JLG 3394RT, 4394RT Boom Lift Service Manual
240 pages · Publication 3121642
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What's inside
From the manual's own table of contents: 359 sections, 423 entries. See sample pages (PDF, 670 KB)
General13 topics
- Specifications
- Capacities
- Engines
- Tires
- Machine Dimensions
- Pressure Settings
- Serial Number Locations
- Sensors
- Cylinder Specifications
- Major Component Weights
- Critical Stability Weights
- Lubrication Specifications
- Maintenance Specifications
Fuel Tank
Drive Hub
Hydraulic Oil
Oil Change w/Filter - Deutz - D 2011 L03
Engine Oil Change w/Filter - Deutz D2.9 L4 - T4F
Oil Change w/Filter - GM - Dual Fuel
Engine Fuel Filter - Deutz
Engine Fuel Filter - Deutz D 2.9 L4 - T4F
Engine Fuel Filter (Gasoline) - GM
Air Filter
Electronic Pressure Regulator (LP only)
Fuel Filter (Propane) - GM
Draining Oil Build Up From The Propane Regulator
Propane Fuel Filter Replacement
Propane Fuel System Pressure Relief2 topics
- Torque Charts
- Machine Preparation, Inspection, and Maintenance
General
Preparation, Inspection, and Maintenance
Pre-Start Inspection
Pre-Delivery Inspection and Frequent Inspection
Annual Machine Inspection
Preventative Maintenance1 topic
- Service and Guidelines
Safety and Workmanship
Cleanliness
Show all 360 sections
Components Removal and Installation
Component Disassembly and Reassembly
Pressure-Fit Parts
Bearings
Gaskets
Bolt Usage and Torque Application
Hydraulic Lines and Electrical Wiring
Hydraulic System
Lubrication
Battery
Lubrication and Servicing1 topic
- TABLE OF CONTENTS Lubrication and Information
Changing Hydraulic Oil
Lubrication Specifications1 topic
- Cylinder Drift Test
Platform Drift
Cylinder Drift3 topics
- Pins and Composite Bearing Repair Guidelines
- Preventive Maintenance and Inspection Schedule
- Operating Characteristics
Leveling Jacks
Power Deck
Generator
Lift
Drive1 topic
- Tires, Wheels & Drive Assembly
Tire Inflation
Tire Damage
Tire Replacement
Wheel Replacement
Wheel Installation
Drive Assembly1 topic
- Drive Hub (Fairfield)
Roll and Leak Testing
Tightening and Torquing Bolts
Oil Information
Main Disassembly for Drive Hub
Hub-Spindle Disassembly
Cover Disassembly
Carrier Disassembly
Assembly of the Carrier
Cover Sub-Assembly
Hub-Spindle Sub-Assembly
Main Assembly
Tool List
Re-Aligning Torque Hub Input Coupling1 topic
- Drive Motor (Sauer)
Description
Shaft Seal Replacement
Loop Flushing Valve
Troubleshooting
Disassembly
Inspection
Assembly
Initial Start-up Procedures1 topic
- Front Axle
Steering Assembly
Axle Assembly
Front Axle - Tow Bar Installation (If Equipped)
Axle Lockout Cylinder1 topic
- Leveling Jacks (If Equipped)
Cylinder Removal
Assembly Removal1 topic
- Platform
Deck Extension Cylinders (If Equipped)1 topic
- TABLE OF CONTENTS Platform Control Station
Joystick Controller1 topic
- Scissor Arms
Lift Cylinder Removal
Scissor Arms Removal
Scissor Arm Assembly Removal2 topics
- Side Compartment Covers
- Ground Control Station
Control Station Removal
Ground Control Station4 topics
- Fuel Tank
- Hydraulic Tank
- Battery
- Dual Fuel/LPG System
Changing From Gasoline to LP Gas
Changing From LP Gas to Gasoline
Using Liquid Petroleum (LP) Gas1 topic
- Deutz Engine
Engine Tray
Deutz EMR 4
Generator (if equipped)
Exhaust System
Air Cleaner System
Relays
Pumps
Pump Coupling
Engine Removal
Radiator1 topic
- GM Engine
Maintenance of the Drive Belt
Engine Electrical System Maintenance
Checking/Filling Engine Oil Level
Changing The Engine Oil
Fuel Components1 topic
- GM Engine Dual Fuel System
Fuel Filter
Electric Lock Off
Electronic Pressure Regulator Assembly
Low Pressure Regulator (LPR)
Air Fuel Mixer
Electronic Throttle Control (ETC)
Engine Control Module (ECM)
Heated Exhaust Gas Oxygen Sensor (HEGO)
Gasoline Multi Point Fuel Injection System (MPFI)
Gasoline Fuel Pump
Gasoline Pressure And Temperature Sensor Manifold
Fuel Injector Rail
Fuel Injector2 topics
- GM Engine Fuel System Repair
- TABLE OF CONTENTS Propane Fuel System Pressure Relief
Propane Fuel System Leak Test
Electronic Pressure Regulator (EPR) Assembly Replacement
