JLG 80HX-HX-6-HXER Service Manual

SERVICE & MAINTENANCE

Model

80HX

80HX+6

80HXER

3120863

May 14, 2002

AUSTRALIAN OFFICE	EUROPEAN OFFICE		CORPORATE OFFICE
JLG INDUSTRIES, INC.	JLG INDUSTRIES (EUROPE)		JLG INDUSTRIES, INC.
P.O. Box 5119	Kilmarting Place,		1 JLG Drive
11 Bolwarra Road	Tannochside Park		McConnellsburg, PA.
Port Macquarie, Australia	Uddingston, Scotland, G71 5PH		17233-9533
Telephone: [phone]	Telephone: [phone]		USA
Fax: [phone]	Main Fax:	01698 811055	Telephone:	[phone]
	Parts Fax:	01698 811455	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/OPER-

ATOR.

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.

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.

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

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

•USE ONLY APPROVED, NONFLAMMABLE CLEANING SOLVENTS.

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A-1

INTRODUCTION

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

A-2

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TABLE OF CONTENTS

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

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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

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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

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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

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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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SECTION 1 - SPECIFICATIONS

SECTION 1. SPECIFICATIONS

1.1CAPACITIES

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%.

1.2COMPONENT 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.

Horsepower - 70 @ 2400 RPM, no load

Tires

Foam-Filled Tires - 15 x 19.5

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.

Swing System

Swing Motor - Displacement - 74 cc/Rev.

Swing Hub - Ratio - 69.50:1.

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

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SECTION 1 - SPECIFICATIONS

Hydraulic Pump

Hydraulic Filter - Tank

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.

Return - Bypass Type.

10 Microns Nominal.

Hydraulic Filter - Inline (Racine Valve Only)

Return - Non-Bypass Type.

10 Microns Nominal.

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.

1.3PERFORMANCE DATA

Travel Speed

5.6 KM/HR.

Gradeability

25%.

Turning Radius (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.

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

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.

Swing Speed 360°

Swing Speed 360° - 110-200 Seconds.

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

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3120863

SECTION 1 - SPECIFICATIONS

UNPLATED CAP SCREWS

VALUES FOR ZINC PLATED BOLTS ONLY

UNBRAKO1960SERIES SOCKETHEADCAPSCREW	WITHLOC-WELPATCH	TORQUE	(asreceived)	NM
		CLAMPLOAD (KG)
8NUTS	TORQUE	(LOCTITE	)242OR271	NM
BOLTS&GRADE		ORY(DR	263).LOC	MN NM
		(LOCTITE	262)
		(LUB.)
SAEGRADE8				NM
	CLAMP	LOAD (KG)
2NUTS	TORQUE	(LOCTITE	)242OR271	NM
BOLTS&GRADE		ORY(DR	263).LOC	MN NM
		(LOCTITE	262)
		(LUB.)
SAEGRADE5				NM
	CLAMP	LOAD (KG)
THREAD	STRESS AREA		(SQ.CM)
BOLT DIA. (CM)
	THD
	SIZE

1 1 2 2 4 4
2 2 3 3 5 5
245	272	372	417	572	599

1	1 2		2		3 3
1 1		2	2		4 4
172	191	263	277		408	426
0.0153	0.0168	0.0232	0.0258		0.0356	0.0374
0.2845		0.3505			0.4166
40		32		40	32		36
	48
4		6			8

5 6
7 8
717	817

4 4
5 6
508	583
0.0445	0.0508
0.4826
24
	32
10

18	19
1442	1651
18	21

12	14
16	19
1297	1488
12	16

9	10
11	14
916	1052
0.0808	0.0925
0.6350
20
	28
1/4

34	37		61	68		95	102		149	156		210	224
2377	2631		3493	3983		4822	5384		6437	7253		8256	9208
41	41		68	75		109	122		163	183		224	258
30	34		54	61		85	95		130	146		188	209
25	27		48	48		75	81		109	122		149	176
34	34		61	68		95	109		149	163		204	231
2141	2821		3175	3583		4332	4854		5783	6532		7539	8278
26	29		48	54		75	81		115	136		163	183
22	23		38	43		61	68		92	108		133	148
18	19		31	34		48	68		75	88		109	122
23	26		41	48		68	75		102	122		149	163
1515	1678		2241	2540		3085	3425		4105	4854		5262	5874
0.1331	0.1473		0.1969	0.2230		0.2700	0.3015		0.3604	0.4061		0.4623	0.5156
0.7938			0.9525			1.1112			1.2700			1.4288
18		24	16		24	14		20	13		20	12
													18
5/16			3/8			7/16			1/2			9/16

