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JLG 80SL Service Maintenance Manual

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Service & Maintenance Manual
Model
80SL
3121325
March 24, 2011

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Summary of Contents for JLG 80SL

  • Page 1 Service & Maintenance Manual Model 80SL 3121325 March 24, 2011...
  • Page 3 • USE ONLY APPROVED, NONFLAMMABLE CLEANING ous pressures. Every effort should be made to SOLVENTS. relieve any system pressure prior to disconnecting or removing any portion of the system. 3121325 – JLG Lift –...

  • Page 4: Revision Log

    Original Issue - February 6, 2007 Revised - March 5, 2007 Revised - June 7, 2007 Revised - November 20, 2007 Revised - March 10, 2008 Revised - July 26, 2010 Revised - March 24, 2011 – JLG Lift – 3121325...

  • Page 5: Table Of Contents

    Operator Maintenance ............2-5 3121325 – JLG Lift –...
  • Page 6 Cylinders - Theory of Operation ...........4-1 – JLG Lift –...
  • Page 7 Outrigger Safety Valves ........... . 4-25 SECTION 5 - JLG CONTROL SYSTEM Main Terminal Box Circuit Boards .
  • Page 8 HD30/HDP20 Series Disassembly..........6-11 – JLG Lift –...
  • Page 9 Piston Seals ..............4-5 3121325 – JLG Lift –...
  • Page 10 Electrical Schematic - Sheet 1 of 15 ..........6-12 – JLG Lift –...
  • Page 11 Hydraulic Schematic - 1001091321 RevC ......... . .6-42 3121325 – JLG Lift –...
  • Page 12 Main Terminal Box Wiring Description ..........6-27 viii – JLG Lift – 3121325...

  • Page 13: Operating Specifications

    128 psi (9 kg/cm²) Tires 85 psi (6 kg/cm²) 17,020 lbs Maximum Outrigger Pad Load (7720 kg) 14,595 lbs Maximum Tire Load Rating (6620 kg) Electrical System Voltage 24 V 10.8 in. Ground Clearance (27.4 cm) 3121325 – JLG Lift –...

  • Page 14: Engine

    Outriggers Selected - Limit switch senses ground contact for all outriggers to enable platform to be raised. NOTE: JLG recommends that once any locknut is removed Outriggers Not Selected - Limit switch senses when all from the machine it is discarded and replaced with a outriggers are retracted to enable platform to be raised new one.

  • Page 15: Limit Switch Locations

    2. High Drive Speed Cutout Limit Switch 6. Outrigger Sensor (all 4 outriggers) 3. Maximum Drive Height/Maximum Height without 7. Oscillating Axle Limit Switches (rear axle) Outriggers Limit Switch 4. Maximum Height Limit Switch Figure 1-1. Limit Switch Locations 3121325 – JLG Lift –...

  • Page 16: Pressure Setting

    JLG Industries Inc. recommends setting the pressures with the operating temperature between 59° - Table 1-10. Hydraulic Oil 68°F (15°- 20°C). JLG Industries Inc. also recommends the use of a calibrated gauge. The pressures may be set with HYDRAULIC SYSTEM OPERATING SAE VISCOSITY GRADE a tolerence of 43.5 psi ( ±...

  • Page 17: Engine Operating Temperature Specifications

    SECTION 1 - SPECIFICATIONS Figure 1-2. Engine Operating Temperature Specifications 3121325 – JLG Lift –...
  • Page 18 SECTION 1 - SPECIFICATIONS 1.12 TORQUE CHARTS Figure 1-3. Torque Chart (SAE Fasteners - Sheet 1 of 3) – JLG Lift – 3121325...
  • Page 19 SECTION 1 - SPECIFICATIONS Figure 1-4. Torque Chart (SAE Fasteners - Sheet 2 of 3)) 3121325 – JLG Lift –...
  • Page 20 SECTION 1 - SPECIFICATIONS Figure 1-5. Torque Chart (SAE Fasteners - Sheet 3 of 3) – JLG Lift – 3121325...
  • Page 21 SECTION 1 - SPECIFICATIONS Figure 1-6. Torque Chart (METRIC Fasteners - Sheet 1 of 3) 3121325 – JLG Lift –...
  • Page 22 SECTION 1 - SPECIFICATIONS Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 2 of 3)) 1-10 – JLG Lift – 3121325...
  • Page 23 SECTION 1 - SPECIFICATIONS Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 3 of 3) 3121325 – JLG Lift – 1-11...
  • Page 24 SECTION 1 - SPECIFICATIONS NOTES: 1-12 – JLG Lift – 3121325...

  • Page 25: Machine Preparation, Inspection, And Maintenance

    Annual Machine Inspection. JLG Indus- tries, Inc. recognizes a Factory-Certified Service Techni- Preparation, Inspection, and Maintenance cian as a person who has successfully completed the JLG Service Training School for the subject JLG product It is important to establish and conform to a comprehen- model.

  • Page 26: Service And Guidelines

    At each Operator change. Service and Maintenance Pre-Delivery Prior to each sale, lease, or Qualified JLG Owner, Dealer, or User Manual and applicable JLG Inspection rental delivery. Mechanic inspection form. In service for 3 months or 150 hours, which- ever comes first; or...

  • Page 27: Component Disassembly And Reassembly

    Rinse with clean water. After cleaning, thoroughly dry battery and coat terminals with an anti corrosion compound. Lubrication and Servicing Components and assemblies requiring lubrication and servicing are shown in the Lubrication Chart in Section 1. 3121325 – JLG Lift –...

  • Page 28: Lubrication And Information

    Multipurpose Grease having a minimum dripping point of 350°F (177°C). Excellent water resistance and 2. JLG recommends Mobilfluid 424 hydraulic oil, which adhesive qualities, and being of extreme pressure has an SAE viscosity of 10W-30 and a viscosity type. (Timken OK 40 pounds minimum.) index of 152.

