JLG 80HX Service And Maintenance Manual
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JLG 80HX Service And Maintenance Manual

JLG 80HX Service And Maintenance Manual

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Service and Maintenance Manual
Model
80HX
80HX+6
80HXER
3120271
November 19, 2003
ANSI

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Summary of Contents for JLG 80HX

  • Page 1 Service and Maintenance Manual Model 80HX 80HX+6 80HXER 3120271 November 19, 2003 ANSI...
  • Page 2 CALIFORNIAN PROPOSITION 65 BATTERY WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemical known to the State of California to cause cancer and reproductive harm. WASH HANDS AFTER HANDLING!

  • Page 3: A General

    Relieve system pressure by cycling the applicable control several times with the engine stopped and ignition on, to direct any line pressure back into the reservoir. Pressure 3120271 – JLG Lift –...
  • Page 4 INTRODUCTION REVISON LOG March, 1986 - Original Issue February, 1997 - Revised March 1, 1999 - Revised September 7, 2000 - Revised May 21, 2003 - Revised November 19, 2003 - Revised – JLG Lift – 3120271...

  • Page 5: Table Of Contents

    80HX w/Hydraulic Controls........
  • Page 6 Welding on JLG Equipment ............2-6 Do the Following When Welding on JLG Equipment ......2-6 Do NOT Do the Following When Welding on JLG Equipment .
  • Page 7 Footswitch Adjustment ............3-42 3120271 – JLG Lift –...
  • Page 8 Boom Lift Cylinder Installation ..........5-15 – JLG Lift –...
  • Page 9 Racine Proportional Valve Pressure Setting - Prior to Mid 1987 (Sheet 1 of 2) ....5-17 5-13. Racine Proportional Valve Pressure Setting - Prior to Mid 1987 (Sheet 2 of 2) ....5-18 3120271 – JLG Lift –...
  • Page 10 Hydraulic Schematic (Sheet 6 of 6) ..........6-45 – JLG Lift –...
  • Page 11 Electrical System - Troubleshooting ..........6-18 3120271 – JLG Lift –...
  • Page 12 TABLE OF CONTENTS (Continued) This page left blank intentionally. viii – JLG Lift – 3120271...

  • Page 13: Capacities

    Mid RPM - 1800, no load. High RPM - 3000, no load. Alternator - 40 Amp, belt drive. Battery - 1000 cold cranking Amps, 210 minutes reserve capacity, 12 VDC. Horsepower - 63 @ 2800 RPM, no load. 3120271 – JLG Lift –...

  • Page 14: Engine - Ford Lrg-423

    Steer, Rotate - 9.5 GPM (36 LPM). February 1988 - 42.5:1. 2WD with Racine proportional valves built February 1988 Clockwise Rotation. to present - 43:1. 2WD with Racine or Vickers proportional valves built prior to October 1989 - 30.04:1. – JLG Lift – 3120271...

  • Page 15: Auxiliary Power Pump

    Return - Non-Bypass Type. 10 Microns Nominal. Maximum Tire Load 80HX - 15500 lbs. (7037 kg) @103 psi (7.1 Bar) 80HX + 6 - 18295 (8299 kg) @107 psi (7.4 Bar) Wheelbase 10 ft. (3 m) 3120271 – JLG Lift –...

  • Page 16: Torque Requirements

    * Check swing bearing bolts for security after first 50 hours of operation and every 600 hours thereafter. **Retorque after first 200 hours of operation and every 500 hours thereafter. NOTE: See Procedure Section for tightening sequence of turntable bearing bolts. – JLG Lift – 3120271...

  • Page 17: Lubrication Diagram

    SECTION 1 - SPECIFICATIONS Figure 1-1. Lubrication Diagram 3120271 – JLG Lift –...

  • Page 18: Lubrication Chart

    Boom Chain Extension Sheave 2 Grease Fittings Remote Access Swing Bearing 1 Grease Fitting Remote Access Lift Cylinder (Barrel End) 1 Grease Fitting Remote Access Master Cylinder (Barrel End) 1 Grease Fitting Master Cylinder (Rod End) – JLG Lift – 3120271...
  • Page 19 Pinion Gear Teeth Apply by brush Axle Beam (Extendable Axles) Apply by brush Axle Lock Pin (Extendable Axles) Oscillating Axle Pivot 1 Grease Fitting 2 Grease Fittings Oscillation Cylinder 2 Grease Fittings Extend-A-Reach Pivot (If Equipped) 3120271 – JLG Lift –...
  • Page 20 Lubrication intervals are based on machine operation under normal conditions. For machines used in multi shift operations and/or exposed to hostile environments or conditions, lubrication frequencies must be increased accordingly. EPGL Extreme Pressure Gear Lube Hydraulic Fluid (Mobil #424 or equivalent) Multi-Purpose Grease – JLG Lift – 3120271...

  • Page 21: Ford Engines

    -5° F - +70° F. 10W-30 -5° F - +85° F. 10W-40 +15° F - +75° F. 15W-30 Above +15° F. 15W-40 * This viscosity can be used at colder temperatures only with engine oil preheating. 3120271 – JLG Lift –...

  • Page 22: Lubrication Specifications

    Mobil DTE11. Table 1-6.Lubrication Specifications SPECIFICATIONS NOTE: Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may Multipurpose Grease having a minimum dripping point of not contain the same required additives or be of 350 degrees F.

  • Page 23: Hx W/Hydraulic Controls

    SECTION 1 - SPECIFICATIONS 80HX w/Hydraulic Controls Rotate - 2500 psi (172 Bar) Level - 1500 psi, 2500 psi Split Valve (103 Bar, Proportional Relief - Standard 3200 psi (220 Bar); 172 Bar Split Valve). Prop. Tele 3850 psi (265 Bar).

  • Page 24: Boom Tape

    Blue - 193.9 in. (492.5 cm). Complete Machine - 4WD No Options 1320 29106 Canadian Standard Complete Machine (80HX+6) 2WD No Options 1444 31856 Red - 53 in. (134.6 cm). Yellow - 42 in. (106.7 cm). Blue - 171.8 in. (436.4 cm).

