JLG 80SL Service Maintenance Manual Download Page 1

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Service & Maintenance Manual

Model

80SL

3121325

March 24, 2011

Summary of Contents for 80SL

Page 1: ...Service Maintenance Manual Model 80SL 3121325 March 24 2011...

Page 2: ......

Page 3: ...hould be noted that the machines hydraulic sys tems operate at extremely high potentially danger ous pressures Every effort should be made to relieve any system pressure prior to disconnecting or remo...

Page 4: ...NANCE SAFETY PRECAUTIONS b JLG Lift 3121325 REVISION LOG Original Issue February 6 2007 Revised March 5 2007 Revised June 7 2007 Revised November 20 2007 Revised March 10 2008 Revised July 26 2010 Rev...

Page 5: ...Component Weights 1 4 1 10 Critical Stability Weights 1 4 1 11 Lubrication 1 4 SECTION 2 GENERAL 2 1 Machine Preparation Inspection and Maintenance 2 1 General 2 1 Preparation Inspection and Maintenan...

Page 6: ...Deutz Engine 3 14 Engine Tray Slide 3 15 Glow Plugs 3 16 Engine Solenoid Fuse 3 16 Hydraulic Pump Assembly 3 17 Hydraulic Pump 3 18 Exhaust Pipe Assembly 3 19 Air Filter Assembly 3 20 Engine Removal...

Page 7: ...Valve 4 24 Outrigger Safety Valves 4 25 SECTION 5 JLG CONTROL SYSTEM 5 1 Main Terminal Box Circuit Boards 5 1 5 2 Control Card Complex 2 5 2 General Description of Components and Functions 5 2 5 3 Niv...

Page 8: ...s 6 4 Requirements 6 4 Procedure 6 4 6 3 Applying Silicone Dielectric Compound To Amp Connectors 6 5 Assembly 6 6 Disassembly 6 8 Wedge Lock 6 8 Service Voltage Reading 6 9 6 4 Working With Deutsch Co...

Page 9: ...haust Pipe Assembly 3 19 3 18 Air Filter Assembly 3 20 3 19 Engine Removal 3 21 3 20 Hydraulic Tank Removal 3 22 3 21 Pressure Filter Removal 3 23 3 22 Fuel Tank Removal 3 24 3 23 Ground Control Panel...

Page 10: ...ake Valve 4 18 4 35 Brake Valve Adjustment 4 18 4 36 Drive Valve 4 19 4 37 Main Valve Block 4 20 4 38 Pressure Test Port 4 21 4 39 Proportional Valve Pressure Adjustment 4 21 4 40 Pump Engage Disengag...

Page 11: ...Electrical Schematic Sheet 9 of 15 6 20 6 27 Electrical Schematic Sheet 10 of 15 6 21 6 28 Electrical Schematic Sheet 11 of 15 6 22 6 29 Electrical Schematic Sheet 12 of 15 6 23 6 30 Electrical Schem...

Page 12: ...3 3 3 2 Drive Motor Specs 3 7 3 3 Tightening Torques 3 8 3 4 Engine Technical Data 3 14 3 5 Variable Displacement Axial Piston Pump Specs 3 18 3 6 Joystick Specifications 3 28 3 7 Plug Loading Chart...

Page 13: ...ed slow 0 4mph 0 6ft sec 0 2m s Drive Speed fast 1 9mph 0 86m s Sideslope MachineStowed 5 Gradeability MachineStowed 25 LiftSpeed no load 125sec Lowering Speed 80 sec MaximumOperatingHydraulic Pressur...

Page 14: ...t Switch Once the platform has reached it s maximum height of 80 ft 24 5 m the lifting function will be cut off by the maxi mum height limit switch When maximum height is reached the Lift Cutout Indic...

Page 15: ...itch 5 Tilt Sensor 2 High Drive Speed Cutout Limit Switch 6 Outrigger Sensor all 4 outriggers 3 Maximum Drive Height Maximum Height without Outriggers Limit Switch 7 Oscillating Axle Limit Switches re...

Page 16: ...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 Indus tries for proper recommenda...

Page 17: ...SECTION 1 SPECIFICATIONS 3121325 JLG Lift 1 5 Figure 1 2 Engine Operating Temperature Specifications...

Page 18: ...SECTION 1 SPECIFICATIONS 1 6 JLG Lift 3121325 1 12 TORQUE CHARTS Figure 1 3 Torque Chart SAE Fasteners Sheet 1 of 3...

Page 19: ...SECTION 1 SPECIFICATIONS 3121325 JLG Lift 1 7 Figure 1 4 Torque Chart SAE Fasteners Sheet 2 of 3...

Page 20: ...SECTION 1 SPECIFICATIONS 1 8 JLG Lift 3121325 Figure 1 5 Torque Chart SAE Fasteners Sheet 3 of 3...

Page 21: ...SECTION 1 SPECIFICATIONS 3121325 JLG Lift 1 9 Figure 1 6 Torque Chart METRIC Fasteners Sheet 1 of 3...

Page 22: ...SECTION 1 SPECIFICATIONS 1 10 JLG Lift 3121325 Figure 1 7 Torque Chart METRIC Fasteners Sheet 2 of 3...