Temperature Manifold Absolute Pressure (TMAP) Sensor
Electronic Throttle Control Replacement
Mixer Replacement
Coolant Hose Replacement
Vapor Hose Replacement
Engine Control Module Replacement
Heated Exhaust Gas Oxygen Sensor Replacement1 topic
- GM Engine LPG Fuel System Diagnosis
Fuel System Description
Diagnostic Aids2 topics
- Cylinders - Theory of Operation
- Valves - Theory of Operation
Solenoid Control Valves (Bang-Bang)
Relief Valves
Crossover Relief Valves1 topic
- Cylinder Checking Procedure
Cylinders Without Counterbalance Valves
Cylinders With Single Counterbalance Valve1 topic
- Oscillating AXLE - Lockout Cylinder Test (if equipped)
Left Side Wheel Test
Right Side Wheel Test1 topic
- Cylinder Repair
Cleaning and Inspection3 topics
- Drive Pump Start-up Procedure
- Hydraulic Component Start-Up Procedures & Recommendations
- Hydraulic Gear Pump
Pump Disassembly
Parts Inspection
Pump Reassembly1 topic
- Valves
Main Valve
Flow Divider Valve
Leveling Jacks Directional Valve
Powerdeck Valves
Leveling Jack Valves
Pressure Setting Procedures1 topic
- Gear Pump
Gear Pump Priming1 topic
- Axial HI 45 Pump
General Repair Instructions
Start-Up Procedure
Removing the pump
Electric Control Module
Control Solenoids
Shaft Seal, Roller Bearing & Shaft Replacement
Charge Pump
Charge Check/HPRV
Charge Pressure Relief Valve
Pressure Limiter Valve Replacement3 topics
- Charge Pump Filter
- TABLE OF CONTENTS Auxiliary Pump Motor
- Cylinder Assemblies
Oscillating Axle Cylinder Bleeding Procedure1 topic
- Hand Held Analyzer
To Connect the Hand Held Analyzer
Using the Analyzer
Changing the Access Level of the Hand Held Analyzer
Adjusting Parameters Using the Hand Held Analyzer
Machine Setup1 topic
- Calibrations
Elevation Sensor Calibration
Joystick Calibration
Tilt Sensor Calibration
Tilt Sensor3 topics
- Flash Codes and Descriptions
- General
- Multimeter Basics
Grounding
Backprobing
Min/Max
Polarity
Scale
Continuity Measurement Over Long Distances
Requirements
Procedure1 topic
- Applying Silicone Dielectric Compound To Amp Connectors
Wedge Lock
Service - Voltage Reading1 topic
- Working With Deutsch Connectors
DT/DTP Series Assembly
DT/DTP Series Disassembly
HD30/HDP20 Series Assembly
HD30/HDP20 Series Disassembly1 topic
- Switches
Basic check
Limit Switches
Automatic Switches
Switch Wiring - Low Side, High Side1 topic
- Schematics
Serial Number Location
Maintenance and Lubrication Diagram
Engine Operating Temperature Specifications - Deutz
Engine Operating Temperature Specifications - GM
Filter Lock Assembly
Torque Chart - Sheet 1 of 5 - (SAE Fasteners)
Torque Chart - Sheet 2 of 5 - (SAE Fasteners)
Torque Chart - Sheet 3 of 5 - (SAE Fasteners)
Torque Chart - Sheet 4 of 5 - (METRIC Fasteners)
Torque Chart - Sheet 5 of 5 - (METRIC Fasteners)
Drive Assembly (Bosch Rexroth )
Drive Assembly - (Fairfield/Sauer)
Drive Hub (Cross-Section)
Cluster Gear Punch Marks
Drive Motor Cross Section
Removing the Shaft Seal
Loop Flushing Spool
Plugs, Fittings, and Speed Sensor
End Cap
Valve Plate & Rear Shaft Bearing
Cylinder Kit
Shaft Seal
Shaft & Front Bearing
Swash Plate & Servo Piston
Cylinder Kit Disassembly
Servo Piston
Cylinder Kit Assembly
Swash Plate and Journal Bearing
Shaft and Front Bearing
Cylinder Kit Installation
Servo Spring and Minimum Angle Stop
Valve Plate and Rear Bearing
Plugs and Fittings Installation
Tow Bar Installation (If Equipped)
Leveling Jack Cylinder Removal
Leveling Jacks Assembly
Platform Removal
Deck Extension Cylinders Removal
Platform Control Station
Scissor Assembly Removal - Chassis Connection
Ground Control Station Removal
Fuel Tank Removal
Hydraulic Tank Removal
Battery Removal
Engine Tray Swing
Generator (Deutz Engine)
Exhaust System (Deutz Engine)
Air Cleaner System (Deutz Engine)
Relays (Deutz Engine)
Pump Assemblies (Deutz Engine)
Pump Coupling (Deutz Engine)
Engine Removal (Deutz Engine)
Radiator (Deutz Engine)
Engine Oil Dip Stick
Generator (GM Engine)
GM Exhaust System (GM Engine)
Air Cleaner System (GM Engine)
Radiator (GM Engine)
Fuel Components (GM Engine)
Pump Assemblies (GM Engine)
