Oshkosh Corporation JLG 260MRT Service Maintenance Manual Download

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Service & Maintenance Manual

Model

260MRT

3121801

April 19, 2013

Summary of Contents for JLG 260MRT

Page 1: ...Service Maintenance Manual Model 260MRT 3121801 April 19 2013...

Page 2: ......

Page 3: ...e noted that the machines hydraulic sys tems operate at extremely high potentially danger ous pressures Every effort should be made to relieve any system pressure prior to disconnecting or removing an...

Page 4: ...Lift 3121801 Original Issue April 13 2000 Revised January 24 2002 Revised April 22 2004 Revised July 3 2006 Revised August 30 2006 Revised October 11 2007 Revised April 28 2008 Revised December 19 20...

Page 5: ...eration 2 3 2 6 Component Functional Description 2 4 2 7 Wear Pads 2 4 2 8 Cylinder Checking Procedures 2 4 2 9 Lift Cylinder Removal and Installation 2 5 2 10 Cylinder Repair 2 8 2 11 Steer Cylinder...

Page 6: ...Jack Assembly S N 105371to S N 141689 2 18 2 18 Leveling Jack Assembly S N 141689 to Present 2 19 2 19 Valve Components 2 20 2 20 Automatic Choke Adjustment DF 750 2 22 2 21 Joystick Controller JLG P...

Page 7: ...rating Specifications 1 1 1 2 Capacities 1 1 1 3 WG750 B Kubota Gasoline LP 1 1 1 4 D905 B Kubota Diesel 1 1 1 5 D1005 Kubota Diesel 1 1 1 6 Tire Specifications 1 2 1 7 Pump Specifications 1 2 1 8 Hyd...

Page 8: ...iv JLG Lift 3121801 TABLE OF CONTENTS This page left blank intentionally...

Page 9: ...n Ground Clearance 20 3cm 8in Max Windspeed 12 5m s 28 mph MaxHorizontal ManualSideForce 400N 90lbf NumberofPersons 2 Table 1 2 Capacities Fuel Tank 27 2L 7 2gal HydraulicOilTank 56 8L 15 gal Hydrauli...

Page 10: ...in the same required additives or be of comparable viscosities If use of hydraulic oil other than Mobilfluid 424 is desired contact JLG Indus tries for proper recommendations 1 5 LUBRICATION SPECIFICA...

Page 11: ...CRITICAL TO STABILITY SUCH AS ENGINES AXLES OR TIRES WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY Table 1 10 Cylinder Specifications Description B...

Page 12: ...te is affixed to the machine The plate is located on the rear center of the machine frame just below the middle step of the lad der In addition if the serial number plate is damaged or missing the mac...

Page 13: ...ease EPGL Extreme Pressure Gear Lube HO Hydraulic Oil Mobil 424 TO AVOID PERSONAL INJURY USE SAFETY PROP FOR ALL MAINTENANCE REQUIRING PLATFORM TO BE ELEVATED NOTE Be sure to lubricate like items on e...

Page 14: ...SECTION 1 SPECIFICATIONS 1 6 JLG Lift 3121801 4150548_E Figure 1 3 Operating Temperature Specifications Kubota...

Page 15: ...08 9 16 12 0 5625 0 1820 11600 110 149 80 108 120 163 98 133 18 0 5625 0 2030 12950 120 163 90 122 135 184 109 148 5 8 11 0 6250 0 2260 14400 150 203 110 149 165 224 135 183 18 0 6250 0 2560 16300 170...

Page 16: ...VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 LB IN LB N m IN LB N m IN LB N m 1320 43 5 1580 60 7 1800 68 8 2860 143 16 129 15 3280 164 19 148 17 LB FT LB N m FT LB N m F...

Page 17: ...485 335 455 315 430 7 8 9 0 8750 0 4620 41600 515 700 485 660 455 620 14 0 8750 0 5090 45800 570 775 535 730 500 680 1 8 1 0000 0 6060 51500 730 995 685 930 645 875 12 1 0000 0 6630 59700 845 1150 795...

Page 18: ...515 315 430 7 8 9 0 8750 0 4620 41600 605 825 545 740 455 620 14 0 8750 0 5090 45800 670 910 600 815 500 680 1 8 1 0000 0 6060 51500 860 1170 775 1055 645 875 12 1 0000 0 6630 59700 995 1355 895 1215...

