Stone Lift Jockey LJS2000, Service & Parts Manual

Page 1: ...SERVICE PARTS MANUAL MODEL LJS2000 REVISION B 6 2003 PN 56590 Lift Jockey Narrow A 100 employee owned American manufacturer...

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Page 3: ...20 Know Your Lift 20 Fluids and Lubrication 21 Fuel Tank 22 Hydraulic Oil 22 Hydraulic Oil Filter 23 Hydraulic Breather Cap 23 Lubrication Points 24 Engine 25 Cooling System Valve Clearance Battery Po...

Page 4: ...ank Assembly 52 53 Steering Handle Fuel Tank Assembly 54 55 Platform Brake Pedal Assembly 56 57 Brake Linkage Assembly 58 59 Wheel Motor Brake Tire Assembly 60 61 Quick Change Hub Assembly 62 63 Hand...

Page 5: ...er maintenance and the use of incorrect operating materials are not covered by the warranty The above information does not extend the warranty and liability conditions of business of Stone Constructio...

Page 6: ...odification to this warranty or additional warranties binding on Manufacturer Therefore additional statements whether oral or written do not constitute warranty and should not be relied upon The Manuf...

Page 7: ...wered Height m 5 9 1 8 6 3 1 9 6 9 2 1 Raised Height m 10 9 3 3 11 9 3 6 12 9 3 9 Mast Capacity 12 load center kg 1 000 lbs 455 Mast Tilt Forw ard 4o Mast Tilt Rear 6o W heelbase cm 48 122 Engine kW 8...

Page 8: ...in 3600 RPM Battery 12 Volt System Battery BCI Group U1 12 165 cca 5 amp Charge System Fuel Type Gasoline 86 Octane minimum Fuel Tank Capacity 1 7 gallons 26 5 liters Fuel Consumption 1 14 gallons per...

Page 9: ...ry 15 2000 Meter Type Simpson Model 886 2 Type 2 Test Date June 2 2003 Test Conditions Temperature 65 degrees Fahrenheit 18 degree Celsius Ambient Sound dba fast mode Soil Condition Silts and clays Mo...

Page 10: ...Operator Controls One piece all welded steel frame provides low center of gravity for maxi mum stability Familiarization with locations and operation of controls is necessary before attempting to ope...

Page 11: ...1 3 4 10 750 282 382 7 8 9 875 322 436 5 7 8 9 875 454 615 1 8 1 000 483 655 1 8 1 000 682 925 SAE GRADE 5 Fine Thread Zinc Plated SAE GRADE 8 Fine Thread Zinc Plated SIZE TORQUE SIZE TORQUE ft lbs Nm...

Page 12: ...9 ZINC PLATED Coarse Thread Fine Thread SIZE Nm ft lbs Nm ft lbs M6 14 10 NA NA M8 34 25 35 26 M10 67 49 68 50 M12 117 86 125 92 M14 185 136 192 142 M16 285 210 295 218 M20 550 406 600 443 M24 950 70...

Page 13: ...13 TECHNICAL DATA Hardware...

Page 14: ...n Keep your machine in proper working condition Unauthorized modifications to the machine may impair the function and or safety and affect machine life If you do not understand any part of this manual...

Page 15: ...is running or while it is still hot If fuel is spilled during refueling wipe it off from the engine immediately and discard the rag in a safe place Do not operate the equipment if fuel or oil leaks ex...

Page 16: ...ed and latched during the operation close and latch cowl immediately after starting Keep hands clothing and jewelry away from all moving parts Keep all guards in place Never place your hands or any so...

Page 17: ...ne elements that must be raised for service work Keep all parts in good condition and properly installed Repair damage immediately Replace worn or broken parts Remove any buildup of grease oil or debr...

Page 18: ...to recover and recycle used air conditioning refrigerants Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center SAFETY DECALS FOR THE SAFETY OF YOU...

Page 19: ...19 MAINTENANCE F IMPORTANT The person attempting any of the following maintenance tasks must be authorized to do so and have read and understood all sections within this manual Tasks...

