JCB LK1 Personnel Platform Service Manual 9803-3700-3

Description

• Model List:
  • 532-120, 535-125, 535-140, 537-135 (550), 540-140 (550-140), 540-170 (550-170, 5508)

• 1. Introduction
• 2. General Information ……………………………………………………………………………1
• 3. Machine Model and Serial Number ………………………………………………….1
• 4. About this Supplement …………………………………………………………………..1
• 5. Safety Check List ……………………………………………………………………………….2
• 6. System Overview ……………………………………………………………………………….4
• 7. Introduction …………………………………………………………………………………..4
• 8. Controls ……………………………………………………………………………………….4
• 9. Remote Servo Control ……………………………………………………………………4
• 10. Emergency Operation ……………………………………………………………………4
• 11. Motion Cut Out (MC) (if fitted) …………………………………………………………4
• 12. Component Location and Identification …………………………………………….5
• 13. System Operation ………………………………………………………………………….7
• 14. Service Procedures
• 15. RCU Engine Start Procedure ……………………………………………………………….9
• 16. Fault Finding ……………………………………………………………………………………10
• 17. Introduction …………………………………………………………………………………10
• 18. Tables ……………………………………………………………………………………….. 11
• 19. Servicemaster Tools …………………………………………………………………………13
• 20. Manplatform Diagnostics – User Guide ………………………………………………..14
• 21. Introduction …………………………………………………………………………………14
• 22. Care and Safety ………………………………………………………………………….14
• 23. Installing Manplatform Diagnostics …………………………………………………14
• 24. Connecting Manplatform Diagnostics ……………………………………………..15
• 25. Starting the Manplatform Diagnostics Software ………………………………..18
• 26. Remote Control Unit Test ……………………………………………………………..19
• 27. Internal Monitor …………………………………………………………………………..20
• 28. Error log ……………………………………………………………………………………..21
• 29. 540 Valve (540-170 machine only) …………………………………………………21
• 30. Cabin Joystick …………………………………………………………………………….21
• 31. Remote Control …………………………………………………………………………..21
• 32. Stabilizer Joystick (3 Stage Only) …………………………………………………..22
• 33. Connector I-O ……………………………………………………………………………..23
• 34. Manplatform Calibration – User Guide …………………………………………………30
• 35. Introduction …………………………………………………………………………………30
• 36. Care and Safety ………………………………………………………………………….30
• 37. Installing Manplatform Calibration ………………………………………………….30
• 38. Connecting Manplatform Calibration ………………………………………………31
• 39. Starting the Manplatform Calibration Software …………………………………34
• 40. Introduction …………………………………………………………………………………35
• 41. Manplatform Enable – Machines With Motion Cut Out (MCO) ……………36
• 42. Machine Model Setup …………………………………………………………………..37
• 43. Load Signal ………………………………………………………………………………..40
• 44. Stabilizer Joystick Setup (3-Stage Boom Machines) …………………………42
• 45. Travel Speeds (Part 1) ………………………………………………………………….43
• 46. Travel Speeds (Part 2) ………………………………………………………………….46
• 47. Hydraulic Control Sensitivity ………………………………………………………….49
• 48. Electrics
• 49. Fuses and Relays …………………………………………………………………………….52
• 50. Quick Reference ………………………………………………………………………….53
• 51. Schematic Circuits ……………………………………………………………………………70
• 52. Machines with R-Series Engines ……………………………………………………70
• 53. Machines with JCB Dieselmax Engines ………………………………………….76
• 54. Engine Start Operation – Cabin Mode ………………………………………………….77
• 55. Engine Start Operation – Remote Mode ………………………………………………78
• 56. Stabilizer Legs Down ……………………………………………………………………79
• 57. Park Brake ON ……………………………………………………………………………80
• 58. Emergency Isolation Switch ………………………………………………………….81
• 59. Receiver Signal Integrity ………………………………………………………………82
• 60. Remote Mode Select ……………………………………………………………………83
• 61. Starter Motor Operation ………………………………………………………………..84
• 62. Machine Operation – Remote Mode ……………………………………………………85
