JLG 80HX-HX-6-HXER Service Manual

SERVICE & MAINTENANCE

Model

80HX

80HX+6

80HXER

AUSTRALIAN OFFICE

JLG INDUSTRIES, INC. P.O. Box 5119 11 Bolwarra Road Port Macquarie, Australia Telephone: 065 811111 Fax: 065 810122

3120863

May 14, 2002

EUROPEAN OFFICE

JLG INDUSTRIES (EUROPE) Kilmarting Place, Tannochs i d e Park Uddingston, Scotland, G71 5PH Telephone: 01698 811005 Main Fax: 01698 811055 Parts Fax: 01698 811455

CORPORATE OFFICE

JLG INDUSTRIES, INC. 1 JLG Drive McConnellsburg, PA. 17233-9533 USA Telephone: (717) 485-5161 Fax: (717) 485-6417

INTRODUCTION

SECTION A. INTRODUCTION - MAINTENANCE SAFETY

PRECAUTIONS

A GENERAL

This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others, or damage to the equipment. A maintenance program must be followed to ensure that the machine is safe to operate.

MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST AS SAFE AS ORIGINALLY MANUFACTURED, IS A SAFETY VIOLATION.

The specific precautions to be observed during maintenance are inserted at the appropriate point in the manual. These precautions are, for the most part, those that apply when servicing hydraulic and larger machine component parts.

Your safety, and that of others, is the first consideration when engaging in the maintenance of equipment. Always be conscious of weight. Never attempt to move heavy parts without the aid of a mechanical device. Do not allow heavy objects to rest in an unstable position. When raising a portion of the equipment, ensure that adequate support is provided.

SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE FIELD INSPECTION AND MAINTENANCE, SAFETY IN THIS AREA RESPONSIBILITY OF THE OWNER/OPERATOR.

B HYDRAULIC SYSTEM SAFETY

It should be noted that the machines hydraulic systems operate at extremely high potentially dangerous pressures. Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of the system.

feed lines to system components can then be disconnected with minimal fluid loss.

C MAINTENANCE

FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION MAY RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A SAFETY VIOLATION.

• NO SMOKING IS MANDATORY. NEVER REFUEL DURING ELECTRICAL STORMS. ENSURE THAT FUEL CAP IS CLOSED AND SECURE AT ALL OTHER TIMES.

• REMOVE ALL RINGS, WATCHES AND JEWELRY WHEN PERFORMING ANY MAINTENANCE.

• DO NOT WEAR LONG HAIR UNRESTRAINED, OR LOOSE-FITTING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME CAUGHT ON OR ENTANGLED IN EQUIPMENT.

• OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS ON MACHINE AND IN SERVICEMANUAL.

• KEEP OIL, GREASE, WATER, ETC. WIPED FROM STANDING SURFACES AND HAND HOLDS.

• USE CAUTION WHEN CHECKING A HOT, PRESSURIZED COOLANT SYSTEM.

• NEVER WORK UNDER AN ELEVATED BOOM UNTIL BOOM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING, OR BOOM SAFETY PROP HAS BEEN ENGAGED.

• BEFORE MAKING ADJUSTMENTS, LUBRICATING OR PERFORMING ANY OTHER MAINTENANCE, SHUT OFF ALL POWER CONTROLS.

• BATTERY SHOULD ALWAYS BE DISCONNECTEDDURING REPLACEMENT OF ELECTRICAL COMPONENTS.

• KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS STOWED IN THEIR PROPER PLACE.

• USE ONLY APPROVED, NONFLAMMABLE CLEANING SOLVENTS.

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

3120863 – JLG Lift – A-1

INTRODUCTION

REVISON LOG

October, 1997 - Original Issue March 1, 1999 - Revised September 7, 2000 - Revised May 14, 2002 - Revised

A-2 – JLG Lift – 3120863

TABLE OF CONTENTS

SUBJECT - SECTION, PARAGRAPH PAGE NO.

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

B Hydraulic System Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

C Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

SECTION 1 - SPECIFICATIONS

1.1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 Component Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Engine - Deutz F4L912 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Drive Motor Displacement Machines Built Prior to Jan. 1992. . . . . . . . . . . . . . . . . . . . . . . . 1-1

Drive Motor Displacement Machines Built from Jan. 1992 to Present . . . . . . . . . . . . . . . . . 1-1

Drive Hub Ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Steer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Swing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Auxiliary Power Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Hydraulic Filter - Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Hydraulic Filter - Inline (Racine Valve Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3 Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Gradeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Turning Radius (Outside) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Boom Speed (Telescope) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Boom Speed (Lift) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Swing Speed 360° . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Boom Elevation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Machine Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Machine Stowed Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Machine Stowed Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Machine Width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Maximum Tire Load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.4 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1.5 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

Deutz Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1.6 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10

80 HX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

80HX w/Hydraulic Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

80HX w/Oscillating Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

1.7 Major Components Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11

1.8 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11

1.9 Boom Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11

1.10 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

1.11 Serial Number Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12

SECTION 2 - PROCEDURES

2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.2 Servicing and Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Components Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

3120863 – JLG Lift – i

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (continued)

SUBJECT - SECTION, PARAGRAPH PAGE NO.

Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Pressure-Fit Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Hydraulic Lines and Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.3 Lubrication Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.4 Cylinders - Theory Of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

Double Acting Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.5 Valves - Theory Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

Holding Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Solenoid Control Valves (Bang-Bang) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Proportional Control Valve - Vickers (See Figure 2-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Main Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.6 Boom Chains (See Figure 2-2.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Adjusting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Inspection Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Auxiliary Boom Chains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2.7 Wear Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2.8 Cylinder Checking Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

Cylinders Without Counterbalance Valves - Steer Cylinder and Master Cylinder . . . . . . . . 2-9

Cylinders With Single Counterbalance Valve - Lift Cylinder, Telescope Cylinder

and Extend- A-Reach Lift Cylinder 2-10

Cylinders With Dual Counterbalance Valves - Platform Slave Level Cylinder,

Lockout Cylinder and Extend-A-Reach Level Cylinder 2-10

2.9 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

2.10 Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-19

Telescope Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Telescope Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Boom Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Boom Lift Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

2.11 Telescope Cylinder Eccentric Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

2.12 Boom Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

2.13 Tilt Alarm Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

Manual Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

Voltmeter Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

2.14 Limit Switch Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29

ii – JLG Lift – 3120863

TABLE OF CONTENTS

TABLE OF CONTENTS (continued)

SUBJECT - SECTION, PARAGRAPH PAGE NO.

