Stone Lift Jockey LJS2000 Service & Parts Manual
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Stone Lift Jockey LJS2000 Service & Parts Manual

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SERVICE/PARTS MANUAL
MODEL: LJS2000
Lift Jockey™ Narrow
A 100% employee-owned American manufacturer
REVISION: B 6/2003
PN 56590

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Summary of Contents for Stone Lift Jockey LJS2000

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

  • Page 3: Table Of Contents

    Table of Contents Lift Jockey™ TABLE OF CONTENTS ....................3-4 FOREWORD ........................5 LIMITED WARRANTY ....................6 TECHNICAL DATA ......................7-13 Specifications........................7 Machine Data/Lubrication Specifications ..............8 Machine Sound Level ..................... 9 Operator Controls ......................10 Imperial Torque Chart ..................... 11 Metric Torque Chart .......................

  • Page 4: Table Of Contents

    Table of Contents Lift Jockey™ EXPLODED DIAGRAM AND PARTS LIST ..............39-83 Tilt Cylinder & Front Cowl Assembly................40-41 Engine Cowl Assembly....................42-43 Engine Assembly ......................44-45 Pump Assembly ......................46-47 Battery/Hose Clamp Assembly ..................48-49 Steering Housing Assembly .................... 50-51 Hydraulic Tank Assembly ....................

  • Page 5: Foreword

    Battery Type: _______________________________ operation and the pertinent regulations for the prevention of accidents. Battery S/N: ________________________________ Stone Construction Equipment, Inc. is not Location of above information: liable for the function of the machine when used in an improper manner or for other 1.

  • Page 6: Limited Warranty

    No claim will be allowed for products lost or damaged in transit. Such claims should be filed with the carrier within fifteen days. Effective July 2002. Stone Construction Equipment, Inc. • 8662 Main Street, P. O. Box 150 •...

  • Page 7: Technical Data

    TECHNICAL DATA Specifications Stone Lift Jockey™ – Specifications LJS2000 SPECIFICATIONS 2,070 lbs. (941) Ba se W e ight (kg) W e ight (kg) (7’6" M a st) 2,470 lbs (1123) Le ngth (cm ) (He e l of forks W alk-behind / Ride-on 86"...

  • Page 8: Machine Data/Lubrication Specifications

    TECHNICAL DATA Machine Data Engine Type 8 hp 4-Stroke, Overhead Valve, Single Cylinder Engine Make Honda Engine Model GX240 Max Torque @ 2500 RPM 12.3 ft lb (16.8) Nm Idle Speed 1400 RPM min Operating Speed 3600 RPM Battery 12 Volt System Battery BCI Group U1- 12 165 cca 5 amp Charge System Fuel Type Gasoline 86 Octane minimum...

  • Page 9: Machine Sound Level

    TECHNICAL DATA Machine Sound Level MACHINE SOUND LEVEL TEST Machine Type: Lift Jockey LJS2000 Sound Level Meter Calibration Date: February 15, 2000 Meter Type: Simpson Model 886-2 Type 2 Test Date: June 2, 2003 Test Conditions Temperature: 65 degrees Fahrenheit / 18 degree Celsius...

  • Page 10: Operator Controls

    TECHNICAL DATA 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 operate this vehicle. - 10 -...

  • Page 11: Imperial Torque Chart

    TECHNICAL DATA Imperial Torque Chart SAE GRADE 5 SAE GRADE 8 Coarse Thread, Zinc-Plated Coarse Thread, Zinc-Plated SIZE TORQUE SIZE TORQUE ft. lbs. ft. lbs. 1/4 - 20 (.250) 1/4 - 20 (.250) 5/16 - 18 (.3125) 5/16 - 18 (.3125) 3/8 - 16 (.375) 3/8 - 16 (.375) 7/16 - 14 (.4375)

  • Page 12: Metric Torque Chart

    TECHNICAL DATA Metric Torque Chart Property Class 8.8 ZINC-PLATED Coarse Thread Fine Thread SIZE ft. lbs. ft. lbs. Property Class 10.9 ZINC-PLATED Coarse Thread Fine Thread SIZE ft. lbs. ft. lbs. 1000 Property Class 12.9 ZINC-PLATED Coarse Thread Fine Thread SIZE ft.

  • Page 13: Hardware Identification

    TECHNICAL DATA Hardware - 13 -...

