JLG 4394RT Parts Manual

Illustrated Parts Manual

Models

3394RT

& 4394RT

SN 0200191606

to Present

P/N

3121250

February 7, 2014

REVISION LOG

NOTE: Machines SN 0200186972, 0200187002 & 0200187013 are also built to specs contained in this manual.

NOTE: Machines SN 0200186972, 0200187002, 0200187013 & All Machines 0200191606 to Present are built to B/M 0010583 Revision 56 or higher.

October 15, 2008 - Original Issue Of Manual (Manual edited to B/M 0010583 Revision 57)

January 1, 2009 - Revised Manual (Manual edited to B/M 0010583 Revision 62)

June 1, 2009 - Revised Manual (Manual edited to B/M 0010583 Revision 64)

October 1, 2010 - Revised Manual (Manual edited to B/M 0010583 Revision 69)

March 23, 2011 - Revised Manual (Manual edited to B/M 0010583 Revision 70)

June 16, 2011 - Revised Manual (Manual edited to B/M 0010583 Revision 72)

September 22, 2011 - Revised Manual (Manual edited to B/M 0010583 Revision 74)

February 14, 2012 - Revised Manual (Manual edited to B/M 0010583 Revision B)

June 27, 2012 - Revised Manual (Manual edited to B/M 0010583 Revision C)

September 7, 2012 - Revised Manual (Manual edited to B/M 0010583 Revision C)

January 21, 2013 - Revised Manual (Manual edited to B/M 0010583 Revision C)

April 30, 2013 - Revised Manual (Manual edited to B/M 0010583 Revision M)

July 22, 2013 - Revised Manual (Manual edited to B/M 0010583 Revision M)

October 14, 2013 - Revised Manual (Manual edited to B/M 0010583 Revision M)

February 7, 2014 - Revised Manual (Manual edited to B/M 0010583 Revision S & B/M 1001160090 Revision B)

3121250 3394RT & 4394RT A

REVISION LOG

B 3394RT & 4394RT 3121250

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

SECTION 1 - FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1-1 AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE

(SN 0200191606 TO SN 0200223954). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-2 AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE

(SN 0200223954 TO PRESENT)1-6

1-3 AXLE AND STEERING INSTALLATION WITH TOW PACKAGE . . . . . . . . . . . . . . . . . . 1-8

1-4 TIRE AND WHEEL DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

1-5 DRIVE MOTOR/HUB ASSEMBLY (REXROTH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

1-6 DRIVE MOTOR ASSEMBLY (SAUER-DANFOSS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

1-7 DRIVE HUB ASSEMBLIES (FAIRFIELD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

1-8 BEACON LIGHT & LEVELING JACKS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . 1-28

SECTION 2 - GROUND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2-1 CONTROL VALVES, HORN & ALARMS INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . 2-2

2-2 MAIN CONTROL VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2-3 FLOW DIVIDER VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2-4 LEVELING JACK VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2-5 ENGINE INSTALLATION (DEUTZ D2011 ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2-6 ENGINE INSTALLATION (DEUTZ D2.9l4 ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

2-7 ENGINE INSTALLATION (GM) (SN 0200191606 to SN 0200198947) . . . . . . . . . . . . . 2-30

2-8 ENGINE INSTALLATION (GM) (SN 0200198947 to PRESENT) . . . . . . . . . . . . . . . . . . 2-36

2-9 PISTON PUMP ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

2-10 AUXILIARY PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46

2-11 TANKS AND TANK TRAY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48

2-12 GROUND CONTROL BOX INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52

2-13 HOODS AND LADDERS INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56

2-14 GENERATOR INSTALLATION (DEUTZ D2011ENGINE OPTIONS) . . . . . . . . . . . . . . . 2-62

2-15 7500W GENERATOR INSTALLATION (DEUTZ D2.9L4 ENGINE OPTIONS) . . . . . . . . 2-66

2-16 GENERATOR INSTALLATION (GM ENGINE OPTIONS) . . . . . . . . . . . . . . . . . . . . . . . 2-70

SECTION 3 - SCISSORS ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3-1 SCISSORS ARMS INSTALLATION (3394RT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2 SCISSOR ARMS INSTALLATION (4394RT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3-3 ARM GUARDS INSTALLATION (CE SPEC ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