Boom Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

Horizontal Cut-Out Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

Drive Cut-Out Switch - Dutch Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

2.15 Throttle Checks and Adjustments - Deutz Engine (See Figure 2-16.) . . . . . . . . . . . . . . . . . . . . . .2-30

2.16 Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32

2.17 Racine Proportional Air Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32

2.18 Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-44

Turntable Bearing Mounting Bolt Condition Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44

Wear Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45

Swing Bearing Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45

2.19 Torque Hub (See Figure 2-33.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-47

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49

Input Shaft Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51

2.20 Drive Brake, Ausco - Machines Built Prior to 1992 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-55

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57

2.21 Drive Brake, Mico - Machines Built From 1992 to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59

2.22 Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60

PQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60

OEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60

VICKERS (All Hydraulic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60

2.23 Oscillating Axle Bleeding Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60

Lockout Cylinder Bleeding (Without Holding Valves) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60

Lockout Cylinder Bleeding (With Holding Valves) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60

2.24 Oscillating Axle Lockout Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-61

2.25 Basket Rotator Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-61

2.26 Free Wheeling Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-62

To Disengage Drive Motors and Brakes (Free Wheel) for Towing, etc. . . . . . . . . . . . . . . . . 2-62

To Engage Drive Motors and Brakes (Normal Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62

2.27 Spark Arrestor Mufflers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-62

2.28 Footswitch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-62

2.29 Hydraulic Pump W/Hayes Pump Drive Coupling Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-62

2.30 Dual Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-62

Changing from gasoline to LP-Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62

Changing from LP Gas to Gasoline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62

2.31 Preventive Maintenance and Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-63

2.32 Capacity Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-66

Capacity Indicator Cable Adjustment.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66

Capacity Indicator Boom Tape Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66

Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66

Capacity Indicator Dial Decal Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66

Indicator Decal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66

SECTION 3 - TROUBLESHOOTING

3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.2 Troubleshooting Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.3 Hydraulic Circuit Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3120863 – JLG Lift – iii

TABLE OF CONTENTS (Continued)

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

1-1. Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-2. Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

1-3. Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

2-1. Proportional Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

2-2. Typical Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2-3. Boom Positioning and Support - Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2-4. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

2-5. Typical Hydraulic Cylinders (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

2-6. Typical Hydraulic Cylinders (Sheet 2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13

2-7. Typical Hydraulic Cylinders (Sheet 3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

2-8. Typical Hydraulic Cylinders (Sheet 4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15

2-9. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16

2-10. Poly-Pak Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17

2-11. Telescope Cylinder Eccentric Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

2-12. Boom Assembly (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22

2-13. Boom Assembly (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23

2-14. Tilt Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28

2-15. Tilt Switch Adjustment - Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29

2-16. Adeco Actuator Adjustments - F4L912 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31

2-17. Racine Proportional Air Gap Adjustment, Machines Built Prior to Mid 1987 . . . . . . . . . . . . . . . . .2-32

2-18. Vickers Proportional Valve Pressure Setting - Mid 1992 to Present (Sheet 1 of 4) . . . . . . . . . . . . 2-33

2-19. Vickers Proportional Valve Pressure Setting - Mid 1992 to Present (Sheet 2 of 4) . . . . . . . . . . . . 2-34

2-20. Vickers Proportional Valve Pressure Setting - Mid 1992 to Present (Sheet 3 of 4) . . . . . . . . . . . . 2-35

2-21. Vickers Proportional Valve Pressure Setting - Mid 1992 to Present (Sheet 4 of 4) . . . . . . . . . . . . 2-36

2-22. Pressure Setting - All Hydraulic Machines (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37

2-23. Pressure Setting - All Hydraulic Machines (Sheet 2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38

2-24. Pressure Setting - All Hydraulic Machines (Sheet 3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39

2-25. Pressure Setting - All Hydraulic Machines (Sheet 4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40

2-26. Solenoid Valve Pressure Settings - Machines Built to Present . . . . . . . . . . . . . . . . . . . . . . . . . . .2-41

2-27. Solenoid Valve Pressure Settings - 4 Wheel Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-42

2-28. Extend-A-Reach Valve Pressure and Speed Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-43

2-29. Swing Bearing Tolerance Boom Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-44

2-30. Swing Bearing Bolt Feeler Gauge Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-44

2-31. Swing Bearing Tolerance Measuring Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-45

2-32. Swing Bearing Torquing Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-46

2-33. Torque Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48

2-34. Drive Brake, Ausco - Machines Built Prior to 1992 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56

2-35. Drive Brake, Mico - Machines Built from 1992 to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-58

2-36. Spring Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59

2-37. Belleville Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-61

2-38. Boom Tape Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-66

2-39. Capacity indicator Dial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-66

3-1. Wiring Schematic (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20

3-2. Wiring Schematic (Sheet 2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

3-3. Wiring Schematic (Sheet 3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22

3-4. Wiring Schematic (Sheet 4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23

3-5. Hydraulic Schematic (Sheet 1 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24

3-6. Hydraulic Schematic (Sheet 2 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

3-7. Hydraulic Schematic (Sheet 3 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

3-8. Hydraulic Schematic (Sheet 4 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

3-9. Hydraulic Schematic (Sheet 5 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28

3-10. Hydraulic Schematic (Sheet 6 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29

iv – JLG Lift – 3120863

TABLE OF CONTENTS

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

1-1 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-2 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1-3 Mobil EAL 224 H Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1-4 Mobil DTE 13M Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-5 Lubrication Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1-6 Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

1-7 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11

1-8 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

1-9 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11

2-1 Chain Stretch Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

2-2 Cylinder Piston Nut Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-19

2-3 Holding Valve Torque Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-19

2-4 Preventive Maintenance and Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-64

3-1 Platform Assembly - Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2 Boom Assembly - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

3-3 Turntable Assembly - Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

3-4 Chassis Assembly - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

3-5 Hydraulic System - Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15

3-6 Electrical System - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18

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TABLE OF CONTENTS (Continued)

THIS PAGE LEFT BLANK INTENTIONALLY.

vi – JLG Lift – 3120863

SECTION 1 - SPECIFICATIONS

SECTION 1. SPECIFICATIONS

1.1 CAPACITIES

Fuel Tank - 98 L.

Hydraulic Oil Tank - 208 L.

Hydraulic System (Including Tank) - Approx. 250 L

Torque Hub, Drive - 1.3 L.

Torque Hub, Swing - 0.5 L.

NOTE: Torque Hubs should be one-half full of lubricant.

(EPGL-90)

Engine Crankcase (Ford LSG & LRG 423) w/Filter - 4.7 L.

Engine Crankcase (Deutz F4L912) w/Filter - 9 L.

Tolerance on all engine rpm settings is plus or minus 10%.

1.2 COMPONENT DATA

Engine - Deutz F4L912

Oil Capacity - 9 L w/Filter, 8 L w/o Filter.

Low RPM 1800.

High RPM 2400.

Alternator - 60 Amp, belt drive.

Battery - 85 Amphour, 550 CCA, 12 VDC.

Drive Motor Displacement Machines Built Prior to Jan. 1992

Cessna - 82.6 cc/rev.

Vickers - 41cc/rev.

2 Speed Cessna - 40.6 cc/rev.

Gear Reducer - Vickers Drive Motors only - 3.6:1.

Drive Motor Displacement Machines Built from Jan. 1992 to Present

Rexroth - 46 cc/rev.

Drive Hub Ratios

2WD/2WS with fixed or oscillating front axle - 24:1.

2WD/4WS with oscillating front axle - 24:1.

4WD - 24:1.

2WD/4WS with fixed front axle/Vickers proportional

valves - 73:1.

4WD with Vickers Proportional valves - 30.04:1.

Steer System

Toe-in, adjust for 6.35 mm overall.