  • Page 14: Health & Safety

    HEALTH & SAFETY Safety Precautions Before using this equipment, study this entire manual to When warning decals are destroyed or missing, contact become familiar with its operation. Do not allow the Manufacturer immediately at 1-800-888-9926 for untrained or unauthorized personnel, especially children, replacement.
  • Page 15 HEALTH & SAFETY Safety Precautions UNDERSTAND SIGNAL WORDS • A signal word – DANGER, WARNING, or CAUTION – is used with the safety-alert symbol. DANGER identifies the most serious hazards. • DANGER or WARNING safety signs are located near specific hazards.
  • Page 16 HEALTH & SAFETY Safety Precautions • Never perform any work on the equipment while it is running. • Before working on the equipment, stop the engine and disconnect the spark plug wire(s) to prevent accidental starting. On electric models, disconnect the electric cord at the equipment. •...
  • Page 17 HEALTH & SAFETY Safety Precautions Warning-Eye Protection • Always wear splash goggles when operating equipment. • Starting fluid (ether) is highly flammable, do not use or an explosion or fire may result. • Never operate unit in a poorly ventilated or enclosed area. •...
  • Page 18 HEALTH & SAFETY Safety Precautions DISPOSE OF WASTE PROPERLY • Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries. • Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

  • Page 19: Maintenance

    MAINTENANCE Tasks 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. - 19 -...

  • Page 20: Introduction

    Engine Cowl - Allows easy access to all mainte- findings to Stone. We value our customer’s input nance points for quick service. Provides optimum and welcome any and all comments on how the airflow for cooler running and longer life on compo- product may serve you better.

  • Page 21: Fluids And Lubrication

    MAINTENANCE Fluids/Lubrication FLUIDS AND LUBRICATION Gasoline Fuel--Always use fresh, unleaded gaso- line (86 octane min.). Fresh gasoline is blended for Hydraulic Oil--Check the hydraulic fluid level. the season and reduces gum deposits that could clog Use the sight gage located on the hydraulic tank. the fuel system.

  • Page 22: Fuel Tank

    MAINTENANCE Fuel Tank/Hydraulic Oil coupler, replace the inspection cover and then start WARNING engine to see if the problem has been corrected. Do not run the engine or operate the Lift with the cover removed or not firmly attached. D O N O T R U N U N I T I N A N E N - CLOSED, NON-VENTILATED AREA AVOID PROLONGED BREATHING WARNING...

  • Page 23: Hydraulic Oil Filter

    Hydraulic Oil Filter/ MAINTENANCE Hydraulic Breather Cap Moving Joints, Hinges, Throttle, Controls, • Add fresh hydraulic oil until level is visible Cables--Lubricate with oil every 50 hours. Avoid in the sight gauge. A 1/4 – 1/2 air bubble over-lubricating lift chain. This can cause dust and will be seen at the top of the gauge.

  • Page 24: Lubrication Points

    MAINTENANCE Lubrication Points Lubrication Points--Refer to diagram below. Lube grease fittings with Lithium based grease 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 •...

  • Page 25: Engine

    MAINTENANCE Engine SPARK PLUG ENGINE Recommended spark plug: Refer to engine manual for specific engine informa- BPR6ES (NGK) tion. W20EPR-U (NIPPONDENSO) To ensure proper engine operation, the spark plug ENGINE OIL AND FILTER must be properly gapped and free of deposits. •...

  • Page 26: Cooling System/Valve Clearance/Battery Policy

    Battery warranty begins when equipment is sold from Stone Construction Equipment, Inc. or a Stone Battery--Battery replacement is a Crown U1-12 or dealer to a customer. equal 165 CCA battery. See Engine Specifications Section for battery requirements.

  • Page 27: Power Train/Transmission

    MAINTENANCE Power Train/Transmission not run the engine or operate the lifter with the cover Power Train removed or not firmly attached. See Lubrication Specifications Section. Check hydraulic oil level daily using the sight gauge CAUTION: This breather is designed to pressurize the reservoir to 5 PSI.

  • Page 28: Transmission Control Adjustment

    MAINTENANCE Transmission Adjustment Transmission Control Adjustment 3. Start machine. Increase engine throttle to full speed while checking for front drive wheel rotation. If wheels rotate proceed to Step 4. If no The transmission is controlled by two cables and a rotation is observed shut off machine and follow control bracket assembly.