  • Page 29: Operator Maintenance

    3. Engine Compartment 4. Tie Rod End 5. Spindles 6. Oscillating Axle 7. Lift Cylinder 8. Fuel Tank (Opposite Side) 9. Deck/Arm Pivot Pin 10. Upper Slide Pads 11. Lower Slide Pads Figure 2-1. Lubrication Diagram 3121325 – JLG Lift –...
  • Page 30 • Interval - Every 3 months or 150 hours of operation • Oil Drain Plug (1) • Lube Points - 4 Grease Fittings • Capacity - As Required • Lube - MPG • Interval - As Required – JLG Lift – 3121325...
  • Page 31 • Maintenance - Replaceable Element • Interval - Change every 500 hours or 6 months, which- (JLG P/N H005232 & 70000054) ever comes first. Change filter every time engine oil is • Interval - Every 6 months or 300 hours of operation changed.
  • Page 32 • Lube Points - 2 Grease Fittings • Capacity - As Required • Capacity - As Required • Lube - MPG • Lube - MPG • Interval - As Required • Interval - As Required – JLG Lift – 3121325...
  • Page 33 • Capacity - As Required • Lube - MPG • Interval - As Required • Lube Points - 2 Grease Fittings • Capacity - As Required • Lube - MPG • Interval - As Required 3121325 – JLG Lift –...

  • Page 34: Cylinder Drift Test

    NOTE: Test cylinder drift with machine oil at ambient tem- perature. NOTE: This machine requires periodic safety and mainte- nance inspections by a JLG Dealer. A decal located on the frame affords a place to record (stamp) 1. Place maximum work load onto platform (Refer to inspection dates.

  • Page 35: Preventive Maintenance And Safety Inspection

    19. Scissor Arms 20. Safety Props 21. Sliding Wear Pads 8,12 22. Pivot Pins/Bolts 23. Switches, Ground Control 1,11 24. Control Tags 25. Frame - including doubler plate, 1, 4 gussets, and surrounding area 3121325 – JLG Lift – 2-11...
  • Page 36 SECTION 2 - GENERAL NOTES: 2-12 – JLG Lift – 3121325...

  • Page 37: Section 3 - Chassis, Platform & Scissor Arms

    NOTE: Refer to Section 5.3, Nivolux - Automatic Self-Level- the rear drive motors (C3 to D3) and (C4 to D4). This ing System for detailed information regarding the allows the rear drive motors to free wheel. automatic leveling system. 3121325 – JLG Lift –...

  • Page 38: Drive Hub

    However, should it need to be serviced the oil will need to be drained and replaced. In the event of servicing, fill the unit with Arco H.D. 120# Drum or Exxon GX 80W-90. – JLG Lift – 3121325...

  • Page 39: Tire Replacement

    Please 1. Start all nuts by hand to prevent cross threading. DO refer to the JLG Parts Manual for the part number of the NOT use a lubricant on threads or nuts.

  • Page 40: Wheel Assembly Removal

    1. Elevate machine with jacks or other suitable device and secure. Installation 1. Remove 6 Wheelnuts (1). • Follow the removal steps in reverse order when install- 2. Carefully remove tire from Drive Hub (2). ing the wheel assembly. – JLG Lift – 3121325...

  • Page 41: Hub Torque Values

    Drive Motor Side 1. Torque to 354 lb ft Dry (480 Nm) 2. Torque to 230.9 lb ft Dry (313 Nm) 3. Torque to 230.9 lb ft Dry (313 Nm) Figure 3-3. Hub Torque Values 3121325 – JLG Lift –...

  • Page 42: Torque Hub Assembly

    10. Planetary Gear 23. Bearing 36. O-Ring 49. Reduction Gear Kit 11. Pin 24. Circlip 37. Blocking Ring 12. Thrust Washer 25. Circlip 38. O-Ring 13. Spacer 26. Disc 39. Blocking Ring Figure 3-4. Torque Hub Assembly – JLG Lift – 3121325...

  • Page 43: Drive Motor

    Figure 3-5. Drive Motor (OMR 100) Table 3-2. Drive Motor Specs Displacement 99.8 cm³ Max Speed 600 rpm 177 lb ft Max Torque (240 Nm) Max Power 13 kw 15.9 gal/min Max Oil Flow (60 L/min) 3121325 – JLG Lift –...

  • Page 44: Motor Disassembly

    5. Place the Axel Needle Bearing (5) back onto shaft. 6. Output Shaft (6): Grease the journals with hydraulic oil. The rear shaft end must be marked before fitted. The mark must be positioned vertically above a – JLG Lift – 3121325...

  • Page 45: Steering Assembly

    Installation 1. Remove Steer Cylinder (19) by removing Bolts (20, 31), Washers (21, 22, 23, 32), Nuts (25) and Pins 1. Follow the Removal Steps in reverse order when (26, 33). assembling the steering system. 3121325 – JLG Lift –...

  • Page 46: Rear Axle

    3. When installing the axle, torque the Capscrews (14) to 450 lb ft (610 Nm) dry. 4. The Plate can be removed from the Axle (1) by unscrewing and removing the two Bolts (10), Lock- washers (11), and Bushings (12 and 13). 3-10 – JLG Lift – 3121325...

  • Page 47: Outrigger Cylinder Removal

    6. Carefully lower the Cylinder out of the frame. 3. Remove the Valve Assembly, Limit Switch Bracket (8) and Limit Switch from the top of Outrigger Cylin- der (4)by removing the four Bolts (5) and Lockwash- ers (6). 3121325 – JLG Lift – 3-11...

