JLG Scissor Lift RT5394 Parts Manual 3122566400

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JLG Scissor Lift RT5394 Parts Manual 3122566400
Size: 26.27 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Scissor Lift
Type of Manual: Parts Manual
Model: JLG RT5394 Scissor Lift
Part Number: 3122566400
Publication Date: 2025
Number of Pages: 376 Pages

Contents:
SECTION 1 - FRAME

FIGURE 1-1. AXLE INSTALLATION - OSCILLATING​

FIGURE 1-2. STEER INSTALLATION​

FIGURE 1-3. WHEEL DRIVE INSTALLATION​

FIGURE 1-4. DRIVE HUB ASSEMBLY - FRONT​

FIGURE 1-5. DRIVE HUB AND BRAKE ASSEMBLY - REAR​

FIGURE 1-6. DRIVE MOTOR ASSEMBLY​

FIGURE 1-7. TIRE AND WHEEL INSTALLATION - 12 X 16.5 FOAM FILLED​

FIGURE 1-8. TIRE AND WHEEL INSTALLATION - 12 X 16.5 FOAM FILLED NON-MARKING​

FIGURE 1-9. TIRE AND WHEEL INSTALLATION - IN395/45/D20 FOAM FILLED​

FIGURE 1-10. TIRE AND WHEEL INSTALLATION - IN395/45/D20 FOAM FILLED NON-MARKING​

FIGURE 1-11. BEACON/STROBE LIGHT INSTALLATION - OPTIONAL (WITHOUT CLEARSKY BEACON CS550)​

FIGURE 1-12. LEVELING JACKS INSTALLATION​

FIGURE 1-13. LEVELING JACKS ASSEMBLY​

FIGURE 1-14. LEVELING JACKS VALVE ASSEMBLY​

SECTION 2 - GROUND CONTROLS

FIGURE 2-1. VALVE INSTALLATION​

FIGURE 2-2. MAIN VALVE ASSEMBLY​

FIGURE 2-3. FLOW DIVIDER VALVE ASSEMBLY​

FIGURE 2-4. TANKS & HORN INSTALLATION - DIESEL​

FIGURE 2-5. TANKS AND HORN INSTALLATION - GASOLINE​

FIGURE 2-6. HYDRAULIC TANK ASSEMBLY​

FIGURE 2-7. ELECTRICAL COMPONENTS INSTALLATION - DIESEL​

FIGURE 2-8. ELECTRICAL COMPONENTS INSTALLATION - KUBOTA GASOLINE​

FIGURE 2-9. GROUND CONTROL BOX ASSEMBLY - KUBOTA DIESEL​

FIGURE 2-10. GROUND CONTROL BOX ASSEMBLY - KUBOTA GASOLINE​

FIGURE 2-11. MOTION ALARM INSTALLATION​

FIGURE 2-12. HOODS AND LADDERS INSTALLATION​

SECTION 3 - ENGINE

FIGURE 3-1. ENGINE INSTALLATION - KUBOTA DIESEL​

FIGURE 3-2. ENGINE AND PUMP SUB-ASSEMBLY - KUBOTA DIESEL​

FIGURE 3-3. ENGINE ASSEMBLY - KUBOTA DIESEL​

FIGURE 3-4. ENGINE INSTALLATION - KUBOTA DIESEL T4F WITH GENERATOR​

FIGURE 3-5. ENGINE AND PUMP SUB-ASSEMBLY - KUBOTA DIESEL WITH GENERATOR​

FIGURE 3-6. ENGINE ASSEMBLY - KUBOTA DIESEL WITH GENERATOR​

FIGURE 3-7. ENGINE COMPONENTS - KUBOTA DIESEL​

FIGURE 3-8. ENGINE INSTALLATION - KUBOTA GASOLINE​

FIGURE 3-9. ENGINE AND PUMP SUB-ASSEMBLY - KUBOTA GASOLINE​

FIGURE 3-10. ENGINE ASSEMBLY - KUBOTA GASOLINE​

FIGURE 3-11. ENGINE INSTALLATION - KUBOTA GASOLINE WITH GENERATOR​

FIGURE 3-12. ENGINE AND PUMP SUB-ASSEMBLY - KUBOTA GASOLINE WITH GENERATOR​

FIGURE 3-13. ENGINE ASSEMBLY - KUBOTA GASOLINE WITH GENERATOR​

FIGURE 3-14. ENGINE COMPONENTS - KUBOTA GASOLINE​

FIGURE 3-15. FUEL/WATER SEPARATOR ASSEMBLY - DIESEL ENGINES​

FIGURE 3-16. COUPLING KIT - DIESEL ENGINES​

FIGURE 3-17. COUPLING KIT - GASOLINE ENGINES​

FIGURE 3-18. PISTON PUMP ASSEMBLY​

FIGURE 3-19. FAN GUARD INSTALLATION - KUBOTA​

FIGURE 3-20. GENERATOR INSTALLATION - 4000W (KUBOTA DIESEL STAGE III)​