Horsepower - 70 @ 2400 RPM, no load

Tires

Foam-Filled Tires - 15 x 19.5

Swing System

Swing Motor - Displacement - 74 cc/Rev.

Swing Hub - Ratio - 69.50:1.

Swing Brake - Automatic spring applied, hydraulically released disc brakes.

3120863 – JLG Lift – 1-1

SECTION 1 - SPECIFICATIONS

Hydraulic Pump

Deutz and Wisconsin engines with Single Speed Drive Motors (with Racine Valves).

First Section to Proportional Valve-Drive, Lift, Swing 91 LPM.

Second Section to High Drive - 91 LPM.

Third Section to Bang-Bang Valve Level, Telescope, Steer, Rotate - 36 LPM.

Clockwise Rotation.

Wisconsin Engines with 2 Speed Drive Motors and Deutz Engines with Single Speed Drive Motors (with Racine Valves).

First Section to Proportional Valve-Drive, Lift, Swing 72 LPM.

Second Section to High Drive - 72 LPM.

Third Section to Bang-Bang Valve Level, Telescope, Steer, Rotate - 36 LPM.

Clockwise Rotation.

Deutz Engines with 2 Speed Drive Motors (with Racine Valves).

First Section to Proportional Valve-Drive, Lift, Swing 72 LPM.

Second Section to High Drive - 55 LPM.

Third Section to Bang-Bang Valve Level, Telescope, Steer, Rotate - 36 LPM.

Hydraulic Filter - Tank

Return - Bypass Type.

10 Microns Nominal.

Hydraulic Filter - Inline (Racine Valve Only)

Return - Non-Bypass Type.

10 Microns Nominal.

1.3 PERFORMANCE DATA

Travel Speed

5.6 KM/HR.

Gradeability

25%.

Turnin g R a d i us (Outside)

7.3 m with axles extended.

Boom Speed (Telescope)

Extend 71-133 Seconds

Retract 44-72 Seconds.

Boom Speed (Lift)

Up - 65-100 Seconds

Down - 55-100 Seconds.

Swing Speed 360°

Swing Speed 360° - 110-200 Seconds.

Clockwise Rotation.

Machines with Vickers Valves.

First Section to Proportional Valve-Drive, Lift, Swing 57 LPM.

Second Section to High Drive - 34 LPM.

Third Section to Bang-Bang Valve Level, Telescope, Steer, Rotate - 34 LPM.

Clockwise Rotation.

Auxiliary Power Pump

Two section, 14.2 lpm) each section, 12 VDC motor, clockwise rotation.

Boom Elevation

-16° to +75°

Machine Weight

80HX - approx. 14,424 KG.

80HX+6 - approx. 16,738 KG.

Machine Stowed Height

2.9 M

Machine Stowed Length

80HX - 10.2 M

80HX+6 - 11.2 M

Machine Width

With axles retracted - 2.4 m

With axles extended - 3 m

1-2 – JLG Lift – 3120863

UNPLATED

CAP SCREWS

WITH LOC-WEL PATCH

UNBRAKO 1960 SERIES

SOCKET HEAD CAP SCREW

TORQUE

(as received)

(KG)

CLAMP LOAD

)

(LOCTITE

242 OR 271

262)

(LOCTITE

(LUB.)

SECTION 1 - SPECIFICATIONS

102

149

156

210

224

285

298

495

542

793

861

1173

1241

1681

1871

2373

2549

3145

3308

4122

4433

1442

1651

2377

2631

3493

3983

4822

5384

6437

7253

8256

9208

10251

11612

15150

16919

20956

23088

27488

30074

34610

38828

43954

48671

52391

59648

63731

71669

122

183

224

258

326

359

570

631

895

408

380

456

434

658

624

983

724

678

1492

1342

931

1079

922

1003

1898

2136

1396

1566

1302

1464

2712

2983

1970

2183

1844

2034

3559

4068

2586

2935

2413

2766

4712

5322

3430

3856

3200

3607

109

163

130

146

188

209

244

277

109

122

149

176

231

244

SAE GRADE 8

SAE GRADE 5

VALUES FOR ZINC PLATED BOLTS ONLY

(DRYOR

SAE GRADE 8 BOLTS & GRADE 8 NUTS

CLAMP

(LOCTITE

TORQUE

(DRYOR

SAE GRADE 5 BOLTS & GRADE 2 NUTS

CLAMP

AREA

STRESS

THREAD

DIA.

BOLT

LOC. 263)

(KG)

LOAD

)

242 OR 271

262)

(LUB.)

LOC. 263)

(KG)

LOAD

(SQ. CM)

(CM)

245

272

172

191

0.0168

0.0153

0.2845

372

417

263

277

0.0258

0.0232

0.3505

572

599

408

426

0.0374

0.0356

0.4166

717

817

508

583

0.0445

0.0508

0.4826

1297

1488

916

1052

0.0808

0.0925

0.6350

2141

2821

1515

1678

0.1473

0.1331

0.7938

3175

3583

2241

2540

0.2230

0.1969

0.9525

109

4332

4854

3085

3425

0.3015

0.2700

1.1112

149

163

5783

6532

115

136

108

102

122

4105

4854

0.4061

0.3604

1.2700

204

231

7539

8278

163

183

133

148

109

122

149

163

5874

5262

0.5156

0.4623

1.4288

298

326

9231

10433

224

258

183

207

149

176

204

231

7394

6532

0.6502

0.5740

1.5875

515

570

15241

13653

387

448

325

363

271

298

407

353

9662

10796

0.9474

0.8484

1.9050

814

895

18870

20775

644

705

523

576

434

475

637

583

14697

13336

1.2929

1.1735

2.2225

1220

1356

23360

27080

915

997

785

858

651

719

868

949

19142

17509

1.6840

1.5392

2.5400

1736

1953

31162

34927

1139

1254

968

1087

814

895

1085

1193

21546

19187

2.1742

1.9380

2.8575

2468

2712

38554

43818

1593

1762

1368

1516

1139

1247

1519

1681

27035

24404

2.7254

2.4613

3.1750

3227

3688

47174

53570

2068

2373

1792

2042

1492

1708

1980

2278

29076

33113

2.9337

3.3401

3.4925

4284

4827

57380

142200

2746

3118

2379

2676

1980

2224

2630

2983

35381

39781

3.5687

4.0132

3.8100

Figure 1-1. Torque Chart

THD

SIZE

1/4

5/16

3/8

7/16

1/2

9/16

5/8

3/4

7/8

1-1/8

1-1/4

1-1/2

Note: These torque values do not apply to cadium plated fasteners.

3120863 – JLG Lift – 1-3

SECTION 1 - SPECIFICATIONS

Maximum Tire Load

80HX - 7037 kg @ 7.2 kg/cm2

80HX + 6 - 8299 kg @ 7.5 kg/cm2

Wheelbase

3 m

1.4 TORQUE REQUIREMENTS

Table 1-1. Torque Requirements

Description

Turntable (prior to April , 1986) 5 /8 " Bo l ts - We t 5 /8 " Bo l ts - Dr y 7 /8 " Bo l ts - We t 7 /8 " Bo l ts - Dr y

Turntable (April, 1986 to Present) We t D ry

Tor que

Ft. Lbs. Nm

170 220 460 600

170 220

235 304 636 830

235 304

1.5 LUBRICATION

Deutz Engine

Single Viscosity Oils (CD-SE, CD-SF).