  • Page 48: Outrigger Cylinder Removal - (Sheet 2 Of 2)

    3. Place Valve Assembly (7), Limit Switch Bracket (8), and Limit Switch (9) back onto the top of the cylinder and secure with the four Bolts (5) and Lockwashers (6). 4. Reconnect all hydraulic lines and electrical wires. 3-12 – JLG Lift – 3121325...

  • Page 49: Engine Compartment

    Nuts (16). 3. Remove both Bolts (7) and Flatwashers (8) connect- ing hoods to the Cabinet Top Panel (5 & 6). NOTE: Follow the steps in reverse order to re-attach the hood and top panel. 3121325 – JLG Lift – 3-13...

  • Page 50: Deutz Engine

    4 Stroke Diesel Engine Specific Fuel Consumption 214 g/kWh Engine Speed: High 2300 l/min 850 l/min Voltage 24 V Starter Battery (qty 2) 12 V, 88 Ah Alternator 14 V, 60 Ah Weight 256 kg 3-14 – JLG Lift – 3121325...

  • Page 51: Engine Tray Slide

    Slide engine tray outward. 3. Be sure to return engine tray to stowed position when finished servicing. Secure engine tray with the two front Capsrews (1) and Lockwashers (2) and two top Capscrews (3). 3121325 – JLG Lift – 3-15...

  • Page 52: Glow Plugs

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Glow Plugs 1. 30 amp Fuses 2. Timer Relay N6 3. Relay K3 Figure 3-13. Glow Plugs Engine Solenoid Fuse 1. Solenoid 2. 30 amp Fuse Figure 3-14. Engine Solenoid 3-16 – JLG Lift – 3121325...

  • Page 53: Hydraulic Pump Assembly

    #242 to the treads of item (8), Coupling Plate - 4. Remove the Coupling (7) by unscrewing and remov- Screws - M8 x 25mm upon reassembly and torque to ing the six bolts (8) and Lockwashers (9). 25Nm (18.5 lb-ft). 3121325 – JLG Lift – 3-17...

  • Page 54: Hydraulic Pump

    HORSEPOWER CONTROL AND SHOULD NOT BE ADJUSTED. mally-open to tank ports. To generate hydraulic power CONTACT THE JLG SERVICE DEPARTMENT FOR INFORMATION. to the control valve, both dump valves need to be acti- vated.

  • Page 55: Exhaust Pipe Assembly

    NOTE: Follow the previous steps in reverse order to install 3. Loosen the Exhaust Clamp (4). the exhaust system. Be sure to securely tighten the exhaust clamps. 4. The exhaust elbow can now be removed. 3121325 – JLG Lift – 3-19...

  • Page 56: Air Filter Assembly

    2. To remove the Air Filter (1), unscrew and remove the 2 Bolts (2), four Flatwashers (4), and two Locknuts (3). Remove the air cleaner from the bracket. 3-20 – JLG Lift – 3121325...

  • Page 57: Engine Removal

    Port to drain the oil. Run machine) the hose through the opening on the bottom of the engine tray. 4. Unscrew and remove 4 Nuts (3) and Flatwashers (2) from the underside of the engine tray. 3121325 – JLG Lift – 3-21...

  • Page 58: Hydraulic Tank

    7. Open shutoff valve lever to turn on flow of hydraulic fluid. NOTE: Close hydraulic shutoff valve lever when servicing the hydraulic system and components. Make certain to open lever when finished to return flow of hydrau- lic fluid. 3-22 – JLG Lift – 3121325...

  • Page 59: Pressure Filter

    NOTE: Be sure arrow on top of filter points towards the 3. Remove the Pressure Filter. hydraulic tank. NOTE: Replace filter every 250 hours of operation. 2. Insert the four Lockwashers and Capscrews into the holes and tighten. 3. Reconnect hose(s) disconnected during removal. 3121325 – JLG Lift – 3-23...

  • Page 60: Fuel Tank

    Hose Fittings (4, 7). NOTE: Empty fuel tank weighs approximately 36.6 lbs 2. Remove the Fuel Tank (1) by removing the four Nuts (16.6 kg). (9) and Lockwashers (10) on the two fuel Tank Straps (8). 3-24 – JLG Lift – 3121325...

  • Page 61: Ground Control Panel

    2. Remove the panel from the the Electrical Compart- ment (2) by removing the six Bolts (3), Nuts (4), and twelve Flatwashers (5). NOTE: When removing the control panel, take care not to damage any plug receptacles and switches. 3121325 – JLG Lift – 3-25...

  • Page 62: Battery Removal

    4. Reconnect Battery Cables to the battery terminals. both the front (shown) and rear (not shown) Battery Tighten bolt on the terminal clamps. Hold Clamp (7) to the electrical compartment. 3. Remove the Battery Hold Clamp. 4. Remove Batteries(1). 3-26 – JLG Lift – 3121325...

  • Page 63: Platform

    2. Remove the six Screws (3) securing the Control Box Lid (1) to the Control Box (2). 3. Carefully lift the lid from the box. 4. At this point, wires, plugs, and other parts may be disconnected for repair/replacement. 3121325 – JLG Lift – 3-27...

  • Page 64: Joystick Controller

    Centered Output Voltage 12V (±0.25V) Green Steer Left Reverse Voltage 5.5 - 6.5V Yellow Steer Right Forward Voltage 17.5 - 18.5V Brown Pot Out Blue 24V In Enable / 24V Out White / Black Ground 3-28 – JLG Lift – 3121325...

  • Page 65: Receptacles

    2. Disconnect all wires connected to the 110V Recep- tacle (5) and Platform Control Box Outlet (6). 3. Remove the four Bolts (2), eight Flatwashers (3), and four Nuts (4). 4. Lift box from platform. 3121325 – JLG Lift – 3-29...

  • Page 66: Main Platform Side Rails

    Cotter Pin (2) from the Pin (3). Remove the Pin 1. Follow the removal procedures in reverse order from the Bar (4) and Pin (5) located on the end rail. when installing the side rails. 3-30 – JLG Lift – 3121325...

