Jlg 260MRT Service Manual Instrukcja Użytkownika

Service & Maintenance ManualModel260MRT3121801April 19, 2013

SECTION 1 - SPECIFICATIONS1-2 – JLG Lift – 3121801Tires PumpsSteer/Drive SystemTire - Pneumatic or foam filled - 26 x 12 15 lugNOTE: Inflate pneumatic

SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3-34 – JLG Lift – 31218012792402 TFigure 3-28. Hydraulic Schematic - Prior to S/N 141689

SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121801 – JLG Lift – 3-352792717 DFigure 3-29. Hydraulic Schematic - S/N 141689 to Present

SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3-36 – JLG Lift – 31218012792448 BFigure 3-30. Hydraulic Diagram (Generator)

SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121801 – JLG Lift – 3-372792686 CFigure 3-31. Hydraulic Diagram (Leveling Jacks)

SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3-38 – JLG Lift – 3121801NOTES:

Corporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USA (717) 485-5161 (717) 485-6417JLG Worldwide LocationsJLG Industries (

SECTION 1 - SPECIFICATIONS3121801 – JLG Lift – 1-31.6 CYLINDER SPECIFICATIONS1.7 PRESSURE SETTINGS1.8 LIMIT SWITCHESThe machine is equipped with the f

SECTION 1 - SPECIFICATIONS1-4 – JLG Lift – 31218011.11 SERIAL NUMBER LOCATIONSFor machine identification, a serial number plate is affixedto the machi

SECTION 1 - SPECIFICATIONS3121801 – JLG Lift – 1-5Figure 1-2. Lubrication DiagramTable 1-14. Lubrication ChartINDEX NO COMPONENT NUMBER/TYPE LUBE POI

SECTION 1 - SPECIFICATIONS1-6 – JLG Lift – 31218014150548_EFigure 1-3. Operating Temperature Specifications - Kubota

SECTION 1 - SPECIFICATIONS3121801 – JLG Lift – 1-71.12 TORQUE CHARTSFigure 1-4. Torque Chart (SAE Fasteners - Sheet 1 of 7)REFERENCE JLG ANEROBIC THR

SECTION 1 - SPECIFICATIONS1-8 – JLG Lift – 3121801Figure 1-5. Torque Chart (SAE Fasteners - Sheet 2 of 7))Size TPI Bolt DiaTensile Stress AreaClamp L

SECTION 1 - SPECIFICATIONS3121801 – JLG Lift – 1-9Figure 1-6. Torque Chart (SAE Fasteners - Sheet 3 of 7)Size TPI Bolt DiaTensile Stress AreaClamp Lo

SECTION 1 - SPECIFICATIONS1-10 – JLG Lift – 3121801Figure 1-7. Torque Chart (SAE Fasteners - Sheet 4 of 7)Size TPI Bolt DiaTensile Stress AreaClamp L

SECTION 1 - SPECIFICATIONS3121801 – JLG Lift – 1-11Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 5 of 7))Size PITCHTensile Stress AreaClamp Load

SECTION 1 - SPECIFICATIONS1-12 – JLG Lift – 3121801Figure 1-9. Torque Chart (METRIC Fasteners - Sheet 6 of 7)Size PITCHTensile Stress AreaClamp LoadT

SECTION 1 - SPECIFICATIONS3121801 – JLG Lift – 1-13Figure 1-10. Torque Chart (METRIC Fasteners - Sheet 7 of 7)Size PITCHTensile Stress AreaClamp Load

SECTION 1 - SPECIFICATIONS1-14 – JLG Lift – 3121801NOTES:

SECTION 2 - PROCEDURES3121801 – JLG Lift – 2-1SECTION 2. PROCEDURES2.1 GENERALThis section provides information necessary to performmaintenance on th

SECTION 2 - PROCEDURES2-2 – JLG Lift – 31218014. Lubricate new or used serviceable bearings beforeinstallation. When pressing a bearing into a retaine

SECTION 2 - PROCEDURES3121801 – JLG Lift – 2-3density, 100VAC heater to a minimum temperature of-26°C (-15°F).3. The only exception to the above is to

SECTION 2 - PROCEDURES2-4 – JLG Lift – 3121801valve. Integral actuator port relief valves, anti-cavitationcheck valves, and load check valves are stan

SECTION 2 - PROCEDURES3121801 – JLG Lift – 2-5Cylinders w/Single Counterbalance Valves - Lift CylinderOPERATE ALL FUNCTIONS FROM GROUND CONTROL STATIO