285	298
10251	11612
326	359
244	277
231	244
298	326
9231	10433
224	258
183	207
149	176
204	231
6532	7394
0.5740	0.6502
1.5875
11
	18
5/8

495	542	793	861
15150	16919	20956	23088
570	631	895	983
408	456	658	724
380	434	624	678
515	570	814	895
13653	15241	18870	20775
387	448	644	705
325	363	523	576
271	298	434	475
353	407	583	637
9662	10796	13336	14697
0.8484	0.9474	1.1735	1.2929
1.9050		2.2225
10		9
	16		14
3/4		7/8

1173	1241		1681	1871		2373	2549		3145	3308		4122	4433
27488	30074		34610	38828		43954	48671		52391	59648		63731	71669
1342	1492		1898	2136		2712	2983		3559	4068		4712	5322
931	1079		1396	1566		1970	2183		2586	2935		3430	3856
922	1003		1302	1464		1844	2034		2413	2766		3200	3607
1220	1356		1736	1953		2468	2712		3227	3688		4284	4827
23360	27080		31162	34927		38554	43818		47174	53570		57380	142200
915	997		1139	1254		1593	1762		2068	2373		2746	3118
785	858		968	1087		1368	1516		1792	2042		2379	2676
651	719		814	895		1139	1247		1492	1708		1980	2224
868	949		1085	1193		1519	1681		1980	2278		2630	2983
17509	19142		19187	21546		24404	27035		29076	33113		35381	39781
1.5392	1.6840		1.9380	2.1742		2.4613	2.7254		2.9337	3.3401		3.5687	4.0132
2.5400			2.8575			3.1750			3.4925			3.8100
8		12	7		12	7		12	6		12	6
													12
1			1-1/8			1-1/4			1-1/2			1-1/2

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

SAE GRADE 5 SAE GRADE 8

Figure 1-1. Torque Chart

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1-3

SECTION 1 - SPECIFICATIONS

	Maximum Tire Load		1.5 LUBRICATION
	80HX - 7037 kg @ 7.2 kg/cm2
				Deutz Engine
	80HX + 6 - 8299 kg @ 7.5 kg/cm2
				Single Viscosity Oils (CD-SE, CD-SF).
	Wheelbase			When Outside Temp	Use SAE
				is Consistently	Viscosity Number
	3 m			-29° C - -4° C.	*10W
				-9.5° C - + 10° C.	20W-20
				+4.5° C - + 29.5° C.	30
				Above 24° C.	40

1.4TORQUE REQUIREMENTS

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

Table 1-1. Torque Requirements

Description	Torque			Interval
	Ft. Lbs.		Nm	Hours
Turntable (prior to April, 1986)	-		-
5/8" Bolts - Wet	170		235
5/8" Bolts - Dry	220		304	50/600*
7/8" Bolts - Wet	460		636
7/8" Bolts - Dry
	600		830
Turntable (April, 1986 to Present)	-		-	50/600*
Wet	170		235
Dry	220		304
Wheel Lugs	-		-	100
Wet	220		304
Dry	300		415
Drive Hub	-		-	200/500**
Wet	110		149
Dry	150		207
Swing Hub	-		-	200/500**
Wet	80		110
Dry	110		149

* 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.

NOTE: When maintenance becomes necessary or a fastener has loosened, refer to the Torque Chart to determine proper torque value.

When Outside Temp	Use SAE
is Consistently	Viscosity Number
-40° C - +24° C.	*5W-20
	(Synthetic)
-20.5° C - +21° C.	10W-30
-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.

.

Table 1-2.Hydraulic Oil

Hydraulic System Operating	SAE Viscosity
Temperature Range	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.