When Outside Temp

is Consistently

-29° C - -4° C. *10W

-9.5° C - + 10° C. 20W-20

+4.5° C - + 29.5° C. 30

Above 24° C. 40

Multi-Viscosity Oils (CD-SE, CD-SF).

When Outside Temp

is Consistently

Interval

-40° C - +24° C. *5W-20

Hours

-20.5° C - +21° C. 10W-30

50/600*

-20.5° C - +29.5° C. 10W-40

-9.5° C - +24° C. 15W-30 Above +9.5° C. 15W-40

* This viscosity can be used at colder temperatures only with engine oil preheating.

50/600*

Ta b l e 1 - 2 . H y d r a u l i c Oi l

U se S A E

Viscosity Number

U se S A E

Viscosity Number

(Synthetic)

Wheel Lugs We t D ry

Drive Hub We t D ry

Swing Hub We t D ry

* 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.

220 300

110 150

110

100 304 415

200/500** 149 207

200/500** 110 149

NOTE: See Procedure Section for tightening sequence of

turntable bearing bolts.

NOTE: When maintenance becomes necessary or a fas-

tener has loosened, refer to the Torque Chart to determine proper torque value.

Hydraulic System Operating

Temperature Range

SAE Viscosity

Grade

0° to +23° F(-18° to -5° C) 10W

0° to +210° F(-18° to +100° C) 10W-20, 10W-30

+50° to +210° F(+10° to +99° C) 20W-20

NOTE: Hydraulic oils must have anti-wear qualities at least

to API Service Classification GL-3, and sufficient chemical stability for mobile hydraulic system service. JLG Industries recommends Mobilfluid 424 hydraulic oil, which has an SAE viscosity index of 152 .

NOTE: When temperatures remain consistently below 20

degrees F (-7 degrees C.), JLG Industries recommends the use of Mobil DTE11.

NOTE: Aside from JLG recommendations, it is not advisable

to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities. If use of hydraulic oil other than Mobilfluid 424 is desired, contact JLG Industries for proper recommendations.

1-4 – JLG Lift – 3120863

Table 1-3. Mobil EAL 224 H Specs

Type Biodegradable Vegetable Oil

ISO Viscosity Grade 32/46

Specific Gravity .922

Pour Point, Max

Flash Point, Min.

Weight

Viscosity

at 104° F (40° C) 37 cSt

at 212° F (100° C) 8.4 cSt

Viscosity Index 213

Operating Temp 0-180° F (-17 - -162°C)

Note: Must be stored above 32° F (14° C)

-25°F (-32°C)

428°F (220°C)

7.64 lb. per gal. (0.9 kg per liter)

SECTION 1 - SPECIFICATIONS

Lubrication Specifications

Table 1-5.Lubrication Specifications

KEY SPECIFICATIONS

MPG Multipurpose Grease having a minimum dripp ing point of 350

degrees F. Excellent water resista nce and adhesive qualities; and being of extreme pr essure type (Timken OK 40 pounds minimum).

EPGL Extreme Pressure Gear Lube (oil) meeti ng API Service Classi-

fication GL-5 or M il-Spec Mil-L-2105.

HO Hydraulic Oil. API Service Classification GL-3, SAE 10 W-20,

Viscosity Index 152.

EO Engine (crankcase) Oil. Gas - API SF/SG class, MIL-L-2104.

Diesel - API CC/CD cl ass, MIL-L-2104B/MIL-L-2104C.

Refer to Lubrication Chart for specific lubrication procedures.

NOTE: The lubrication intervals in the following paragraphs

are equivalent to the following:

Table 1-4. Mobil DTE 13M Specs

Type Petroleum Base

ISO Viscosity Grade 32

Specific Gravity .877

Pour Point, Max

Flash Point, Min.

Viscosity

at 104° F (40° C) 33 cSt

at 212° F (100° C) 6.5 cSt

Viscosity Index 140

-40°F (-40°C)

330°F (166°C)

150 hours = 3 months 300 hours = 6 months

600 hours = 1 year

1200 hours = 2 years

3120863 – JLG Lift – 1-5

SECTION 1 - SPECIFICATIONS

Figure 1-2. Lubrication Diagram

1-6 – JLG Lift – 3120863

Table 1-6. Lubrication Chart

SECTION 1 - SPECIFICATIONS

Components

Wheel Drive Hubs

Slave Cylinder (Rod)

Slave Cylinder (Barrel )

Platform Pivot

Rotating Column

(Optional)

Rotary Worm Gear

(Optional)

Platform Hinges

Platform Lat ch

Boom Chain Extension

Sheave

Swing Bearing

Number/Type

Lube Points

Capacity Lube

Level/Fill Plug 1.3 L. (1/2 full) EPGL

(SAE90)

Interval Hours

3 Months

150 hrs

6 Months

300 hrs

1 Year

600 hrs

2 Years

1200 hrs

Comments

X Check level every 150 hours; change @ 1200

hours

1 Grease Fitting A/R MPG X

1 Grease Fitting A/R MPG X Gain access through boom fly section.

1 Grease Fitting A/R MPG X

2 Grease Fittings A/R MPG X

N/A A/R MPG X Br ush on.

2 Grease Fittings A/R MPG X

N/A A/R EO X

1 Grease Fitting A/R MPG X Align access holes in mid and fly boom.

2 Grease Fittings A/R MPG X Remote Acc ess

Lift Cylinder (Barrel End)

Master Cylinder (B arrel

End)

Master Cylinder (R od

End)

1 Grease Fitting A/R MPG X Remote Access

1 Grease Fitting A/R MPG X

3120863 – JLG Lift – 1-7

SECTION 1 - SPECIFICATIONS

Table 1-6. Lubrication Chart

Components

Boom Chain Retract

Sheave

Boom Pivot Bushings

Engine Crankcase

Engine Oil Filter

Engine Coolant

Hydraulic Oil

Hydraulic Oil Return

Filters

Hydraulic Reservoir

Suction Filter

Tie Rod Ends

King Pins

Steer Cylinder (Rod

End)

Steer Cylinder (Barre l

End)

Wheel Bearings

Swing Drive Hub

Swing Bearing and

Pinion Gear Teeth

Axle Beam (Extendable

Axles)

Axle Lock Pin

(Extendable Axles)

Oscillating Axle Pivot

Oscillation Cylinder

Extend-A-Reach Pivot (If

Equipped)

Number/Type

Lube Points

Capacity Lube

Interval Hours

3 Months

150 hrs

6 Months

300 hrs

1 Year

600 hrs

2 Years

1200 hrs

Comments

1 Grease Fitting A/R MPG X

2 Grease Fittings A/R MoS

Fill Cap Refer to Engine Manual EO Check daily. Change in accordance wth

engine manual.

N/A N/A N/A Change in accordance with engine manual.