Page 20: ...ess and reliability on a job site Forks Four interchangeable adjustable fork options provide efficient handling of all types of loads Choose from round block forks or box forks for several different p...

Page 21: ...n mark is recommended for general all temperature use Check daily for proper oil level DO NOT OVERFILL See Engine Owner s Manual for specifications ENGINE IS EQUIPPED WITH LOW OIL SHUTDOWN UNIT WILL S...

Page 22: ...th engine running check the coupler between the engine and the hydraulic pump Do not make this inspection while engine is running It will be necessary to remove the inspection cover After adjusting an...

Page 23: ...oil it is recommended to also change the hydraulic oil filter HYDRAULIC OIL FILTER Replace every 100 hours Never let the filter be completely clogged Use Stauff Filter P N 45150 CAUTION Never overfil...

Page 24: ...at steering column every three 3 months or 50 hours Use lube oil on the directional control pivots sheave pins lift chains and tilt cylinder pins with engine oil every 3 three months or 50 hours Avoi...

Page 25: ...Replace elements if damaged or excessively dirty SPARK PLUG Recommended spark plug BPR6ES NGK W20EPR U NIPPONDENSO To ensure proper engine operation the spark plug must be properly gapped and free of...

Page 26: ...to avoid damage to the electrical system Keep batteries clean by wiping them with a damp cloth Keep all connections clean and tight Remove any corrosion and wash terminals with a solution of 1 part ba...

Page 27: ...are extremely reliable and will ordinarily not need maintenance or repair If a vibration is experienced with engine running check the coupler between the engine and the hydraulic pump Do not make thi...

Page 28: ...3 8 clearance between forward control lever and lever stop Continue to adjust control cable until clearance is achieved Make sure control bracket does not contact control bracket stop 3 Start machine...

Page 29: ...ESULT IN SERIOUS INJURY OR DEATH WARNING WARNING WARNING Transmission Adjustment Brake Adjustment Brake Adjustments Brakes are adjusted at factory and will need to be adjusted as brake shoes wear Chec...

Page 30: ...n 1 Position machine inner wheel over 2x4 and apply parking brake 2 Remove large tee bolt in center of wheel with crow bar figure 7 3 Remove outside wheel with quick change hub attached 4 Repeat above...

Page 31: ...There are two ways of lifting the unit from the side or from the lifteye Lift hood to access lifteye Proper Tie Down Practices Tie unit down with proper devices Make sure all blocking is secure Proper...

Page 32: ...and discarded at the end of the storage period together with the fuel filter element s 4 Operate the engine until it is warm Stop the engine and drain the lubricating oil from the oil pan 5 Preservat...

Page 33: ...eners threads are clean and that you properly start thread engagement This will prevent them from failing when tightening Hoses Fittings and Leakage Check weekly for loose hose fittings damage and lea...

Page 34: ...34 MAINTENANCE Periodic Maintenance Schedule...

Page 35: ...35 MAINTENANCE Periodic Maintenance Schedule...

Page 36: ...es 300 hours Hydraulic Oil 800 hours Hydraulic Filter 100 hours Hydraulic Breather 100 hours Battery monthly Grease Rear Tire Hub Steering Column weekly Grease Front Wheel Hubs yearly Lubricate Cables...

Page 37: ...Fill tank Charge or replace Tighten clean terminals Tighten Lift Jockey will not move forward or reverse Low hydraulic oil Faulty hydraulic pump Faulty hydraulic drive Check level add if required Repl...

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Page 39: ...ic Tank Assembly 52 53 Steering Handle Fuel Tank Assembly 54 55 Platform Brake Pedal Assembly 56 57 Brake Linkage Assembly 58 59 Wheel Motor Brake Tire Assembly 60 61 Quick Change Hub Assembly 62 63 H...

Page 40: ...40 PARTS LIST Tilt Cylinder Front Cowl Assembly...