SECTION 2 - PROCEDURES2-6 – JLG Lift – 3121801.Figure 2-1. Arms and Platform Positioning and Support, Cylinder Repair

SECTION 2 - PROCEDURES3121801 – JLG Lift – 2-71234567891011121314151617181920201. Barrel2. Rod3. Solenoid Valve4. Cotter Pin5. Cable Adaptor6. Restric

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS3121801 – JLG Lift – aSECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSAGENERALThis section conta

SECTION 2 - PROCEDURES2-8 – JLG Lift – 31218012.10 CYLINDER REPAIRDisassemblyDISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ONA CLEAN WORK SURFACE IN

SECTION 2 - PROCEDURES3121801 – JLG Lift – 2-911. Insert the cap screw(s) in the threaded holes in theouter piece of the tapered bushing. Progressivel

SECTION 2 - PROCEDURES2-10 – JLG Lift – 31218011. A special tool is used to install a new rod seal intothe applicable cylinder head gland groove.WHEN

SECTION 2 - PROCEDURES3121801 – JLG Lift – 2-117. If applicable, correctly place new seals and guidelock rings in the outer piston diameter groove. (A

SECTION 2 - PROCEDURES2-12 – JLG Lift – 312180116. Place new guide locks and seals in the applicableoutside diameter grooves of the cylinder piston.(S

SECTION 2 - PROCEDURES3121801 – JLG Lift – 2-132.11 STEER CYLINDER REPAIRRemovalBefore beginning this procedure, ensure that the parkingbrake is engag

SECTION 2 - PROCEDURES2-14 – JLG Lift – 3121801AssemblyNOTE: Prior to cylinder assembly, ensure that the propercylinder seal kit is used. Apply a ligh

SECTION 2 - PROCEDURES3121801 – JLG Lift – 2-15154367891011122Figure 2-15. Steer Cylinder Assembly1. Barrel2. Rod3. Locknut4. Seal5. Piston6. O-Ring7

SECTION 2 - PROCEDURES2-16 – JLG Lift – 31218011. Barrel2. Counter Balance Valve3. Check Valve4. Plug5. Nut6. Locking Screw7. Flatwasher, 1 1/4"

SECTION 2 - PROCEDURES3121801 – JLG Lift – 2-1712345678910119812131415161718191820211. Barrel2. Check Valve3. Counter Balance Valve4. Plug5. Rod6. Nut

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSb – JLG Lift – 3121801Original Issue - April 13, 2000Revised - January 24, 2002Revised - April 22, 2004Re

SECTION 2 - PROCEDURES2-18 – JLG Lift – 3121801123431211109876513141315161. Barrel2. Rod3. Wear Ring4. Seal5. Wear Ring6. O-Ring7. Back-Up Ring8. Head

SECTION 2 - PROCEDURES3121801 – JLG Lift – 2-192.12 LIMIT SWITCH ADJUSTMENTPlatform Limit SwitchThe platform limit switch is located on the left side

SECTION 2 - PROCEDURES2-20 – JLG Lift – 3121801Main Valve Components.1234567891011121. Tow Brake Release Acuator2. Valve Knob3. Brake Solenoid4. Dump

SECTION 2 - PROCEDURES3121801 – JLG Lift – 2-21Leveling Jacks Directional ValveFigure 2-20. Leveling Jacks Directional ValvePA1PA3PA4PA2PB1PB2PB4PB3L

SECTION 2 - PROCEDURES2-22 – JLG Lift – 31218012.14 DRIVE PUMP START-UP PROCEDURETHE FOLLOWING PROCEDURE SHOULD ALWAYS BE PER-FORMED WHEN STARTING A N

SECTION 2 - PROCEDURES3121801 – JLG Lift – 2-232.15 AUTOMATIC CHOKE - FIELD ADJUSTMENT (DF-750)InspectionNOTE: All automatic choke assemblies have bee

SECTION 2 - PROCEDURES2-24 – JLG Lift – 31218012.16 JOYSTICK CONTROLLER Figure 2-22. Joystick Controller - (JLG P/N 1600308)Table 2-4. Joystick Spec

SECTION 2 - PROCEDURES3121801 – JLG Lift – 2-25Figure 2-23. Joystick Controller - (JLG P/N 1600403)Table 2-6. Joystick SpecificationsInput Voltage 5V

SECTION 2 - PROCEDURES2-26 – JLG Lift – 31218012.17 TILT SENSORTilt Sensor, JLG P/N 4000006: Tilt Sensor Removal:NOTE: Refer to Figure 2-24., Tilt Sen