SECTION 4 - PLATFORM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4-1 PLATFORM ATTACH AND MODULE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4-2 MANUAL SINGLE DECK EXTENSION AND PLATFORM ASSEMBLY . . . . . . . . . . . . . 4-4

4-3 MANUAL DUAL DECK EXTENSION AND PLATFORM ASSEMBLY . . . . . . . . . . . . . . . 4-8

4-4 POWER DECK EXTENSION AND PLATFORM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 4-12

4-5 RAILS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

4-6 PLATFORM CONSOLE BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

4-7 DRIVE/STEER CONTROLLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

3121250 3394RT & 4394RT i

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

SECTION 5 - CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5-1 AXLE LOCKOUT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5-2 LEVELING JACK CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5-3 LIFT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5-4 PLATFORM EXTENSION CYLINDER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5-5 STEER CYLINDER ASSEMBLY (SN 0200191606 TO SN 0200223954) . . . . . . . . . . . . 5-12

5-6 STEER CYLINDER ASSEMBLY (SN 0200223954 TO PRESENT) . . . . . . . . . . . . . . . . . 5-14

SECTION 6 - HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6-1 STANDARD HYDRAULIC DIAGRAM - STANDARD (REXROTH DRIVE

COMPONENTS) (SN 0200191606 TO SN 0200207753) . . . . . . . . . . . . . . . . . . . . . 6-2

6-2 STANDARD HYDRAULIC DIAGRAM - STANDARD (SAUER-DANFOSS/

FAIRFIELD DRIVE COMPONENTS) (SN 0200207753 TO PRESENT) . . . . . . . . . . . 6-6

6-3 LEVELING JACK HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

6-4 POWER DECK EXTENSION HYDRAULIC DIAGRAM (SN 0200191606 TO

SN 0200210269) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

6-5 POWER DECK EXTENSION HYDRAULIC DIAGRAM (SN 0200210269 TO

PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

6-6 POWER DECK EXTENSION HYDRAULIC DIAGRAM (MEGADECK) (OPTIONAL). . . . 6-20

6-7 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

SECTION 7 - ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

7-1 ELECTRICAL COMPONENTS INSTALLATION (DEUTZ D2011 ENGINE &

GM ENGINE MACHINES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7-2 ELECTRICAL COMPONENTS INSTALLATION (DEUTZ D2.9L4 ENGINE

MACHINES). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

SECTION 8 - DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-1 DECAL INSTALLATION (ANSI SPEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8-2 DECAL INSTALLATION (ANSI EXPORT SPEC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

8-3 DECAL INSTALLATION (AUSTRALIAN & CE SPECs). . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

SECTION 9 - RECOMMENDED SERVICE PARTS STOCK . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

SECTION 10 - SPECIAL OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1

SECTION 11 - PART NUMBER INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1

ii 3394RT & 4394RT 3121250

SECTION 1

FRAME

3121250 3394RT & 4394RT 1-1

SECTION 1 FRAME

131310

101 103

101 112

110

126

102 121 122 123

105 124

120 124

116

106

119 113

108

118

108

116

111

109

12A

117

104

101

107

118

125

FIGURE 1-1. AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE (SN

0200191606 TO SN 0200223954)

1-2 3394RT & 4394RT 3121250

SECTION 1 FRAME

FIGURE 1-1. AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE (SN

0200191606 TO SN 0200223954)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1001102170 Ref OSCILLATING AXLE INSTALLATION D

1 0100011 AR Locking, Compound 2 0100019 AR Locking, Compound 3 0100038 AR Primer, Locking 4 0641822 8 Bolt 1/2in-13NC x 2-3/4in 5 0642012 1 Bolt 5/8in-11NC x 1-1/2in 6 0961950 2 Bearing 7 1684465 2 Oscillating Axle Cylinder Assembly (See CYLINDER SECTION for

Breakdown) 8 3422592 1 Pin, Axle Pivot 9 3841258 1 Keeper, Pin

10 4740158 1 Washer, Thrust 11 4891800 8 Flatwasher 1/2 Hardened 12 1001093380 1 Axle Weldment E

12A 1001100424 2 Block, Cylinder

13 4740541 2 Washer, Thrust

Ref STEERING INSTALLATIONS

1001106832 Ref Machines with Rexroth Motor & Hubs (SN 0200191606 to

SN 0200207753)