Page 19: ...157 68 3 219 164 197 241 18 2 5 192 83 5 301 226 271 331 20 2 5 245 106 5 426 320 383 469 22 2 5 303 132 0 581 436 523 639 24 3 353 153 5 737 553 663 811 27 3 459 199 5 1080 810 970 1130 30 3 5 561 2...

Page 20: ...19 5 430 385 325 20 2 5 245 152 5 610 550 460 22 2 5 303 189 0 830 750 625 24 3 353 222 0 1065 960 800 27 3 459 286 0 1545 1390 1160 30 3 5 561 349 5 2095 1885 1575 33 3 5 694 432 5 2855 2570 2140 36...

Page 21: ...5 365 345 325 20 2 5 245 152 5 520 490 460 22 2 5 303 189 0 705 665 625 24 3 353 220 0 900 845 790 27 3 459 286 0 1315 1235 1160 30 3 5 561 349 5 1780 1680 1575 33 3 5 694 432 5 2425 2285 2140 36 4 8...

Page 22: ...SECTION 1 SPECIFICATIONS 1 14 JLG Lift 3121801 NOTES...

Page 23: ...discon nected clear adjacent areas as well as the openings and fittings themselves As soon as a line or compo nent is disconnected cap or cover all openings to prevent entry of foreign matter 3 Clean...

Page 24: ...n water After cleaning thoroughly dry batteries and coat terminals with an anti corrosion compound Lubrication and Servicing Components and assemblies requiring lubrication and servicing are shown in...

Page 25: ...oil by actuating the corresponding control valve to the piston side of the cylinder forces the piston to travel toward the rod end of the barrel extending the cylinder rod piston attached to rod When...

Page 26: ...valve is used to hold the platform in place when raised A cable is connected to the valve which when pulled manu ally opens the lift down port and allows the platform to be lowered in the event hydrau...

Page 27: ...ace the machine on a flat and level surface Start the motor and raise the platform Shut down the engine and attach a suitable lifting device to the plat form 2 Remove the bolt and locknut securing the...

Page 28: ...SECTION 2 PROCEDURES 2 6 JLG Lift 3121801 Figure 2 1 Arms and Platform Positioning and Support Cylinder Repair...

Page 29: ...15 16 17 18 19 20 20 1 Barrel 2 Rod 3 Solenoid Valve 4 Cotter Pin 5 Cable Adaptor 6 Restrictor Check Valve 7 Locknut 8 Wear Ring 9 Seal 10 Piston 11 O Ring 12 Spacer 13 O Ring 14 Back Up Ring 15 Wear...

Page 30: ...nment Using an allen wrench loosen the cylinder head retainer cap screws and remove cap screws from cylinder barrel 6 Using a spanner wrench loosen the end cap or head retainer and remove from cylinde...

Page 31: ...sharp edges Dress applicable surfaces as nec essary 9 Inspect cylinder head inside diameter for scoring or other damage and for ovality and tapering Replace as necessary 10 Inspect threaded portion o...

Page 32: ...e Install a new wear ring into the applicable cylinder head gland groove 3 Place a new o ring and back up seal in the applica ble outside diameter groove of the cylinder head 4 Install washer ring ont...

Page 33: ...and mat ing end of rod must be free of oil 11 Assemble the tapered bushing loosely into the pis ton and insert JLG capscrews not vendor cap screws through the drilled holes in the bushing and into th...

Page 34: ...artridge type holding valve and fittings in the rod port block using new o rings as applicable See Table 2 1 Cylinder Component Torque Specifications IF THE CYLINDER IS TO BE TESTED PRIOR TO INSTALLAT...

Page 35: ...ing and wear ring 6 Using suitable protection clamp the cylinder rod in a vise or similar holding fixture 7 Carefully remove the head from the cylinder rod and remove and discard the wiper rod seal o...

Page 36: ...inder rod assembly insert the cylinder rod assembly into the cylinder barrel Ensure that the piston T seal and o ring are not dam aged or dislodged 9 Continue pushing the rod assembly into the cylinde...