Page 23: ...SECTION 1 SPECIFICATIONS 3121325 JLG Lift 1 11 Figure 1 8 Torque Chart METRIC Fasteners Sheet 3 of 3...

Page 24: ...SECTION 1 SPECIFICATIONS 1 12 JLG Lift 3121325 NOTES...

Page 25: ...n ser vice for 3 months or 150 hours whichever comes first out of service for a period of more than 3 months or when purchased used The frequency of this inspection must be increased as environment se...

Page 26: ...ir contain ers 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...

Page 27: ...rque 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 enga...

Page 28: ...at the oil with a low density electrical heater to a minimum temperature of 15 F 26 C Changing Hydraulic Oil 1 Use of any of the recommended crankcase or hydraulic oils eliminates the need for changin...

Page 29: ...nments or conditions lubrication frequencies must be increased accordingly Operate hydraulic functions through one complete cycle before checking hydraulic oil level in tank Oil should be visible in A...

Page 30: ...e Fittings Capacity As Required Lube MPG Interval As Required 2 Outrigger Cylinders Lube Points 4 Grease Fittings Capacity As Required Lube MPG Interval As Required 3 Engine Compartment a Engine Oil C...

Page 31: ...d c Fuel Filter Maintenance Replaceable Element JLG P N 7020023 Interval Change every year or 600 hours of operation whichever comes first d Air Filter Maintenance Replaceable Element JLG P N H005232...

Page 32: ...G Interval As Required 5 Spindles Lube Points 2 Grease Fittings Capacity As Required Lube MPG Interval As Required 6 Oscillating Axle Lube Points 3 Grease Fittings Capacity As Required Lube MPG Interv...

Page 33: ...l periodically during each shift 9 Deck Arm Pivot Pin Lube Points 2 Grease Fittings Capacity As Required Lube MPG Interval As Required 10 Upper Slide Pads Lube Points 2 Grease Fittings Capacity As Req...

Page 34: ...ch that component is to be checked The checks and services listed in this schedule are not intended to replace any local or regional regulations that may pertain to this type of equipment nor should t...

Page 35: ...Valves 1 5 4 HydraulicFilter ANNUAL 5 HydraulicHosesandTubing 1 5 6 HydraulicOilTank 5 3 4 8 LiftCylinder 1 12 5 6 13 4 9 LimitSwitch 1 7 10 TiltAlarmSwitch 1 7 11 PlacardsandDecals 1 2 12 WheelandTir...

Page 36: ...SECTION 2 GENERAL 2 12 JLG Lift 3121325 NOTES...

Page 37: ...olux Automatic Self Level ing System for detailed information regarding the automatic leveling system 3 2 WHEEL ASSEMBLY Drive System Wheel drive is achieved by orbital type 100cc rev hydraulic motors...

Page 38: ...ly occur at the pipe plugs the main seal or wherever o rings are located The exact location of a leak can usually be detected by brushing a soap and water solution around the main seal and where the o...

Page 39: ...extremely important to apply and maintain proper wheel mounting torque WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE TO PREVENT LOOSE WHEELS BROKEN STUDS AND POSSIBLE DANGEROUS SEP...

Page 40: ...tach ing the Drive Motor to the Drive Hub Carefully remove the Drive Motor 6 Remove the eight Bolts 3 and Flatwashers 4 attaching the Drive Hub to the Spindle 8 Carefully remove the Drive Hub Installa...

Page 41: ...3 CHASSIS PLATFORM SCISSOR ARMS 3121325 JLG Lift 3 5 1 Torque to 354 lb ft Dry 480 Nm 2 Torque to 230 9 lb ft Dry 313 Nm 3 Torque to 230 9 lb ft Dry 313 Nm Figure 3 3 Hub Torque Values Drive Motor Sid...

Page 42: ...pling 7 Thrust Washer 8 Thrust Washer 9 Circlip 10 Planetary Gear 11 Pin 12 Thrust Washer 13 Spacer 14 Sun Pinion 15 Piston 16 Spring 17 Disc 18 Disc 19 Lock Nut 20 Bearing 21 Bearing 22 Bearing 23 Be...

Page 43: ...OMR 100 1 Dust Seal 2 Motor Housing 3 Shaft Seal 4 Bearing Race 5 Axel Needle Bearing 6 Output Shaft 7 Cardan Shaft 8 O Ring 9 Distributor Plate 10 Gear Wheel Set 11 End Cover 12 Washer 13 Screw Tabl...

Page 44: ...ock it into position with a plastic hammer and appropriate mandrel 4 Fit the Bearing Race 4 onto the shaft and mount together with the shaft 5 Place the Axel Needle Bearing 5 back onto shaft 6 Output...

Page 45: ...5 Remove Bolts 6 Lockwashers 7 Cap 3 O Ring 8 Ring 9 and Bushings 10 The Spindle can now be removed for repair replacement Installation 1 Follow the Removal Steps in reverse order when assembling the...

Page 46: ...nscrewing and removing the two Bolts 10 Lock washers 11 and Bushings 12 and 13 Installation 1 Follow the removal steps in reverse order when installing the limit switches and or any of the compo nents...

Page 47: ...trigger Cylin der 4 by removing the four Bolts 5 and Lockwash ers 6 NOTE Support cylinder rod to prevent rod extension and consequential oil spillage After Removal Step 3 the frame must be elevated gr...