Radiator Cap Refer to Engine Manual Refer to engine manual for coolant specifica-

tions. Check daily with engine cold.

Fill Cap 56 gallons HO X Check daily. Change every 1200 hours.

N/A N/A N/A Check filter gauges for element construction

daily. Replace as necessary.

N/A N/A N/A X Replace filter element every 600 hours; clean

mesh as necessary.

2 Grease Fittings A/R MPG X

1 Grease Fitting A/R MPG X

N/A A/R MPG X Repack

Fill Plug 0.5 L. (1/2 Full) EPGL

(SAE90)

X Check oil level weekly; change every 600

hours

N/A A/R MPG X Apply by brush onto bearing and gear teeth

N/A A/R MPG X Apply by brush

1 Grease Fitting A/R MPG X

2 Grease Fittings A/R MPG X

Extend-A-Reach Lift

Cylinder (Barrel End)

Extend-A-Reach Lift

Cylinder (Ro d End)

1 Grease Fitting A/R MPG X

1-8 – JLG Lift – 3120863

Table 1-6. Lubrication Chart

SECTION 1 - SPECIFICATIONS

Interval Hours

3 Months

150 hrs

6 Months

300 hrs

1 Year

600 hrs

2 Years

1200 hrs

Comments

Components

Extend-A-Reach - Boom

End (If Equipped)

Extend-A-Reach -

Platform End (if Equipped)

Extend-A-Reach - Slave

Cylinder Rod End (If Equipped)

Extend-A-Reach Link -

Slave Cylinder Pivot Point (If Eq uipped )

Extend-A-Reach Link -

Slave Cylinder Pivot Point (If Eq uipped )

Number/Type

Lube Points

Capacity Lube

2 Grease Fittings A/R MPG X

1 Grease Fitting A/R MPG X

1 Grease Fittings A/R MPG X

1 Grease Fitting A/R MPG X

NOTES: KEY TO LUBRICANTS

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

Engine Oil

Extreme Pres sure Gear Lube Hydraulic Fluid (Mobil #424 or equivalent)

Multi-Pu rpose Grease

MPG

3120863 – JLG Lift – 1-9

SECTION 1 - SPECIFICATIONS

1.6 PRESSURE SETTINGS

NOTE: All pressure are given in pounds per square inch

(psi), with the metric equivalent, Bar, in parentheses.

80 HX

Proportional Relief - Standard 220 Bar;

Prop. Tele 265 Bar.

Sequence (Load Sense) - 31 Bar.

Pressure Reducing (Pilot Press) - 38 Bar.

Drive - 214 Bar; Prop. Tele. 259 Bar.

Lift Up - 207 Bar.

Lift Down - 103 Bar

Swing - 103 Bar.

Telescope In - 207 Bar; Prop. Tele 259 Bar.

Tele Out - 103 Bar.

Solenoid Main Relief - 214 Bar.

2 Wheel Steer - 138 Bar; w/axle lift cyl. - 152 Bar

2 Wheel Steer w/4WD - 138 Bar; w/axle lift cyl. 152 Bar.

4 Wheel Steer - 138 Bar w/axle lift cyl. - 152 Bar.

Extend-A-Reach Up - 172 Bar.

Extend-A-Reach Down - 76 Bar.

80HX w/Oscillating Axle

Proportional Relief - Standard 220 Bar;

Prop. Tele 265 Bar.

Sequence (Load Sense) - 31 Bar.

Pressure Reducing (Pilot Press) - 38 Bar).

Drive - 214 Bar; Prop. Tele. 259 Bar.

Lift Up - 207 Bar.

Lift Down - 103 Bar

Swing - 103 Bar.

Telescope In - 207 Bar Prop. Tele 259 Bar.

Tele Out - 103 Bar.

Solenoid Main Relief - 214 Bar

2 Wheel Steer - 103 Bar

2 Wheel Steer w/4WD - 103 Bar.

4 Wheel Steer; Axle Lift Cyl. - 152 Bar.

Extend-A-Reach Up - 172 Bar

Extend-A-Reach Down - 76 Bar

NOTE: Refer to Section 2 for pressure setting procedures.

Extend-A-Reach Down - 76 Bar.

80HX w/Hydraulic Controls

Proportional Relief - Standard 220 Bar;

Prop. Tele 265 Bar.

Sequence (Load Sense) - 28 to 41 Bar.

Pressure Reducing (Pilot Press) - 41 Bar.

Hyd. Controls Back Pressure - Relief 8.6 Bar;

Press. Red. 5.5 to 8.2 Bar

Drive - 214 Bar; Prop. Tele. 259 Bar.

Lift Up - 207 Bar.

Lift Down - 103 Bar

Swing - 103 Bar.

Telescope In - 207 Bar; Prop. Tele 259 Bar.

Tele Out - 103 Bar.

Solenoid Main Relief - 214 Bar

2 Wheel Steer - 138 Bar; w/axle lift cyl.- 152 Bar

2 Wheel Steer w/4WD - 138 Bar; w/axle lift cyl.- 152 Bar.

4 Wheel Steer - 138 Bar; w/axle lift cyl. - 152 Bar.

Extend-A-Reach Up - 172 Bar.

1-10 – JLG Lift – 3120863

SECTION 1 - SPECIFICATIONS

1.7 MAJOR COMPONENTS WEIGHTS

Table 1-7. Major Component Weights

Component Lbs. KG.

Platform w/o Control Box

Boom (includes Lif t Cylinder, Rotator, and Support)

Turntable Complete (includes E ngine)

Frame Complete (in cludes Tires and Wheels)

Complete Machine - 2WD No Options

Complete Machine - 4WD No Options

Complete Machine (80 HX+6) 2WD No Options

236

4816

14972

9290

28605

29106

31856

107

2184

6790

4213

12973

13200

14447

1.8 CYLINDER SPECIFICATIONS

Table 1-8. Cylinder Specifications

DESCRIPTION BORE STROKE ROD DIA.

Master Level 63.5 mm 387 mm 31.75 mm

Slave Level 63.5 mm 387 mm 31.75 mm

Lift 203 mm 781 mm 89 mm

Lockout

(Oscillating Axle)

Lockout

(4WD)

Telescope 89 mm 6551 mm 63.5 mm

Steer (2WD) 76 mm 205 mm 31.75 mm

Steer (4WD) 76 mm 249 mm 38 mm

102 mm 124 mm 31.75 mm

102 mm 108 mm 31.75 mm

1.9 BOOM TAPE

Red - 99 cm.

Yellow - 86.4 cm.

Blue - 492.5 cm.

1.10 CRITICAL STABILITY WEIGHTS

Table 1-9. Critical Stability Weights

Component Lb.s KG.

Engines

Tire & Wheels

Deutz F4L912

Ford LRG 423

Cummins 4B3.9

15x19.5 Tire

Wheel

Foam Fill

837 380

410 186

680 309

130 59

72 33

320 145

Extend-A-Reach

Lift 76 mm 322 mm 51 mm

Slave 89 mm 184 mm 44.5 mm

3120863 – JLG Lift – 1-11

SECTION 1 - SPECIFICATIONS

1.11 SERIAL NUMBER LOCATION

A serial number plate is affixed to the left rear front of the turntable. If the serial number plate is damaged or missing, the machine serial number is stamped on the left side of the frame between front and rear wheels, below turnta-

ble bearing. In addition, the last five digits of the serial number are stamped on top of the fly, mid and base end of the boom and on the left side of the turntable.

