JLG 80SL Manuals

Manuals and User Guides for JLG 80SL. We have 1 JLG 80SL manual available for free PDF download: Service Maintenance Manual

JLG 80SL Service Maintenance Manual

JLG 80SL Service Maintenance Manual (162 pages)

Brand: JLG | Category: Boom Lifts | Size: 17 MB

Table of Contents

Revision Log
4
Table of Contents
5
Operating Specifications
13
Engine
14
Limit Switch Locations
15
Pressure Setting
16
Engine Operating Temperature Specifications
17
Section 2 - General

25
Section 3 - Chassis, Platform & Scissor Arms

37
- Operating Characteristics
  37
  - Leveling Jacks
    37
- Wheel Assembly
  37
  - Drive System
    37
  - Drive Hub
    38
  - Roll Test
    38
  - Leak Test
    38
  - Lubricant
    38
  - Tire Replacement
    39
  - Wheel Replacement
    39
  - Wheel Installation
    39
- Wheel Assembly Removal
  40
- Hub Torque Values
  41
- Torque Hub Assembly
  42
  - Drive Motor
    43
    
    Motor Disassembly
    44
    
    Motor Assembly
    44
  - Steering Assembly
    45
  - Rear Axle
    46
    
    Limit Switches
    46
  - Outrigger Cylinder Removal
    47
- Outrigger Cylinder Removal - (Sheet 2 of 2)
  48
  - Engine Compartment
    49
    
    Hood Assembly
    49
    
    Deutz Engine
    50
    
    Engine Tray Slide
    51
    
    Glow Plugs
    52
    
    Engine Solenoid Fuse
    52
    
    Hydraulic Pump Assembly
    53
    
    Hydraulic Pump
    54
    
    Exhaust Pipe Assembly
    55
    
    Air Filter Assembly
    56
    
    Engine Removal
    57
    
    Hydraulic Tank
    58
    
    Pressure Filter
    59
  - Fuel Tank
    60
  - Ground Control Panel
    61
  - Battery Removal
    62
  - Platform
    63
    
    Platform Control Box
    63
    
    Joystick Controller
    64
    
    Receptacles
    65
    
    Main Platform Side Rails
    66
    
    Main Platform End Rails
    67
    
    Platform Extension Side Rails
    68
    
    Platform Extension End Rail
    69
    
    Platform Removal
    70
- Platform Removal - 2 of 2 (Rear of Platform)
  71
  - Ladder Installation
    72
  - Beacon Installation (Option)
    73
  - Scissor Arms
    74
    
    Limit Switches
    74
    
    Scissor Arm Assembly Removal
    75
    
    Lift Cylinder Removal
    78
    
    Scissor Arms Disassembly
    79
Section 4 - Hydraulics

81
- Cylinders - Theory of Operation
  81
  - Deck Extension Cylinder
    81
  - Lift Cylinder
    81
  - Outrigger Cylinders
    81
  - Steer Cylinder
    81
- Valves - Theory of Operation
  81
  - Solenoid Control Valves (Bang-Bang)
    81
  - Relief Valves
    81
  - Crossover Relief Valves
    81
- Cylinder Checking Procedure
  82
- Cylinder Repair
  82
  - Disassembly
    82
- Load Check Valve Romoval
  83
- Cylinder Head Removal
  84
- Piston Seals
  85
  - Cleaning and Inspection
    86
  - Assembly
    87
- Spacer Installation
  88
- Rod Installation
  89
- Load Check Valve Installation
  90
- Lifting Cylinder Assembly
  91
- Steering Cylinder Assembly
  92
- Outrigger Cylinder Assembly
  93
- Axle Locking Cylinder Assembly
  94
- Extension Cylinder Assembly
  95
- Arms and Platform Positioning and Support
  96
  - Valves
    97
    
    Valve Compartment
    97
    
    Pressure Switch, Drive Enable
    97
    
    Brake Valve
    98
    
    Drive Valve
    99
    
    Main Valve Block
    100
    
    Pump Engage/Disengage Valve
    101
    
    Hand Pump
    102
    
    Load Holding Valve
    103
    
    Lift/Lower Valve Block
    104
    
    Platform Lower Flow Valve
    104
    
    Outrigger Safety Valves
    105
Section 5 - Jlg Control System

107
- Main Terminal Box Circuit Boards
  107
- Control Card Complex 2
  108
  - General Description of Components and Functions
    108
- J1 Connector
  109
- Complex 2 Circuit Board
  110
  - Nivolux - Automatic Self-Leveling System
    111
    
    Introduction
    111
    
    The System
    111
    
    Operation
    111
    
    NIVOLUX Board Led's
    112
    
    Setting and Adjustment of the NIVOLUX Board
    112
- NIVOLUX Circuit Board
  113
  - PNP5 Circuit Board
    114
    
    System
    114
    
    Operation
    114
    
    Adjustment
    114
  - Trigger Control Circuit Card
    114
    
    Relay K1
    114
    
    Relay K2
    114
    
    Relay K3
    115
  - Limit Switch & Sensor Operation
    115
    
    Height Limit Switches
    115
    
    Tilt Switch
    116
    
    Oscillating Axle Limit Switches
    116
    
    Outrigger Limit Switches
    116
    
    Pressure Switch
    116
  - Engine Control System
    117
    
    Functional Description
    117
- Deutz Engine Control Board
  118
Section 6 - General Electrical Information & Schematics

119
- General
  119
- Multimeter Basics
  119
  - Grounding
    119
  - 3121325 - JLG Lift
    119
- Backprobing
  119
- Min/Max
  119
- Polarity
  119
- Scale
  119
- Voltage Measurement (DC)
  120
- Continuity Measurement
  121
  - Continuity Measurement over Long Distances
    122
  - Requirements
    122
  - Procedure
    122
- Applying Silicone Dielectric Compound to Amp Connectors
  123
  - Assembly
    124
- Connector Assembly (3 of 4)
  125
  - Disassembly
    126
  - Wedge Lock
    126
  - Service - Voltage Reading
    127
- Working with Deutsch Connectors
  128
  - DT/DTP Series Assembly
    128
  - DT/DTP Series Disassembly
    128
  - HD30/HDP20 Series Assembly
    128
  - HD30/HDP20 Series Disassembly
    129
- Electrical Schematic - Sheet 1 of 15
  130
- Electrical Schematic - Sheet 2 of 15
  131
- Electrical Schematic - Sheet 3 of 15
  132
- Electrical Schematic - Sheet 4 of 15
  133
- Electrical Schematic - Sheet 5 of 15
  134
- Electrical Schematic - Sheet 6 of 15
  135
- Electrical Schematic - Sheet 7 of 15
  136
- Electrical Schematic - Sheet 8 of 15
  137
- Electrical Schematic - Sheet 9 of 15
  138
- Electrical Schematic - Sheet 10 of 15
  139
- Electrical Schematic - Sheet 11 of 15
  140
- Electrical Schematic - Sheet 12 of 15
  141
- Electrical Schematic - Sheet 13 of 15
  142
- Electrical Schematic - Sheet 14 of 15
  143
- Electrical Schematic - Sheet 15 of 15
  144
- Main Terminal Box Wiring Description
  145
- Electrical Diagram - Page 1 of 2
  156
- Electrical Diagram - Page 2 of 2
  157

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