• 63. Receiver Signal Integrity ………………………………………………………………86
• 64. Stabilizer and Sway Isolation …………………………………………………………87
• 65. Boom Angle Limit (4 Stage Boom) …………………………………………………88
• 66. Engine Speed Actuator Operation ………………………………………………….89
• 67. L.M.I. Operation ……………………………………………………………………………….90
• 68. L.M.I. Operation (3 Stage Boom) ……………………………………………………90
• 69. L.M.I. Operation (4 Stage Boom) ……………………………………………………91
• 70. Control Valve Operation ……………………………………………………………………92
• 71. Control Valve Operation (3 Stage Boom) ………………………………………..93
• 72. Control Valve Operation (4 Stage Boom) ………………………………………..94
• 73. Joystick Operation ……………………………………………………………………………95
• 74. Emergency Pump Operation ……………………………………………………………..96
• 75. Harness Drawings ……………………………………………………………………………97
• 76. Introduction …………………………………………………………………………………97
• 77. Quick Reference ………………………………………………………………………….97
• 78. Chassis Harness …………………………………………………………………………98
• 79. Panel Harness ………………………………………………………………………….. 110
• 80. Stabilizer Harness ……………………………………………………………………..145
• 81. Joystick …………………………………………………………………………………………149
• 82. Removal and Replacement …………………………………………………………149
• 83. LMI Transducers …………………………………………………………………………….150
• 84. Removal and Replacement …………………………………………………………150
• 85. Electronic Control Unit (LK1 ECU) ……………………………………………………151
• 86. Removal and Replacement …………………………………………………………151
• 87. Electronic Control Unit (LK1 ECU) Battery …………………………………………152
• 88. Removal and Replacement …………………………………………………………152
• 89. Stabilizer Pressure Switches ……………………………………………………………153
• 90. Removal and Replacement …………………………………………………………153
• 91. Proximity Switches …………………………………………………………………………154
• 92. Locations ………………………………………………………………………………….154
• 93. Radio Receiver ………………………………………………………………………………156
• 94. Removal and Replacement …………………………………………………………156
• 95. Engine Speed Actuator ……………………………………………………………………158
• 96. Removal and Replacement …………………………………………………………158
• 97. Hydraulics
• 98. Technical Data ……………………………………………………………………………….160
• 99. 3-Stage Boom Machines …………………………………………………………….160
• 100. 4-Stage Boom Machines …………………………………………………………….161
• 101. Schematic Circuits ………………………………………………………………………….162
• 102. 3-Stage Boom Machines …………………………………………………………….162
• 103. 4-Stage Boom Machines …………………………………………………………….168
• 104. Control Valve (3-Stage Boom Machines) ……………………………………………178
• 105. Operation ………………………………………………………………………………….178
• 106. Control Valve Layout ………………………………………………………………….180
• 107. Pressure Testing ………………………………………………………………………..182
• 108. Removal and Replacement …………………………………………………………186
• 109. Dismantling and Assembly ………………………………………………………….187
• 110. Control Valve (4-Stage Boom Machines) ……………………………………………195
• 111. Operation ………………………………………………………………………………….195
• 112. Removal and Replacement …………………………………………………………196
• 113. Dismantling and Assembly ………………………………………………………….197
• 114. Pilot Control Valves (4-Stage Boom Machines) …………………………………..198
• 115. Locations ………………………………………………………………………………….198
• 116. Removal and Replacement …………………………………………………………199
• 117. Needle Valve (Slewing Platforms only) ………………………………………………200
• 118. Adjustment ……………………………………………………………………………….200
• 119. Removal and Replacement …………………………………………………………200
• 120. Non-Return Valves …………………………………………………………………………201
• 121. Removal and Replacement …………………………………………………………201
• 122. Tilt Ram – Counterbalance Valves …………………………………………………….202
• 123. Removal and Replacement …………………………………………………………202
• 124. Emergency Pump …………………………………………………………………………..203
• 125. Removal and Replacement …………………………………………………………203