Page 48: ...t Switch Bracket 8 and Limit Switch 9 back onto the top of the cylinder and secure with the four Bolts 5 and Lockwashers 6 4 Reconnect all hydraulic lines and electrical wires 5 Return flow of hydraul...

Page 49: ...de Compart ment 4 Remove the Air Intake Pipe 9 by removing the four Bolts 10 Flatwashers 11 and Locknuts 12 5 Remove the Cabinet Top Panel 5 6 by removing the 4 Bolts 13 eight Flatwashers 14 and four...

Page 50: ...4L 2011 Table 3 4 Engine Technical Data Description Deutz F4L 2011 Deutz D2011 L04 i ofcylinders 4 Cylinder Arrangement VerticalIn Line Bore 94mm Stroke 112mm Total Displacement 3108cm WorkingCycle 4S...

Page 51: ...ws 1 and Lockwashers 2 on the front of the engine tray 2 Loosen the two top Capscrews 3 at both ends of the engine compartment Slide engine tray outward 3 Be sure to return engine tray to stowed posit...

Page 52: ...N 3 CHASSIS PLATFORM SCISSOR ARMS 3 16 JLG Lift 3121325 Glow Plugs Engine Solenoid Fuse 1 30 amp Fuses 2 Timer Relay N6 3 Relay K3 Figure 3 13 Glow Plugs 1 Solenoid 2 30 amp Fuse Figure 3 14 Engine So...

Page 53: ...ckwashers 9 INSTALLATION 1 Follow the Removal Procedures in reverse order when installing the hydraulic pump assembly Torque item 5 Capscrews and lockwasher to 50Nm 37 lb ft DRY NOTE Do not reuse the...

Page 54: ...ONTROL AND SHOULD NOT BE ADJUSTED CONTACT THE JLG SERVICE DEPARTMENT FOR INFORMATION 1 2 3 Figure 3 16 Variable Displacement Axial Piston Pump 1 Drain Port tighten to 177 lb ft 240 Nm 2 Pressure Port...

Page 55: ...can now be removed 5 Remove the Exhaust Flex Pipe 5 by loosening the Exhaust Clamp 6 Slide the pipe out of the Tailpipe 7 6 The tail pipe can be removed by unscrewing and removing the two Bolts 8 and...

Page 56: ...he Air Filter 1 unscrew and remove the 2 Bolts 2 four Flatwashers 4 and two Locknuts 3 Remove the air cleaner from the bracket 3 Lift the latches on the end of the Air Filter for access to the safety...

Page 57: ...the underside of the engine tray 5 Remove all 4 Bolts 1 and second set of Flatwash ers 6 Carefully lift engine from engine compartment with appropriate lifting device NOTE When installing the engine...

Page 58: ...ulic shutoff valve lever when servicing the hydraulic system and components Make certain to open lever when finished to return flow of hydrau lic fluid Installation 1 Place tank into engine compartmen...

Page 59: ...r every 250 hours of operation Installation 1 Align the pressure filter so that the screw holes match up with the screw holes on the holding bracket NOTE Be sure arrow on top of filter points towards...

Page 60: ...the four Nuts 9 and Lockwashers 10 on the two fuel Tank Straps 8 Installation 1 Place Fuel Tank onto the chassis Secure tank with Fuel Tank Strap Fasten with Bolts and Lockwashers 2 Secure Hose Fittin...

Page 61: ...ving the six Bolts 3 Nuts 4 and twelve Flatwashers 5 NOTE When removing the control panel take care not to damage any plug receptacles and switches Installation 1 Attach the Ground Control Panel to th...

Page 62: ...lation 1 Place Batteries into electrical compartment 2 Align Battery Hold Clamps with bolt holes on floor 3 Secure Clamps with Bolts and Lockwashers 4 Reconnect Battery Cables to the battery terminals...

Page 63: ...he machine 2 Remove the six Screws 3 securing the Control Box Lid 1 to the Control Box 2 3 Carefully lift the lid from the box 4 At this point wires plugs and other parts may be disconnected for repai...

Page 64: ...Joystick Specifications Input Voltage 24V 0 05V CenteredOutputVoltage 12V 0 25V ReverseVoltage 5 5 6 5V Forward Voltage 17 5 18 5V Table 3 7 Plug Loading Chart Terminal Color Function 1 Green SteerLe...

Page 65: ...he four Bolts 2 eight Flatwashers 3 and four Nuts 4 4 Lift box from platform 5 The 110V Receptacle 5 can be removed from the box by removing the four screws on the backside 6 The Platform Control Box...

Page 66: ...Remove the Cotter Pins 9 from the Pins 10 on all three Hinge Brackets 11 Pull the Pin out of the side rail Carefully fold rail down to the stowed posi tion 3 Side rail can now be removed from the pla...

Page 67: ...lates 9 5 Carefully remove the rail 6 The Gate 3 can be detached from the right side End Rail 1 by removing the screws on the two Hinges 11 Installation NOTE Place the rail s on the platform in their...

Page 68: ...the pin out of the bracket 3 Carefully fold rails inward to the stowed position 4 Remove the Bolts 11 Locknuts 13 Flatwashers 12 and Chain Assembly Mounting Plates 14 The rail can now be removed Insta...