Page 37: ...EDURES 3121801 JLG Lift 2 15 1 5 4 3 6 7 8 9 10 11 12 2 Figure 2 15 Steer Cylinder Assembly 1 Barrel 2 Rod 3 Locknut 4 Seal 5 Piston 6 O Ring 7 Back Up Ring 8 Wear Ring 9 Guide 10 Wiper 11 O Ring 12 R...

Page 38: ...5 Nut 6 Locking Screw 7 Flatwasher 1 1 4 Narrow 8 Guidelock 9 Polyseal 10 Piston 11 O Ring 12 Spacer Tube 13 O Ring 14 Wear Ring 15 Head 16 Hydrolock 17 Wiper Seal 18 Cap 19 Rod 20 Plate 21 Trailer B...

Page 39: ...arrel 2 Check Valve 3 Counter Balance Valve 4 Plug 5 Rod 6 Nut 7 Flatwasher 1 1 4 Narrow 8 Guidelock 9 Polyseal 10 Piston 11 O Ring 12 O Ring 13 Wear Ring 14 Head 15 Hydrolock 16 Wiper Seal 17 Cap 18...

Page 40: ...8 7 6 5 13 14 13 15 16 1 Barrel 2 Rod 3 Wear Ring 4 Seal 5 Wear Ring 6 O Ring 7 Back Up Ring 8 Head 9 Polyseal 10 Wiper Seal 11 Washer Ring 12 Screw 5 16 13 Retaining Ring 14 Plate 15 Screw 1 2 16 Ja...

Page 41: ...port MP located on the front upper right side of the valve body The port is identified by a stamping on the valve body 2 From the platform control station activate the Lift Up function by selecting th...

Page 42: ...1 2 3 4 5 6 7 8 9 10 11 12 1 Tow Brake Release Acuator 2 Valve Knob 3 Brake Solenoid 4 Dump Valve 5 Lift Relief 6 Steer Relief Right 7 Main Relief 8 Steer Relief Left 9 Steer Solenoid Right 10 Lift So...

Page 43: ...ure 2 20 Leveling Jacks Directional Valve PA1 PA3 PA4 PA2 PB1 PB2 PB4 PB3 LP T PA1 PA3 PA4 PA2 PB1 PB2 PB4 PB3 LP T Leveling Jacks Pressure Relief Valve Location Table 2 3 Leveling Jacks Directional V...

Page 44: ...r to start up Fill housing by pouring fil tered oil into upper case drain port Install a 0 to 35 bar 0 to 500 psi pressure gauge in the charge pressure gauge port to monitor charge pressure during sta...

Page 45: ...adjust the choke at 21 C 70 F ambient remove the air horn and reinstall the nut that holds the choke and support bracket securely making sure the choke moves freely 3 Loosen the 3 top cover screws an...

Page 46: ...V 0 1V CenteredOutputVoltage 2 2V 0 1V FullPositive Rev DeflectionOutputVoltage 4 0V 0 1V FullNegative Fwd Output Voltage 0 4V 0 1V Table 2 5 Joystick Plug Loading Chart Terminal Color Function 1 Yell...

Page 47: ...ltage 5V CenteredOutputVoltage 4 25Vto2 60V ReverseVoltage 4 60Vto4 80V ForwardVoltage 0 40Vto0 60V Table 2 7 Joystick Plug Loading Chart Terminal Color Function 1 Yellow SteerRight 2 Green SteerLeft...

Page 48: ...the Tilt Sensor 1 from the Ground Control Box NOTE Follow the above procedures in reverse order when installing the tilt sensor assembly After installing be sure to calibrate the tilt sensor refer to...

Page 49: ...oved from the Sensor Mount 2 by removing the three Screws 7 NOTE Follow the above procedures in reverse order when installing the tilt sensor assembly After installing be sure to calibrate the tilt se...

Page 50: ...e open the Ground Control box carefully Observe whether the tilt sensor is properly seated c Tilt sensor has developed an offset shift Remove the tilt sensor from the Ground Control box but keep both...

Page 51: ...angles other than 20 0 attempt to calibrate If machine will not calibrate note the reason displayed on Analyzer a SENSOR FAILURE tilt sensor internal fre quency is out of range replace sensor b NOT L...

Page 52: ...NOTE The cable has a four pin connector at each end of the cable the cable cannot be connected back wards 2 Power up the Control System by turning the lower key to the platform position and pulling bo...

