Jlg 80hx User manual

AUSTRALIAN OFFICE

JLG INDUSTRIES, INC.

P.O. Box 5119

11 Bolwarra Road

Port Macquarie, Australia

Telephone: 065 811111

Fax: 065 810122

EUROPEAN OFFICE

JLG INDUSTRIES (EUROPE)

Kilmarting Place,

Tannochside Pa rk

Uddingston, Scotland, G71 5PH

Telephone: 01698 811005

Main Fax: 01698 811055

Parts Fax: 01698 811455

CORPORATE OFFICE

JLG INDUSTRIES, INC.

1 JLG Drive

McConnellsburg, PA.

17233-9533

USA

Telephone: (717) 485-5161

Fax: (717) 485-6417

Model

80HX

80HX+6

80HXER

3120863

May 14, 2002

SERVICE & MAINTENANCE

INTRODUCTION

3120863 – JLG Lift – A-1

SECTION A. INTRODUCTION - MAINTENANCE SAFETY

PRECAUTIONS

A GENERAL

This section contains the general safety precautions which

must be observed during maintenance of the aerial plat-

form. It is of utmost importance that maintenance person-

nel pay strict attention to these warnings and precautions

to avoid possible injury to themselves or others, or dam-

age 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 VIOLA-

TION.

The specific precautions to be observed during mainte-

nance 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 CON-

TROL OVER THE FIELD INSPECTION AND MAINTENANCE,

SAFETY IN THIS AREA RESPONSIBILITY OF THE OWNER/OPER-

ATOR.

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 pres-

sure 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

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 DUR-

ING 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 CAU-

TIONS ON MACHINE AND IN SERVICEMANUAL.

• KEEP OIL, GREASE, WATER, ETC. WIPED FROM

STANDING SURFACES AND HAND HOLDS.

• USE CAUTION WHEN CHECKING A HOT, PRESSUR-

IZED 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 DISCONNECTED-

DURING REPLACEMENT OF ELECTRICAL COMPO-

NENTS.

• KEEP ALL SUPPORT EQUIPMENT AND ATTACH-

MENTS STOWED IN THEIR PROPER PLACE.

• USE ONLY APPROVED, NONFLAMMABLE CLEANING

SOLVENTS.

INTRODUCTION

A-2 –JLG Lift –3120863

REVISON LOG

October, 1997 - Original Issue

March 1, 1999 - Revised

September 7, 2000 - Revised

May 14, 2002 - Revised

3120863 –JLG Lift –i

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