  • Page 25: Critical Stability Weights

    Ford LRG 423 Cummins 4B3.9 Tire & Wheels 15x19.5 Tire Wheel Foam Fill Figure 1-2. Serial Number Locations 3120271 – JLG Lift – 1-13...

  • Page 26: Torque Chart - (In/Lb - Ft/Lb). (For Astm Fasteners)

    SECTION 1 - SPECIFICATIONS Figure 1-3. Torque Chart - (In/Lb - Ft/Lb). (For ASTM Fasteners) 1-14 – JLG Lift – 3120271...

  • Page 27: Torque Chart (Metric Conversion) - (For Astm Fasteners)

    SECTION 1 - SPECIFICATIONS Figure 1-4. Torque Chart (Metric Conversion) - (For ASTM Fasteners) 3120271 – JLG Lift – 1-15...

  • Page 28: Torque Chart - (N, M) - (For Metric Class Fasteners)

    698.0 5860 4400 4690 6440 Note: These torque values do not apply to cadmium plated fasteners. METRIC CLASS 8.8 METRIC CLASS 10.9 Figure 1-5. Torque Chart - (N, m) - (For Metric Class Fasteners). 1-16 – JLG Lift – 3120271...

  • Page 29: Section 2 - General

    Factory-Certified Service Technician as a per- Preparation, Inspection, and Maintenance son who has successfully completed the JLG Service Training School for the subject JLG product model. Refer- It is important to establish and conform to a comprehen- ence the machine Service and Maintenance Manual and sive inspection and preventive maintenance program.

  • Page 30: Service And Guidelines

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

  • Page 31: Component Disassembly And Reassembly

    If a bolt is too short, there will not be enough thread area to engage and hold the part properly. When replacing bolts, use only those having the same specifications of the original, or one which is equivalent. 3120271 – JLG Lift –...

  • Page 32: Lubrication And Information

    Avoid mixing petroleum and synthetic base oils. JLG tion. Every precaution must be taken to keep Industries recommends changing the hydraulic oil hydraulic oil clean, including reserve oil in storage.

  • Page 33: Cylinder Drift Test

    If the cylinder passes this test, it is acceptable. age the bearing during installation and opera- tion. NOTE: This information is based on 6 drops per minute cyl- inder leakage. 3120271 – JLG Lift –...

  • Page 34: Welding On Jlg Equipment

    Silicone Dielectric Compound must be used on all electri- cal connections for the following reasons: Do the Following When Welding on JLG • To prevent oxidation at the mechanical joint between Equipment male and female pins.

  • Page 35: Preventive Maintenance And Inspection Schedule

    “Annual Machine for straightness of rod. Inspection Report” form. Forms are supplied with each new machine and are also available from JLG Customer 14. Check for condition of element; replace as neces- Service. Form must be completed and returned to JLG sary.

  • Page 36: Preventive Maintenance And Inspection Schedule

    Platform Rotator 5,11 Footswitch 1,11 Controllers 1,11 1,11 Switches Placards and Decals Control Tags Valves 1,11 Carrier (Hoses and Cables) Hydraulic Hoses Capacity Indicator Pins Bushings Wear Pads Chains Chain Adjusters Cylinders 1,5,6,13 Sheaves Drift Test* – JLG Lift – 3120271...
  • Page 37 Main Hydraulic Pump Auxiliary Power Pump Valves 1,11 Hydraulic Filters Hydraulic Hoses Hydraulic Oil Tank** 6,14 Breather Hydraulic Tank Fuel Tank Cylinders 1,5,6,13 Hood Doors Placards and Decals Swing Bearing 9, 12 Swing Brake 1,5,6 Swing Hub 3120271 – JLG Lift –...
  • Page 38 SECTION 2 - GENERAL This page left blank intentionally. 2-10 – JLG Lift – 3120271...

  • Page 39: Section 3 - Chassis & Turntable

    With seal removed, outside bearing cone (4) can be removed. 10. If necessary, remove inner and outer bearing cones (3,5) using a suitable slide hammer puller. IMPORTANT WHEN REBUILDING TORQUE HUB, REMOVE AND REPLACE ALL O-RINGS AND RETAINING RINGS. 3120271 – JLG Lift –...

  • Page 40: Torque Hub Assembly

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-1. Torque Hub Assembly – JLG Lift – 3120271...

  • Page 41: Repair

    (15). 6. Repeat steps 1 thru 5 for remaining two cluster gears. 7. Clean and inspect all parts in accordance with para- graph b. Replace parts as necessary. 3120271 – JLG Lift –...

  • Page 42: Input Shaft Assembly

    EYE PROTECTION SHOULD BE WORN DURING RETAINING RING REMOVAL AND INSTALLATION. 1. Carefully remove retaining ring (34) from input shaft (35) and discard retaining ring. 2. Remove two spacers (31) and spring (32) from input shaft. – JLG Lift – 3120271...
  • Page 43 5. internal gear. 6. Place bearing shim (8) over end of spindle and against bearing cone. EYE PROTECTION SHOULD BE WORN DURING RETAINING RING INSTALLATION. 3120271 – JLG Lift –...
  • Page 44 Find punch marked tooth on each large gear and locate at 12 o’clock (straight up) from each planet pin. Marked tooth will be located just under carrier on upper two gears. – JLG Lift – 3120271...
  • Page 45 (18). Counterbore in bore of input gear must be to outside of carrier assembly. 22. Place cover assembly over ring gear with oil level check plug in cover located approximately 90 degrees from oil fill plug in hub. 3120271 – JLG Lift –...

  • Page 46: Drive Brake, Ausco - Machines Built Prior To October 1987

    I.D. grooves. Back-up rings will be damaged and should not be removed if replacement is not planned. 7. Bleeder (19) can be removed and inspected to assure spring loaded ball moves freely and is free of contamination. – JLG Lift – 3120271...

  • Page 47: Cleaning And Inspection

    4. Assemble piston (14) into power plate (20) using a shop press, being careful not to damage the o-rings or teflon back-up rings. Visually align the center of the cutouts in the piston with the torque pin (9) holes in the power plate. 3120271 – JLG Lift –...