Figure 1-3. Serial Number Locations

1-12 – JLG Lift – 3120863

SECTION 2. PROCEDURES

SECTION 2 - PROCEDURES

2.1 GENERAL

This section provides information necessary to perform maintenance on the aerial platform. Descriptions, techniques and specific procedures are designed to provide the safest and most efficient maintenance for use by personnel responsible for ensuring the correct installation and operation of machine components and systems.

WHEN AN ABNORMAL CONDITION IS NOTED AND PROCEDURES CONTAINED HEREIN DO NOT SPECIFICALLY RELATE TO THE NOTED IRREGULARITY, WORK SHOULD BE STOPPED AND TECHNICALLY QUALIFIED GUIDANCE OBTAINED BEFORE WORK IS RESUMED.

The maintenance procedures included consist of servicing and component removal and installation, disassembly and assembly, inspection, lubrication and cleaning. Information on any special tools or test equipment is also provided where applicable.

2.2 SERVICING AND MAINTENANCE GUIDELINES

General

2. At any time when air, fuel, or oil lines are disconnected, clear adjacent areas as well as the openings and fittings themselves. As soon as a line or component is disconnected, cap or cover all openings to prevent entry of foreign matter.

3. Clean and inspect all parts during servicing or maintenance, and assure that all passages and openings are unobstructed. Cover all parts to keep them clean. Be sure all parts are clean before they are installed. New parts should remain in their containers until they are ready to be used.

Components Removal and Installation

1. Use adjustable lifting devices, whenever possible, if mechanical assistance is required. All slings (chains, cables, etc.) should be parallel to each other and as near perpendicular as possible to top of part being lifted.

2. Should it be necessary to remove a component on an angle, keep in mind that the capacity of an eyebolt or similar bracket lessens, as the angle between the supporting structure and the component becomes less than 90 degrees.

3. If a part resists removal, check to see whether all nuts, bolts, cables, brackets, wiring, etc., have been removed and that no adjacent parts are interfering.

The following information is provided to assist you in the use and application of servicing and maintenance procedures contained in this chapter.

Safety and Workmanship

Cleanliness

1. The most important single item in preserving the long service life of a machine is to keep dirt and foreign materials out of the vital components. Precautions have been taken to safeguard against this. Shields, covers, seals, and filters are provided to keep air, fuel, and oil supplies clean; however, these items must be maintained on a scheduled basis in order to function properly.

Component Disassembly and Reassembly

When disassembling or reassembling a component, complete the procedural steps in sequence. Do not partially disassemble or assemble one part, then start on another. Always recheck your work to assure that nothing has been overlooked. Do not make any adjustments, other than those recommended, without obtaining proper approval.

Pressure-Fit Parts

When assembling pressure-fit parts, use an “anti-seize” or molybdenum disulfide base compound to lubricate the mating surface.

3120863 – JLG Lift – 2-1

SECTION 2 - PROCEDURES

Bearings

1. When a bearing is removed, cover it to keep out dirt and abrasives. Clean bearings in nonflammable cleaning solvent and allow to drip dry. Compressed air can be used but do not spin the bearing.

2. Discard bearings if the races and balls (or rollers) are pitted, scored, or burned.

3. If bearing is found to be serviceable, apply a light coat of oil and wrap it in clean (waxed) paper. Do not unwrap reusable or new bearings until they are ready to install.

4. Lubricate new or used serviceable bearings before installation. When pressing a bearing into a retainer or bore, apply pressure to the outer race. If the bearing is to be installed on a shaft, apply pressure to the inner race.

Gaskets

Check that holes in gaskets align with openings in the mating parts. If it becomes necessary to hand-fabricate a gasket, use gasket material or stock of equivalent material and thickness. Be sure to cut holes in the right location, as blank gaskets can cause serious system damage.

Bolt Usage and Torque Application

Hydraulic System

1. Keep the system clean. If evidence of metal or rubber particles are found in the hydraulic system, drain and flush the entire system.

2. Disassemble and reassemble parts on clean work surface. Clean all metal parts with non-flammable cleaning solvent. Lubricate components, as required, to aid assembly.

Lubrication

Service applicable components with the amount, type, and grade of lubricant recommended in this manual, at the specified intervals. When recommended lubricants are not available, consult your local supplier for an equivalent that meets or exceeds the specifications listed.

Battery

Clean battery, using a non-metallic brush and a solution of baking soda and water. 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 Section 1.

1. Use bolts of proper length. A bolt which is too long will bottom before the head is tight against its related part. 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.

2. Unless specific torque requirements are given within the text, standard torque values should be used on heat-treated bolts, studs, and steel nuts, in accordance with recommended shop practices. (See the Torque Chart in Section 1)

Hydraulic Lines and Electrical Wiring

Clearly mark or tag hydraulic lines and electrical wiring, as well as their receptacles, when disconnecting or removing them from the unit. This will assure that they are correctly reinstalled.

2.3 LUBRICATION INFORMATION

Hydraulic System

1. The primary enemy of a hydraulic system is contamination. Contaminants enter the system by various means, e.g., using inadequate hydraulic oil, allowing moisture, grease, filings, sealing components, sand, etc., to enter when performing maintenance, or by permitting the pump to cavitate due to insufficient system warm-up or leaks in the pump supply (suction) lines.

2. The design and manufacturing tolerances of the component working parts are very close, therefore, even the smallest amount of dirt or foreign matter entering a system can cause wear or damage to the components and generally results in faulty operation. Every precaution must be taken to keep hydraulic oil clean, including reserve oil in storage. Hydraulic system filters should be checked, cleaned, and/or replaced as necessary, at the specified intervals required in Section 1. Always examine filters for evidence of metal particles.

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3. Cloudy oils indicate a high moisture content which permits organic growth, resulting in oxidation or corrosion. If this condition occurs, the system must be drained, flushed, and refilled with clean oil.

4. It is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities. Good grade mineral oils, with viscosities suited to the ambient temperatures in which the machine is operating, are recommended for use.

NOTE: Metal particles may appear in the oil or filters of new

machines due to the wear-in of meshing components.

Hydraulic Oil

1. Refer to Section 1 for recommendations for viscosity ranges.

2. JLG recommends Mobilfluid 424 hydraulic oil, which has an SAE viscosity of 10W-20 and a viscosity index of 152, or BP Energol SHS46.

NOTE: Start-up of hydraulic system with oil temperatures

below -26° C (-15° F). is not recommended. If it is necessary to start the system in a sub-zero environment, it will be necessary to heat the oil with a low density, 100VAC heater to a minimum temperature of

-26° C (-15° F).

2. Use every precaution to keep the hydraulic oil clean. If the oil must be poured from the original container into another, be sure to clean all possible contaminants from the service container. Always clean the mesh element of the filter and replace the cartridge any time the system oil is changed.