Page 53: ...ted during power up the display will read HELP EVERYTHING OK If ENTER is pressed again the display moves to the fol lowing display LOGGED HELP 1 STARTUP 2 1 At this point the analyzer will display the...

Page 54: ...S LEVEL menu For exam ple MENU ACCESS LEVEL 2 Press ENTER to select the ACCESS LEVEL menu Using the UP or DOWN arrow keys enter the first digit of the password 3 Then using the RIGHT arrow key positio...

Page 55: ...he effect of the machine digit value is displayed along with its value The above display would be selected if the machine was equipped with a ground alarm and you wanted it to sound when driving There...

Page 56: ...MANENTLYSELECTED Anoutriggerselectswitchintheplatformcontrolboxclosedatstartuporformorethantenseconds Releaseswitchtoclearfault FUNCTIONPROBLEM STARTPERMANENTLYSELECTED Startswitchintheplatformcontrol...

Page 57: ...IONCUTOUTACTIVE PLATFORMOVERLOAD ELEVPROXPERMANENTLYCLOSED CHECKPROX CAMSWITCHADJUSTMENT LEVELPREVENTED CHASSISTILTEDEXCESSIVELY 2 6 FRONTLEFTLEVELINGJACKSHORTTOGROUND FRONTRIGHTLEVELINGJACKSHORTTOGRO...

Page 58: ...E M F R L J PSI SY ST E M R L L J PS I SY ST E M R R L J PS I SY ST E M F L L J SW SY ST E M F R L J S W V A L V E S R E V E R SE V A L V E S ST E E R L E FT V A L V E S ST E E R R IG H T V A L V E S...

Page 59: ...O PE N S T A R T C L O S E H O R N O PE N H O R N C L O SE SPE E D S E L O PE N S PE E D S E L C L O SE F U E L S E L O PE N F U E L S E L FR O M S H E E T 1 NOTE SOME SCREENS MAY NOT BE AVAILABLE DE...

Page 60: ...FT G A IN L IFT D R O O P L IFT S T A B IL IT Y PE R S O N A L IT IE S ID L E ID L E E N G IN E S PD PE R S O N A L IT IE S JO Y S T IC K JO Y S T IC K F W D M A X JO Y S T IC K F W D M IN JO Y S T IC...

Page 61: ...S O R L E V E L V E H IC L E Y E S E N T E R N O E SC C A L IB R A T IO N S JO Y ST IC K JO Y ST IC K Y E S E N T E R N O E S C L E V E L IN G JA C K S 2 Y E S S PL L E N G T H L E V E L V E H IC L E...

Page 62: ...to65 50 50 ENGINESPD 2800to3800RPM 3600 3000 GAIN 0to 999 180 50 DROOP 0to 999 200 250 STABILITY 0to 999 170 80 LIFT ACCEL 0 2TO5 0 3 3 DECEL 0 2TO5 0 0 5 0 5 UPMINENG 1400TO2200RPM 2000 1800 UP MAXEN...

Page 63: ...iltConfiguration 0 1 2 CEW OCUT DefalutsettingforCEmachines Tiltanleis3degreesidetoside 5degreefront toback DOM CSAW CUT Cutoutliftupanddriveiftiltedandelevated RequiredforCSAmarket Tiltangleis3degree...

Page 64: ...e Inspection Report form Forms are supplied with each new machine and are also available from JLG Customer Service Form must be completed and returned to JLG Industries JLG INDUSTRIES REQUIRES THAT A...

Page 65: ...p 1 5 7 Valves 1 5 8 HydraulicFilter SeeLubricationChart 5 14 14 9 HydraulicHosesandTubing 1 5 10 HydraulicOilTank 3 5 4 11 HydraulicTankBreather 6 14 12 FuelTank 3 5 4 13 LiftCylinder 1 12 5 6 13 4 1...

Page 66: ...SECTION 2 PROCEDURES 2 44 JLG Lift 3121801 NOTES...

Page 67: ...y If the connector is the sealed type great care must be taken to avoid damaging the seal around the wire It is best to use probes or probe tips specifically designed for this technique especially on...

Page 68: ...orrect range See multimeter s operation manual Use firm contact with meter leads First test meter and leads by touching leads together Resistance should read a short circuit very low resis tance Circu...