  • Page 67: Main Platform End Rails

    Chain Assembly Mounting Plates (9). 5. Carefully remove the rail. 6. The Gate (3) can be detached from the right side End Rail (1) by removing the screws on the two Hinges (11). 3121325 – JLG Lift – 3-31...

  • Page 68: Platform Extension Side Rails

    1. Disconnect Side Rails (1) from end rail by removing Cotter Pin (2) from Pin (3). 1. Follow the removal instructions in reverse order. NOTE: The Chain Assembly/Pin/Cotter Pin can be removed by removing the Bolt (4), Lockwasher (5), and Flat- washer (6). 3-32 – JLG Lift – 3121325...

  • Page 69: Platform Extension End Rail

    4. Carefully lower rail to its stowed position. 5. Secure rail. 6. Remove the Bolts (5), Locknuts (6), Flatwashers (7), and Chain Assembly Mounting Plate (8). 7. Carefully remove the rail. 8. Remove the Tube (9) from the rail. 3121325 – JLG Lift – 3-33...

  • Page 70: Platform Removal

    3. Place machine on safety prop and leave the fork- page) truck in place. If removal of the platform becomes necessary use the above procedure to stabilize the platform for pin and plat- form removal. 3-34 – JLG Lift – 3121325...

  • Page 71: Platform Removal - 2 Of 2 (Rear Of Platform)

    2. Remove the fourteen Bolts (2) and Lockwashers (3) attaching both Platform Retaining Brackets (1) to the Platform. 3. Lift the platform from the armstack. 3121325 – JLG Lift – 3-35...

  • Page 72: Ladder Installation

    (3), and Flatwashers (4). 2. Secure ladder to the chassis with the four Bolts (2), Spring Lockwashers (3), and Flatwashers (4). USE CAUTION WHEN REMOVING THE LADDER. THE LADDER WEIGHS APPROXIMATELY 104 LBS (47.2 KG). 3-36 – JLG Lift – 3121325...

  • Page 73: Beacon Installation (Option)

    4. The Mounting Bracket (2) can be removed from the Brown X1/34B-1 Front chassis by removing the two Screws (3) and Wash- Blue X1/1-3 ers (4). Brown X1/34B-2 Rear 5. Repair/Replace if necessary. Blue X1/1-4 Installation: 1. Follow Removal Procedures in reverse order. 3121325 – JLG Lift – 3-37...

  • Page 74: Scissor Arms

    Limit Switch (2) when platform is at a height of NOTE: The limit switch plate can be removed by removing 12.1 ft (3.7 m). the bolts, washers and nuts at each end of the mounting plate. 3-38 – JLG Lift – 3121325...

  • Page 75: Scissor Arm Assembly Removal

    (refer to Figure 3-32., Platform Removal - 1 of 2 (Front of Platform) and Figure 3-33., Platform Removal - 2 of 2 (Rear of Platform)). 2. Disconnect all hoses and wires connecting the scis- sor assembly to the chassis and platform. STRAP STRAP 3121325 – JLG Lift – 3-39...
  • Page 76 4. Locknut, M16 (not shown) 7. Slightly lift the scissor stack up with the overhead crane so that the rear sliding blocks in the chassis are free. 1. Bolt, M20 x 34mm 3. Pin 2. Lockwasher, M20 3-40 – JLG Lift – 3121325...
  • Page 77 13. The arm stack can now be moved away from the NOTE: Follow the removal steps in reverse order when machine. Place the arm stack in a holding device or installing the arm assembly. on secure blocks. 3121325 – JLG Lift – 3-41...

  • Page 78: Lift Cylinder Removal

    Pin (4) out of the machine. 1. Lift Cylinder 3. Lockwasher, M20 2. Bolt, M20 x 35mm 4. Pin Figure 3-37. Lift Cylinder Removal NOTE: Follow the removal procedures in reverse order when installing the lift cylinder. 3-42 – JLG Lift – 3121325...

  • Page 79: Scissor Arms Disassembly

    Bend the lip on the corre- 2. Nut (80mm or 100mm) sponding Retaining Washer into the notch on the lock nuts. 3. Retaining Washer (60mm, 80mm, or 100mm) 4. Washer & Pin Figure 3-38. Scissor Arm Removal (Left Side) 3121325 – JLG Lift – 3-43...
  • Page 80 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS NOTES: 3-44 – JLG Lift – 3121325...

  • Page 81: Section 4 - Hydraulics

    Once the cir- cuit is deactivated (control returned to neutral), the valve spool returns to neutral (center) and oil flow is then 3121325 – JLG Lift –...

  • Page 82: Cylinder Checking Procedure

    Shut breakdowns and for specific parts references. Refer down engine. to JLG Parts Manual 3121326 for seal kits and part 2. Carefully disconnect hydraulic hoses from retract numbers. port of cylinder. There will be some initial weeping of...

  • Page 83: Load Check Valve Romoval

    4. To prevent damage, remove the safety valve and limit switch from the top of the outrigger cylinders. Limit Switch Figure 4-4. Cylinder Barrel Support Safety Valve Outrigger Cylinder Figure 4-3. Safety Valve and Limit Switch Removal 3121325 – JLG Lift –...

  • Page 84: Cylinder Head Removal

    10. With the barrel clamped securely, apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel. Piston Cylinder Figure 4-8. Piston Removal Figure 4-6. Cylinder Rod Support – JLG Lift – 3121325...

  • Page 85: Piston Seals

    (Outrigger Cylinder Only) Wiper Seal Cylinder Backup Ring (Outrigger and Axle Cylinder Lockout Cylinders Only) Head Head Seal O-Ring Figure 4-12. Cylinder Head Seals Figure 4-10. Spacer Removal 16. Remove the rod from the holding fixture. 3121325 – JLG Lift –...

