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4394RT
JLG 4394RT Service Manual
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Se
r
vice and Main
tenanc
e Manual
Model(s)
3394R
T
4394R
T
S/N 0200239053 to
Present
P/N - 3121642
Januar
y 23, 2018
A
S/NZS
2
Table of Contents
Default Chapter
5
Table of Contents
5
Subject - Section, Paragraph
15
Specifications
15
Capacities
15
Engines
15
Tires
16
Machine Dimensions
16
Pressure Settings
16
Serial Number Locations
16
Sensors
17
Cylinder Specifications
17
1.10 Major Component Weights
17
1.11 Critical Stability Weights
17
1.12 Lubrication Specifications
18
1.13 Maintenance Specifications
19
Fuel Tank
19
Engine Operating Temperature Specifications - Deutz
20
Engine Operating Temperature Specifications - GM
21
Drive Hub
22
Hydraulic Oil
22
Oil Change W/Filter - Deutz - D 2011 L03
23
Engine Oil Change W/Filter - Deutz D2.9 L4 - T4F
23
Oil Change W/Filter - GM - Dual Fuel
23
Engine Fuel Filter - Deutz
23
Engine Fuel Filter - Deutz D 2.9 L4 - T4F
24
Engine Fuel Filter (Gasoline) - GM
24
Air Filter
24
Electronic Pressure Regulator (LP Only)
24
Fuel Filter (Propane) - GM
24
Draining Oil Build up from the Propane Regulator
25
Propane Fuel Filter Replacement
26
Propane Fuel System Pressure Relief
26
1.14 Torque Charts
27
Torque Chart - Sheet 2 of 5 - (SAE Fasteners)
28
Torque Chart - Sheet 3 of 5 - (SAE Fasteners)
29
Torque Chart - Sheet 4 of 5 - (METRIC Fasteners)
30
Torque Chart - Sheet 5 of 5 - (METRIC Fasteners)
31
General
33
Machine Preparation, Inspection, and Maintenance
33
Preparation, Inspection, and Maintenance
33
Pre-Start Inspection
33
Pre-Delivery Inspection and Frequent Inspection
33
Annual Machine Inspection
33
Preventative 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
To Connect the Hand Held Analyzer
177
Using the Analyzer
178
Changing the Access Level of the Hand Held Analyzer
178
Adjusting Parameters Using the Hand Held Analyzer
180
Machine Setup
180
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
Other manuals for JLG 4394RT
Operation And Safety Manual
104 pages
Service Maintenance Manual
228 pages
Quick Start Guide
8 pages
5
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JLG 4394RT Specifications
General
Fuel Type
Diesel
Gradeability
30 %
Engine Type
Diesel
Number of Cylinders
4
Fuel Tank Capacity
25 gal
Maximum Platform Height
43 ft
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