3. While the unit is shut down, a good preventive maintenance measure is to make a thorough inspection of all hydraulic components, lines, fittings, etc., as well as a functional check of each system, before placing the machine back in service.

Lubrication Specifications

Specified lubricants, as recommended by the component manufacturers, are always the best choice, however, multi-purpose greases usually have the qualities which meet a variety of single purpose grease requirements. Should any question arise, regarding the use of greases in maintenance stock, consult your local supplier for evaluation. Refer to Section 1 for an explanation of the lubricant key designations appearing in the Lubrication Chart.

3. The only exception to the above is to drain and fill the system with Mobil DTE 11 oil or its equivalent. This will allow start up at temperatures down to -29° C (-20°F). However, use of this oil will give poor per- formance at temperatures above 49° C (120° F). Sys- tems using DTE 11 oil should not be operated at temperatures above 93° C (200°F). under any condition.

Changing Hydraulic Oil

1. Use of any of the recommended crankcase or hydraulic oils eliminates the need for changing the oil on a regular basis. However, filter elements must be changed after the first 40 hours of operation and every 250 hours thereafter. If it is necessary to change the oil, use only those oils meeting or exceeding the specifications appearing in this manual. If unable to obtain the same type of oil supplied with the machine, consult local supplier for assistance in selecting the proper equivalent. Avoid mixing petroleum and synthetic base oils. JLG Industries recommends changing the hydraulic oil annually.

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2.4 CYLINDERS - THEORY OF OPERATION

Double Acting Cylinders

Cylinders are of the double-acting type. Systems incorporating double-acting cylinders are as follows: Lift, Telescope, Platform Leveling, Steer and Lockout. A double acting cylinder is one that requires oil flow to operate the cylinder rod in both directions. Directing oil (by actuating the corresponding control valve to the piston side of the cylinder) forces the piston to travel toward the rod end of the barrel, extending the cylinder rod (piston attached to rod). When the oil flow is stopped, movement of rod will stop. By directing oil to the rod side of the cylinder, the piston will be forced in the opposite direction and the cylinder rod will retract.

2.5 VALVES - THEORY OF OPERATION

Holding Valves

Holding Valves are used in the Lift, Telescope, Slave Level and lockout circuits to prevent retraction of the cylinder rod, should a hydraulic line rupture or a leak develop between the cylinder and its related control valve.

Solenoid Control Valves (Bang-Bang)

Control valves used are four-way three-position solenoid valves of the sliding spool design. When a circuit is activated and the control valve solenoid energizes, the spool is shifted and the corresponding work port opens to permit oil flow to the component in the selected circuit with the opposite work port opening to reservoir. Once the circuit is deactivated (control returned to neutral) the valve spool returns to neutral (center) and oil flow is then directed through the valve body and returns to reservoir. A typical control valve consist of the valve body, sliding spool, and two solenoid assemblies. The spool is machine fitted in the bore of the valve body. Lands on the spool divide the bore into various chambers, which when the spool is shifted, align with corresponding ports in the valve body open to common flow. At the same time other ports would be blocked to flow. The spool is spring loaded to center position, therefore when the control is released, the spool automatically returns to neutral, prohibiting any flow through the circuit.

Proportional Control Valve - Vickers (See Figure 2-1)

CMX series valves provide a power output matching that required by the load. A small line connected to a loadsensing port feeds load pressure back to the pump. The pump senses the difference between the load and pump outlet pressures, and varies the pump displacement to keep the difference constant. This differential pressure is applied across the valves meter-in spool, with the effect that pump flow is determined by the degree of spool opening, independent of load pressure. Return lines are connected together simplifying routing of return flow and to help reduce cavitation. Load sensing lines connect through shuttle valves to feed the highest load signal back to the pump. Integral actuator port relief valves, anti-cavitation check valves, and load check valves are standard. The load drop check prevents any drop of a suspended load before upward movement.

Main Relief Valves

Main relief valves are installed at various points with the hydraulic system to protect associated systems and components against excessive pressure. Excessive pressure can be developed when a cylinder reaches its limit of travel and the flow of pressurized fluid continues from the system control. The relief valve provides an alternate path for the continuing flow from the pump, thus preventing rupture of the cylinder, hydraulic line or fitting. Complete failure of the system pump is also avoided by relieving circuit pressure. The relief valve is installed in the circuit between the pump outlet (pressure line) and the cylinder of the circuit, generally as an integral part of the system valve bank. Relief pressures are set slightly higher than the load requirement, with the valve diverting excess pump delivery back to the reservoir when operating pressure of the component is reached.

Relief Valves

Crossover relief valves are used in circuits where the actuator requires an operating pressure lower than that supplied to the system. When the circuit is activated and the required pressure at the actuator is developed, the crossover relief diverts excess pump flow to the reservoir, individual, integral reliefs are provided for each side of the circuits.

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SECTION 2 - PROCEDURES

Figure 2-1. Proportional Control Valve

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Figure 2-2. Typical Boom Assembly

2.6 BOOM CHAINS (SEE FIGURE 2-2.)

Adjusting Procedures

ENSURE THE MACHINE IS ON A FIRM AND LEVEL SURFACE.

1. Fully retract the boom in the horizontal position (± 5°) with no load in the platform.

2. Extend the platform approximately 1 meter (3 ft.).

3. Torque the boom retract chain adjuster to 69 NM (50 ft. lbs.), then torque the boom extend chain adjuster to 69 NM (50 ft. lbs.).

4. Retract the platform approximately 0.3 m (1 ft.).

5. Check the boom extend chain adjusters (69 NM {50 ft. lbs.} required).

6. Retract the platform approximately 0.3 m (1 ft.) once again.

7. Recheck the extend chain adjusters (69 NM {50 ft. lbs.} required).

8. Extend the platform approximately 0.3 m (1 ft.). Check for proper operation of boom.

9. Recheck the retract chain adjuster torque. (69 NM {50 ft. lbs.} required).

10. Fully extend and retract the boom and check for proper operation.

JLG Industries, Inc. requires a complete boom disassembly, per instructions outlined in Section 2.12, Boom Maintenance, every two years. All boom chains and related components (i.e., sheaves, pins, sprockets, wear pads, etc.) must also be inspected and replaced (as necessary) during this disassembly.

An immediate disassembly of the boom assembly and inspection of the boom chains and related components is required if any of the following conditions occur:

1. After the machine is exposed to hostile environments or conditions (i.e. extreme cold, dust, sand, blasting grit, salt, chemicals, etc.), which could adversely affect boom operation.

2. Erratic boom operation or unusual noise exists. See the Troubleshooting section in this Service Manual.

3. Chain adjustment is required more often than specified in the Preventive Maintenance and Inspection Schedule in this Service Manual or links need to be removed (chain shortened) to make the proper adjustment.