  • Page 29: Brake Adjustment

    Transmission Adjustment/ MAINTENANCE Brake Adjustment 5. Next tighten nuts on reverse control to tighten Brake Adjustments cable at pump control bracket. Squeeze reverse handle grip and check for 1/16” clearance Brakes are adjusted at factory and will need to be between pump control bracket and forward adjusted as brake shoes wear.

  • Page 30: Harware/Changing Wheel/Quick Release Wheel

    Tires, Lugnuts, Hardware/Changing MAINTENANCE Wheel/Quick Release Wheel Tires, Lugnuts and Hardware WARNING - Check that all lugnuts are tight weekly using a torque of 90 ft. lbs. (122 Nm). This is important on new machines or newly replaced W H E N R E P L A C I N G T I R E S wheels.

  • Page 31: Parking & Transportation/Lifting Points

    Parking & Transporting / MAINTENANCE Lifting Points PARKING/TRANSPORTING Proper Tie Down Practices--Tie unit down with proper devices. Make sure all blocking is secure. Parking on a Grade--Parking the unit on a grade should be avoided if possible. If unit has to be Proper Transportation Practices--Always know parked on a grade, park it at right angles to the slope overall height to allow proper clearance for over-...

  • Page 32: Capacity & Load/Spring Start-Up

    Capacity & Load/Cleaning & MAINTENANCE Storage/Spring Start-Up normal fuel but the fuel must be drained 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.

  • Page 33: Hardware Guidelines/Hoses, Fittings/Cleaning & Storage

    Hardware Guidelines/ MAINTENANCE Hoses, Fittings 7. Check hydraulic connectors for looseness or leaking. 8. Reacquaint yourself with Operations and Owner’s Manuals. Hardware Guidelines Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade. Fasteners should be replaced with the same or higher grade.

  • Page 34: Periodic Maintenance Schedule

    MAINTENANCE Periodic Maintenance Schedule - 34 -...
  • Page 35 MAINTENANCE Periodic Maintenance Schedule - 35 -...

  • Page 36: Service Record

    MAINTENANCE Service Record Model No. Serial No. Record Hours and Dates of Maintenance Below Engine Oil and Filter (100 hours) Air Cleaner (300 hours) Spark Plugs (100 hours) Valves (300 hours) Hydraulic Oil (800 hours) Hydraulic Filter (100 hours) Hydraulic Breather (100 hours) Battery (monthly)

  • Page 37: Troubleshooting

    MAINTENANCE Troubleshooting 3UREOHP &DXVH 5HPHG\ Engine lacks power Fuel line plugged Clean or replace Dirty fuel filter Clean or replace Air filter dirty Clean or replace Worn cylinder & piston rings Replace Too much oil in crankcase Drain Oil consumption Worn valve guides Clean or replace Worn cylinder &...

  • Page 39: Exploded Diagram And Parts List

    PARTS LIST Exploded Views with Parts Tilt Cylinder & Front Cowl Assembly................40-41 Engine Cowl Assembly....................42-43 Engine Assembly ......................44-45 Pump Assembly ......................46-47 Battery/Hose Clamp Assembly ..................48-49 Steering Housing Assembly .................... 50-51 Hydraulic Tank Assembly ....................52-53 Steering Handle/Fuel Tank Assembly ................

  • Page 40: Tilt Cylinder & Front Cowl Assembly

    PARTS LIST Tilt Cylinder & Front Cowl Assembly - 40 -...
  • Page 41 PARTS LIST Tilt Cylinder & Front Cowl Assembly - 41 -...

  • Page 42: Engine Cowl Assembly

    PARTS LIST Engine Cowl Assembly - 42 -...
  • Page 43 PARTS LIST Engine Cowl Assembly - 43 -...

  • Page 44: Engine Assembly

    PARTS LIST Engine Assembly - 44 -...
  • Page 45 PARTS LIST Engine Assembly - 45 -...

  • Page 46: Pump Assembly

    PARTS LIST Pump Assembly - 46 -...
  • Page 47 PARTS LIST Pump Assembly - 47 -...

  • Page 48: Battery/Hose Clamp Assembly

    PARTS LIST Battery/Hose Clamp Assembly - 48 -...
  • Page 49 PARTS LIST Battery/Hose Clamp Assembly - 49 -...