  • Page 48: Drive Brake, Mico - Machines Built Prior To October 1987

    9. Remove bearings (7,23) from shaft using an appro- priate bearing puller. The discs and friction discs will then slide off either end of shaft. 10. Remove dowel pins (22), springs (20,21) and oil seal (24) from housing (25). 3-10 – JLG Lift – 3120271...

  • Page 49: Bleeding

    Torque capscrews to 55 ft. lbs. (75 NM). top port. Pressure should not exceed 100 psi (6.9 Bar) during bleeding. 3. Apply sufficient pressure to release brake and check for proper operation. 3120271 – JLG Lift – 3-11...

  • Page 50: Drive Brake, Ausco - Machines Built Prior To 1992

    NOTE: This drive brake was used on 80HX 2WD from Octo- 11. Pressure relief valve (23) can be removed and ber 1987 to January 1992, 80HX 4WD Prior to Febru-...

  • Page 51: Drive Brake, Ausco - Machines Built Prior To 1992

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-4. Drive Brake, Ausco - Machines Built Prior to 1992 3120271 – JLG Lift – 3-13...

  • Page 52: Drive Brake, Mico - Machines Built From 1992 To Present

    2. Remove case seal (11) from housing (7) then remove bleeder screw (14) from end cover (13). 3. Remove piston (24) from end cover (13). 4. Remove o-ring (20), back-up ring (21), o-ring (18) and back-up ring (19) from piston (24). 3-14 – JLG Lift – 3120271...

  • Page 53: Drive Brake, Mico - Machines Built From 1992 To Present

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-5. Drive Brake, Mico - Machines Built from 1992 to Present 3120271 – JLG Lift – 3-15...

  • Page 54: Spring Loading

    7. Place a new friction disc (22) on shaft (4) until it con- tacts return plate (8). 8. Add additional new discs (23) and new friction discs (22) as required to complete assembly. 9. Insert separators (10) in holes of return plate (8). 3-16 – JLG Lift – 3120271...

  • Page 55: Governor Checks And Adeco Adjustment, Lrg423 & Lrg425

    This should advance the governor throttle lever to the maximum wide open position. Verify the wide open position of the Figure 3-7. Governor Adjustment, LRG-423 & LRG-425 with Adeco 3120271 – JLG Lift – 3-17...

  • Page 56: Adeco Adjustment, Lrg-423 & Lrg-425

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-8. Adeco Adjustment, LRG-423 & LRG-425 3-18 – JLG Lift – 3120271...

  • Page 57: Precision Governor Adjustment - Lrg-423 & Lrg-425 (Sheet 1 Of 2)

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-9. Precision Governor Adjustment - LRG-423 & LRG-425 (Sheet 1 of 2) 3120271 – JLG Lift – 3-19...

  • Page 58: Precision Governor Adjustment - Lrg-423 & Lrg-425 (Sheet 2 Of 2)

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-10. Precision Governor Adjustment - LRG-423 & LRG-425 (Sheet 2 of 2) 3-20 – JLG Lift – 3120271...

  • Page 59: Adeco Actuator Adjustments - F4L912

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-11. Adeco Actuator Adjustments - F4L912 3120271 – JLG Lift – 3-21...

  • Page 60: Checks

    5. With the aid of an assistant at the platform console, start the engine and allow it to come up to operating temperature. Then have the assistant depress the footswitch and place the engine speed switch to HIGH ENGINE. 3-22 – JLG Lift – 3120271...

  • Page 61: E331 Precision Governor And Adjustments - Ford Engines

    Turn the adjusting screw in small Engine pot. (See E-331 Electronics - Adjustment increments only until response time is correct. Turn- Locations.) ing the adjusting screw too far CW can cause surg- ing (see step 7 above). 3120271 – JLG Lift – 3-23...

  • Page 62: Mounting-Actuator

    SLIGHTLY (PERHAPS 0.030”), SO THAT THE ACTUATOR IS JUST OFF ITS INTERNAL STOP , AND IS PULLING THE BUTTER-FLY AGAINST ITS STOP . This insures that the carburetor can fully close to idle on load dumps, minimiz- ing over speeds. 3-24 – JLG Lift – 3120271...

  • Page 63: Mounting-Controller

    A & B of the 8 pin connector when the Governor is controlling engine speed. Verify this. Improper hook-up can damage electronics. Re-check wiring before applying power. 3120271 – JLG Lift – 3-25...

  • Page 64: Check-Out And Initial Start-Up Procedures

    The ideal gain setting will provide a compromise between quick response and good stability. This will usually show up as 1 to 3 engine pulsation’s before leveling out at the set RPMS when going from idle to high engine. 3-26 – JLG Lift – 3120271...
  • Page 65 8 pin connector on the E-331 (A is +, B is -). Voltage speed. reading should be the same as at battery. If not, shut down, and correct wiring. 10. Re-install the back cover on the E-331. Final mount the controller. 3120271 – JLG Lift – 3-27...
  • Page 66 SECTION 3 - CHASSIS & TURNTABLE 3-28 – JLG Lift – 3120271...

  • Page 67: Troubleshooting

    You should see 5 - 30 5. Damaged Controller or Actuator. VDC. b. The above checks do not guarantee a good speed signal, but their absence proves that there is a problem. 3120271 – JLG Lift – 3-29...
  • Page 68 No binding or rubbing should be felt within the Governor. If steps 1a. thru 1e. can be accomplished as described, the Governor is probably OK. It recognizes underspeed, overspeed, onspeed and is not binding internally. 3-30 – JLG Lift – 3120271...

  • Page 69: Automatic Choke Adjustment Procedure

    1/2 to 1 ball dia. (Ref. to page 43 par. 1). Automatic Choke Adjustment Procedure (For all JLG 1.IL and 2.3L Ford carbureted engines) 1. At 70°F the choke plate should be open 1/3” (not touching the choke bore).

  • Page 70: Cold Weather Starting Difficulty

    NOTE: If EMS switch is pulled on for an extended period of time, i.e. 1 to 2 minutes, without attempting to start the engine, the choke will start to open due to elec- trical heating. 3-32 – JLG Lift – 3120271...