SECTION 2 - PROCEDURES3121801 – JLG Lift – 2-27Tilt Sensor, JLG P/N 4000021: Tilt Sensor Removal:NOTE: Refer to Figure 2-26., Tilt Sensor Removal for

3121801 – JLG Lift – i TABLE OF CONTENTSTABLE OF CONTENTSSUBJECT - SECTION, PARAGRAPH PAGE NO.SECTION A - INTRODUCTION - MAINTENANCE SA

SECTION 2 - PROCEDURES2-28 – JLG Lift – 31218012.18 CALIBRATIONSTilt Sensor Calibration:1. Drive the machine onto a measured level surface(±0.5° for b

SECTION 2 - PROCEDURES3121801 – JLG Lift – 2-29e. The Ground Control Box, as mounted on themachine, does not allow the tilt sensor to belevel.For the

SECTION 2 - PROCEDURES2-30 – JLG Lift – 31218012.19 ELECTRONIC CONTROL SYSTEMHand Held Analyzer To Connect the Hand Held Analyzer1. Connect the four p

SECTION 2 - PROCEDURES3121801 – JLG Lift – 2-31Using the AnalyzerWith the machine power on and the analyzer connectedproperly, the analyzer will displ

SECTION 2 - PROCEDURES2-32 – JLG Lift – 3121801while in access level 2. Remember, you may always can-cel a selected menu item by pressing the ESC key.

SECTION 2 - PROCEDURES3121801 – JLG Lift – 2-33Adjusting Parameters Using the Hand Held AnalyzerOnce you have gained access to level 1, and a personal

SECTION 2 - PROCEDURES2-34 – JLG Lift – 31218012.20 FLASH CODES AND DESCRIPTIONS Table 2-10. Help Messages and Flash Codes - Software P1.XFLASH CODE

SECTION 2 - PROCEDURES3121801 – JLG Lift – 2-352-2 FUNCTION PROBLEM - TRIGGER PERMANENTLY CLOSEDTrigger switch in the platform control box closed at s

SECTION 2 - PROCEDURES2-36 – JLG Lift – 3121801 MENU:DIAGNOSTI CSDIAGNOSTI CS:GROUNDGROUND:PLATFORMGROUND:GROUNDGROUND:LIFT UPGROUND:LIFT DNGROUND:ENG

SECTION 2 - PROCEDURES3121801 – JLG Lift – 2-37MENU:ACTIVATE TESTSRUN SYSTEM TESTYES :ENTER, NO:ESCCLOSE TRIGGER OPEN TRIGGER TEST VLV & ENG?FORW

ii – JLG Lift – 3121801TABLE OF CONTENTS LIST OF FIGURESFIGURE NO. TITLE PAGE NO.1-1. Serial Number Location. . . . . . . . .

SECTION 2 - PROCEDURES2-38 – JLG Lift – 3121801MENU:ACCESS LEVEL 1MENU:PERSONALITIESACCESS LEVEL:CODE 00000PERSONALI TIES:DRIVEDRIVE:ACCELDRIVE:DECELD

SECTION 2 - PROCEDURES3121801 – JLG Lift – 2-39MENU:MACHINE SETUPMODEL:0= 260MRT GAS/LPMODEL:1= 260MRT DIESELMARKET:0= ANSIMARKET:1= ANSI EXPORTLEVELI

SECTION 2 - PROCEDURES2-40 – JLG Lift – 31218012.21 MACHINE MODEL ADJUSTMENT Table 2-11. Machine Model AdjustmentAdjustment Adjustment range Default

SECTION 2 - PROCEDURES3121801 – JLG Lift – 2-412.22 MACHINE CONFIGURATION PROGRAMMING INFORMATIONNOTE: When configuring a MRT scissors machine, themac

SECTION 2 - PROCEDURES2-42 – JLG Lift – 31218012.23 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULEThe preventive maintenance and inspection checks are

SECTION 2 - PROCEDURES3121801 – JLG Lift – 2-43Table 2-13. Preventive Maintenance and Safety InspectionAREA INTERVAL10Hours(Daily)50 Hours(Weekly)200

SECTION 2 - PROCEDURES2-44 – JLG Lift – 3121801NOTES:

SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121801 – JLG Lift – 3-1SECTION 3. GENERAL ELECTRICAL INFORMATION & SCHEMATICS3.1 GENE

SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3-2 – JLG Lift – 3121801 Voltage Measurement Resistance MeasurementFigure 3-1. Voltage M

SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121801 – JLG Lift – 3-3 Continuity Measurement Current MeasurementFigure 3-3. Continuity

3121801 – JLG Lift – iii TABLE OF CONTENTS3-18. Electrical Schematic - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3-4 – JLG Lift – 3121801Continuity Measurement Over Long DistancesWhen trying to determine

SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121801 – JLG Lift – 3-53.3 APPLYING SILICONE DIELECTRIC COMPOUND TO AMP CONNECTORSSilicone

SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3-6 – JLG Lift – 3121801AssemblyCheck to be sure the wedge lock is in the open, or as-shipp

SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121801 – JLG Lift – 3-7Figure 3-8. Connector Assembly (3 of 4)Figure 3-9. Connector Asse

SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3-8 – JLG Lift – 3121801Disassembly5. Insert a 4.8 mm (3/16”) wide screwdriver blade betwee

SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121801 – JLG Lift – 3-9Service - Voltage ReadingDO NOT PIERCE WIRE INSULATION TO TAKE VOLT

SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3-10 – JLG Lift – 31218013.4 WORKING WITH DEUTSCH CONNECTORSDT/DTP Series AssemblyFigure 3-

SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121801 – JLG Lift – 3-1110. Push contact straight into connector grommet until a positive

SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3-12 – JLG Lift – 31218013.5 SWITCHESBasic checkThe following check determines if the switc

SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121801 – JLG Lift – 3-133. Operate system such that the switch actuates. This could be goi

iv – JLG Lift – 3121801TABLE OF CONTENTS This page left blank intentionally.

SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3-14 – JLG Lift – 3121801.Table 3-1. Elevation System TroubleshootingTROUBLE PROBABLE CAUSE

SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121801 – JLG Lift – 3-15Platform raises and lowers erratically Hydraulic system oil low.

SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3-16 – JLG Lift – 3121801 Table 3-2. Chassis TroubleshootingTROUBLE PROBABLE CAUSE REMEDYDr

SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121801 – JLG Lift – 3-17High-Speed Drive function does not operateLoose or damaged wiring

SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3-18 – JLG Lift – 3121801 Machine hard to steer or steering is erratic (cont.)Lack of l

SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121801 – JLG Lift – 3-19Table 3-3. Hydraulic System TroubleshootingTROUBLE PROBABLE CAUSE

SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3-20 – JLG Lift – 3121801Table 3-4. Electrical System TroubleshootingTROUBLE PROBABLE CAUSE

SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121801 – JLG Lift – 3-21No response to a function control switch (cont.)No voltage present

SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3-22 – JLG Lift – 31218011001106560_B Sheet-1Figure 3-18. Electrical Schematic - Sheet 1 o

SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121801 – JLG Lift – 3-231001106560_B Sheet-1Figure 3-19. Electrical Schematic - Sheet 2 o

SECTION 1 - SPECIFICATIONS3121801 – JLG Lift – 1-1SECTION 1. SPECIFICATIONS1.1 SPECIFICATIONS 1.2 CAPACITIES1.3 COMPONENT DATAEngineTable 1-1. Operat

SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3-24 – JLG Lift – 31218011001109660_B Sheet-2Figure 3-20. Electrical Schematic - Sheet 3

SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121801 – JLG Lift – 3-25NOTES:

SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3-26 – JLG Lift – 31218011001109561_B Sheet-1Figure 3-21. Electrical Schematic - (w/ Gener

SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121801 – JLG Lift – 3-271001109561_B Sheet-1Figure 3-22. Electrical Schematic - (w/ Gener

SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3-28 – JLG Lift – 31218011001109561_B Sheet-2Figure 3-23. Electrical Schematic - (w/ Gener

SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121801 – JLG Lift – 3-29NOTES:

SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3-30 – JLG Lift – 3121801MAI NVALVEHIGHPRESSUREFILTERPLATFORMWORKLIGHTSPLATFORMCONTROLBOXPI

SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121801 – JLG Lift – 3-31BEACONLIGHTELEVATIONSWITCHLEVELINGJACKSWITCHESHORNFUELGAUGESENDERG

SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3-32 – JLG Lift – 3121801MAINVALVEPLATFORMWORKLIGHTSPLATFORMCONTROLBOXPISTONPUMPLIFTCYLINDE

SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121801 – JLG Lift – 3-33GROUNDCONTROLBOXBEACONLIGHTFUELGAUGESENDERHORN/ALARMLEVELINGJACKSW