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3120863

SECTION 1 - SPECIFICATIONS

Table 1-3. Mobil EAL 224 H Specs

Type		Biodegradable Vegetable Oil
ISO Viscosity Grade		32/46
Specific Gravity		.922
Pour Point, Max		-25°F (-32°C)
Flash Point, Min.		428°F (220°C)
Weight		7.64 lb. per gal.
		(0.9 kg per liter)
	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)
Table 1-4. Mobil DTE 13M Specs
Type		Petroleum Base
ISO Viscosity Grade		32
Specific Gravity		.877
Pour Point, Max		-40°F (-40°C)
Flash Point, Min.		330°F (166°C)
	Viscosity
at 104° F (40° C)		33 cSt
at 212° F (100° C)		6.5 cSt
Viscosity Index		140

Lubrication Specifications

	Table 1-5.Lubrication Specifications
KEY	SPECIFICATIONS
MPG	Multipurpose Grease having a minimum dripping point of 350
	degrees F. Excellent water resistance and adhesive qualities;
	and being of extreme pressure type (Timken OK 40 pounds
	minimum).
EPGL	Extreme Pressure Gear Lube (oil) meeting API Service Classi-
	fication GL-5 or Mil-Spec Mil-L-2105.
HO	Hydraulic Oil. API Service Classification GL-3, SAE 10W-20,
	Viscosity Index 152.
EO	Engine (crankcase) Oil. Gas - API SF/SG class, MIL-L-2104.
	Diesel - API CC/CD class, 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:

150 hours = 3 months

300 hours = 6 months

600 hours = 1 year

1200 hours = 2 years

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SECTION 1 - SPECIFICATIONS

Figure 1-2. Lubrication Diagram

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– JLG Lift –

3120863

SECTION 1 - SPECIFICATIONS

Table 1-6. Lubrication Chart

Number/Type

Interval

Hours

Components

Capacity

Lube

Comments

Lube Points

3 Months

6 Months

1 Year

2 Years

150 hrs

300 hrs

600 hrs

1200 hrs

1

Wheel Drive Hubs

Level/Fill Plug

1.3 L. (1/2 full)

EPGL

X

Check level every 150 hours; change @ 1200

(SAE90)

hours

2	Slave Cylinder (Rod)	1 Grease Fitting	A/R	MPG	X
3	Slave Cylinder (Barrel )	1 Grease Fitting	A/R	MPG	X	Gain access through boom fly section.
4	Platform Pivot	1 Grease Fitting	A/R	MPG	X
5	Rotating Column	2 Grease Fittings	A/R	MPG	X
	(Optional)
6	Rotary Worm Gear	N/A	A/R	MPG	X	Brush on.
	(Optional)
7	Platform Hinges	2 Grease Fittings	A/R	MPG	X
8	Platform Latch	N/A	A/R	EO	X
9	Boom Chain Extension	1 Grease Fitting	A/R	MPG	X	Align access holes in mid and fly boom.
	Sheave
10	Swing Bearing	2 Grease Fittings	A/R	MPG	X	Remote Access

11	Lift Cylinder (Barrel End)	1 Grease Fitting	A/R	MPG	X	Remote Access

12	Master Cylinder (Barrel	1 Grease Fitting	A/R	MPG	X	Remote Access
	End)

13	Master Cylinder (Rod	1 Grease Fitting	A/R	MPG	X
	End)

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1-7

SECTION 1 - SPECIFICATIONS

Table 1-6. Lubrication Chart

		Number/Type			Interval		Hours
	Components		Capacity	Lube					Comments
		Lube Points			3 Months	6 Months	1 Year	2 Years
					150 hrs	300 hrs	600 hrs	1200 hrs
14	Boom Chain Retract	1 Grease Fitting	A/R	MPG	X
	Sheave
15	Boom Pivot Bushings	2 Grease Fittings	A/R	MoS2	X
16	Engine Crankcase	Fill Cap	Refer to Engine Manual	EO					Check daily. Change in accordance wth
									engine manual.
17	Engine Oil Filter	N/A	N/A	N/A					Change in accordance with engine manual.
18	Engine Coolant	Radiator Cap	Refer to Engine Manual						Refer to engine manual for coolant specifica-
									tions. Check daily with engine cold.
19	Hydraulic Oil	Fill Cap	56 gallons	HO				X	Check daily. Change every 1200 hours.
20	Hydraulic Oil Return	N/A	N/A	N/A					Check filter gauges for element construction
	Filters								daily. Replace as necessary.
21	Hydraulic Reservoir	N/A	N/A	N/A			X		Replace filter element every 600 hours; clean
	Suction Filter								mesh as necessary.
22	Tie Rod Ends	2 Grease Fittings	A/R	MPG	X
23	King Pins	2 Grease Fittings	A/R	MPG	X
24	Steer Cylinder (Rod	1 Grease Fitting	A/R	MPG	X
	End)
25	Steer Cylinder (Barrel	1 Grease Fitting	A/R	MPG	X
	End)
26	Wheel Bearings	N/A	A/R	MPG			X		Repack
27	Swing Drive Hub	Fill Plug	0.5 L. (1/2 Full)	EPGL			X		Check oil level weekly; change every 600
				(SAE90)					hours
28	Swing Bearing and	N/A	A/R	MPG			X		Apply by brush onto bearing and gear teeth
	Pinion Gear Teeth
29	Axle Beam (Extendable	N/A	A/R	MPG		X			Apply by brush
	Axles)
30	Axle Lock Pin	N/A	A/R	MPG	X				Apply by brush
	(Extendable Axles)
31	Oscillating Axle Pivot	1 Grease Fitting	A/R	MPG	X
32	Oscillation Cylinder	2 Grease Fittings	A/R	MPG	X
33	Extend-A-Reach Pivot (If	2 Grease Fittings	A/R	MPG	X
	Equipped)