1001102242 Ref Machines with Sauer-Danfoss Motors & Fairfield Hubs

(SN 0200207753 to Present)

101 0100011 AR Locking, Compound 102 4740538 AR Thrustwasher 103 0641606 16 Bolt 3/8in-16NC x 3/4in 104 0681828 4 Bolt 1/2in-13NC x 3-1/2in (Grade 8) 105 0440291 2 Bearing 106 0962140 2 Bearing 107 1684412 1 Steer Cylinder Assembly (See CYLINDER SECTION for

Breakdown): 108 3312008 4 Nut 5/8in-11NC 109 3322201 2 Nut 3/4in-16NC 110 3423081 4 Kingpin 111 3841517 2 Rod-End with Teflon Bearing 112 3900109 4 Screw, Shoulder 113 0440271 2 Thrustwasher

114 to 115 Not Used

116 4740086 4 Washer, Thrust 117 4751800 4 Flatwasher 1/2in Wide 118 4846070 2 Tie-Rod 119 3780182 2 O-Ring 120 0440274 2 Bearing 121 4740539 AR Thrustwasher 122 4740540 AR Thrustwasher 123 4740537 AR Thrustwasher 124 3020029 AR Grease, Bearing

3121250 3394RT & 4394RT 1-3

SECTION 1 FRAME

FIGURE 1-1. AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE (SN

0200191606 TO SN 0200223954) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

125 1 Spindle Options (Left Side from Operators Position):

4130403 SN 0200191606 to SN 0200207753 4130405 SN 0200207753 to Present

126 1 Spindle Options (Right Side from Operators Position):

4130404 SN 0200191606 to SN 0200207753 4130406 SN 0200207753 to Present

Ref FRAME WELDMENTS

1001106831 Ref Frame for Machines with Rexroth Motor & Hubs (SN 0200191606

to SN 0200207753)

1001094159 Ref Frame for with Sauer-Danfoss Motors & Fairfield Hubs

(SN 0200207753 to Present)

1-4 3394RT & 4394RT 3121250

SECTION 1 FRAME

FIGURE 1-1. AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE (SN

0200191606 TO SN 0200223954) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121250 3394RT & 4394RT 1-5

SECTION 1 FRAME

116

118

116

120

101

106

113

117

103

102

115

109

115

101 105

110

118

112

108

118A

114

6810

101 105

101 111

112

FIGURE 1-2. AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE (SN

0200223954 TO PRESENT)

1-6 3394RT & 4394RT 3121250

SECTION 1 FRAME

FIGURE 1-2. AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE (SN

0200223954 TO PRESENT)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1001139626 Ref OSCILLATING AXLE INSTALLATION A

1 0100011 AR Locking, Compound 2 0641822 8 Bolt 1/2in-13NC x 2-3/4in 3 0100038 AR Primer, Locking 4 1001098130 1 Axle 5 0642012 1 Bolt 5/8in-11NC x 1-1/2in 6 0961950 2 Bearing 7 1684465 2 Oscillating Axle Cylinder Assembly (See CYLINDER SECTION for

Breakdown) 8 3422592 1 Pin, Axle Pivot 9 3841258 1 Keeper, Pin

10 4740158 1 Washer, Thrust 11 4891800 8 Flatwasher 1/2 Hardened

1001139935 Ref STEERING INSTALLATION D

101 0100011 AR Locking, Compound 102 0440271 2 Thrustwasher 103 0440291 2 Bearing 104 Not Used 105 0641607 18 Bolt 3/8in-16NC x 7/8in 106 0681820 4 Bolt 1/2in-13NC x 2-1/2in (Grade 8) 107 3020029 AR Grease, Bearing 108 3312008 2 Nut 5/8in-11NC 109 3780182 2 O-Ring 110 3841520 2 Keeper 111 3900255 2 Screw, Shoulder 112 4740086 4 Washer, Thrust 113 4891800 4 Flatwasher 1/2in Hardened 114 1001116867 1 Pin, Axle Pivot 115 1001139141 4 Kingpin 116 1001139645 2 Spindle 117 1001139476 2 Bearing 118 1001139892 2 Tie-Rod