  • Page 50: Steering Housing Assembly

    PARTS LIST Steering Housing Assembly - 50 -...
  • Page 51 PARTS LIST Steering Housing Assembly - 51 -...

  • Page 52: Hydraulic Tank Assembly

    PARTS LIST Hydraulic Tank Assembly - 52 -...
  • Page 53 PARTS LIST Hydraulic Tank Assembly - 53 -...

  • Page 54: Steering Handle/Fuel Tank Assembly

    Steering Handle Bar/Fuel PARTS LIST Tank Assembly - 54 -...
  • Page 55 Steering Handle Bar/Fuel PARTS LIST Tank Assembly - 55 -...

  • Page 56: Platform/Brake Pedal Assembly

    PARTS LIST Platform/Brake Pedal Assembly - 56 -...
  • Page 57 PARTS LIST Platform/Brake Pedal Assembly - 57 -...

  • Page 58: Brake Linkage Assembly

    PARTS LIST Brake Linkage Assembly - 58 -...
  • Page 59 PARTS LIST Brake Linkage Assembly - 59 -...

  • Page 60: Wheel Motor, Brake & Tire Assembly

    PARTS LIST Wheelmotor/Brake/Tire Assembly - 60 -...
  • Page 61 PARTS LIST Wheelmotor/Brake/Tire Assembly - 61 -...

  • Page 62: Quick Change Hub Assembly

    PARTS LIST Quick Change Hub Assembly - 62 -...
  • Page 63 PARTS LIST Quick Change Hub Assembly - 63 -...

  • Page 64: Hand And Foot Mast Control Assembly

    PARTS LIST Hand/Foot Mast Control Assembly - 64 -...

  • Page 65: Hand And Foot Mast Control Assembly

    PARTS LIST Hand/Foot Mast Control Assembly - 65 -...

  • Page 66: Mast Assembly

    PARTS LIST Mast Assembly - 66 -...
  • Page 67 PARTS LIST Mast Assembly - 67 -...
  • Page 68 PARTS LIST Mast Assembly - 68 -...
  • Page 69 PARTS LIST Mast Assembly - 69 -...

  • Page 70: Lift Frame Assembly

    PARTS LIST Lift Frame Assembly - 70 -...
  • Page 71 PARTS LIST Lift Frame Assembly - 71 -...

  • Page 72: Hydraulic Piping Schematic

    PARTS LIST Hydraulic Piping Schematic - 72 -...
  • Page 73 PARTS LIST Hydraulic Piping Schematic - 73 -...
  • Page 74 PARTS LIST Hydraulic Piping Schematic - 74 -...
  • Page 75 PARTS LIST Hydraulic Piping Schematic - 75 -...

  • Page 76: Hydraulic System Schematic

    PARTS LIST Hydraulic System Schematic - 76 -...
  • Page 77 PARTS LIST Hydraulic System Schematic - 77 -...

  • Page 78: Electrical Wiring Schematic

    PARTS LIST Electrical Wiring Schematic - 78 -...
  • Page 79 PARTS LIST Electrical Wiring Schematic - 79 -...

  • Page 80: Decal Identification/Location

    PARTS LIST Decal Identification 55398 - 80 -...
  • Page 81 PARTS LIST Decal Identification Item No. Part No. Part Description Decal Location 55200 Decal Lift Here 4 At each Fork Loop Lift Point 55398 Decal Warning Hot Surfaces 1 Rear Frame at Muffler 55422 Decal Hydraulic Fluid Mobil 424 1 Hydraulic Tank 55427 Decal Lifting Point 2 Each Side of Lift Eye...
  • Page 82 PARTS LIST Decal Identification - 82 -...
  • Page 83 PARTS LIST Decal Identification Item No. Part No. Part Description Decal Location 55200 Decal Lift Here 4 At each Fork Loop Lift Point 55398 Decal Warning Hot Surfaces 1 Rear Frame at Muffler 55422 Decal Hydraulic Fluid Mobil 424 1 Hydraulic Tank 55427 Decal Lifting Point 2 Each Side of Lift Eye...

  • Page 87: California Proposition 65 Warning

    CALIFORNIA 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- ductive harm. - 87 -...
  • Page 88 The Way It Ought To 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 © 2003 Stone Construction Equipment, Inc. Printed in U.S.A.

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