  • Page 86: Cleaning And Inspection

    Inspect bushing housing for wear or other dam- age. If the bushing housing is worn or damaged, rod/barrel must be replaced. c. Lubricate inside of bushing housing with WD40 prior to bushing installation. – JLG Lift – 3121325...

  • Page 87: Assembly

    Assembly Snap Ring O-Ring NOTE: Prior to cylinder assembly, ensure that the proper (Outrigger Cylinder Only) cylinder seal kit is used. See your JLG Parts Manual Wiper 3121326. Always replace seals when servicing cylin- Seal ders. Apply a light film of hydraulic oil to all components prior to Backup Ring assembly.

  • Page 88: Spacer Installation

    Figure 4-18. Piston Seal Installation 12. Position the cylinder barrel in a suitable holding fix- ture. 8. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible. – JLG Lift – 3121325...

  • Page 89: Rod Installation

    Figure 4-21. Rod Installation Cylinder Barrel 14. Continue pushing the rod into the barrel until the cyl- Valve inder head can be inserted into the barrel cylinder. Block Setscrews NOTE: Lift Cylinder only. Figure 4-23. Valve Block Installation 3121325 – JLG Lift –...

  • Page 90: Load Check Valve Installation

    Figure 4-25. Safety Valve and Limit Switch Installation NOTE: Refer to Figure 1-3., Torque Chart (SAE Fasteners - Sheet 1 of 3) to Figure 1-8., Torque Chart (METRIC Fasteners - Sheet 3 of 3) for setscrew torques. 4-10 – JLG Lift – 3121325...

  • Page 91: Lifting Cylinder Assembly

    9. Rod Seal 15. Capscrew (M8 x 120mm) 4. Piston Seal 10. O-Ring 16. Hydraulic Block 5. O-Ring 11. Cylinder Barrel 17. Pressure Sensor 6. Setscrew 12. Lift/Lower Valve 18. O-Ring Figure 4-26. Lifting Cylinder Assembly 3121325 – JLG Lift – 4-11...

  • Page 92: Steering Cylinder Assembly

    3045.7 psi Max Working Pressure (210 bar) 191.8 lb ft Piston Head Torque (Apply Loctite 242 before tightening) (260 Nm) 1.6 ft/sec Max Speed (0.5 m/sec) -4°F to 176°F Max Operating Temperature (-20°C to 80°C) 4-12 – JLG Lift – 3121325...

  • Page 93: Outrigger Cylinder Assembly

    Piston Head Torque (Apply Loctite 243 prior to tightening)(torque with Rod End) (1000 Nm) 958.8 lb ft Cap Torque (Apply Circlip behind Piston Head prior) (1300 Nm) Max Speed 0.5 m/sec -22°F to 212°F Max Operating Temperature (-30°C to 100°C) 3121325 – JLG Lift – 4-13...

  • Page 94: Axle Locking Cylinder Assembly

    Max Working Pressure (200 bar) 737.8 lb ft Piston Head Torque (Apply Loctite 242 to Piston Head before tightening (1000 Nm) Max Speed 0.5 m/sec. -22°F to 212°F Max Operating Temperature (-30°C to 100°C) 4-14 – JLG Lift – 3121325...

  • Page 95: Extension Cylinder Assembly

    147.5 lb ft Piston Torque (Apply Loctite 242 to Piston Thread before tightening) (200 Nm) 14.8 lb ft Setscrew Torque (20 Nm) Max Speed 0.5 m/sec 22°F to 176°F Max Operating Temperature (-30°C to 80°C) 3121325 – JLG Lift – 4-15...

  • Page 96: Arms And Platform Positioning And Support

    REMOVE ANY LOAD FROM PLATFORM. NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL IT HAS BEEN RESTRAINED FROM MOVEMENT WITH SAFETY PROPS, BLOCKING OR OVERHEAD SLING. STRAP STRAP ARM SAFETY PROP Figure 4-31. Arms and Platform Positioning and Support 4-16 – JLG Lift – 3121325...

  • Page 97: Valves

    Pressure Switch, Drive Enable • Operate the lower function to retract the jacks and adjust the switch (screw on the top of the switch) to trip at 2683 psi (185 bar) Figure 4-33. Pressure Switch Adjustment 3121325 – JLG Lift – 4-17...

  • Page 98: Brake Valve

    (shown to the left) then open the knob 1/2 of a revolution. Figure 4-35. Brake Valve Adjustment 4-18 – JLG Lift – 3121325...

  • Page 99: Drive Valve

    • With 24V on Coils 1 and 2, all oil from the pump will give maximum oil flow through A1 section of the valve to the front wheels resulting in High Speed 2 Wheel Drive. 3121325 – JLG Lift – 4-19...

  • Page 100: Main Valve Block

    2. Platform 3. Drive 2 4. Lift 5. Steer 6. Rear Right Jack 7. Rear Left Jack 8. Front Right Jack 9. Front Left Jack 10. Drive 1 VALVE SCHEMATIC Figure 4-37. Main Valve Block 4-20 – JLG Lift – 3121325...

  • Page 101: Pump Engage/Disengage Valve

    Pump Engage/Disengage Valve 1. Torque to 5 ft lbs (6.8 Nm) 2. Torque to 25 ft lbs (33.9 Nm) • Operating Pressure: 3000 psi (207 bar) • Voltage: 24VDC Figure 4-40. Pump Engage/Disengage Valve 3121325 – JLG Lift – 4-21...

  • Page 102: Hand Pump

    35. Valve Body 24. Plug 8. Seal 36. Knob Assembly 25. Screw 9. Seal 37. Valve Body 26. Fitting, Straight 10. Pin 27. Seal 11. Ring, Retaining Figure 4-41. Hand Pump Assembly (prior to S/N 1200021263) 4-22 – JLG Lift – 3121325...