118A 1001139943 2 Bearing

119 Not Used 120 1001143434 1 Steer Cylinder Assembly (See CYLINDER SECTION for

Breakdown):

1001094159 Ref FRAME WELDMENTS

3121250 3394RT & 4394RT 1-7

SECTION 1 FRAME

205

208

209

206

202 201

203 201

207

124

101 105

119

115

128

129 130

127

104 112

101 106

116

133

126

108

116

101 106

112 103

118

102

123 136

134

121 101

113

120

114

109

135

109

111

12A

131

101

107

132

101

122

109

139

137

138

110

117

204

FIGURE 1-3. AXLE AND STEERING INSTALLATION WITH TOW PACKAGE

1-8 3394RT & 4394RT 3121250

SECTION 1 FRAME

CE SPEC ONLY

204

312

212

311

304

302

311

308

309

310

301

308

309

310

306

313

303 307

305

303 307

306

210

217

215

207

213

207

214

207

214

207

216

215

207

213

207

214

207

3121250 3394RT & 4394RT 1-9

SECTION 1 FRAME

FIGURE 1-3. AXLE AND STEERING INSTALLATION WITH TOW PACKAGE

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1001109295 Ref OSCILLATING AXLE INSTALLATION A

for Breakdown) 8 3422592 1 Pin, Axle Pivot 9 3841258 1 Keeper, Pin

10 4740158 1 Washer, Thrust 11 4891800 8 Flatwasher 1/2in Hardened 12 1001109227 1 Axle Weldment E

12A 1001100424 2 Block, Cylinder

13 4740541 2 Washer, Thrust

Ref STEERING INSTALLATIONS 1001109296 Ref ANSI Spec D 1001127658 Ref CE Spec C

101 0100019 AR Locking, Compound 102 0440271 2 Thrustwasher 103 0440274 2 Bearing 104 0440291 2 Bearing 105 0641508 1 Bolt 5/16in-18NC x 1in 106 0641606 16 Bolt 3/8in-16NC x 3/4in 107 0681828 4 Bolt 1/2in-13NC x 3-1/2in (Grade 8) 108 0962140 1 Bearing 109 0962292 5 Bearing 110 0962348 1 Bearing 111 1684412 1 Steer Cylinder Assembly (See CYLINDER SECTION for

Breakdown): 112 3020029 AR Grease, Bearing 113 3312008 3 Nut 5/8in-11NC 114 3322201 2 Nut 3/4in-16NC 115 3482848 1 Pin, Hitch 116 3423081 4 Kingpin 117 1 Plate, Hitch Pivot Options:

3574235 ANSI Spec

1001127659 CE Spec 118 3780182 2 O-Ring 119 3841143 1 Keeper, Pin 120 3841517 2 Rod-End with Teflon Bearing 121 3900109 3 Screw, Shoulder 122 3900295 1 Screw, Shoulder 123 3900296 1 Screw, Shoulder 124 4130405 1 Spindle (Left Side from Operators Position) 125 4740086 3 Thrustwasher

1-10 3394RT & 4394RT 3121250

SECTION 1 FRAME

FIGURE 1-3. AXLE AND STEERING INSTALLATION WITH TOW PACKAGE (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

126 4740155 2 Thrustwasher 127 4740537 AR Thrustwasher 128 4740538 AR Thrustwasher 129 4740539 AR Thrustwasher 130 4740540 AR Thrustwasher 131 4751800 4 Flatwasher 1/2in Wide 132 4846070 1 Tie-Rod (Left Side from Operators Position) 133 1001109228 1 Spindle (Right Side from Operators Position) 134 1001109229 1 Tie-Rod (Right Side from Operators Position) 135 1001109290 1 Link, Steer 136 0100011 AR Locking, Compound 137 3312201 1 Nut 3/4in-10NC 138 4712200 1 Flatwasher 3/4in Narrow 139 4740067 3 Thrustwasher

Ref TOW BAR INSTALLATION 1001110451 Ref ANSI Spec A 1001127665 Ref CE Spec A

201 0100011 AR Locking, Compound 202 0641506 2 Bolt 5/16in-18NC x 3/4in 203 0641606 2 Bolt 3/8in-16NC x 3/4in 204 3 Decal - Crushing Options:

1704578 ANSI Spec

1706960 CE Spec 205 4640261 1 Tow Valve Assembly 206 4711500 2 Flatwasher 5/16in Narrow 207 4711600 AR Flatwasher 3/8in Narrow 208 1 Decal - Towing Instruction Options:

1001110261 ANSI Spec

1001128033 CE Spec 209 1001110263 1 Bracket, Mounting 210 1001110267 1 Tow Bar Assembly (See Items 301-313 for Breakdown) 211 Not Used 212 4420051 56in/1.4m Tape, Safety 213 0641610 8 Bolt 3/8in-16NC x 1-1/4in (CE Spec Only) 214 3311605 8 Locknut 3/8in-16NC (CE Spec Only) 215 1001127701 2 Bracket, Bottom Clamp (CE Spec Only) 216 1001127702 2 Bracket, Retainer 217 1001127723 2 Bracket, Retainer

1001110267 Ref TOW BAR ASSEMBLY A

301 0360406 1 Bar, Draw 302 0682040 5 Bolt 5/8in-11NC x 5in Grade 8 303 1060584 2 Lanyard 304 3312005 5 Locknut 5/8in-11NC 305 3420352 1 Pin, Tow Hitch 306 3420372 2 Pin, Cotter

3121250 3394RT & 4394RT 1-11

SECTION 1 FRAME

FIGURE 1-3. AXLE AND STEERING INSTALLATION WITH TOW PACKAGE (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

307 3760170 5 Ring, Split 308 4070450 2 Shim #14 Gauge (.075) 309 4070560 2 Shim (.88) 310 4070561 2 Shim #11 Gauge 311 4752000 10 Flatwasher 5/8in Wide 312 1001110285 1 Arm, Towing 313 1001110384 1 Pin

1001094159 Ref FRAME WELDMENTS

1-12 3394RT & 4394RT 3121250

SECTION 1 FRAME

FIGURE 1-3. AXLE AND STEERING INSTALLATION WITH TOW PACKAGE (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121250 3394RT & 4394RT 1-13

SECTION 1 FRAME

1 2

204

203

201

205

105 106 107

105

113

110

SAUER-DANFOSS

& FAIRFIELD

REXROTH

109

101 103

111

104

102

112

202

FIGURE 1-4.TIRE AND WHEEL DRIVE INSTALLATIONS

1-14 3394RT & 4394RT 3121250

SECTION 1 FRAME

FIGURE 1-4. TIRE AND WHEEL DRIVE INSTALLATIONS

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref NOTE: DRIVE SYSTEM COMPONENTS FROM DIFFERENT

MANUFACTURERS CANNOT BE INTERCHANGED.

1001106833 Ref WHEEL DRIVE INSTALLATION (REXROTH) (SN 0200191606 TO

SN 0200207753)

1 0100019 AR Locking, Compound 2 0682012 24 Bolt 5/8in-11NC x 1-1/2in 3 2300016 AR Fluid, Hydraulic 4 2780262 4 Drive Motor/Hub Assembly (Rexroth) (See DRIVE MOTOR/HUB

ASSEMBLY (REXROTH) for Breakdown) 5 3300106 36 Lugnut 6 4892000 24 Washer, Hardened

1001102804 Ref WHEEL DRIVE INSTALLATION (SAUER-DANFOSS/FAIRFIELD)

(SN 0200207753 TO PRESENT)

101 0100011 AR Locking, Compound 102 0100019 AR Locking, Compound 103 0681810 4 Bolt 1/2in-13NC x 1-1/4in 104 0682014 24 Bolt 5/8in-11NC x 1-3/4in 105 2300016 AR Fluid, Hydraulic 106 2780267 2 Drive Hub with Brake Assembly (Rear) (Fairfield) (See DRIVE

HUB ASSEMBLIES (FAIRFIELD) for Breakdown)

107 2780268 2 Drive Hub without Brake Assembly (Front) (Fairfield) (See DRIVE

HUB ASSEMBLIES (FAIRFIELD) for Breakdown)

108 3300106 18 Lugnut 109 3311801 4 Nut 1/2in-13NC 110 3960526 4 Gasket 111 4891800 8 Flatwasher 1/2in Hardened 112 4892000 24 Flatwasher 5/8in Hardened 113 1001102805 4 Drive Motor Assembly (Sauer-Danfoss) (See DRIVE MOTOR