  • Page 71: Checking The Ignition

    3. Check Fuel Filter: 2. Check the Spark Plugs for presence of spark. If NOTE: Some JLG machines have a fuel return line between there is no spark at the plugs during cranking: the fuel pump and carburetor, if this return line is a.

  • Page 72: Throttle Checks And Adjustments - Deutz Engine

    NOTE: This check is designed to replace the existing bear- Figure 3-12. Swing Bearing Bolt Feeler Gauge Check ing bolt torque checks on JLG Lifts in service. This check must be performed after the first 50 hours of machine operation and every 600 hours of machine operation thereafter.

  • Page 73: Wear Tolerance

    ON AN AERIAL LIFT. IT IS HERE THAT THE STRESSES OF LIFT- ING ARE CONCENTRATED, AT THE CENTER OF ROTATION. BECAUSE OF THIS, PROPER MAINTENANCE OF THE SWING BEARING BOLTS IS A MUST FOR SAFE OPERATION. 3120271 – JLG Lift – 3-35...
  • Page 74 2. Apply a layer of Devcon (or equivalent) filler approxi- mately 0.125 inches (0.318 cm) thick on the bearing mounting plate on the frame. 3-36 – JLG Lift – 3120271...

  • Page 75: Swing Bearing Tolerance Boom Placement

    STRUCTURAL LINK BETWEEN THE FRAME AND TURNTABLE, IT from the fore and aft centerline of the turntable). IS IMPERATIVE THAT SUCH REPLACEMENT HARDWARE MEETS JLG SPECIFICATIONS. USE OF GENUINE JLG HARDWARE IS 10. Ensure that all turntable and bearing attachment HIGHLY RECOMMENDED.

  • Page 76: Swing Bearing Torquing Sequence

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-15. Swing Bearing Torquing Sequence 3-38 – JLG Lift – 3120271...

  • Page 77: Swing Bearing Torque Values

    25. At the ground control station, use the boom lift con- trol to lower the boom to the stowed position. 26. Using all applicable safety precautions, activate the hydraulic system and functionally check the swing system for proper and safe operation. 3120271 – JLG Lift – 3-39...

  • Page 78: Oscillating Axle Bleeding Procedure

    12. Transfer the 6 in. (15.2 cm) high block to the left front wheel and repeat steps 2 thru 7, substituting the word “right” for “left” in step 5. 13. Perform oscillating axle lockout test. 3-40 – JLG Lift – 3120271...

  • Page 79: Oscillating Axle Lockout Test

    11. Carefully activate SWING control lever and position boom over left side of machine. 12. With boom over left side of machine, place DRIVE control lever to REVERSE and drive machine off of block and ramp. 3120271 – JLG Lift – 3-41...

  • Page 80: Spark Arrestor Mufflers

    3. While the engine is operating, place the three posi- tion LP/Gasoline switch at the ground control station to the center “off” position. Allow the engine to oper- ate, without load, until the engine begins to “stum- ble” from lack of gasoline. 3-42 – JLG Lift – 3120271...

  • Page 81: Section 4 - Boom & Platform

    Remove the cotter pins, nuts and bolts securing the chain attach blocks to the clevis bolt assem- bly. Remove the attach blocks. e. Separate the top and bottom clevis bolt assem- bly plates. Remove the clevis bolt from the bot- tom plate. 3120271 – JLG Lift –...

  • Page 82: Boom Assembly (Sheet 1 Of 2)

    SECTION 4 - BOOM & PLATFORM Figure 4-1. Boom Assembly (Sheet 1 of 2) – JLG Lift – 3120271...

  • Page 83: Boom Assembly (Sheet 2 Of 2)

    SECTION 4 - BOOM & PLATFORM Figure 4-2. Boom Assembly (Sheet 2 of 2) 3120271 – JLG Lift –...

  • Page 84: Inspection

    13. Inspect all threaded components for damage such which secure the extension chain and retraction as stretching, thread deformation, or twisting. chains to the block; remove the clevis pin, washers Replace as necessary. and chains from the block. – JLG Lift – 3120271...

  • Page 85: Assembly

    10. Slide the fly section into the mid section. Shim the section) as follows: boom, if necessary, for a total of 1/16 inch (.062) a. Align the attaching holes of the chain attach- clearance. ment clevis bolt with those of the extension 3120271 – JLG Lift –...

  • Page 86: Installation

    Properly position the assembled hoses, electri- cal cable, and the harnessing power track onto 12. Adjust the extend and retract chain systems as the base section carrier tube. Carefully feed the required and secure the adjustment locknuts. – JLG Lift – 3120271...

  • Page 87: Boom Chains

    SECTION 4 - BOOM & PLATFORM 13. As necessary, lubricate all points requiring lubrica- JLG Industries, Inc. requires a complete boom disassem- tion. bly, per instructions outlined in Section 4.1, Boom Mainte- nance, every two years. All boom chains and related components (i.e., sheaves, pins, sprockets, wear pads,...

  • Page 88: Inspection Procedures

    Fatigue and ultimate strength failures on anchors and must be corrected promptly. Do not JLG Lifts are incurred as a result of severe abuse as repair chains; if a section of chain is damaged, design specs are well within the rated lifting capacity replace the entire chain set.

  • Page 89: Chain Stretch Tolerance

    Two conditions must be pitch pitches present; corrosive agent and static stress. ARC-LIKE CRACKED PLATES 2.00 in. (5.08 cm) 14 in. (36 cm) or 7 0.42 in. (1.07 cm) (STRESS CORROSION) pitch pitches 3120271 – JLG Lift –...

  • Page 90: Wear Pads

    Figure 4-4. Telescope Cylinder Eccentric Bushing 4.5 HORIZONTAL HIGH SPEED CUTOUT SWITCH ADJUSTMENT PROCEDURE Adjust the switch to trip when the boom reaches 0 degrees +0 degrees /-3 degrees. 4-10 – JLG Lift – 3120271...