Page 69: ...F before testing con tinuity Disconnect component from circuit before testing Use firm contact with meter leads First test meter and leads by touching leads together Meter should produce an audible al...

Page 70: ...wire under test or are within reach of the jumper 1 Disconnect all connections associated with the wire under test and the two additional wires If harness is not com pletely isolated disconnect batte...

Page 71: ...evel conductivity silicone dielectric grease must be packed completely around male and female pins on the inside of the connector after the mating of the housing to the header This is easily achieved...

Page 72: ...ee Figure 3 7 Connector Assembly 2 of 4 2 Pull back on the contact wire with a force of 1 or 2 lbs to be sure the retention fingers are holding the contact See Fig ure 3 7 Connector Assembly 2 of 4 3...

Page 73: ...SECTION 3 GENERAL ELECTRICAL INFORMATION SCHEMATICS 3121801 JLG Lift 3 7 Figure 3 8 Connector Assembly 3 of 4 Figure 3 9 Connector Assembly 4 of 4...

Page 74: ...back and forth over a half turn 1 4 turn in each direction gently pull the wire until the contact is removed Figure 3 10 Connector Disassembly NOTE The wedge lock should never be removed from the hous...

Page 75: ...be wires by piercing the insulation with a sharp point This practice should be discouraged when dealing with the AMPSEAL plug assembly or any other sealed connector system The resulting pinholes in th...

Page 76: ...he wed gelock will snap into place Rectangular wedges are not oriented Thy may go in either way NOTE The receptacle is shown use the same procedure for plug DT DTP Series Disassembly Figure 3 13 DT DT...

Page 77: ...For unused wire cavities insert sealing plugs for full environmental sealing HD30 HDP20 Series Disassembly Figure 3 16 HD HDP Contact Removal 11 With rear insert toward you snap appropriate size extra...

Page 78: ...h by manually operating the sensing arm Another type of limit switch used by JLG is the inductive proximity switch also referred to as a prox switch Inductive proximity switches are actuated only by f...

Page 79: ...eshooting procedures applicable to the aerial platform are listed and defined in following troubleshooting tables Each malfunction within an individual group or system is followed by a listing of prob...

Page 80: ...oil low Replenish oil as necessary Restricted or broken hydraulic line or fit ting Clean repair or replace line or fitting Control valve not functioning properly Repair or replace valve Lift cylinder...

Page 81: ...erly Repair or replace valve Worn seals in lift cylinder Replace seals Lift cylinder not functioning properly Repair or replace lift cylinder Platform drifts down Manual lowering valve not functioning...

Page 82: ...ne drives erratically Microcircuit on controller improperly adjusted Adjust microswitch on controller for proper operation Machine will not travel forward Joystick not activated within three sec onds...

Page 83: ...r form continuity test on wires Repair or replace wires as necessary High speed limit switch not functioning properly Repair or replace limit switch Loose or damaged wiring in valve wiring harness Ens...

Page 84: ...ty test on wires Repair or replace wires as neces sary Solenoid valve not functioning properly Repair or replace valve Restricted or broken hydraulic line on valve bank or hydraulic pump Clean repair...

Page 85: ...il viscosity too high Drain system and replace with recom mended oil Refer to Hydraulic Oil Main relief valve set too high Adjust relief valve to proper pressure Hydraulic system oil low Replenish oil...

Page 86: ...h not positioned properly Placeapplicableemergencystopswitch toon Power selector switch on ground control box not positioned properly Place power selector switch to platform or ground as required Circ...

Page 87: ...elay to engine forproperconnectionordamage Repair or replace cable as necessary No voltage present at applicable control valve coil Check applicable wire for proper con nection at terminal strip valve...

Page 88: ...SECTION 3 GENERAL ELECTRICAL INFORMATION SCHEMATICS 3 22 JLG Lift 3121801 1001106560_B Sheet 1 Figure 3 18 Electrical Schematic Sheet 1 of 3...

Page 89: ...SECTION 3 GENERAL ELECTRICAL INFORMATION SCHEMATICS 3121801 JLG Lift 3 23 1001106560_B Sheet 1 Figure 3 19 Electrical Schematic Sheet 2 of 3...