  • Page 103: Load Holding Valve

    1. Torque to 5 ft lbs (6.8 Nm) 2. Torque to 20 ft lbs (27.1 Nm) • Operating Pressure: 3000 psi (207 bar) • Voltage: 24VDC Axle Lockout Cylinder Figure 4-43. Load Holding Valve 3121325 – JLG Lift – 4-23...

  • Page 104: Lift/Lower Valve Block

    • with the rated load on the platform (see Table 1-1), adjust the knob shown to the left to obtain the lowering speed as specified in (Table 1-1) Figure 4-45. Platform Lower Flow Valve 4-24 – JLG Lift – 3121325...

  • Page 105: Outrigger Safety Valves

    SECTION 4 - HYDRAULICS Outrigger Safety Valves Front Outriggers: • Operating Pressure: 116 psi (8 bar) Outrigger Safety Valve Cylinder Rear Outriggers: • Operating Pressure: 14.5 psi (1 bar) Figure 4-46. Outrigger Valves 3121325 – JLG Lift – 4-25...
  • Page 106 SECTION 4 - HYDRAULICS NOTES: 4-26 – JLG Lift – 3121325...

  • Page 107: Section 5 - Jlg Control System

    SECTION 5 - JLG CONTROL SYSTEM SECTION 5. JLG CONTROL SYSTEM 5.1 MAIN TERMINAL BOX CIRCUIT BOARDS KVS K1 KT K 2 TRIGGER PNP5 CONTROL 3 4 5 8 9 10 11 12 LEVEL SENSOR 4 = TT 3 = TB...

  • Page 108: Control Card Complex 2

    SECTION 5 - JLG CONTROL SYSTEM 5.2 CONTROL CARD COMPLEX 2 Figure 5-2. Control Card Complex 2 Board General Description of Components and position, adjust the TP1 potentiometer to obtain the correct creep drive speed of 0.5 km/h. Functions • TP2 - This is used to adjust the ramp time to engage The Complex 2 Control circuit board is an electronic and disengage the drive control valve section.

  • Page 109: J1 Connector

    SECTION 5 - JLG CONTROL SYSTEM Table 5-1. J1 Connector Table 5-2. J2 Connector J1 Connector J2 Connector Drive 24V to Console Drive Height LS Deck Extension Lower Ignition Ground Start Lift Horn Joystick Analog Signal Not Used Pump 1...

  • Page 110: Complex 2 Circuit Board

    SECTION 5 - JLG CONTROL SYSTEM Table 5-4. Complex 2 Circuit Board OUTPUT SIGNAL J1/15 Ignition (signal diesel and relais K) Starter J1/17 J1/1 Drive Signal (during Drive) Drive Signal (during Steering) J1/1 Analog J1/6 Lift J1/5 Lower J1/3 Right Steer...

  • Page 111: Nivolux - Automatic Self-Leveling System

    0.5°. The next lowest outrigger is then • The NIVOLUX automatic self-leveling system on JLG powered to level one axis within 0.5°. MEWPs is a selectable system.

  • Page 112: Nivolux Board Led's

    SECTION 5 - JLG CONTROL SYSTEM Setting and Adjustment of the NIVOLUX • When the system completes the leveling process (sensed angle is within 0.5° of set point in both axis), Board the NIVOLUX system checks that all 4 outriggers have ground contact and then powers up the lift valve.

  • Page 113: Nivolux Circuit Board

    SECTION 5 - JLG CONTROL SYSTEM Table 5-5. NIVOLUX Circuit Board Output Signal RPM (to Deutz box & PNP) Lift wth NIVOLUX J8/4 RPM (to Deutz box & PNP) Lift wthout NIVOLUX J8/4 RPM (to Deutz box & PNP) Lowering...

  • Page 114: Pnp5 Circuit Board

    SECTION 5 - JLG CONTROL SYSTEM 5.4 PNP5 CIRCUIT BOARD Table 5-7. Connector J1 System Drive In J1/1 Power 24V J1/2 The PNP5 circuit board is an electronic printed circuit Series Parallel Out J1/3 board mounted on the Din rail situated in the MTB (refer...

  • Page 115: Relay K3

    SECTION 5 - JLG CONTROL SYSTEM Relay K3 5.6 LIMIT SWITCH & SENSOR OPERATION 1. Energized when there is a trigger output at 3. NOTE: Refer to Figure 1-1., Limit Switch Locations for loca- tions of limit switches. 2. The analogue input signal 4 passes through a set of N.O.

  • Page 116: Tilt Switch

    SECTION 5 - JLG CONTROL SYSTEM • When the platform is below the maximum height, this Adjustment: switch is closed. One contact passes a 24V signal to Place the machine on a flat level surface. Using a digital the Control System (Complex 2 Board) to enable lift level, ensure the chassis is level.

  • Page 117: Engine Control System

    SECTION 5 - JLG CONTROL SYSTEM 5.7 ENGINE CONTROL SYSTEM ehbelectronics ehbelectronics Vertragshandler Vertragshandler Glow Temp. Alt. Start Start 1001094781 H005559 Functional Description c. When a start signal is applied to X1/2 (50e) and the input on X2/10 remains zero, after 1 second of cranking, the output X2/7 is cut and the G LED NOTE: For desciptions in ( ), refer to Figure 6-23., Electrical...

  • Page 118: Deutz Engine Control Board

    SECTION 5 - JLG CONTROL SYSTEM remains on, even if the switch resets, until the igni- tion input X1/1 (15) is recycled. Table 5-13. Deutz Engine 8. The monitoring system will shut the engine down Connector X1 (ouput to X1/7 is cut) if one of the following fault...