34	Extend-A-Reach Lift	1 Grease Fitting	A/R	MPG	X
	Cylinder (Barrel End)
35	Extend-A-Reach Lift	1 Grease Fitting	A/R	MPG	X
	Cylinder (Rod End)

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3120863

									SECTION 1 - SPECIFICATIONS
				Table 1-6. Lubrication Chart
			Number/Type			Interval		Hours
		Components		Capacity	Lube					Comments
			Lube Points			3 Months	6 Months	1 Year	2 Years
						150 hrs	300 hrs	600 hrs	1200 hrs
36 Extend-A-Reach - Boom 2 Grease Fittings				A/R	MPG	X
		End (If Equipped)

37	Extend-A-Reach -	1 Grease Fitting	A/R	MPG	X
	Platform End (if
	Equipped)
38	Extend-A-Reach - Slave	1 Grease Fittings	A/R	MPG	X
	Cylinder Rod End (If
	Equipped)
39	Extend-A-Reach Link -	1 Grease Fitting	A/R	MPG	X
	Slave Cylinder Pivot
	Point (If Equipped)
40	Extend-A-Reach Link -	1 Grease Fitting	A/R	MPG	X
	Slave Cylinder Pivot
	Point (If Equipped)
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 envi-						EO	Engine Oil
ronments or conditions, lubrication frequencies must be increased accordingly.						EPGL	Extreme Pressure Gear Lube
						HO	Hydraulic Fluid (Mobil #424 or equivalent)
						MPG	Multi-Purpose Grease

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1-9

SECTION 1 - SPECIFICATIONS

1.6PRESSURE 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.

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.

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

1.7MAJOR COMPONENTS WEIGHTS

Table 1-7. Major Component Weights

Component	Lbs.	KG.
Platform w/o Control Box	236	107
Boom (includes Lift Cylinder, Rotator, and Support)	4816	2184
Turntable Complete (includes Engine)	14972	6790
Frame Complete (includes Tires and Wheels)	9290	4213
Complete Machine - 2WD No Options	28605	12973
Complete Machine - 4WD No Options	29106	13200
Complete Machine (80HX+6) 2WD No Options	31856	14447

1.8CYLINDER 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	102 mm	124 mm	31.75 mm
(Oscillating Axle)
Lockout	102 mm	108 mm	31.75 mm
(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

Extend-A-Reach

Lift	76 mm	322 mm	51 mm
Slave	89 mm	184 mm	44.5 mm

1.9BOOM 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		Deutz F4L912	837	380
		Ford LRG 423	410	186
		Cummins 4B3.9	680	309
Tire & Wheels		15x19.5 Tire	130	59
		Wheel	72	33
		Foam Fill	320	145

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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

2.1GENERAL

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.

2.2SERVICING AND MAINTENANCE GUIDELINES

General

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

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.

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.

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.

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.

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Bearings

Hydraulic System

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

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.

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.

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).

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 performance at temperatures above 49° C (120° F). Systems 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.

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.

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2.4CYLINDERS - 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.

2.5VALVES - 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-cavi- tation 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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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.

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.

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 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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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

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.

ARC-LIKE CRACKED PLATES

(STRESS CORROSION)

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.

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

		PIN TO PIN	ALLOWABLE
	CHAIN SIZE		STRETCH 14 IN.
		MEASUREMENT
			SPAN
	0.50 in. (1.27 cm)	36 cm or 28	1.07 cm
	pitch	pitches
	1.00 in. (2.54 cm)	36 cm or 14	1.07 cm
	pitch	pitches
	1.75 in. (4.45 cm)	36 cm or 8	1.07 cm
	pitch	pitches
	2.00 in. (5.08 cm)	36 cm or 7	1.07 cm
	pitch	pitches

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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