Page 69: ...rail to its stowed position 5 Secure rail 6 Remove the Bolts 5 Locknuts 6 Flatwashers 7 and Chain Assembly Mounting Plate 8 7 Carefully remove the rail 8 Remove the Tube 9 from the rail Installation...

Page 70: ...ork truck in place If removal of the platform becomes necessary use the above procedure to stabilize the platform for pin and plat form removal NOTE Procedures apply to both left and right sides Remov...

Page 71: ...en Bolts 2 and Lockwashers 3 attaching both Platform Retaining Brackets 1 to the Platform 3 Lift the platform from the armstack Installation 1 The removal steps should be followed in reverse order whe...

Page 72: ...hers 4 USE CAUTION WHEN REMOVING THE LADDER THE LADDER WEIGHS APPROXIMATELY 104 LBS 47 2 KG Installation 1 Lift ladder so that the four mounting brackets align with the bolt holes on the chassis 2 Sec...

Page 73: ...Front Beacon Cable behind the Guiding Rods 8 to avoid contact with the tie bar Follow route of the signal cable for Outrigger 1 Fix with tie straps 3 Route Rear Beacon Cable together with signal cable...

Page 74: ...e Height Max Height without Outriggers Limit Switch 3 when platform is at a height of 65 ft 20 m 4 Adjust Cam 4 8 to activate Max Height Limit Switch 4 when platform exceeds a height of 68 9 ft 21 m N...

Page 75: ...hole unit 1 Remove the platform from the scissor arm assembly refer to Figure 3 32 Platform Removal 1 of 2 Front of Platform and Figure 3 33 Platform Removal 2 of 2 Rear of Platform 2 Disconnect all h...

Page 76: ...1 Flatwashers 2 and Lockn nuts 4 on the bottom arm pin at the rear of the machine 7 Slightly lift the scissor stack up with the overhead crane so that the rear sliding blocks in the chassis are free 8...

Page 77: ...E LIFT CYLINDER WHEN THERE IS NO LOAD ON THE CYLINDER THE CYLINDER IS SINGLE ACTING AND WILL HAVE NO MEANS OF RETRACTING 12 Disconnect the Lift Cylinder from the arm stack by removing the Bolt 3 and L...

Page 78: ...SURE THE FITTING ON THE LEAK OIL LINE IS CLOSED TO PREVENT EXTENSION OF THE CYLINDER WHILE LIFTING FROM THE MACHINE 3 Place a strap attached to an overhead lifting device through the top portion of t...

Page 79: ...e the Retaining Washer 3 and Washer and Pin 4 6 Move to the right side of the machine The Arm Pin 1 can now be pulled out of the scissor arm stack Remove the four Bushings 2 two Ball Thrust Bear ings...

Page 80: ...SECTION 3 CHASSIS PLATFORM SCISSOR ARMS 3 44 JLG Lift 3121325 NOTES...

Page 81: ...opposite work port opening to reservoir Once the cir cuit is deactivated control returned to neutral the valve spool returns to neutral center and oil flow is then directed through the valve body and...

Page 82: ...activate cylinder through one complete cycle and check for leaks If leakage continues at a rate of 6 8 drops per minute or more cylinder repairs must be made 4 4 CYLINDER REPAIR NOTE The following ar...

Page 83: ...A 5 Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES SURE 6 Ope...

Page 84: ...draw the complete rod assembly from the cylinder barrel 11 Using suitable protection clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible 12 If applicable loo...

Page 85: ...f applicable remove and discard the cylinder head seal rod seal wiper o ring s back up ring and snap ring O Ring Piston Piston Seal Snap Ring Outrigger Cylinder Only Figure 4 9 Piston Seals Spacer Cyl...

Page 86: ...readed portion of head for damage Dress threads as necessary 11 Inspect seal and o ring grooves in head for burrs and sharp edges Dress applicable surfaces as nec essary 12 Inspect cylinder head outsi...

Page 87: ...SPACED PLACES TO AID IN RETENTION OF THE SEAL 2 Use a soft mallet to tap a new wiper seal into the applicable cylinder head gland groove Install a new rod seal into the applicable cylinder head gland...

Page 88: ...he piston as possible 9 If applicable carefully thread the piston clock wise on the cylinder rod hand tight until it abuts the spacer ensuring that the o ring snap ring and pis ton seals are not damag...

Page 89: ...to the barrel until the cyl inder head can be inserted into the barrel cylinder 15 Using a spanner wrench tighten the cylinder head onto the barrel NOTE Steps 16 applies only the Lift and Axle Lockout...

Page 90: ...Figure 1 8 Torque Chart METRIC Fasteners Sheet 3 of 3 for setscrew torques Cylinder Barrel Load Check Valve Figure 4 24 Load Check Valve Installation NOTE Axle Lockout Cylinder only Outrigger Cylinder...

Page 91: ...12 1 Piston Rod 2 Bushing 3 Piston 4 Piston Seal 5 O Ring 6 Setscrew 7 Cylinder Head 8 Wiper 9 Rod Seal 10 O Ring 11 Cylinder Barrel 12 Lift Lower Valve 13 Solenoid Valve 14 Check Valve 15 Capscrew M8...