FIGURE 3-21. GENERATOR INSTALLATION - 4000W (KUBOTA DIESEL T4F)​

FIGURE 3-22. GENERATOR INSTALLATION - 4000W (KUBOTA GASOLINE) (DUAL FUEL)​

FIGURE 3-23. GENERATOR INSTALLATION - 7500W (KUBOTA DIESEL STAGE III)​

FIGURE 3-24. GENERATOR INSTALLATION - 7500W (KUBOTA DIESEL T4F)​

FIGURE 3-25. GENERATOR INSTALLATION - 7500W (KUBOTA GASOLINE) (DUAL FUEL)​

FIGURE 3-26. JUNCTION BOX ASSEMBLY - 4000W GENERATOR (ALL SPECS EXCEPT AUSTRALIAN, CE & UK CA SPECS)​

FIGURE 3-27. JUNCTION BOX ASSEMBLY - 7500W GENERATOR (ALL SPECS EXCEPT AUSTRALIAN, CE & UK CA SPECS)​

FIGURE 3-28. JUNCTION BOX ASSEMBLY - 4000W/7500W GENERATOR (AUSTRALIAN, CE & UK CA SPECS)​

FIGURE 3-29. QUICKFIT OIL DRAIN INSTALLATION - KUBOTA DIESEL ENGINE​

FIGURE 3-30. QUICKFIT OIL DRAIN INSTALLATION - KUBOTA GASOLINE ENGINE​

SECTION 4 - SCISSORS ARMS

FIGURE 4-1. SCISSORS ARMS INSTALLATION WITH AC CABLE​

FIGURE 4-2. SCISSORS ARMS INSTALLATION WITH GENERATOR​

FIGURE 4-3. SCISSORS ARMS ASSEMBLY​

FIGURE 4-4. ARM GUARDS INSTALLATION​

SECTION 5 - PLATFORM

FIGURE 5-1. LADDER INSTALLATION​

FIGURE 5-2. PLATFORM WITH SINGLE EXTENTION INSTALLATION​

FIGURE 5-3. PLATFORM WITH DUAL EXTENSION INSTALLATION​

FIGURE 5-4. RAIL INSTALLATION - PLATFORM WITH SINGLE EXTENSION​

FIGURE 5-5. RAIL INSTALLATION - PLATFORM WITH DUAL EXTENSION​

FIGURE 5-6. PLATFORM CONSOLE BOX INSTALLATION - DIESEL MACHINES​

FIGURE 5-7. PLATFORM CONSOLE BOX INSTALLATION - GASOLINE MACHINES​

FIGURE 5-8. CONTROLLER ASSEMBLY​

FIGURE 5-9. PLATFORM MODULE INSTALLATION​

FIGURE 5-10. PIPE RACK INSTALLATION​

FIGURE 5-11. WELDER ASSEMBLY​

FIGURE 5-12. WORKSTATION INSTALLATION (OPTIONAL)​

SECTION 6 - CYLINDER

FIGURE 6-1. AXLE LOCKOUT CYLINDER ASSEMBLY​

FIGURE 6-2. LOWER LIFT CYLINDER​

FIGURE 6-3. UPPER LIFT CYLINDER​

FIGURE 6-4. LEVELING JACK CYLINDER ASSEMBLY​

FIGURE 6-5. STEER CYLINDER ASSEMBLY​

SECTION 7 - HYDRAULIC

FIGURE 7-1. HYDRAULIC DIAGRAM - OSCILLATING AXLE​

FIGURE 7-2. HYDRAULIC DIAGRAM - SCISSOR ARMS​

SECTION 8 - ELECTRICAL

FIGURE 8-1. AC BOX AT PLATFORM INSTALLATION - 110V GFI (ANSI, ANSI EXPORT, CHINA, CSA AND JAPANESE SPECS)​

FIGURE 8-2. BOX AT PLATFORM INSTALLATION - 220V (ANSI EXPORT, CSA, CHINA AND JAPANESE SPECS)​

FIGURE 8-3. AC BOX AT PLATFORM INSTALLATION - 110V IEC YELLOW (CE & UK CA SPEC)​

FIGURE 8-4. AC BOX AT PLATFORM INSTALLATION - 220V IEC BLUE (CE & UK CA SPEC)​

FIGURE 8-5. AC BOX AT PLATFORM INSTALLATION - 220V AFSINT107 (CE & UK CA SPEC)​

FIGURE 8-6. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 POST GROUND WITH 2X4 BOX (CE & UK CA SPEC)​

FIGURE 8-7. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 POST GROUND WITH 70X70 BOX (CE & UK CA SPEC)​

FIGURE 8-8. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 SIDE GROUND WITH 2X4 BOX (CE & UK CA SPEC)​

FIGURE 8-9. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 SIDE GROUND WITH 70X70 BOX (CE & UK CA SPEC)​