  • Page 91: Capacity Indicator Boom Tape Replacement

    READING OF CAPACITY INDICATOR. Indicator Decal Installation 1. Clean and dry wheel surface before installing decal. 2. Locate bottom of dial decal 1/16” from 1/8” dia. hole on face of gage wheel. Figure 4-7. Belleville Washers 3120271 – JLG Lift – 4-11...
  • Page 92 SECTION 4 - BOOM & PLATFORM This page left blank intentionally. 4-12 – JLG Lift – 3120271...

  • Page 93: Section 5 - Hydraulics

    3120271 – JLG Lift –...
  • Page 94 SECTION 5 - HYDRAULICS Figure 5-1. Proportional Control Valve – JLG Lift – 3120271...

  • Page 95: Cylinder Checking Procedure

    5. If used, remove the boom prop from beneath the boom, activate the hydraulic system and run the cyl- inder through one complete cycle to check for leaks. 3120271 – JLG Lift –...

  • Page 96: Cylinders With Dual Counterbalance Valves

    7. If used, remove the lifting device from the upright or remove the prop from below the boom, activate the hydraulic system and run the cylinder through one complete cycle to check for leaks. – JLG Lift – 3120271...
  • Page 97 SECTION 5 - HYDRAULICS Figure 5-2. Boom Positioning and Support - Cylinder Repair 3120271 – JLG Lift –...
  • Page 98 SECTION 5 - HYDRAULICS Figure 5-3. Typical Hydraulic Cylinders (Sheet 1 of 4) – JLG Lift – 3120271...
  • Page 99 SECTION 5 - HYDRAULICS Figure 5-4. Typical Hydraulic Cylinders (Sheet 2 of 4) 3120271 – JLG Lift –...
  • Page 100 SECTION 5 - HYDRAULICS Figure 5-5. Typical Hydraulic Cylinders (Sheet 3 of 4) – JLG Lift – 3120271...
  • Page 101 SECTION 5 - HYDRAULICS Figure 5-6. Typical Hydraulic Cylinders (Sheet 4 of 4) 3120271 – JLG Lift –...
  • Page 102 CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES. 8. With the barrel clamped securely, apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel. 5-10 – JLG Lift – 3120271...

  • Page 103: Cleaning And Inspection

    12. If applicable, inspect the thread ring for scoring or material. Repair as necessary. other damage. Dress the threads or applicable sur- faces as necessary. 3120271 – JLG Lift – 5-11...

  • Page 104: Assembly

    NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. WHEN REBUILDING THE LIFT, SLAVE LEVEL, TELESCOPE, Apply a light film of hydraulic oil to all components STEER, AND EXTEND-A-REACH SLAVE AND LIFT CYLINDERS, prior to assembly.

  • Page 105: Cylinder Piston Nut Torque Specifications

    NOTE: After torquing piston nut spot drill cylinder rod for port plug. Also plug the extend and retract ports until setscrews. cylinder is installed in boom. 3120271 – JLG Lift – 5-13...

  • Page 106: Cylinder Removal And Installation

    10. Attach a suitable sling to the telescope cylinder. each side of the boom. Note that loctite 242 is Support the cylinder with an overhead crane or required on the capscrew threads. other suitable lifting device. 5-14 – JLG Lift – 3120271...

  • Page 107: Boom Lift Cylinder Removal

    Lithium Soap Base retaining hardware. Grease (TEXACO CODE 1912 OR EQUIVALENT) prior to assembly. 3. Remove the cylinder port plugs and hydraulic line caps and correctly attach the lines to the cylinder ports. 3120271 – JLG Lift – 5-15...

  • Page 108: Racine Proportional Air Gap Adjustment

    Lightly tap the end of the plunger with all parts assembled. 9. Extend - A - Reach Valve Pressure and Speed Set- Recheck the air gap. tings are shown in Figure 5-30. 5-16 – JLG Lift – 3120271...
  • Page 109 SECTION 5 - HYDRAULICS Figure 5-12. Racine Proportional Valve Pressure Setting - Prior to Mid 1987 (Sheet 1 of 2) 3120271 – JLG Lift – 5-17...
  • Page 110 SECTION 5 - HYDRAULICS Figure 5-13. Racine Proportional Valve Pressure Setting - Prior to Mid 1987 (Sheet 2 of 2) 5-18 – JLG Lift – 3120271...

  • Page 111: Vickers Proportional Valve Pressure Setting - Prior To 1989 With Accessory Valve (Sheet 1 Of 4)

    SECTION 5 - HYDRAULICS Figure 5-14. Vickers Proportional Valve Pressure Setting - Prior to 1989 with Accessory Valve (Sheet 1 of 4) 3120271 – JLG Lift – 5-19...

  • Page 112: Vickers Proportional Valve Pressure Setting - Prior To 1989 With Accessory Valve (Sheet 2 Of 4)

    SECTION 5 - HYDRAULICS Figure 5-15. Vickers Proportional Valve Pressure Setting - Prior to 1989 with Accessory Valve (Sheet 2 of 4) 5-20 – JLG Lift – 3120271...

  • Page 113: Vickers Proportional Valve Pressure Setting - Prior To 1989 With Accessory Valve (Sheet 3 Of 4)

    SECTION 5 - HYDRAULICS Figure 5-16. Vickers Proportional Valve Pressure Setting - Prior to 1989 with Accessory Valve (Sheet 3 of 4) 3120271 – JLG Lift – 5-21...

  • Page 114: Vickers Proportional Valve Pressure Setting - Prior To 1989 With Accessory Valve (Sheet 4 Of 4)

    SECTION 5 - HYDRAULICS Figure 5-17. Vickers Proportional Valve Pressure Setting - Prior to 1989 with Accessory Valve (Sheet 4 of 4) 5-22 – JLG Lift – 3120271...

  • Page 115: Solenoid Valve Pressure Settings - Prior To Mid 1992 With Steering Wheel

    SECTION 5 - HYDRAULICS Figure 5-18. Solenoid Valve Pressure Settings - Prior to Mid 1992 with Steering Wheel 3120271 – JLG Lift – 5-23...