Page 41: ...41 PARTS LIST Tilt Cylinder Front Cowl Assembly...

Page 42: ...42 PARTS LIST Engine Cowl Assembly...

Page 43: ...43 PARTS LIST Engine Cowl Assembly...

Page 44: ...44 PARTS LIST Engine Assembly...

Page 45: ...45 PARTS LIST Engine Assembly...

Page 46: ...46 PARTS LIST Pump Assembly...

Page 47: ...47 PARTS LIST Pump Assembly...

Page 48: ...48 PARTS LIST Battery Hose Clamp Assembly...

Page 49: ...49 PARTS LIST Battery Hose Clamp Assembly...

Page 50: ...50 PARTS LIST Steering Housing Assembly...

Page 51: ...51 PARTS LIST Steering Housing Assembly...

Page 52: ...52 PARTS LIST Hydraulic Tank Assembly...

Page 53: ...53 PARTS LIST Hydraulic Tank Assembly...

Page 54: ...54 PARTS LIST Steering Handle Bar Fuel Tank Assembly...

Page 55: ...55 PARTS LIST Steering Handle Bar Fuel Tank Assembly...

Page 56: ...56 PARTS LIST Platform Brake Pedal Assembly...

Page 57: ...57 PARTS LIST Platform Brake Pedal Assembly...

Page 58: ...58 PARTS LIST Brake Linkage Assembly...

Page 59: ...59 PARTS LIST Brake Linkage Assembly...

Page 60: ...60 PARTS LIST Wheelmotor Brake Tire Assembly...

Page 61: ...61 PARTS LIST Wheelmotor Brake Tire Assembly...

Page 62: ...62 PARTS LIST Quick Change Hub Assembly...

Page 63: ...63 PARTS LIST Quick Change Hub Assembly...

Page 64: ...64 PARTS LIST Hand Foot Mast Control Assembly...

Page 65: ...65 PARTS LIST Hand Foot Mast Control Assembly...

Page 66: ...66 PARTS LIST Mast Assembly...

Page 67: ...67 PARTS LIST Mast Assembly...

Page 68: ...68 PARTS LIST Mast Assembly...

Page 69: ...69 PARTS LIST Mast Assembly...

Page 70: ...70 PARTS LIST Lift Frame Assembly...

Page 71: ...71 PARTS LIST Lift Frame Assembly...

Page 72: ...72 PARTS LIST Hydraulic Piping Schematic...

Page 73: ...73 PARTS LIST Hydraulic Piping Schematic...

Page 74: ...74 PARTS LIST Hydraulic Piping Schematic...

Page 75: ...75 PARTS LIST Hydraulic Piping Schematic...

Page 76: ...76 PARTS LIST Hydraulic System Schematic...

Page 77: ...77 PARTS LIST Hydraulic System Schematic...

Page 78: ...78 PARTS LIST Electrical Wiring Schematic...

Page 79: ...79 PARTS LIST Electrical Wiring Schematic...

Page 80: ...80 PARTS LIST 55398 Decal Identification...

Page 81: ...er 7 55469 Decal Control Tilt 1 Hood LHS Control Lever 8 55471 Decal Caution Instruction LJ100 1 Hood Opposite Control levers 9 55472 Decal Warning Instruction LJ100 1 Hood Centered Above Handle 10 55...

Page 82: ...82 PARTS LIST Decal Identification...

Page 83: ...er 7 55469 Decal Control Tilt 1 Hood LHS Control Lever 8 55471 Decal Caution Instruction LJ100 1 Hood Opposite Control levers 9 55472 Decal Warning Instruction LJ100 1 Hood Centered Above Handle 10 55...

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Page 87: ...FORNIA PROPOSITION 65 WARNING Operation of this equipment and or engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other repro ducti...

Page 88: ...Be Stone Construction Equipment Inc P O Box 150 Honeoye New York 14471 Phone 800 888 9926 Fax 585 229 2363 e mail sceny stone equip com www stone equip com A 100 employee owned American manufacturer...