FIGURE 8-10. BATTERY CABLE KIT - DIESEL ENGINES​

FIGURE 8-11. BATTERY CABLE KIT - GASOLINE ENGINES​

FIGURE 8-12. BREAKER BOX KIT - SINGLE DOUBLE POLE BREAKER​

FIGURE 8-13. CHASSIS HARNESS INSTALLATION​

FIGURE 8-14. CHASSIS HARNESS - PRIMARY​

FIGURE 8-15. CHASSIS HARNESS - SECONDARY​

FIGURE 8-16. CLEARSKY CS550 BEACON INSTALLATION​

FIGURE 8-17. DUAL FUEL HARNESS​

FIGURE 8-18. ENGINE HARNESS - KUBOTA DIESEL​

FIGURE 8-19. ENGINE HARNESS - KUBOTA GASOLINE​

FIGURE 8-20. GENERATOR CONTROL HARNESS - 4000W GENERATOR (GENERATOR TO CONTROL BOX)​

FIGURE 8-21. GENERATOR CONTROL HARNESS - 4000W GENERATOR (CONTROL BOX TO GENERATOR CONTROL)​

FIGURE 8-22. GENERATOR CONTROL HARNESS - 7500W GENERATOR (GENERATOR TO CONTROL BOX)​

FIGURE 8-23. GENERATOR CONTROL HARNESS - 7500W GENERATOR (CONTROL BOX TO GENERATOR CONTROL)​

FIGURE 8-24. GROUND CONTROL BOX HARNESS - LOWER​

FIGURE 8-25. GROUND CONTROL BOX HARNESS - UPPER​

FIGURE 8-26. GROUND TO LOWER AUXILIARY HOLDING VALVE HARNESS​

FIGURE 8-27. GROUND TO UPPER AUXILIARY HOLDING VALVE HARNESS​

FIGURE 8-28. GROUND TO LOWER LIFT CYLINDER HARNESS​

FIGURE 8-29. GROUND TO UPPER LIFT CYLINDER HARNESS​

FIGURE 8-30. GROUND TO PLATFORM HARNESS​

FIGURE 8-31. GROUND WIRE HARNESS​

FIGURE 8-32. HYDRAULIC COMPARTMENT HARNESS​

FIGURE 8-33. LEVELING JACK HARNESS​

FIGURE 8-34. LSS HARNESS​

FIGURE 8-35. OSCILLATING AXLE HARNESS​

FIGURE 8-36. PLATFORM CONTROL BOX HARNESS​

FIGURE 8-37. PLATFORM MODULE HARNESS​

FIGURE 8-38. RECEPTACLE ASSEMBLY (MACHINES WITH GENERATORS) (ALL SPECS EXCEPT AUSTRALIAN, CE & UK CA SPEC)​

FIGURE 8-39. RECEPTACLE BOX KIT - 110V GFI​

FIGURE 8-40. RECEPTACLE BOX KIT - 110V IEC YELLOW (CE & UK CA SPEC)​

FIGURE 8-41. RECEPTACLE BOX KIT - 220V IEC BLUE (CE & UK CA SPEC)​

FIGURE 8-42. RECEPTACLE BOX KIT - 220V AFSINT 107 (CE & UK CA SPEC)​

FIGURE 8-43. RECEPTACLE BOX KIT - 220V CEE7 SIDE GROUND (CE & UK CA SPEC)​

FIGURE 8-44. RECEPTACLE BOX KIT - 220V CEE7 POST GROUND (CE & UK CA SPEC)​

FIGURE 8-45. RECEPTACLE BOX KIT - 220V CEE7 POST GROUND 70MM X 70MM BOX (CE & UK CA SPEC)​

FIGURE 8-46. RECEPTACLE BOX KIT - 220V CEE7 SIDE GROUND 70MM X 70MM BOX (CE & UK CA SPEC)​

FIGURE 8-47. SCISSORS ARMS GUARD HARNESS​

SECTION 9 - DECALS

FIGURE 9-1. DECAL INSTALLATION - ANSI AND ANSI EXPORT SPECS (ENGLISH)​

FIGURE 9-2. DECAL INSTALLATION - AUSTRALIAN AND JAPANESE SPECS​

FIGURE 9-3. DECAL INSTALLATION - BRAZIL SPECS (SPANISH/PORTUGUESE)​

FIGURE 9-4. DECAL INSTALLATION - CE & UK CA SPEC​

FIGURE 9-5. DECAL INSTALLATION - CHINESE SPECS (ENGLISH/CHINESE)​

FIGURE 9-6. DECAL INSTALLATION - CSA (ENGLISH/FRENCH)​

FIGURE 9-7. DECAL INSTALLATION - KOREAN SPECS (ENGLISH/KOREAN)​

FIGURE 9-8. DECAL INSTALLATION - LATIN AMERICAN SPECS (ENGLISH/SPANISH)​

FIGURE 9-9. DECAL INSTALLATION - OPTIONS​

SECTION 10 - RECOMMENDED SERVICE PARTS STOCK

FIGURE 10-1. RECOMMENDED SERVICE PARTS STOCK​

SECTION 11 - SPECIAL OPTIONS/ACCESSORIES/KITS

FIGURE 11-1. SPECIAL OPTIONS/ACCESSORIES/KITS​

PART NUMBER INDEX