Page 90: ...SECTION 3 GENERAL ELECTRICAL INFORMATION SCHEMATICS 3 24 JLG Lift 3121801 1001109660_B Sheet 2 Figure 3 20 Electrical Schematic Sheet 3 of 3...

Page 91: ...SECTION 3 GENERAL ELECTRICAL INFORMATION SCHEMATICS 3121801 JLG Lift 3 25 NOTES...

Page 92: ...SECTION 3 GENERAL ELECTRICAL INFORMATION SCHEMATICS 3 26 JLG Lift 3121801 1001109561_B Sheet 1 Figure 3 21 Electrical Schematic w Generator Sheet 1 of 3...

Page 93: ...SECTION 3 GENERAL ELECTRICAL INFORMATION SCHEMATICS 3121801 JLG Lift 3 27 1001109561_B Sheet 1 Figure 3 22 Electrical Schematic w Generator Sheet 2 of 3...

Page 94: ...SECTION 3 GENERAL ELECTRICAL INFORMATION SCHEMATICS 3 28 JLG Lift 3121801 1001109561_B Sheet 2 Figure 3 23 Electrical Schematic w Generator Sheet 3 of 3...

Page 95: ...SECTION 3 GENERAL ELECTRICAL INFORMATION SCHEMATICS 3121801 JLG Lift 3 29 NOTES...

Page 96: ...M AIN VAL VE HIGH PRESSURE FIL TER PLA TFORM W ORK LIGHTS PLA TFORM CONTROL BO X PISTON PUM P LIFT CYLINDER GENERATOR TO ENGINE COM PONENTS TO O VERLOAD LEVELING JACK VAL VES RECEPTACLE A TPLA TFORM F...

Page 97: ...L INFORMATION SCHEMATICS 3121801 JLG Lift 3 31 BEACON LIGHT ELEVA TION SW ITCH LEVELING JACK SW ITCHES HORN FUEL GAUGE SENDER GROUND CONTROL BO X ALARM Figure 3 25 Electrical Componants Installation P...

Page 98: ...801 MAIN VALVE PLATFORM WORK LIGHTS PLATFORM CONTROL BOX PISTON PUMP LIFT CYLINDER GENERATOR TO ENGINE COMPONENTS TO OVERLOAD RECEPTACLE AT PLATFORM DESIGN MAY VARY CIRCUIT BREAKER CE SPEC ONLY Figure...

Page 99: ...ONTROL BOX BEACON LIGHT FUEL GAUGE SENDER HORN ALARM LEVELING JACK SWITCHES CONTROLLER MODULE IGN SPLICE GROUND SPLICE ELEVATION SWITCH GROUND SPLICE RESISTOR DIRECTIONAL VALVE ANALYZER TO PROXIMITY S...

Page 100: ...SECTION 3 GENERAL ELECTRICAL INFORMATION SCHEMATICS 3 34 JLG Lift 3121801 2792402 T Figure 3 28 Hydraulic Schematic Prior to S N 141689...

Page 101: ...SECTION 3 GENERAL ELECTRICAL INFORMATION SCHEMATICS 3121801 JLG Lift 3 35 2792717 D Figure 3 29 Hydraulic Schematic S N 141689 to Present...

Page 102: ...SECTION 3 GENERAL ELECTRICAL INFORMATION SCHEMATICS 3 36 JLG Lift 3121801 2792448 B Figure 3 30 Hydraulic Diagram Generator...

Page 103: ...SECTION 3 GENERAL ELECTRICAL INFORMATION SCHEMATICS 3121801 JLG Lift 3 37 2792686 C Figure 3 31 Hydraulic Diagram Leveling Jacks...

Page 104: ...SECTION 3 GENERAL ELECTRICAL INFORMATION SCHEMATICS 3 38 JLG Lift 3121801 NOTES...

Page 105: ......

Page 106: ...nce 33 0 5 53 88 31 70 33 0 5 53 88 31 79 JLG Deutschland GmbH Max Planck Str 21 D 27721 Ritterhude Ihlpohl Germany 49 0 421 69 350 20 49 0 421 69 350 45 JLG Equipment Services Ltd Rm 1107 Landmark No...

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Oshkosh Corporation JLG 260MRT, Service Maintenance Manual

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