ASSEMBLY (SAUER-DANFOSS) for Breakdown)

114 3020008

.742gl/2.81l

Lubricant, Mobilube HD 80W-90 (23.75 oz Per Hub)

Ref TIRE AND WHEEL INSTALLATIONS

Ref 3394RT Options: 0270650 Ref 12 x 16.5 Pneumatic Non-Marking Tires B 0270653 Ref 12 x 16.5 Foam-Filled Non-Marking Tires B 0274789 Ref 31 x 15.5-15 Grass Master Tire A 0271785 Ref 33/16LL x 16.1 Foam-Filled Sand Tire A 0271718 Ref 33/16LL x 16.5 Pneumatic Lug Tire A 0271719 Ref 33/16LL x 16.5 Foam-Filled Lug Tire A

1001102190 Ref IN315/55D20 Pneumatic Lug Tire B 1001102196 Ref IN315/55D20 Foam-Filled Lug Tire B

Ref 4394RT Options: 0270653 Ref 12 x 16.5 Foam-Filled Non-Marking Tires B 0274371 Ref 12 x 16.5 Pneumatic Non-Marking Tires (Counterweight

Required)

0271785 Ref 33/16LL x 16.1 Foam-Filled Sand Tire A

3121250 3394RT & 4394RT 1-15

SECTION 1 FRAME

FIGURE 1-4. TIRE AND WHEEL DRIVE INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0271788 Ref 33/16LL x 16.5 Pneumatic Lug Tire A

0271719 Ref 33/16LL x 16.5 Foam-Filled Lug Tire A 1001103818 Ref IN315/55D20 Pneumatic Lug Tire (Counterweight Required) C 1001102196 Ref IN315/55D20 Foam-Filled Lug Tire A

2 12 x 16.5 Foam-Filled Right Side Non-Marking Tire

Use 1001148869 SN 0200191606 to SN 0200221363 (was p/n 0270654) B

1001148869 SN 0200221363 to Present C

2 12 x 16.5 Foam-Filled Left Side Non-Marking Tire

Use 1001148870 SN 0200191606 to SN 0200221363 (was p/n 0270655) B

1001148870 SN 0200221363 to Present C

2 12 x 16.5 Pneumatic Right Side Non-Marking Tire

Use 1001148867 SN 0200191606 to SN 0200221363 (was p/n 0270651) B

1001148867 SN 0200221363 to Present B

2 12 x 16.5 Pneumatic Left Side Non-Marking Tire

Use 1001148868 SN 0200191606 to SN 0200221363 (was p/n 0270652) B

1001148868 SN 0200221363 to Present B

4520571 4 31 x 15.5-15 Grass Master Tire B

0272268 4 33/16LL x 16.1 Foam-Filled Right Side Sand Tire C

0257755 2 33/16LL x 16.5 Pneumatic Right Side Lug Tire C

0257756 2 33/16LL x 16.5 Pneumatic Left Side Lug Tire C

0258011 2 33/16LL x 16.5 Foam-Filled Right Side Lug Tire E

0258012 2 33/16LL x 16.5 Foam-Filled Left Side Lug Tire E 1001101513 2 IN315/55D20 Pneumatic Right Side Lug Tire A 1001101512 2 IN315/55D20 Pneumatic Left Side Lug Tire A 1001102195 2 IN315/55D20 Pneumatic Right Side Lug Tire A 1001102194 2 IN315/55D20 Pneumatic Left Side Lug Tire A

Ref Note: Assemblies may require ballast/foam filling to

manufacturer’s specifications prior to installing on a machine. Refer to Operation & Safety or Service & Maintenance Manuals. Purchase individual tire and/or rim only if able to foam fill tire & wheel assembly, otherwise, purchase complete assembly,

201 1 Decal Options:

1702740 Decal - 90PSI (Pneumatic Only):

1702137 Decal - 60PSI (Pneumatic Only) (Grass Master):

202 1 Tire Options:

4520240 12 x 16.5 OTR NHS Non-Marking Tire

4520576 31 x 15.5-15 Grass Tire

4520262 33/16LL x 16.1 Sand Tire

4520217 33/16LL x 16.5 Lug Tire

4520608 IN315/55D20 Lug Tire

203 1 Valve, Air Options:

4640113 With Pneumatic Tire/Wheel Assemblies

8786514 With 0258011 & 0258012 Foam-Filled Tire/Wheel

Assemblies

4640113 All Foam-Filled Tire/Wheel Assemblies except 0258011

& 0258012

1-16 3394RT & 4394RT 3121250

SECTION 1 FRAME

FIGURE 1-4. TIRE AND WHEEL DRIVE INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

203 Cont’d 4641122 1 Valve, Air-Liquid (Foam-Filled Tire/Wheel Assemblies

1001148869 & 1001148870) (SN 0200221363 to Present)

1001149953 1 Cap (Foam-Filled Tire/Wheel Assemblies 1001148869 &

1001148870) (SN 0200221363 to Present)

204 1 Rim, Wheel

4520570 15 x 13 (Use with 31 x 15.5-15 Grass Tire)

16.5 x 9.75 (Use with 12 x 16.5 Lug Tires)

Use 1001147274 SN 0200191606 to SN 0200221363 (was p/n

4860213)

1001147274 SN 0200221363 to Present

4860179 16.5 x 12 (Use with 33/16LL x 16.5 Lug Tires) 4860237 19.5 x 14 (Use with 33/16LL x 16.1 Sand Tires)

1001101511 20 x 11 (Use with IN315/55D20 Lug Tire)

205 1001105700 4 Decal - Transport Wheel Warning (IN315/55D20 Tires

Only)

3121250 3394RT & 4394RT 1-17

SECTION 1 FRAME

120 60 55 44 88 224 1 11 15 17 2 34

337330294619231220

301

302

303

304

305

27 28

FIGURE 1-5. DRIVE MOTOR/HUB ASSEMBLY (REXROTH)

1-18 3394RT & 4394RT 3121250

SECTION 1 FRAME

FIGURE 1-5. DRIVE MOTOR/HUB ASSEMBLY (REXROTH)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

2780262 Ref DRIVE MOTOR/HUB ASSEMBLY (REXROTH) D

Ref Note: Unless there is capability to torque shaft (item 4) to 626

ft/lbs. (850Nm) Repair beyond this level is NOT advised.

1 Use 7022544 4 Gear, Planet 2 Use 7022545 3 Gear, Planet 3 7021325 1 Gear, Sun 4 Use 7024047 1 Nut, Shaft

Ref Note: Unless there is capability to torque shaft nut (item 4) to

626 ft/lbs. (850Nm) Repair beyond this level is NOT advised.

5 7021326 3 Pin, Planet 6 7021327 1 Ring, Support 7 7021328 1 Carrier, Planet 8 Use 7021329 1 Cover

9Not Used 10 Use 7022545 3 Bearing, Roller 11 Use 7022544 4 Bearing, Roller 12 Use 7024047 2 Bearing, Tapered Roller 13 Not Used 14 Use 7022545 3 Ring, Retaining 15 Use 7022544 4 Ring, Retaining 16 7021341 1 Ring, Retaining 17 Use 7022545 3 Disk, Support 18 Not Used 19 Use 7024047 1 O-Ring 20 Use 7024047 1 Seal, Shaft 21 Use 7021329 3 Plug, screw 22 7024048 3 Ring, Seal 23 Use 7024047 3 Bolt

24 to 26 Not Used

27 70002303 1 O-Ring 28 70002304 1 Seal 29 7024049 1 Washer, Thrust 30 7021346 1 Gear, Ring

31 to 32 Not Used

33 See Note 1 O-Ring (Note: Use Item 303 or 304) 34 Use 7021329 1 Ring, Retaining

35 to 42 Not Used

43 7021347 1 Shaft, Sun Gear 44 7024050 1 Shaft, Input

45 to 48 Not Used

49 7024051 1 Washer, Thrust 50 Not Used 51 See Note 1 Cover (Note: Use Item 304 or 305) 52 Use 7021329 1 Sleeve 53 See Note 2 Bolt (Note: Use Item 304 or 305) 54 See Note 1 O-Ring (Note: Use Item 304 or 305) 55 7024053 1 Spring 56 Use 7024054 1 Rod, Shift