Page 92: ...rew 6 Spacer 7 Head 8 Head Seal 9 Rod Seal 10 Wiper 11 O Ring 12 Rod Figure 4 27 Steering Cylinder Assembly Table 4 1 Steer Cylinder Specs Max WorkingPressure 3045 7psi 210bar PistonHead Torque ApplyL...

Page 93: ...ck up Ring 13 Head 14 Rod Seal 15 Wiper 16 Snap Ring 17 O Ring 18 Rod Assembly Figure 4 28 Outrigger Cylinder Assembly Table 4 2 Outrigger Cylinder Specs MaxWorking Pressure 2683 1psi 185bar Piston He...

Page 94: ...rew 7 Head Seal 8 Backup Ring 9 O Ring 10 Head 11 Rod Seal 12 Wiper 13 Rod 14 O Ring Figure 4 29 Axle Locking Cylinder Assembly Table 4 3 Axle Locking Cylinder Specs MaxWorking Pressure 2900 7psi 200b...

Page 95: ...11 Head Seal 12 Rod 13 Bushing Figure 4 30 Extension Cylinder Assembly Table 4 4 Deck Extension Cylinder Specs Max Working Pressure 3045 7psi 210bar FullBore Relief Pressure 1160 3psi 80bar PistonTorq...

Page 96: ...25 STRAP REMOVE ANY LOAD FROM PLATFORM NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL IT HAS BEEN RESTRAINED FROM MOVEMENT WITH SAFETY PROPS BLOCKING OR OVERHEAD SLING ARM SAFETY PROP STRAP Figure 4 31 A...

Page 97: ...2 3 4 1 Pressure Switch Drive Enable Brake Valve 2 Drive Valve 3 Main Valve Block 4 Hand Pump Figure 4 32 Valve Hydraulic Compartment Figure 4 33 Pressure Switch Adjustment Operate the lower function...

Page 98: ...s 6 8 Nm 2 Torque to 20 ft lbs 27 1 Nm Operating Pressure 3000 psi 207 bar Voltage 24VDC Figure 4 35 Brake Valve Adjustment To achieve smooth deceleration when the joystick is returned quickly from th...

Page 99: ...hrough the flow dividers as it enters the A1 and A2 ports of the mani fold splitting 50 of the oil to each axle resulting in Dif ferential Lock Tractor Drive C4 D4 C3 D3 C2 D2 C1 D1 C4 D4 C3 D3 C2 D2...

Page 100: ...2 LIFTING STEERING LEVELING REAR RIGHT LEVELING REAR LEFT LEVELING FRONT RIGHT LEVELING FRONT RIGHT DRIVE 1 VALVE SCHEMATIC Figure 4 37 Main Valve Block 1 Main Pressure Block 2 Platform 3 Drive 2 4 Li...

Page 101: ...adjustment port pressure should be set to maximum of 210 bar 3045 8 psi Adjust the setting screw fully in clockwise direc tion see Figure 4 39 Pump Engage Disengage Valve Figure 4 39 Proportional Valv...

Page 102: ...200021263 Pump Assembly 1 Valve Suction 2 Plug 3 Plug 4 Body 5 Rod connecting 6 Lever 7 Piston 8 Seal 9 Seal 10 Pin 11 Ring Retaining 12 Ball 13 Ring 14 Washer 15 RIng Internal Retaining 16 Seal 17 Sp...

Page 103: ...Load Holding Valve B S VALVE SCHEMATIC Figure 4 42 Hand Pump Valve Schematic 1 2 Axle Lockout Cylinder Figure 4 43 Load Holding Valve 1 Torque to 5 ft lbs 6 8 Nm 2 Torque to 20 ft lbs 27 1 Nm Operati...

Page 104: ...1 Torque to 5 ft lbs 6 8 Nm 2 Torque to 60 ft lbs 44 25 Nm Operating Pressure 3500 psi 240 bar Check Valve 3 Torque to 20 ft lbs 27 1 Nm Operating Pressure 3500 psi 240 bar Figure 4 44 Lift Lower Valv...

Page 105: ...AULICS 3121325 JLG Lift 4 25 Outrigger Safety Valves Safety Valve Outrigger Cylinder Front Outriggers Operating Pressure 116 psi 8 bar Rear Outriggers Operating Pressure 14 5 psi 1 bar Figure 4 46 Out...

Page 106: ...SECTION 4 HYDRAULICS 4 26 JLG Lift 3121325 NOTES...

Page 107: ...L SYSTEM 5 1 MAIN TERMINAL BOX CIRCUIT BOARDS C2 J1A C2 J1B C2 J2B C2 J2A COMPLEX 2 N2J10 N2J1 J8 J5 J6 J7 NIVOLUX 2 PNP5 KTC KVS K1 1 2 3 4 5 6 7 8 9 10 11 12 K1 K2 K3 1 BB 2 BT 3 TB 4 TT KT K 2 D TR...

Page 108: ...ve control valve section With the platform in an elevated position fast drive speed limit switch tripped and operating the machine with the console in the platform position adjust the TP1 potentiomete...

Page 109: ...nd 22 PlatformOut 23 Horn 24 24VPower Table 5 1 Key OutputSignal InputSignal NotUsed Table 5 2 J2 Connector J2 Connector 1 24Vto Console 2 DeckExtension 3 Ignition 4 Start 5 Horn 6 NotUsed 7 NotUsed 8...