  • Page 116: Pressure And Flow Settings - Machines Prior To Mid 1992 With Steering Wheel

    SECTION 5 - HYDRAULICS Figure 5-19. Pressure and Flow Settings - Machines Prior to Mid 1992 with Steering Wheel 5-24 – JLG Lift – 3120271...

  • Page 117: Vickers Proportional Valve Pressure Setting - Mid 1992 To Present (Sheet 1 Of 4)

    SECTION 5 - HYDRAULICS Figure 5-20. Vickers Proportional Valve Pressure Setting - Mid 1992 to Present (Sheet 1 of 4) 3120271 – JLG Lift – 5-25...

  • Page 118: Vickers Proportional Valve Pressure Setting - Mid 1992 To Present (Sheet 2 Of 4)

    SECTION 5 - HYDRAULICS Figure 5-21. Vickers Proportional Valve Pressure Setting - Mid 1992 to Present (Sheet 2 of 4) 5-26 – JLG Lift – 3120271...

  • Page 119: Vickers Proportional Valve Pressure Setting - Mid 1992 To Present (Sheet 3 Of 4)

    SECTION 5 - HYDRAULICS Figure 5-22. Vickers Proportional Valve Pressure Setting - Mid 1992 to Present (Sheet 3 of 4) 3120271 – JLG Lift – 5-27...

  • Page 120: Vickers Proportional Valve Pressure Setting - Mid 1992 To Present (Sheet 4 Of 4)

    SECTION 5 - HYDRAULICS Figure 5-23. Vickers Proportional Valve Pressure Setting - Mid 1992 to Present (Sheet 4 of 4) 5-28 – JLG Lift – 3120271...

  • Page 121: Pressure Setting - All Hydraulic Machines (Sheet 1 Of 4)

    SECTION 5 - HYDRAULICS Figure 5-24. Pressure Setting - All Hydraulic Machines (Sheet 1 of 4) 3120271 – JLG Lift – 5-29...

  • Page 122: Pressure Setting - All Hydraulic Machines (Sheet 2 Of 4)

    SECTION 5 - HYDRAULICS Figure 5-25. Pressure Setting - All Hydraulic Machines (Sheet 2 of 4) 5-30 – JLG Lift – 3120271...

  • Page 123: Pressure Setting - All Hydraulic Machines (Sheet 3 Of 4)

    SECTION 5 - HYDRAULICS Figure 5-26. Pressure Setting - All Hydraulic Machines (Sheet 3 of 4) 3120271 – JLG Lift – 5-31...

  • Page 124: Pressure Setting - All Hydraulic Machines (Sheet 4 Of 4)

    SECTION 5 - HYDRAULICS Figure 5-27. Pressure Setting - All Hydraulic Machines (Sheet 4 of 4) 5-32 – JLG Lift – 3120271...

  • Page 125: Solenoid Valve Pressure Settings - Machines Built To Present

    SECTION 5 - HYDRAULICS Figure 5-28. Solenoid Valve Pressure Settings - Machines Built to Present 3120271 – JLG Lift – 5-33...

  • Page 126: Solenoid Valve Pressure Settings - 4 Wheel Steer

    SECTION 5 - HYDRAULICS Figure 5-29. Solenoid Valve Pressure Settings - 4 Wheel Steer 5-34 – JLG Lift – 3120271...

  • Page 127: Extend-A-Reach Valve Pressure And Speed Settings

    SECTION 5 - HYDRAULICS Figure 5-30. Extend-A-Reach Valve Pressure and Speed Settings 3120271 – JLG Lift – 5-35...
  • Page 128 SECTION 5 - HYDRAULICS This page left blank intentionally. 5-36 – JLG Lift – 3120271...

  • Page 129: General

    For aid in troubleshooting, refer to It should be noted that there is no substitute for a thor- the illustrated parts manual for hydraulic diagrams of the ough knowledge of the equipment and related systems. various circuits. 3120271 – JLG Lift –...

  • Page 130: Platform Assembly - Troubleshooting

    Repair or replace pump. Restricted or broken hydraulic line or fitting. Clean, repair, or replace line or fitting. Slave cylinder not functioning properly. Repair or replace cylinder. Electrical failure. See proper wiring diagram. Orifice plugged. Clean orifice. – JLG Lift – 3120271...

  • Page 131: Boom Assembly - Troubleshooting

    Determine cause and repair or replace valve. Electrical malfunction. See wiring diagram. Hydraulic system oil low. Replenish oil as necessary. Restricted or broken supply line on valve bank or Clean or replace line. hydraulic pump. 3120271 – JLG Lift –...
  • Page 132 Control valve not functioning properly. Repair or replace valve. Worn seals in lift cylinder. Replace seals. Cylinder not functioning properly. Repair or replace cylinder. Boom drifts down. Worn seals in lift cylinder. Replace seals. – JLG Lift – 3120271...
  • Page 133 Repair or replace control valve. Restricted or broken hydraulic line or fitting. Clean, repair, or replace line or fitting. Pressure setting incorrect. Check pressure/re-adjust as necessary. Telescope cylinder not functioning properly. Repair or replace cylinder. 3120271 – JLG Lift –...
  • Page 134 Repair or replace valve. Foreign object(s) wedged between swing motor Remove object(s), check for damage and repair pinion and swing gear. or replace component(s) as required. Swing control switch not functioning properly. Repair or replace swing control switch. – JLG Lift – 3120271...
  • Page 135 Swing motor not functioning properly. Repair or replace swing control switch. Worn or broken teeth on swing gear or swing Replace gear(s) as required. motor pinion. Restrictor valves(s) plugged. Clean or replace restrictor valve. 3120271 – JLG Lift –...

  • Page 136: Turntable Assembly - Troubleshooting

    Valve spool scored. Repair or replace valve. Excessive back pressure caused by restricted Remove line and clear obstruction or replace line return line to reservoir. as necessary. Damaged valve seals. Repair or replace valve as necessary. – JLG Lift – 3120271...

