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JLG 260MRT Service Manual

JLG 260MRT
106 pages
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Service & Maintenance Manual
Model
260MRT
3121801
July 23, 2018 - Rev K

Table of Contents

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JLG 260MRT Specifications

General IconGeneral
Platform Height26 ft
Machine Width59 in
Machine Length103 in
Drive Speed3.5 mph
Power SourceDiesel
Working Height32 ft
Drive Speed - Elevated0.5 mph
Travel Speed3.5 mph

Summary

SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

GENERAL SAFETY PRECAUTIONS

General safety precautions for aerial platform maintenance personnel.

HYDRAULIC SYSTEM SAFETY

Precautions for working with high-pressure hydraulic systems.

MAINTENANCE SAFETY PRECAUTIONS

Essential safety rules to prevent damage, injury, or death during maintenance.

REVISION LOG

SECTION 1 - SPECIFICATIONS

OPERATING SPECIFICATIONS

Key operational parameters of the machine, including dimensions and capacities.

CAPACITIES

Fluid capacities for fuel, hydraulic oil, and engine crankcase.

COMPONENT DATA

Specifications for engine models, including power and fuel consumption.

LUBRICATION

Information on hydraulic oil requirements and torque specifications.

LUBRICATION SPECIFICATIONS

Details on recommended lubricants and their specifications.

CYLINDER SPECIFICATIONS

Bore, stroke, and rod diameter for lift and steer cylinders.

PRESSURE SETTINGS

Main relief, steer, lift, and leveling jack relief pressure settings.

LIMIT SWITCHES

Description of machine limit switches and their functions.

MAJOR COMPONENT WEIGHTS

Weight specifications for major machine components.

CRITICAL STABILITY WEIGHTS

Warning against replacing critical stability components with different specifications.

SERIAL NUMBER LOCATIONS

Location of machine serial number plates and stamped numbers.

TORQUE CHARTS

Torque values for various fasteners and components.

LUBRICATION CHART

Recommended lubrication points, methods, and intervals.

SECTION 2 - PROCEDURES

GENERAL PROCEDURES

Overview of procedures for safe and efficient maintenance.

SERVICING AND MAINTENANCE GUIDELINES

Guidelines for safety, workmanship, and cleanliness during maintenance.

LUBRICATION INFORMATION

Details on hydraulic system contamination, oil types, and changing intervals.

CYLINDERS - THEORY OF OPERATION

Explanation of how double-acting cylinders function in the lift and steer systems.

VALVES - THEORY OF OPERATION

Explanation of solenoid and proportional control valve operation.

COMPONENT FUNCTIONAL DESCRIPTION

Functional description of hydraulic pumps and lift cylinder valves.

WEAR PADS

Specifications for sliding pads and when they need replacement.

CYLINDER CHECKING PROCEDURES

Steps for checking steer and lift cylinders for leaks and proper function.

LIFT CYLINDER REMOVAL AND INSTALLATION

Step-by-step guide for removing and installing the lift cylinder.

CYLINDER REPAIR

Detailed procedures for disassembling, cleaning, and inspecting cylinders.

STEER CYLINDER REPAIR

Procedures for removing, disassembling, cleaning, and inspecting steer cylinders.

LIMIT SWITCH ADJUSTMENT

Procedure for adjusting the platform limit switch.

PRESSURE SETTING PROCEDURES

Steps for adjusting main pressure and lift/steer relief pressures.

DRIVE PUMP START-UP PROCEDURE

Steps for safely starting up a new or reinstalled drive pump.

AUTOMATIC CHOKE - FIELD ADJUSTMENT (DF-750)

Procedures for inspecting and adjusting the automatic choke assembly.

JOYSTICK CONTROLLER SPECIFICATIONS

Specifications and plug loading chart for the joystick controller.

JOYSTICK CONTROLLER SPECIFICATIONS

Specifications and plug loading chart for a different joystick model.

TILT SENSOR INFORMATION

Information on tilt sensor removal and harness connections.

TILT SENSOR INFORMATION

Information on tilt sensor location, removal, and harness connections.

TILT SENSOR CALIBRATION

Procedure for calibrating the tilt sensor, including troubleshooting.

JOYSTICK CALIBRATION

Procedure for calibrating the joystick and troubleshooting calibration failures.

ELECTRONIC CONTROL SYSTEM OVERVIEW

Introduction to the Hand Held Analyzer and its connection.

ELECTRONIC CONTROL SYSTEM OPERATION

Adjusting parameters and machine setup using the Analyzer.

FLASH CODES AND DESCRIPTIONS

Table of help messages and flash codes for software P1.X.

MACHINE MODEL ADJUSTMENT

Default values for drive, lift, and idle adjustments based on machine model.

MACHINE CONFIGURATION PROGRAMMING INFORMATION

Information on configuring machine settings and personality settings.

PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE

Schedule for routine maintenance and safety inspections.

SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

GENERAL ELECTRICAL INFORMATION

Guidance on using schematics for troubleshooting operating problems.

MULTIMETER BASICS

Fundamental principles and techniques for using a multimeter.

APPLYING SILICONE DIELECTRIC COMPOUND TO AMP CONNECTORS

Procedure and reasons for applying dielectric compound to AMP connectors.

WORKING WITH DEUTSCH CONNECTORS

Procedures for assembling and disassembling DT/DTP and HD30/HDP20 series connectors.

SWITCHES OPERATION

Basic checks for switch functionality and types of switches.

GENERAL TROUBLESHOOTING

General approach and information for troubleshooting machine problems.

HYDRAULIC SYSTEM TROUBLESHOOTING

Common hydraulic system issues and their probable causes and remedies.

ELECTRICAL SCHEMATICS OVERVIEW

Overview of electrical schematic sheets and ground electronics connections.

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