JLG Scissor Lift RT5394 Service & Maintenance Manual 31221548 2025

[Hyundai]

Download this document, you need 2725 Gallons

JLG Scissor Lift RT5394 Service & Maintenance Manual 31221548 2025
Size: 28.04 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Scissor Lift
Type of Manual: Service & Maintenance Manual, Electrical and Hydraulic Diagrams
Model: JLG RT5394 Scissor Lift
Part Number: 31221548
Publication Date: 2025
Number of Pages: 378 Pages

Contents:
Coverpage
Effectivity Page
Safety

General​

1.1.1 Disclaimer​

1.1.2 Operation & Safety Manual​

Safety Information​

1.2.1 Safety Alert System and Signal Words​

Safety Hazards​

1.3.1 Personal Hazards​

1.3.2 Equipment Hazards​

1.3.3 General Hazards​

1.3.4 Operational Hazards​

Safety Decals​

Machine Verification​

General Machine Information and Specifications

Specifications​

2.1.1 Operating Specifications​

2.1.2 Dimensional Data​

2.1.3 Tires​

2.1.4 Platform Height/Tilt Limit Settings​

2.1.5 Hydraulic Pressure Settings​

2.1.6 Critical Stability Weights​

2.1.7 Major Component Weights​

2.1.8 Generator Specifications (If Equipped)​

2.1.9 Drive Information​

2.1.10 Steering Information​

2.1.11 Hydraulic Cylinder Specifications​

2.1.12 Engine Specifications​

Serial Number Locations​

Fluids and Lubrication​

2.3.1 Hydraulic System​

2.3.2 Changing Hydraulic Oil​

2.3.3 Oil Information​

2.3.4 Hydraulic Oil Specifications​

2.3.5 Lubrication Specifications​

2.3.6 Capacities​

2.3.7 Fluids​

Clearsky Smart Fleet (If Equipped)​

2.4.1 General​

2.4.2 ClearSky Smart Fleet™ — Access Control​

Maintenance and Inspection Schedules

Machine Preparation, Inspection, and Maintenance​

3.1.1 General​

3.1.2 Preparation, Inspection and Maintenance​

3.1.3 Pre-Start Inspection​

3.1.4 Pre-Delivery Inspection and Frequent Inspection​

3.1.5 Annual Machine Inspection​

3.1.6 Preventive Maintenance​

Service and Guidelines​

3.2.1 General​

3.2.2 Safety and Workmanship​

3.2.3 Cleanliness​

3.2.4 Components Removal and Installation​

3.2.5 Component Disassembly and Reassembly​

3.2.6 Pressure-Fit Parts​

3.2.7 Bearings​

3.2.8 Gaskets​

3.2.9 Bolt Usage and Torque Application​

3.2.10 Hydraulic Lines and Electrical Wiring​

3.2.11 Hydraulic System​

3.2.12 Lubrication​

3.2.13 Battery​

3.2.14 Lubrication and Servicing​

Preventive Maintenance and Inspection Schedule​

3.3.1 Maintenance and Inspection Schedule Codes​

Pins and Composite Bearing Repair Guidelines​

Tires & Wheels​

3.5.1 Tire Inflation​

3.5.2 Tire Damage​

3.5.3 Tire Replacement​

3.5.4 Wheel Replacement​

Service Maintenance Components​

3.6.1 Setting Scissor Arm Safety Prop​

3.6.2 General Maintenance Tips​

3.6.3 Fuel Tank​

3.6.4 Drive Hub​

3.6.5 Scissor Arms - Sliding Wear Pads​

3.6.6 Hydraulic Oil Tank​

3.6.7 Hydraulic Charge Filter​

3.6.8 Oil Change with Filter​

3.6.9 Fuel/Water Separator Filter (Diesel) - Kubota​

3.6.10 Fuel Strainer (Diesel) - Kubota​

3.6.11 Fuel Filter (Gas) - Kubota​

3.6.12 Air Filter​

3.6.13 Engine Coolant​

Drive Motor (Hengli) Inspection​

Testing, Calibrations and Special Procedures

Special Tools​

4.1.1 Multimeter​

4.1.2 Continuity Measurement Over Long Distances​

4.1.3 Requirements​

4.1.4 Procedure​

4.1.5 Threadlocking Compound​

4.1.6 Tool List​

Testing Procedures​

4.2.1 Preparation​

4.2.2 Testing LSS Control System Warnings and Interlocks:​

4.2.3 Testing LSS Platform Load Performance with Calibrated Weights:​

4.2.4 Testing LSS Platform Load Reading with a Known Weight:​

4.2.5 Oscillating Axle - Lockout Cylinder Test (if equipped)​

4.2.6 Roll and Leak Testing​

4.2.7 Tightening and Torquing Bolts​

Calibration Procedures​

4.3.1 JLG Analyzer​

4.3.2 Calibration Preparation​

4.3.3 Load Sensing System Calibration​