Pump Coupling (GM Engine)
Engine Removal (GM Engine)
Electric Fuel Lock Off
EPR Assembly
Low Pressure Regulators
ETC throttle control device
LPG Engine Control Unit (ECM)
ECM Assembly
Gasoline Fuel Pressure and Temperature Manifold Assembly
Pressure Regulator Section
(TMAP) Sensor & Electronic Throttle Control (ETC)
Mixer Assembly
Lift Cylinder Holding Valve and Fitting Removal
Cylinder Barrel Support
Lift Cylinder Cap Screw Removal
Cylinder Rod Support
Tapered Bushing Removal
Bushing Installation
Rod Seal Installation
Poly-Pak Piston Seal Installation
Wiper Seal Installation
Installation of Head Seal Kit
Piston Seal Kit Installation
Tapered Bushing Installation
Seating the Tapered Bearing
Rod Assembly Installation
Hydraulic Compartment
Main Valve Block
Main Valve Schematic
Powerdeck Valve (Single)
Powerdeck Valve (Double)
Gear Pump
Axial HI 45 Pump
Axial HI 45 Pump - Cross Section View
Charge Pump Filter
Auxiliary Pump Motor
Steer Cylinder
Lift Cylinder
Lift Cylinder Valve Cartridge Torque Values
Oscillating Axle Cylinder
Leveling Jack Cylinder
Leveling Jack Torques
Deck Extension Cylinder
Oscillating Axle Cylinder Bleeding
Hand Held Analyzer
Analyzer Connection
Limit Switch Location
Tilt Sensor Location
Tilt Sensor Removal
Analyzer Flow Chart - SW P1.X - Sheet 1 of 3
Analyzer Flow Chart - SW P1.X - Sheet 2 of 3
Analyzer Flow Chart - SW P1.X - Sheet 3 of 3
Voltage Measurement (DC)
Resistance Measurement
Continuity Measurement
Current Measurement (DC)
AMP Connector
Connector Assembly (1 of 4)
Connector Assembly (2 of 4)
Connector Assembly (3 of 4)
Connector Assembly (4 of 4)
Connector Disassembly
Connector Installation
DT/DTP Contact Installation
DT/DTP Contact Removal
HD/HDP Contact Installation
HD/HDP Locking Contacts Into Position
HD/HDP Contact Removal
HD/HDP Unlocking Contacts
Electrical Components Installation
Electrical Schematic - Diesel
Electrical Schematic - Dual Fuel
Hydraulic Schematic
Hydraulic Schematic (CE)
Operating Specifications
Capacities
Deutz - D 2.9 - L4 - Engine Specifications (Tier 4 Final Engine)
Deutz D2011 L03 T41-Flex Specifications (Tier 4 Flex Engine)
GM 3.0L Specifications
Tire Specifications
Main Control Valve Relief Settings
High Drive Cut-Out Height
Tilt Sensor Indicators
Cylinder Specifications
Major Component Weights
Critical Stability Weights
Mobil DTE 13M Specs
Mobil 424 Specs
Inspection and Maintenance
Preventive Maintenance and Safety Inspection
Wheel Torque Chart
Drive Hub Part Description
Excessive Noise and/or Vibration
System Operating Hot
Won’t Shift or Slow to Start
Displacement Identifiers
Slipper Foot Thickness & End Play
Cylinder Block Measurements
Joystick Specifications
Joystick Plug Loading Chart
Generator Specifications
LPF Fuel System Diagnosis
Symptom Diagnosis
DTC to SPN/FMI Cross Reference Chart
Cylinder Piston Nut Torque Specifications
Holding Valve Torque Specifications
Main Valve Torque Specs
Porting Specs
Leveling Jacks Directional Valve Torque Specs
Powerdeck Valve Torque Specs
Leveling Jack Valves Torque Specs
Gear Pump Specs
Axial HI 45 Pump Specs
Tilt Sensor Harness
Fault Code Listing - Software P1.X
Machine Configuration Programming Information
Machine Tilt Configuration
Machine Model Adjustment
Inside this manual
Real pages from this service manual (240 pages). Open the sample pages (PDF, 667 KB)
- Specifications, page 15: SECTION 1 - SPECIFICATIONS
- Troubleshooting, page 126: Table 3-14. Symptom Diagnosis
- Diagram, page 216: SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
- Color page: SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS
- Color page: SECTION 1 - SPECIFICATIONS
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the 3394RT, 4394RT are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.
This manual: Service Manual 3121642$69.85
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This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 240 pages
Quantity one is the manual described above.
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Other editions and similar models
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