  • Page 137: Chassis Assembly - Troubleshooting

    Damaged wiring on speed control switch or high Repair or replace wiring. engine solenoid. Drive controller not functioning properly. Replace controller. Actuator not functioning properly. Repair or replace solenoid. Excessive load on engine. Reduce load. 3120271 – JLG Lift –...
  • Page 138 Machine being moved up too steep a grade. Remove machine from grade and check that drive system operates correctly. Grade too steep. See WARNING Placard on platform for specified grades and sideslopes. Towing valve not closed. Close towing valve. 6-10 – JLG Lift – 3120271...
  • Page 139 Repair or replace motor(s). Circuit breaker open. Determine and correct cause; reset circuit breaker. Counterbalance valve sticking on return side. Adjust return counterbalance out 3 turns - cycle drive - return to original position. 3120271 – JLG Lift – 6-11...
  • Page 140 Damaged wiring on control switch or solenoid See proper wiring diagram. valve. Control switch not functioning properly. Replace switch. Restricted or broken hydraulic line on valve Clean, repair or replace line. bank, hydraulic pump or rotary coupling. (If equipped.) 6-12 – JLG Lift – 3120271...
  • Page 141 Take pressure reading at steer valve and adjust as necessary. Bent cylinder rod. Repair or replace cylinder. Damaged tie rod. Replace tie rod. Crossover relief valve sticking. Repair crossover relief valve. Cylinder packing defective. Repair or replace cylinder. 3120271 – JLG Lift – 6-13...
  • Page 142 Crossover relief valve set too low or not function- Reset, repair or replace valve as required. ing properly. Steer linkages loose. Tighten linkage. Steer wheel toe-in not set properly. Adjust toe-in for 1/4 inch overall. Spindle bushings badly worn. Replace bushings. 6-14 – JLG Lift – 3120271...

  • Page 143: Hydraulic System - Troubleshooting

    Main relief valve set too low. Reset valve as required. Hydraulic system oil low. Replenish oil as necessary. Port relief set too high. Reset valve as required. Restricted or blocked return line. Repair or replace line. 3120271 – JLG Lift – 6-15...
  • Page 144 Determine and correct cause; reset circuit breaker. Engine is running. Shut down engine. Check valve in system leaking. Repair or replace check valve. Battery requires charging or will not hold a Charge or replace battery as required. charge. 6-16 – JLG Lift – 3120271...
  • Page 145 Control switch not functioning properly. Replace switch. Restricted or broken hydraulic line or fitting. Clean, repair or replace line or fitting. Pump motor solenoid not functioning properly. Replace solenoid. Pump motor not functioning properly. Repair or replace motor. 3120271 – JLG Lift – 6-17...

  • Page 146: Electrical System - Troubleshooting

    Faulty ignition and/or starter circuit wiring. Check wiring continuity. See proper wiring dia- gram. Malfunctioning starter solenoid or motor. Replace solenoid or motor in accordance with applicable manufacturer’s manual. Faulty start switch. Replace switch. 6-18 – JLG Lift – 3120271...
  • Page 147 Repair or replace limit switch. Drive controller defective. Replace controller. High engine solenoid malfunctioning. Repair or replace solenoid valve. Drive pressure switch malfunctioning. Replace pressure switch. Electrical malfunction. See wiring diagram. Defective engine governor. Repair or replace governor. 3120271 – JLG Lift – 6-19...
  • Page 148 SECTION 6 - TROUBLESHOOTING & SCHEMATICS This page left blank intentionally. 6-20 – JLG Lift – 3120271...

  • Page 149: Wiring Schematic Dual Fuel

    SECTION 6 - TROUBLESHOOTING & SCHEMATICS 4932813- Figure 6-1. Wiring Schematic Dual Fuel 3120271 – JLG Lift – 6-21...

  • Page 150: Wiring Diagram - Generator (Deutz Engines)

    SECTION 6 - TROUBLESHOOTING & SCHEMATICS 4931693 E Figure 6-2. Wiring Diagram - Generator (Deutz Engines) 6-22 – JLG Lift – 3120271...

  • Page 151: Wiring Diagram - Generator (Ford Engine)

    SECTION 6 - TROUBLESHOOTING & SCHEMATICS 4932806 B Figure 6-3. Wiring Diagram - Generator (Ford Engine) 3120271 – JLG Lift – 6-23...

  • Page 152: Wiring Diagram - Platform Console Standard Controls (Sheet 1 Of 2)

    SECTION 6 - TROUBLESHOOTING & SCHEMATICS Figure 6-4. Wiring Diagram - Platform Console Standard Controls (Sheet 1 of 2) 6-24 – JLG Lift – 3120271...

  • Page 153: Wiring Diagram - Platform Console Standard Controls (Sheet 2 Of 2)

    SECTION 6 - TROUBLESHOOTING & SCHEMATICS 1281682-B Figure 6-5. Wiring Diagram - Platform Console Standard Controls (Sheet 2 of 2) 3120271 – JLG Lift – 6-25...
  • Page 154 SECTION 6 - TROUBLESHOOTING & SCHEMATICS This page left blank intentionally. 6-26 – JLG Lift – 3120271...

  • Page 155: Wiring Diagram - Platform Console Hydraulic Controls

    SECTION 6 - TROUBLESHOOTING & SCHEMATICS 4932027D Figure 6-6. Wiring Diagram - Platform Console Hydraulic Controls 3120271 – JLG Lift – 6-27...

  • Page 156: Wiring Diagram - Standard (Deutz Engine/Fixed Axle/Standard Controls) (Sheet 1 Of 2)

    SECTION 6 - TROUBLESHOOTING & SCHEMATICS Figure 6-7. Wiring Diagram - Standard (Deutz Engine/Fixed Axle/Standard Controls) (Sheet 1 of 2) 6-28 – JLG Lift – 3120271...

  • Page 157: Wiring Diagram - Standard (Deutz Engine/Fixed Axle/Standard Controls)(Sheet 2 Of 2)

    SECTION 6 - TROUBLESHOOTING & SCHEMATICS 1280750 G Figure 6-8. Wiring Diagram - Standard (Deutz Engine/Fixed Axle/Standard Controls)(Sheet 2 of 2) 3120271 – JLG Lift – 6-29...