Page 110: ...1 17 1 1 DriveSignal duringDrive J1 1 1 1 1 1 DriveSignal duringSteering J1 1 1 1 1 1 Analog J1 6 1 1 1 Lift J1 5 1 1 X 1 1 1 Lower J1 3 1 1 X 1 1 RightSteer J1 9 1 1 1 LeftSteer J1 10 1 1 1 SER PAR J...

Page 111: ...utomatic self leveling system on JLG MEWPs is a selectable system Deployment of the outriggers is necessary to achieve the maximum platform height The system is intended for use when the machine is po...

Page 112: ...xis Y longitudinal and X lateral to set a zero point There are three measuring points to accommo date a conventional voltmeter To Check and Set Adjustment 1 Place the MEWP on an even flat and level su...

Page 113: ...LiftwthoutNIVOLUX J8 4 1 1 1 1 RPM toDeutzbox PNP Lowering J8 4 1 1 LiftValve J8 7 1 1 1 DriveOKwithNIVOLUX J8 10 0 1 1 0 1 DriveOKwithoutNIVOUX J8 10 1 1 1 FrontLeftIN J7 1 1 1 0 FrontLeftOUTduringle...

Page 114: ...o input from the trigger switch no input on 2 the start ouput signal passes through the N C contacts on relays K1 and K2 to 6 3 When a trigger input signal is present at 2 there is a 6 second window t...

Page 115: ...IVOLUX Board also uses this signal to enable the outrigger valve outputs The second bypasses the oscillating axle sensing switches When this switch is activated the drive speed is limited to slow spee...

Page 116: ...e wired in series with the S8m Limit Switch The S2 5m Limit Switch signal bypasses both switches When the axle is within 1 5 of the frame the switches are closed and permit a 24V signal to the S8m Swi...

Page 117: ...ures the engine is running before cutting the start signal c When a start signal is applied to X1 2 50e and the input on X2 10 remains zero after 1 second of cranking the output X2 7 is cut and the G...

Page 118: ...ntrol Board OUT Start Solenoid Fuel Solenoid Throttle Solenoid RPM IN X2 7 X2 8 X2 9 Ignition X1 1 1 1 1 Start X1 2 1 RPM X1 3 1 OilPressureSwitch Ground X2 1 0 Alternator D X2 2 TemperatureSwitch Gro...

Page 119: ...y If the connector is the sealed type great care must be taken to avoid damaging the seal around the wire It is best to use probes or probe tips specifically designed for this technique especially on...

Page 120: ...orrect range See multimeter s operation manual Use firm contact with meter leads First test meter and leads by touching leads together Resistance should read a short circuit very low resis tance Circu...

Page 121: ...F before testing con tinuity Disconnect component from circuit before testing Use firm contact with meter leads First test meter and leads by touching leads together Meter should produce an audible al...

Page 122: ...wire under test or are within reach of the jumper 1 Disconnect all connections associated with the wire under test and the two additional wires If harness is not com pletely isolated disconnect batte...

Page 123: ...evel conductivity silicone dielectric grease must be packed completely around male and female pins on the inside of the connector after the mating of the housing to the header This is easily achieved...

Page 124: ...ee Figure 6 7 Connector Assembly 2 of 4 2 Pull back on the contact wire with a force of 1 or 2 lbs to be sure the retention fingers are holding the contact See Fig ure 6 7 Connector Assembly 2 of 4 3...

Page 125: ...SECTION 6 GENERAL ELECTRICAL INFORMATION SCHEMATICS 3121325 JLG Lift 6 7 Figure 6 8 Connector Assembly 3 of 4 Figure 6 9 Connector Assembly 4 of 4...

Page 126: ...back and forth over a half turn 1 4 turn in each direction gently pull the wire until the contact is removed Figure 6 10 Connector Disassembly NOTE The wedge lock should never be removed from the hous...

Page 127: ...be wires by piercing the insulation with a sharp point This practice should be discouraged when dealing with the AMPSEAL plug assembly or any other sealed connector system The resulting pinholes in th...

Page 128: ...he wedge lock will snap into place Rectangular wedges are not oriented Thy may go in either way NOTE The receptacle is shown use the same procedure for plug DT DTP Series Disassembly Figure 6 13 DT DT...

Page 129: ...For unused wire cavities insert sealing plugs for full environmental sealing HD30 HDP20 Series Disassembly Figure 6 16 HD HDP Contact Removal 11 With rear insert toward you snap appropriate size extra...

Page 130: ...A 20 X4A 21 LED GND FAST X4A 6 X4A 15 X4A 22 X4A 6 X4A 15 X4A 22 red 2 1 R1 1K R3 2 8 9 3 7 RED GR GR GR Yellow RIGHT LED GLOW PLUG 2 2k HEIGHT 2 2 3 1 START 5 1 S HORN 13 14 2 SUPPLY 4 12 S EMERGENCY...

Page 131: ...J 1 A B LEFT 9D 9D J2 3 PLATFORM J2 2 HORN X4A 9 X4A 5 X4A 13 LIFT X4A 2 RIGHT X4A 14 X4A 12 JOYSTICK JOYSTICK GND X4A 16 X4A 10 SCISSORS CABLE SOCKET C D E F K TC 11 Input Lower Start output Control...