4.3.4 Testing & Evaluation​

4.3.5 Chassis Tilt Sensor Calibration​

4.3.6 Oscillating Axle Tilt Sensor​

4.3.7 Set Stow Elevation​

Special Procedures​

4.4.1 Joystick Controller​

4.4.2 Cylinder Checking Procedure​

4.4.3 Cylinder Drift Test​

4.4.4 Re-Aligning Torque Hub Input Coupling​

4.4.5 Hydraulic Component Start-Up Procedures and Recommendations​

4.4.6 Oscillating Axle Cylinder Bleeding Procedure​

4.4.7 Drive Pump Start-Up Procedure​

4.4.8 Drive Pump Pre-Fill Procedure​

4.4.9 Pressure Relief Valve - Setting Procedures​

4.4.10 Initial Start-up Procedures​

4.4.11 Start-Up Procedure​

Service Mode Procedures​

4.5.1 ECM Override (Dual Fuel Only)​

4.5.2 Elevation Service​

4.5.3 EEPROM Reset​

4.5.4 Allow Drive​

4.5.5 Allow Leveling Jack Retract​

Operating Characteristics​

4.6.1 Leveling Jacks​

4.6.2 Generator​

4.6.3 Lift​

4.6.4 Drive​

Calibration Menu​

System Software

Load Sensing System (LSS)​

5.1.1 Theory of Operation​

5.1.2 Description​

5.1.3 LSS Connector Pin Assignments​

5.1.4 Personalities​

5.1.5 Diagnostic Menu​

5.1.6 Machine Setup Menu​

JLG Analyzer​

5.2.1 Connecting the JLG Control System Analyzer​

5.2.2 Connecting the JLG Control System Analyzer​

5.2.3 Hand Held Analyzer​

5.2.4 To Connect the Hand Held Analyzer​

5.2.5 Using the Analyzer​

5.2.6 Changing the Access Level of the Hand Held Analyzer​

5.2.7 Adjusting Parameters Using the Hand Held Analyzer​

5.2.8 Analyzer Menu Flow Charts​

Analyzer Software Accessibility​

5.3.1 Machine Configuration and Programming Settings​

ClearSky (CS550) Configuration and Troubleshooting​

5.4.1 ClearSky Smart FleetTM CS550 Configuration​

5.4.2 Troubleshooting​

Fault Codes

Introduction​

6.1.1 System Fault/DTC Indication​

Diagnostic Trouble Codes (DTC) (concept)​

DTC Check Tables​

6.3.1 Diagnostic Troubleshooting Codes (DTC’s) and Flash Codes Description​

6.3.2 Help Menu and Fault Codes​

6.3.3 ClearSky Smart Fleet DTC Fault Codes​

6.3.4 LSS Troubleshooting​

6.3.5 Drive Motor (Sauer) Troubleshooting​

Hydraulics

Theories of Operation​

7.1.1 Cylinders​

7.1.2 Valves​

Torque Values​

7.2.1 Main Hydraulic Valve​

7.2.2 Flow Divider Valve​

7.2.3 Leveling Jack Directional Valve​

7.2.4 Leveling Jack Valves​

7.2.5 Lift Cylinder Valve Cartridge​

7.2.6 Leveling Jack​

Gear Pump​

7.3.1 Gear Pump Priming​

Hydraulic Diagrams​

7.4.1 Oscillating Axle​

Electricals

General Information​

8.1.1 General​

8.1.2 Applying Silicone Dielectric Compound to Electrical Connections​

8.1.3 Dielectric Grease Application​

8.1.4 AMP Mate-N-Lok​

8.1.5 AMP Faston​

8.1.6 AMP Micro-Fit​

8.1.7 AMP Mini Fit Jr​

8.1.8 Mini Fit Sr​

8.1.9 DIN Connectors​

8.1.10 Exceptions​

Electrical Connectors​

8.2.1 Deutsch Connectors​

AMP Connector​

8.3.1 Assembly​

8.3.2 Disassembly​

8.3.3 Wedge Lock​

8.3.4 Service - Voltage Reading​

Switches​

8.4.1 Basic Check​

8.4.2 Leveling Jacks Limit Switch​

8.4.3 Automatic Switches​

8.4.4 Switch Wiring - Low Side, High Side​

Location of Additional Sensors​

Board Layouts​

8.6.1 Jack/Option Control Module Pin Connections​

Removal and Installation

Wheels​

9.1.1 Wheel Installation​

Battery​

9.2.1 Removal​

9.2.2 Installation​

Chassis Tilt Sensor Installation​

9.3.1 Removal​

9.3.2 Installation​

Ground Control Station​

9.4.1 Control Station Removal​

9.4.2 Options Control Module​

Hydraulic Tank​

9.5.1 Removal​

9.5.2 Installation​

Scissor Arms​

9.6.1 Lift Cylinder​

9.6.2 Scissor Arms Removal​

9.6.3 Scissor Arm Assembly Removal​

Platform​

9.7.1 Removal​

9.7.2 Installation​

Axle Installation​

9.8.1 Front Axle Assembly (Fixed)​

9.8.2 Front Axle Assembly (Oscillating)​

9.8.3 Steering Assembly​

9.8.4 Axle Lockout Cylinder​

Levelling Jacks​