  • Page 158: Wiring Diagram - Standard (Deutz Engine/Oscillating Axle/Standard Controls)(Sheet 1 Of 2)

    SECTION 6 - TROUBLESHOOTING & SCHEMATICS Figure 6-9. Wiring Diagram - Standard (Deutz Engine/Oscillating Axle/Standard Controls)(Sheet 1 of 2) 6-30 – JLG Lift – 3120271...

  • Page 159: Wiring Diagram - Standard (Deutz Engine/Oscillating Axle/Standard Controls)(Sheet 2 Of 2)

    SECTION 6 - TROUBLESHOOTING & SCHEMATICS 4932833 E Figure 6-10. Wiring Diagram - Standard (Deutz Engine/Oscillating Axle/Standard Controls)(Sheet 2 of 2) 3120271 – JLG Lift – 6-31...

  • Page 160: Wiring Diagram - Standard (Deutz Engine/Hydraulic Controls)(Sheet 1 Of 2)

    SECTION 6 - TROUBLESHOOTING & SCHEMATICS Figure 6-11. Wiring Diagram - Standard (Deutz Engine/Hydraulic Controls)(Sheet 1 of 2) 6-32 – JLG Lift – 3120271...

  • Page 161: Wiring Diagram - Standard (Deutz Engine/Hydraulic Controls)(Sheet 2 Of 2)

    SECTION 6 - TROUBLESHOOTING & SCHEMATICS 1280992 F Figure 6-12. Wiring Diagram - Standard (Deutz Engine/Hydraulic Controls)(Sheet 2 of 2) 3120271 – JLG Lift – 6-33...

  • Page 162: Wiring Diagram - Standard (Ford Engine/Fixed Axle/Standard Controls)(Sheet 1 Of 2)

    SECTION 6 - TROUBLESHOOTING & SCHEMATICS Figure 6-13. Wiring Diagram - Standard (Ford Engine/Fixed Axle/Standard Controls)(Sheet 1 of 2) 6-34 – JLG Lift – 3120271...

  • Page 163: Wiring Diagram - Standard (Ford Engine/Fixed Axle/Standard Controls)(Sheet 2 Of 2)

    SECTION 6 - TROUBLESHOOTING & SCHEMATICS 1282458 C Figure 6-14. Wiring Diagram - Standard (Ford Engine/Fixed Axle/Standard Controls)(Sheet 2 of 2) 3120271 – JLG Lift – 6-35...

  • Page 164: Wiring Diagram - Standard (Ford Engine/Oscillating Axle/Standard Controls)(Sheet 1 Of 2)

    SECTION 6 - TROUBLESHOOTING & SCHEMATICS Figure 6-15. Wiring Diagram - Standard (Ford Engine/Oscillating Axle/Standard Controls)(Sheet 1 of 2) 6-36 – JLG Lift – 3120271...

  • Page 165: Wiring Diagram - Standard (Ford Engine/Oscillating Axle/Standard Controls)(Sheet 2 Of 2)

    SECTION 6 - TROUBLESHOOTING & SCHEMATICS 4932834 E Figure 6-16. Wiring Diagram - Standard (Ford Engine/Oscillating Axle/Standard Controls)(Sheet 2 of 2) 3120271 – JLG Lift – 6-37...

  • Page 166: Wiring Diagram - Standard (Ford Engine/Hydraulic Controls)(Sheet 1 Of 2)

    SECTION 6 - TROUBLESHOOTING & SCHEMATICS Figure 6-17. Wiring Diagram - Standard (Ford Engine/Hydraulic Controls)(Sheet 1 of 2) 6-38 – JLG Lift – 3120271...

  • Page 167: Wiring Diagram - Standard (Ford Engine/Hydraulic Controls)(Sheet 2 Of 2)

    SECTION 6 - TROUBLESHOOTING & SCHEMATICS 1282616- Figure 6-18. Wiring Diagram - Standard (Ford Engine/Hydraulic Controls)(Sheet 2 of 2) 3120271 – JLG Lift – 6-39...

  • Page 168: Hydraulic Schematic (Sheet 1 Of 6)

    SECTION 6 - TROUBLESHOOTING & SCHEMATICS Figure 6-19. Hydraulic Schematic (Sheet 1 of 6) 6-40 – JLG Lift – 3120271...

  • Page 169: Hydraulic Schematic (Sheet 2 Of 6)

    SECTION 6 - TROUBLESHOOTING & SCHEMATICS 2792231- Figure 6-20. Hydraulic Schematic (Sheet 2 of 6) 3120271 – JLG Lift – 6-41...

  • Page 170: Hydraulic Schematic (Sheet 3 Of 6)

    SECTION 6 - TROUBLESHOOTING & SCHEMATICS Figure 6-21. Hydraulic Schematic (Sheet 3 of 6) 6-42 – JLG Lift – 3120271...

  • Page 171: Hydraulic Schematic (Sheet 4 Of 6)

    SECTION 6 - TROUBLESHOOTING & SCHEMATICS 2792231- Figure 6-22. Hydraulic Schematic (Sheet 4 of 6) 3120271 – JLG Lift – 6-43...

  • Page 172: Hydraulic Schematic (Sheet 5 Of 6)

    SECTION 6 - TROUBLESHOOTING & SCHEMATICS Figure 6-23. Hydraulic Schematic (Sheet 5 of 6) 6-44 – JLG Lift – 3120271...

  • Page 173: Hydraulic Schematic (Sheet 6 Of 6)

    SECTION 6 - TROUBLESHOOTING & SCHEMATICS 2792231- Figure 6-24. Hydraulic Schematic (Sheet 6 of 6) 3120271 – JLG Lift – 6-45...
  • Page 174 SECTION 6 - TROUBLESHOOTING & SCHEMATICS This page left blank intentionally. 6-46 – JLG Lift – 3120271...
  • Page 176 England Fax: (49) 421 693 5035 Fax: (61) 2 65 810122 Phone: (44) 870 200 7700 Fax: (44) 870 200 7711 JLG Latino Americana Ltda. JLG Europe B.V. JLG Industries (Norge AS) JLG Polska Rua Eng. Carlos Stevenson, Jupiterstraat 234 Sofeimyrveien 12 UI.

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