  • Page 119: Section 6 - General Electrical Information & Schematics

    = kilo = 1,000 * (Displayed Number) m = milli = (Displayed Number) / 1,000 μ = micro = (Displayed Number) / 1,000,000 Example: 1.2 k = 1200  Example: 50 mA = 0.05 A 3121325 – JLG Lift –...

  • Page 120: Voltage Measurement (Dc)

    • Circuit power must be turned OFF before testing resistance • Disconnect component from circuit before testing • If meter is not auto ranging, set it to the correct range (See multimeter’s operation manual) • Use firm contact with meter leads – JLG Lift – 3121325...

  • Page 121: Continuity Measurement

    (See multi meter’s operation manual) • Use firm contact with meter leads • Use firm contact with meter leads • First test meter and leads by touching leads together. Meter should produce an audible alarm, indicating continuity 3121325 – JLG Lift –...

  • Page 122: Continuity Measurement Over Long Distances

    One can find the continuity of two wires, here #1 and #2, at once by following steps 1 through 4. If there is a problem the third wire is used to troubleshoot the other wires. To find the problem, start at step 1 and use the entire procedure. – JLG Lift – 3121325...

  • Page 123: Applying Silicone Dielectric Compound To Amp Connectors

    2. Pierce one of the unused wire seals to allow the trapped air inside the housing to escape. 3. Install a hole plug into this and/or any unused wire seal that has silicone dielectric compound escaping from it. Figure 6-5. AMP Connector 3121325 – JLG Lift –...

  • Page 124: Assembly

    (See Figure 6-8. Connector Assembly (3 of 4)). 4. Slide the wedge lock into the housing until it is flush with the housing (See Figure 6-9. Connector Assembly (4 of 4)). Figure 6-7. Connector Assembly (2 of 4) – JLG Lift – 3121325...

  • Page 125: Connector Assembly (3 Of 4)

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-8. Connector Assembly (3 of 4) Figure 6-9. Connector Assembly (4 of 4) 3121325 – JLG Lift –...

  • Page 126: Disassembly

    The wedge lock has slotted openings in the forward, or mating end. These slots accommodate circuit testing in the field, by using a flat probe such as a pocket knife. DO NOT use a sharp point such as an ice pick. – JLG Lift – 3121325...

  • Page 127: Service - Voltage Reading

    This nullifies the effectiveness of the connector seals and could result in system failure. Figure 6-11. Connector Installation 3121325 – JLG Lift –...

  • Page 128: Working With Deutsch Connectors

    7. Hold the rear seal in place, as removing the contact may displace the seal. HD30/HDP20 Series Assembly Figure 6-14. HD/HDP Contact Installation 8. Grasp contact about 25mm behind the contact crimp barrel. 9. Hold connector with rear grommet facing you. 6-10 – JLG Lift – 3121325...

  • Page 129: Hd30/Hdp20 Series Disassembly

    12. Slide tool along into the insert cavity until it engages contact and resistance is felt. 13. Pull contact-wire assembly out of connector. Figure 6-17. HD/HDP Unlocking Contacts NOTE: Do Not twist or insert tool at an angle. 3121325 – JLG Lift – 6-11...

  • Page 130: Electrical Schematic - Sheet 1 Of 15

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Electrical Schematic Figure 6-18. Electrical Schematic - Sheet 1 of 15 6-12 – JLG Lift – 3121325...

  • Page 131: Electrical Schematic - Sheet 2 Of 15

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-19. Electrical Schematic - Sheet 2 of 15 3121325 – JLG Lift – 6-13...

  • Page 132: Electrical Schematic - Sheet 3 Of 15

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-20. Electrical Schematic - Sheet 3 of 15 6-14 – JLG Lift – 3121325...

  • Page 133: Electrical Schematic - Sheet 4 Of 15

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-21. Electrical Schematic - Sheet 4 of 15 3121325 – JLG Lift – 6-15...

  • Page 134: Electrical Schematic - Sheet 5 Of 15

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-22. Electrical Schematic - Sheet 5 of 15 6-16 – JLG Lift – 3121325...

  • Page 135: Electrical Schematic - Sheet 6 Of 15

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-23. Electrical Schematic - Sheet 6 of 15 3121325 – JLG Lift – 6-17...

  • Page 136: Electrical Schematic - Sheet 7 Of 15

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-24. Electrical Schematic - Sheet 7 of 15 6-18 – JLG Lift – 3121325...

  • Page 137: Electrical Schematic - Sheet 8 Of 15

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-25. Electrical Schematic - Sheet 8 of 15 3121325 – JLG Lift – 6-19...

  • Page 138: Electrical Schematic - Sheet 9 Of 15

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS DWNOUTP DWNINP DRVOUTP DRVINP STARTOUTP STARTINP DEADOUTP DEADINP SUPPLY Figure 6-26. Electrical Schematic - Sheet 9 of 15 6-20 – JLG Lift – 3121325...

  • Page 139: Electrical Schematic - Sheet 10 Of 15

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-27. Electrical Schematic - Sheet 10 of 15 3121325 – JLG Lift – 6-21...

  • Page 140: Electrical Schematic - Sheet 11 Of 15

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-28. Electrical Schematic - Sheet 11 of 15 6-22 – JLG Lift – 3121325...

  • Page 141: Electrical Schematic - Sheet 12 Of 15

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-29. Electrical Schematic - Sheet 12 of 15 3121325 – JLG Lift – 6-23...

  • Page 142: Electrical Schematic - Sheet 13 Of 15

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-30. Electrical Schematic - Sheet 13 of 15 6-24 – JLG Lift – 3121325...

  • Page 143: Electrical Schematic - Sheet 14 Of 15

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS (black) Figure 6-31. Electrical Schematic - Sheet 14 of 15 3121325 – JLG Lift – 6-25...

  • Page 144: Electrical Schematic - Sheet 15 Of 15

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-32. Electrical Schematic - Sheet 15 of 15 6-26 – JLG Lift – 3121325...