3121250 3394RT & 4394RT 1-19

SECTION 1 FRAME

FIGURE 1-5. DRIVE MOTOR/HUB ASSEMBLY (REXROTH) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

57 to 59 Not Used

60 Use 2780262 1 Housing, Brake

61 to 87 Not Used

88 7021344 9 Stud, Wheel

89 to 99 Not Used

100 7022552 9 Cap, Seal

101 to 119 Not Used

120 7024055 1 Motor, Hydraulic

121 to 223 Not Used

224 Use 7024047 2 Dowel, Spring Sleeve

Ref REPAIR KIT OPTIONS

301 7022544 1 Planet Gear Kit (Includes Items 1,11,15) 302 7022545 1 Planet Gear Kit (Includes Items 2,10, 14,17) 303 7024047 1 Bearing Kit (Includes Items 4,12,19,20,23,33, 224)

Ref Note: Unless there is capability to torque shaft nut (item 4) to

626 ft/lbs. (850Nm) Repair beyond this level is NOT advised.

304 7021329 1 Cover Kit (Includes Items 8,21,22,33,34,51,52,53,54) 305 7024054 1 Mechanical Disconnect Kit (Includes 51,53,54, 56)

1-20 3394RT & 4394RT 3121250

SECTION 1 FRAME

FIGURE 1-5. DRIVE MOTOR/HUB ASSEMBLY (REXROTH) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121250 3394RT & 4394RT 1-21

SECTION 1 FRAME

41340

303433

3231323118

100

FIGURE 1-6. DRIVE MOTOR ASSEMBLY (SAUER-DANFOSS)

1-22 3394RT & 4394RT 3121250

SECTION 1 FRAME

FIGURE 1-6. DRIVE MOTOR ASSEMBLY (SAUER-DANFOSS)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1001102805 Ref DRIVE MOTOR ASSEMBLY (SAUER-DANFOSS) B

1 7022302 2 Bearing, Journal

2 7007446 1 Pin

3 7007438 2 Ring, Retaining

4 7022305 1 Swashplate

5 See Note 2 Pin (Note: Not available for purchase)

6 Use 7022328 1 Gasket

7 7024862 1 Plate, Valve

8 7023907 1 Cylinder Block Kit (Includes Items 8A & 9-17) 8A Use 7023907 1 Block, Cylinder

9 7021277 1 Guide, Slipper Retainer 10 7021275 3 Pin, Slipper Hold Down 11 Use 7023907 9 Piston Assembly 12 7021276 1 Retainer, Hold Down Pin 13 7022310 1 Retainer, Slipper 14 7022311 1 Ring, Retaining 15 7022312 1 Spring 16 7024868 1 Washer 17 7022314 1 Retainer, Spring 18 7023910 1 Shaft 19 7007439 1 Ring, Retaining 20 70000797 1 Cap, End - Axial 21 7022368 5 Screw 22 7021249 1 Bearing, Needle 23 2220886 1 Plug (Includes Item 24) 24 Use 7022328 1 O-Ring 25 2220883 1 Plug (Includes Item 26) 26 Use 7022328 1 O-Ring 27 7027419 2 Plug (Includes Item 28) 28 Use 7022328 2 O-Ring 29 7022369 1 Seat, Spring 30 70001932 1 Housing 31 2220883 2 Plug (Items Item 32) 32 Use 7022328 2 O-Ring 33 2220886 1 Plug (Items Item 34) 34 Use 7022328 1 O-Ring 35 Use 7022328 1 O-Ring 36 Use 7022328 1 Ring, Seal 37 7024854 1 Piston, Servo (Includes Items 35 & 36) 38 7007437 1 Bearing 39 7022326 1 Spring 40 Use 7022328 1 Seal, Lip 41 7022371 1 Washer, Support

— — — — — — — — — — — —

100 7022328 1 Seal Kit (Includes Items 6,24,26,28,32,34,35,36 and 40)

3121250 3394RT & 4394RT 1-23

SECTION 1 FRAME

105

111

110

112

121

102

119

122

123

104

103

101

109

107

108

114

113

116

115

118

117

120

141A1B1C1D1N1G1E1F

200A

200B

201A

201B

201C

201D

106

FIGURE 1-7. DRIVE HUB ASSEMBLIES (FAIRFIELD)

1-24 3394RT & 4394RT 3121250

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