Page 132: ...12 S TILT X1 29 S TILT LIFT 12 11 S1 OSCILLATING LOWER Load holding valves Lifting ram 7E 6B 7C 6 I GND LOWER DRIVE 7H Module 22 21 IN GND DRIVE OK VS K VS VS K VS K VS X1 34 X1 36 X1 30 X1 56 2D 4E...

Page 133: ...D X1 GND GND STEER SER PAR 2D 4 3 2 1 A B C D E F Diesel 80 SL 67 SL 7 8 6 5 G H I 4 3 2 1 J Module Module X1 15 X1 12 24V X1 6 X1 6 2D 3D 2D 2F 2E 2F 6I 6I 24V 3J 5A X1 GND DRIVE 2 X1 GND 21 11 22 12...

Page 134: ...X1 19 X1 23 DP2 X1 41 2G 2G 2F 6B RPM 4J 6A X1 GND PNP5 J2 1 DECK according to type 2 valves FD4 X1 GND Rev A GROUND PANEL PUMP 2 PNP5 J2 2 GND T4 t PNP5 J2 5 X1 24 PLTF OUT PLTF IN X1 22 X1 21 6A X1...

Page 135: ...2 21 X2 10 X2 2 B 3 2 1 A B C D E F 7 8 6 5 G H I 4 3 2 1 J Yellow 2 2k Glow time 6 qmm G M B D W 10A F2 BATTERIE 2x 12V X1 3 X1 2 DIESEL X1 8 X1 9 X1 2 X1 1 Start X1 3 50 15 O K D J8 3 DP1 DP2 DP3 J8...

Page 136: ...J8 2 SUPPLY X1 42 J10 1 J8 1 J10 2 GND K2 DRIVE OK A1 A2 J7 12 J7 11 1 J7 9 J7 10 J7 7 J7 8 4 Page 7 7 LIFTLUX 8 6 5 4 3 2 1 A B C D E F 7 8 6 5 G H I 4 3 2 1 J J10 1 GND DRIVE OK VS K VS LOWER X1 35...

Page 137: ...E X1 6 24V X1 12 COMPLEX J1 1 DRIVE X1 15 COMPLEX J1 12 Ser Par X 1 16 Ser Par Valves X 1 GND X 1 26 X 1 41 X1 23 COMPLEX J1 16 Pump 2 POWER SUPPLY DRIVE SERIAL PARALLEL DRIVE SERIAL PARALLEL J1 1 2 J...

Page 138: ...T 2E J 1 1 7 C o m p l e x B o a r d J 1 1 C o m p l e x B o a r d K 1 K 2 K 3 Page 9 7 LIFTLUX Rev C 8 6 5 4 SCHEMATIC ELECTRICAL Diesel 80 SL 67 SL OP 1 K 1 K 2 K 3 K TC A2 A1 21 11 24 14 2E X 4 A 1...

Page 139: ...S Plattform Down 11 Diff Lock Valve 2 Diff Lock Valve 1 DP2 18 14 15 16 17 11 12 13 13 7 8 9 10 6 6 7 Complex J1 9 Right Complex J1 10 Left Complex J1 12 Ser Par PNP5 J1 3 Complex J1 6 Analog Trigger...

Page 140: ...ST4 21 S Drive Height 12 S 2 5m 22 S Oscillating Axle 11 KL 11 S Drive Height 11 S Oscillating Axle 12 Nivolux J8 8 S Platform Down 12 TOP ST1 21 K1 A1 PNOZZ 57 58 Battery DA2 DA1 Lift Drive Steer S T...

Page 141: ...GROUND PANEL X1 56 P O CONNECTOR GROUND PANEL X1 32 P N CONNECTOR GROUND PANEL X1 41 X1 38 P M CONNECTOR GROUND PANEL P P CONNECTOR GROUND PANEL X1 30 P B CONNECTOR GROUND PANEL X1 2 P A CONNECTOR GR...

Page 142: ...Lower S Pressure Outrigger Valves Nivolux S Drive Height Horn S Plattform Down Scissors Cable Socket Box Drive 2 M 20 M 20 M 20 M 25 M 20 M 25 M 16 3 2 1 A B C D E F 7 8 6 5 G H I 4 3 2 1 J C O M P L...

Page 143: ...r 3 2 1 A B C D E F 7 8 6 5 G H I 4 3 2 1 J Complex Board TP1 TP2 J1 J2 Jumper for ANSI Input Ouput J2 J1 S2 Control Panel Pump not used Max Height Fast Slow S 2 5m Tilt not used D22 D25 D24 D23 D21 D...

Page 144: ...o k Levelling process finished Start Ground bearing pressure and Lifting All Outriggers pulled in Complex Nivolux Outrigger valves Y Pendulum 1 red 2 black 3 green Pressure switch Security relay PNOZZ...

Page 145: ...156918GR X1 6B 3 K VS 13 16 UL156918GR KVS 23 K VS 13 17 UL156918GR X1 34A 4 K VS 14 18 UL156918GR X1 28 3 K VS 24 20 UL156918GR X1 11 3 D20 A 136 UL156918GR KTC 11 D20 K 135 UL156918GR trigcontrJ2 4...