4. The machine is idle for an extended period (6 months or longer.)

5. The boom is overloaded or sustained a shock load.

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FAILURE TO DISASSEMBLE THE BOOM ASSEMBLY AND PROPERLY INSPECT AND/OR REPLACE THE BOOM CHAINS AND RELATED COMPONENTS (I.E., SHEAVES, PINS, SPROCKETS, WEAR PADS, ETC.) COULD RESULT IN THE DAMAGE AND/OR BREAKAGE OF THE BOOM CHAINS AND/OR RELATED COMPONENTS. DAMAGE AND/OR BREAKAGE OF THESE ITEMS COULD RESULT IN UNCONTROLLED EXTENSION OR RETRACTION OF THE BOOM ASSEMBLY AND COULD CAUSE SERIOUS INJURY OR DEATH TO PERSONNEL OPERATING THE JLG BOOM LIFT.

Inspection Procedures

Inspect boom chains for the following condition:

1. Wear: Always inspect that segment of chain that operates over a sheave. As the chain flexes over the extend/retract sheaves, joints and plate edges very gradually wear. Chain “stretch” can be measured using a manufacturers wear scale or steel tape. When chains have elongated 3% they must be removed and replaced. Refer to Table 2-1 for proper chain specifications and allowable stretch tolerances. Peening and wear of chain plate edges are caused by sliding over a chain worn contact face of a sheave, or unusually heavy loads. All of the above require replacement of the chain and correction of the cause. Chain side wear, noticeable when pin heads and outside plates show a definite wear pattern, is caused by misalignment of the sheave/chain anchors and must be corrected promptly. Do not repair chains; if a section of chain is damaged, replace the entire chain set.

SECTION 2 - PROCEDURES

NOTE: The need for lubrication can be determined by the

presence of rust on the exposed portions of chain.

3. Rust and Corrosion: Rust and corrosion will cause a major reduction in the load carrying capacity of the chain, because these are primary reasons for side plate cracking. The initial lubrication at the factory is applied in a hot dip tank to assure full penetration into the joint. Do not steam clean or degrease this lubricant on chains. A grade of SAE 30 or 40 weight, non detergent motor oil should be used as a supplemental lubricant and a film of this oil should be constantly maintained on the surfaces and internal joints. At time of chain installation, factory lube must be supplemented by a maintenance program to provide a film of oil on the chains at all times. If chains are corroded, they must be inspected, especially the outside plates, for cracks in-line with the pins. If cracks are found, replace the chain; if no cracks are discovered, lubricate the chains by dipping in heated oil, and reinstall on the machine. Keep chains lubricated.

4. Fatigue Cracks: Fatigue is a phenomenon that affects most metals, and is the most common cause of chain plate failures. Fatigue cracks are found through the link holes, perpendicular (90 degrees) from the pin in-line position. Inspect chains carefully after long time use and heavy loading for this type of crack. If any cracks are discovered, replace all chains, as seemingly sound plates are on the verge of cracking. Fatigue and ultimate strength failures on JLG Lifts are incurred as a result of severe abuse as design specs are well within the rated lifting capacity of these chains.

5. Tight Joints: All joints in the roller chain should flex

2. Lubrication: One of the most important but often overlooked factors is adequate lubrication. In addition to reducing internal friction, maintaining a film of oil on all chain surfaces will inhibit rusting and corrosion. This is important as corrosion of highly stressed, hardened steel chain components can cause a major reduction in the load capacity of leaf chain and result in link plate cracking.

freely. On roller chain, tight joints are usually caused by rust/corrosion, or the inside plates “walking” off the bushing. Limber up rusty/corroded chains (after inspecting care fully) with a heavy application of oil (preferably a hot oil dip). Tap inside “walking” plates inward; if “walking” persists, replace the chain. This type of problem is accelerated by poor lubrication maintenance practice, and most tight joint chains have been operated with little or no lubrication. Tight joints on leaf chain are generally caused by:

1. Bent pins or plates.

2. Rusty joints.

3. Peened plate edges.

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SECTION 2 - PROCEDURES

ARC-LIKE CRACKED PLATES

(STRESS CORROSION)

Oil rusty chains, and replace chains with bent or peened chain components. Keep chains lubricated.

TIGHT JOINTS

6. Protruding or Turned Pins: Chains operating with inadequate lube generate tremendous friction between the pin and plates (pin and bushing on roller chain). In extreme cases, this frictional torque can actually turn the pins in the outside press-fit plates. Inspect for turned pins, which can be easily spotted as the “V” flats on the pin heads are no longer in line. Replace all chains showing evidence of turned or protruding pins. Keep chains lubricated.

7. Stress Corrosion Cracking: The outside link plates, which are heavily press-fitted to the pins, are particularly susceptible to stress corrosion cracking. Like fatigue cracks, these initiate at the point of highest stress (aperture) but tend to extend in an arc-like path, often parallel to the rolling grain of the material.

ABNORMAL PROTRUSION OR

TURNED PINS

Anchors with worn or broken fingers should be replaced. They should also be adjusted to eliminate twisting the chain for an even load distribution.

Sheaves should be inspected for worn flanges, which would indicate misalignment, and wear on the outside diameter of the sheave. A worn sheave can mean several problems, as follows:

1. Chains too tight.

2. Sheave bearings/pin bad.

3. Bent/misaligned chains.

Table 2-1. Chain Stretch Tolerance

ALLOWABLE

STRETCH 14 IN.

SPAN

1.07 cm

CHAIN SIZE

0.50 in. (1.27 cm) pitch

1.00 in. (2.54 cm) pitch

1.75 in. (4.45 cm) pitch

PIN TO PIN

MEASUREMENT

36 cm or 28

pitches

36 cm or 14

pitches

36 cm or 8

pitches

Also, more then one crack can often appear on a link plate. In addition to rusting, this condition can be caused by exposure to an acidic or caustic medium or atmosphere. Stress corrosion is an environmentally assisted failure. Two conditions must be present; corrosive agent and static stress.

In the chain, static stress is present at the aperture due to the press fit pin. No cycle motion is required and the plates can crack during idle periods. The reactions of many chemical agents (such as battery acid fumes) with hardened metals liberate hydrogen which attacks and weakens the metal grain structure.

8. Chain Anchors, Sheaves and Pins: An inspection of the chain must include a close examination of chain anchors, sheaves and pins. Check chain anchors for wear breakage and misalignment.

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2.00 in. (5.08 cm) pitch

36 cm or 7

pitches

1.07 cm

Auxiliary Boom Chains

The auxiliary boom chains are used as a safety device, to prevent the boom from retracting in the event that an extend chain should break. As the boom would begin to retract, tension would be placed on the auxiliary chain, stopping the boom and tripping a limit switch to shut down the machine.

The auxiliary boom chain is located on top of the boom. One end of the chain is attached to an adjustable clevis on top of the front end of the base section, and uses belleville washers and adjusting nuts to adjust chain tension. The other end of the chain is attached to a fixed clevis on top of the fly section. A limit switch is installed adjacent to the adjustable clevis on the base section, and when tripped, shuts down the machine. Adjust chain tension so there is no slack in the chain and set the cam on the switch so the switch trips when the belleville washers compress 1 to 1.3 cm.

REPLACE THE BELLEVILLE WASHERS ONCE THEY HAVE BEEN COMPRESSED.

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