHER HYDRAULIC OIL BELOW THIS TEMPERATURE DO NOT START UP HYDRAUL...

Page 79: ...BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER PACKAGE IE ENGINE BLOCK HEATER BATTERY WARMER AND HYDRAULIC OIL TANK HEATER NO OPERATION BELOW THIS AMBIENT TEMPERATURE AMBIENT AIR TEMPER...

Page 80: ...TART UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS AND COLD WEATHER HYDRAULIC OIL BELOW THIS TEMPERATURE DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS WITH MOBILE 424 HYDRAULIC OIL BELOW THIS TEMPE...

Page 81: ...A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER PACKAGE IE ENGINE BLOCK HEATER BATTERY WARMER AND HYDRAULIC OIL TANK HEATER NO OPERATION BELOW THIS AMBIENT TEMPERATURE AM...

Page 82: ...START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS AND COLD WEATHER HYDRAULIC OIL BELOW THIS TEMPERATURE DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS WITH MOBILE 424 HYDRAULIC OIL BELOW THIS TEMP...

Page 83: ...2 DriveHubs 3 HydraulicOil Tank 4 SlidingWearPads 5 OilChange w Filter Ford 6 OilChange w Filter Deutz 7 OilChange w Filter GM 8 Fuel Filter Ford 9 FuelFilter Deutz 10 FuelFilter Gasoline GM 11 AirFi...

Page 84: ...i shift operations and or exposed to hostile environments or conditions lubrication frequen cies must be increased accordingly Operate hydraulic functions through one complete cycle before checking hy...

Page 85: ...ll Plugs 4 Lube EPGL Interval Every 2 years or 1200 hours 3 Hydraulic Oil Lube Point Fill Cap Fill Level Lube HO Interval Check oil every 10 hours of operation change oil every 2 years or 1200 hours o...

Page 86: ...4 5 qt 4 25 L Lube EO Interval 3 Months or 150 hours of operation Comments Check level daily Change in accordance with engine manual 6 Oil Change w Filter Deutz Lube Point s Fill Cap Spin on Element J...

Page 87: ...Cap Spin on Element JLG P N 7027965 Capacity 4 5 qt 4 25 L w filter Tier 2 5 0 qt 4 73 L w filter Tier 3 Lube EO Interval 3 Months or 150 hours of operation Comments Check level daily Change in accor...

Page 88: ...Lube Point s Replaceable Element Interval Every 6 months or 300 hours of operation 11 Air Filter Lube Point s Replaceable Element Interval Every 6 months or 300 hours of operation or as indicated by t...

Page 89: ...e tire or tire assembly For polyurethane foam filled tires JLG Industries Inc recom mends that when any of the following are discovered measures must be taken to remove the JLG product from service im...

Page 90: ...ies Inc do not replace a foam filled tire assembly with a pneumatic tire When selecting and installing a replacement tire ensure that all tires are inflated to the pressure recommended by JLG Due to s...

Page 91: ...commended sequence tighten the nuts per wheel torque chart Wheel nuts should be torqued after the first 50 hours of oper ation and after each wheel removal Check torque every 3 months or 150 hours of...

Page 92: ...E REGULATOR 1 Move the equipment to a well ventilated area Ensure there are no external ignition sources 2 Start the engine and bring to operating temperature 3 With the engine running close the manua...

Page 93: ...has been drained reinstall the LPG fuel temperature sensor and reconnect the electrical connector 8 Open the fuel tank manual valve 9 Start the engine and verify all connections are secure 10 Dispose...

Page 94: ...eal 9 Remove and discard mounting plate to lock off o ring seal Installation NOTICE BE SURE TO REINSTALL THE FILTER MAGNET INTO THE HOUSING BEFORE INSTALLING NEW SEAL 1 Install the mounting plate to l...

Page 95: ...d run the vehicle until the engine stalls 3 Turn the ignition switch OFF RESIDUAL VAPOR PRESSURE WILL BE PRESENT IN THE FUEL SYS TEM ENSURE THE WORK AREA IS WELL VENTILATED BEFORE DIS CONNECTING ANY F...

Page 96: ...SECTION 7 INSPECTION AND REPAIR LOG 3121132 JLG Lift 7 1 SECTION 7 INSPECTION AND REPAIR LOG Table 7 1 Inspection and Repair Log Date Comments...

Page 97: ...SECTION 7 INSPECTION AND REPAIR LOG 7 2 JLG Lift 3121132 Table 7 1 Inspection and Repair Log Date Comments...

Page 98: ...NOTE Leased or rented units should not be included on this form Mfg Model _______________________________________________________________ Serial Number ________________________________________________...

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