9.9.1 Leveling Jack Assembly​

9.9.2 Leveling Jack Cylinder​

Side Compartment Covers​

9.10.1 Removal​

9.10.2 Installation​

Fuel Tank​

9.11.1 Removal​

9.11.2 Installation​

Kubota Engine​

9.12.1 Engine Tray - Swing Out​

9.12.2 Engine Removal and Installation​

9.12.3 Dual Fuel/LPG System​

9.12.4 Changing From Gasoline to LP Gas​

9.12.5 Changing From LP Gas to Gasoline​

9.12.6 Using Liquid Petroleum (LP) Gas​

9.12.7 Propane Fuel System Pressure Relief​

9.12.8 Propane Fuel System Leak Test​

9.12.9 Generator (if equipped)​

9.12.10 Exhaust System​

9.12.11 Dual Fuel - Gas/LPG​

9.12.12 Diesel​

9.12.13 Air Cleaner System​

9.12.14 Radiator​

9.12.15 Engine Electrical Component Locations​

9.12.16 Hydraulic Pump Installation​

9.12.17 Pump Coupling Assembly​

9.12.18 Engine Speed Sensor (Kubota Diesel Engine)​

9.12.19 Throttle Actuator Adjustment​

9.12.20 Air Gap Setting​

9.12.21 Diagnosis of Actuator​

9.12.22 Adjustment of the Actuator​

9.12.23 Adjustment Verification of Actuator​

Drive Assembly​

9.13.1 Removal​

9.13.2 Installation​

Charge Pump Filter​

9.14.1 Removal​

9.14.2 Installation​

Drive Motor (Hengli)​

Hydraulic Valves​

9.16.1 Removal​

9.16.2 Installation​

Axial HI 45 Pump​

9.17.1 General Repair Instructions​

9.17.2 Pump Removal​

9.17.3 Electric Control Module​

9.17.4 Control Solenoids​

9.17.5 Shaft Seal, Roller Bearing & Shaft Replacement​

9.17.6 Charge Pump​

9.17.7 Charge Check/HPRV​

9.17.8 Charge Pressure Relief Valve​

9.17.9 Pressure Limiter Valve Replacement​

Ladder Assembly​

9.18.1 Removal​

9.18.2 Installation​

ClearSky® LED Motion / Amber Beacon (CS550) (if equipped)​

9.19.1 ClearSky® LED Motion / Amber Beacon (CS550) (if equipped)​

Disassembly and Assembly

Drive Assembly​

10.1.1 Main Disassembly for Drive Hub​

10.1.2 Hub-Spindle Disassembly​

10.1.3 Cover Disassembly​

10.1.4 Carrier Disassembly​

10.1.5 Carrier Assembly​

10.1.6 Cover Sub-Assembly​

10.1.7 Hub-Spindle Sub-Assembly​

10.1.8 Main Assembly​

Scissor Arm Assembly​

Platform Control Station​

10.3.1 Disassembly​

10.3.2 Assembly​

Ground Control Station​

10.4.1 Ground Control Station Components​

10.4.2 Disassembly​

10.4.3 Assembly​

Cylinder Repair​

10.5.1 Disassembly​

10.5.2 Cleaning and Inspection​

10.5.3 Assembly​

Cylinder Assemblies​

Drive Motor (Hengli)​

Torque/Connection Information

Hydraulic Fittings​

11.1.1 Tapered Thread Types​

11.1.2 Straight Thread Types, Tube and Hose Connections​

11.1.3 Straight Thread Types, Port Connections​

11.1.4 Flange Connection Types​

11.1.5 Tightening Methods​

11.1.6 Assembly and Torque Specifications​

11.1.7 Assembly Instructions for American Standard Pipe Thread Tapered (NPTF) Connections​

11.1.8 Assembly Instructions for British Standard Pipe Thread Tapered (BSPT) Connections​

11.1.9 Assembly Instructions for 37° (JIC) Flare Fittings​

11.1.10 Assembly Instructions for 45° SAE Flare Fittings​

11.1.11 Assembly Instructions for O-ring Face Seal (ORFS) Fittings​

11.1.12 Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS)​

11.1.13 Assembly Instructions for Bulkhead (BH) Fittings​

11.1.14 Assembly Instructions for O-Ring Boss (ORB) Fittings​

11.1.15 Assembly Instructions for Adjustable Port End Metric (MFF) Fittings​

11.1.16 Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends​

11.1.17 Assembly instructions for Adjustable Port End (BSPP) Fittings​

11.1.18 Assembly Instructions for Flange Connections: (FL61 and FL62)​

11.1.19 Double Wrench Method​

11.1.20 FFWR and TFFT Methods​

11.1.21 Adjustable Stud End Assembly​

11.1.22 O-ring Installation (Replacement)​

Torque Charts​

11.2.1 SAE Fastener Torque Chart​

11.2.2 Metric Fastener Torque Chart​

Schematics

Hydraulic Schematics​

Electrical Schematics​