Page 146: ...X1 12 4 55 UL156918GR C2J1A 2 X1 37 4 56 UL156918GR D13 K X1 31 4 139 UL156918GR D13 A C2J1A 3 57 UL156918GR C2J1A 4 X1 A 4 58 UL156918GR C2J1A 4 C2J1B 9 59 UL156918GR D14 K X1 39 4 140 UL156918GR D14...

Page 147: ...GR trigcontrJ2 3 D19 A 138 UL156918GR C2J2B 1 D19 A 130 UL156918GR KTC 24 C2J2B 8 131 UL156918GR X1 31 1 D17 A 137 UL156918GR KTC 11 D17 K 132 UL156918GR KTC A2 X1 I 4 133 UL156918GR KTC A1 trigcontrJ...

Page 148: ...LVE ader1 X1 11 1 1 ader2 X1 G 1 2 92 LIYYJZ2X1 UL PUMP 2 ader1 X1 11 2 1 ader2 X1 H 1 2 93 LIYYJZ4X0 75UL TILTSWITCH ader1 X1 28 1 ader2 X1 29 1 ader3 X1 B 2 GGN 94 LIYYJZ4X0 75UL DRIVE2VALVE ader1 K...

Page 149: ...2 111 LIYYJZ2X1 UL DIFFLOCK VALVE1 ader1 X1 20 2 1 ader2 X1 C 2 2 100 LIYYJZ2X1 UL DIFFLOCK VALVE2 ader1 X1 20 1 1 ader2 X1 D 2 2 101 LIYYJZ2X1 UL BRAKEVALVE ader1 X1 13A 1 1 ader2 X1 E 1 2 102 LIYYJZ...

Page 150: ...r2 X1 17 1 B 1 ader3 X1 C 1 A 2 GGN 109 LIYYJZ12X0 75UL OUTRIGGERVALVES ader1 J7 1 1 OUTRIGGER1VALVE ader2 J7 2 2 ader3 J7 3 PE ader4 J7 4 1 OUTRIGGER2VALVE ader5 J7 5 2 ader6 J7 6 PE ader7 J7 7 1 OUT...

Page 151: ...2 1 C2J2A 1 ader2 X2 2 C2J2A 2 ader3 X2 3 C2J2A 3 ader4 X2 4 C2J2A 4 ader5 X2 5 C2J2A 5 ader6 X2 6 NC ader7 X2 7 NC ader8 X2 8 C2J2A 8 ader9 X2 9 trigcontrJ2 2 ader10 X2 10 C2J2B 2 ader11 X2 11 NC ade...

Page 152: ...ader3 X1 3 1 PC ader4 X1 4 2 PD ader5 X1 5 2 PE ader6 X1 6A 2 PF ader7 X1 7A 2 PG ader8 X1 9 3 PH ader9 X1 21B 2 PJ ader10 X1 22 2 PK ader11 X1 56 2 PL ader12 X1 38 4 PM ader13 X1 41A 4 PN ader14 X1 3...

Page 153: ...1 D 3 KL A2 145 UL156918GR X1 38 1 KL 11 146 UL156918GR D24 K KL A1 147 UL156918GR D25 K KL A1 148 LIYYJZ2X1 ader1 Splice8 L S2 11 ader2 Splice7 R S2 12 D1 DIO BY550 X1 7A 3 X1 8 3 D2 398ANSIDIO X1 8...

Page 154: ...op Top 2 Tob Bottom 3 Bottom Top and 4 Bottom Bottom Refer to Figure 5 1 Main Terminal Box Position 2 The position on the end item if not specified in the table it can be located on the electrical sch...

Page 155: ...SECTION 6 GENERAL ELECTRICAL INFORMATION SCHEMATICS 3121325 JLG Lift 6 37 NOTES...

Page 156: ...SECTION 6 GENERAL ELECTRICAL INFORMATION SCHEMATICS 6 38 JLG Lift 3121325 Electrical Diagram STROBE LIGHTS Figure 6 33 Electrical Diagram Page 1 of 2...

Page 157: ...SECTION 6 GENERAL ELECTRICAL INFORMATION SCHEMATICS 3121325 JLG Lift 6 39 PLATFORM CONSOLE BOX BATTERY DISCONNECT SWITCH Figure 6 34 Electrical Diagram Page 2 of 2...

Page 158: ...SECTION 6 GENERAL ELECTRICAL INFORMATION SCHEMATICS 6 40 JLG Lift 3121325 Hydraulic Diagram Figure 6 35 Hydraulic Components H900067 RevF Page 1 of 2...

Page 159: ...SECTION 6 GENERAL ELECTRICAL INFORMATION SCHEMATICS 3121325 JLG Lift 6 41 Figure 6 36 Hydraulic Components H900067 RevF Sheet 2 of 2...

Page 160: ...SECTION 6 GENERAL ELECTRICAL INFORMATION SCHEMATICS 6 42 JLG Lift 3121325 Hydraulic Schematic Figure 6 37 Hydraulic Schematic 1001091321 RevD...

Page 161: ......

Page 162: ...l Germany 49 0 421 69 350 20 49 0 421 69 350 45 JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong 852 2639 5783 852 2639 5797 JLG Industries Italia s r l V...

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JLG 80SL, Service Maintenance Manual

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