  • Page 145: Main Terminal Box Wiring Description

    X1/29-3 KT/A1 UL1569 18R DIODE3/K X1/60-1 UL1569 18BR DIODE3/A X1/32B-2 UL1569 18BL X1/D-4 BUZ/2 UL1569 18R DIODE4/K X1/60-4 UL1569 18BR DIODE4/A X1/13B-4 UL1569 18R DIODE6/K X1/60-2 UL1569 18BR DIODE6/A X1/38-2 UL1569 18GR X1/60-3 BUZ/1 3121325 – JLG Lift – 6-27...
  • Page 146 C2 J1B/4 X1/23-4 UL1569 18GR C2 J1B/5 trig contr J2/5 UL1569 18GR trig contr J2/6 X1/9-4 UL1569 18GR C2 J1B/6 X1/19-4 UL1569 18GR D15/K X1/21B-4 UL1569 18GR D15/A C2 J1B/7 UL1569 18GR D16/K X1/22-4 6-28 – JLG Lift – 3121325...
  • Page 147 3 X1/50-1 ader 4 X1/51-1 LIYYJZ5X0,5 UL OUTRIGGER 3 SWITCH ader 1 X1/45-1 ader 2 X1/46-2 ader 3 X1/49-1 ader 4 X1/50-2 LIYYJZ5X0,5 UL OUTRIGGER 2 SWITCH ader 1 X1/44-1 ader 2 X1/45-2 3121325 – JLG Lift – 6-29...
  • Page 148 PRESSURE NIVO SWITCH ader 1 X1/53-1 ader 2 X1/54-1 LIYYJZ2X1 UL HORN ader 1 X1/25-1 ader 2 X1/G-2 LIYYJZ2X1 UL S 8M ader 1 X1/36-1 ader 2 X1/37-1 LIYYJZ5X1 UL MAX HEIGHT SWITCH ader 1 X1/36-1 6-30 – JLG Lift – 3121325...
  • Page 149 ENGINE BOX ader 1 X1/8-1 ader 2 X1/9-1 ader 3 X1/41A-1 ader 4 X1/58-3 ader 5 X1/I-1 ader 6 LIYYJZ5X1 UL 2,5m SWITCH ader 1 X1/34A-2 ader 2 X1/26-1 ader 3 X1/35-2 ader 4 X1/36-3 3121325 – JLG Lift – 6-31...
  • Page 150 OUTRIGGER 4 VALVE ader 11 J7/11 J7/12 LIYYJZ25X0,75UL GROUND PANEL ader 1 X1/1-1 ader 2 X1/2-1 ader 3 X1/3-1 ader 4 X1/4-2 ader 5 X1/5-2 ader 6 X1/6A-2 ader 7 X1/7B-2 ader 8 X1/9-2 6-32 – JLG Lift – 3121325...
  • Page 151 KTC/21 ader 17 X2/17 X1/59-1 ader 18 X2/18 C2 LED/GEEL ader 19 X2/19 KL/21 ader 20 X2/20 C2 LED/BLAUW ader 21 X2/21 ader 22 X2/22 C2 LED/ZWART ader 23 X2/23 X1/58-1 ader 24 X2/24 3121325 – JLG Lift – 6-33...
  • Page 152 18 X1/58-2 ader 19 X1/A-1 ader 20 D25/A ader 21 X1/34B-1 ader 22 ader 23 ader 24 LIYYJZ2X1 UL ader 1 Splice6/R S1/11 ader 2 Splice8/R S1/12 UL 1569 18R K VS/Y1 K VS/Y2 6-34 – JLG Lift – 3121325...
  • Page 153 X1/22-3 398 ANSI DIO KD2/A1 KD2/A2 DIO BY550 K TC/A2 K TC/A1 398 ANSI DIO X1/51-3 X1/30-3 398 ANSI DIO X1/56-2 X1/30-2 DIO BY550 KL/A2 KL/A1 CSS 1001 (2x) CSS 1001 (4x) CSS 1009 3121325 – JLG Lift – 6-35...
  • Page 154 These are designated as 1 = Top Top, 2 = Tob Bottom, 3 = Bottom Top, and 4 = Bottom Bottom. Refer to Figure 5-1., Main Terminal Box) Position 2 = The position on the end item (if not specified in the table, it can be located on the electrical schematic). 6-36 – JLG Lift – 3121325...
  • Page 155 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS NOTES: 3121325 – JLG Lift – 6-37...

  • Page 156: Electrical Diagram - Page 1 Of 2

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Electrical Diagram STROBE LIGHTS Figure 6-33. Electrical Diagram - Page 1 of 2 6-38 – JLG Lift – 3121325...

  • Page 157: Electrical Diagram - Page 2 Of 2

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS BATTERY DISCONNECT SWITCH PLATFORM CONSOLE Figure 6-34. Electrical Diagram - Page 2 of 2 3121325 – JLG Lift – 6-39...
  • Page 158 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Hydraulic Diagram Figure 6-35. Hydraulic Components - H900067 RevF - Page 1 of 2 6-40 – JLG Lift – 3121325...
  • Page 159 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-36. Hydraulic Components - H900067 RevF - Sheet 2 of 2 3121325 – JLG Lift – 6-41...
  • Page 160 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Hydraulic Schematic Figure 6-37. Hydraulic Schematic - 1001091321 RevD 6-42 – JLG Lift – 3121325...
  • Page 162 +61 2 65 810122 +44 (0)161 654 1001 JLG Deutschland GmbH JLG Equipment Services Ltd. JLG Industries (Italia) s.r.l. Oshkosh - JLG Singapore T. Max-Planck-Str. 21 Rm 1107 Landmark North Via Po. 22 E. P. Ltd. D - 27721 Ritterhude - Ihlpohl...

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