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JLG 800A 800AJ troubleshooting guide

1.Excessive Noise and/or Vibration

  • Item: Check oil level in reservoir and oil supply to the motor.
  • Description:  Insufficient hydraulic fluid could lead to cavitation that would cause system noise.
  •  Action: Fill the reservoir to the proper level and ensure that oil supply to the motor is adequate and the lines are unobstructed.
  • Item: Check for air in the system.
  • Description:  Air trapped within the system lines, or the motor itself, could  result in cavitation that would cause system noise.
  •  Action:  Ensure that all of the system lines and components are purged  of air
  • Item: Ensure that all of the system lines and components are purged of air
  • Description:  A loose or incorrect shaft coupling will produce vibrations that could result in system noise.
  •  Action: Ensure that the correct coupling is used and that it fits properly onto the shaft.
  • Item: Inspect the output shaft alignment.
  • Description: Misaligned shafts create excessive frictional vibration that could result in system noise
  •  Action: Ensure that the shafts are properly aligned.
  • Item: Hydraulic oil viscosity above limits.
  • Description: Viscosity above acceptable limits will result in cavitation that would lead to system noise.
  • Action: Viscosity above acceptable limits will result in cavitation that would lead to system noise.

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JLG Models 1200SJP 1350SJP Service and Maintenance Manual P/N – 3121142 PDF download

This is the Most Practical Service Repair Manual for the JLG 1200SJP, 13500SJP Workshop Service Repair Manual Download ever compiled by mankind. This DOWNLOAD contains of high quality diagrams and instructions on how to service and repair your JLG.

JLG Models 1200SJP 1350SJP Service and Maintenance Manual

Download JLG 1200SJP, 13500SJP Workshop Service Repair Manual 3121142

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File size: 39.3 MB (41,243,220 )

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The  Repair Manual Covers:

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 Tires 1-1
1 3 Engine Data 1-1
Engine Data Prior to S/N 0300127698 1-1
Engine Data S/N 0300127698 to Present 1-1
1 4 Specifications and Performance Data 1-2
Reach Specifications 1-2
Dimensional Data 1-2
Chassis 1-2
1 5 Torque Requirements 1-3
1 6 Hydraulic Oil 1-3
1 7 Major Component Weights 1-5
1 8 Pressure Settings 1-5
1 9 Lubrication and Operator Maintenance 1-7
SECTION 2 – GENERAL
2 1 Machine Preparation, Inspection, and Maintenance 2-1
General 2-1
Preparation, Inspection, and Maintenance 2-1
Pre-Start Inspection 2-1
Pre-Delivery Inspection and Frequent Inspection 2-1
Annual Machine Inspection 2-1
Preventative Maintenance 2-1
2 2 Service and Guidelines 2-2
General 2-2
Safety and Workmanship 2-2
Cleanliness 2-2
Components Removal and Installation 2-2
Component Disassembly and Reassembly 2-3
Pressure-Fit Parts 2-3
Bearings 2-3
Gaskets 2-3
Bolt Usage and Torque Application 2-3
Hydraulic Lines and Electrical Wiring 2-3
Hydraulic System 2-3
Lubrication 2-3
Battery 2-3
Lubrication and Servicing 2-3
2 3 Lubrication and Information 2-3
Hydraulic System 2-3
Hydraulic Oil 2-4
Changing Hydraulic Oil 2-4
Lubrication Specifications 2-4
2 4 Cylinder Drift Test 2-4
Platform Drift 2-4
Cylinder Drift 2-5
2 5 Pins and Composite Bearing Repair Guidelines 2-5
2 6 Welding on JLG Equipment 2-5
Do the Following When Welding on JLG Equipment 2-5
Do NOT Do the Following When Welding on JLG Equipment 2-5
SECTION 3 – CHASSIS & TURNTABLE
3 1 Tires & Wheels 3-1
Tire Inflation 3-1
Tire Damage 3-1
Wheel and Tire Replacement 3-1
Wheel Installation 3-1
3 2 Extending Axles 3-2
3 3 Axle Limit Switch Adjustment Procedure 3-2
3 4 Drive System 3-3
3 5 Steering Control System 3-3
3 6 Drive/Steering Speed Control 3-4
3 7 Traction Control System 3-4
3 8 Drive Orientation System 3-4
3 9 Oscillating Axle System 3-14
3 10 Oscillating Axle Bleeding Procedure and Lockout Test 3-14
Lockout Cylinder Bleeding 3-14
Oscillating Axle Lockout Test 3-15
3 11 Drive Hub (Prior to S/N 100131) 3-16
Disassembly 3-16
Disassembly of Cover 3-16
Disassembly of the First Stage Planetary Assembly (7) 3-16
Disassembly of Second Stage Planet Gears (1) 3-16
Assembly of First Stage Planetary Assembly (7) 3-17
Assembly of End Cover Unit (8) 3-17
Final Assembly 3-17
Initial Start-up And After Repairs 3-17
Oil Change Interval-Gear Drive 3-17
3 12 Drive Hub – Bonfiglioli (S/N 100128 to Present) 3-20
Product Identification 3-20
Hydraulic Motor Installation 3-20
Installation of the Wheel Drive on the Machine 3-20
Start Up and Running In 3-20
General Information 3-21
Connecting the Brake 3-21
Filling-up the Gearbox with Lubricating Oil 3-21
Gearbox Disengagement 3-23
Maintenance Information 3-25
Changing the Lubricating oil 3-25
Troubleshooting 3-26
Disassembly Information 3-26
Disassembly Procedure 3-26
Inspection of Parts 3-34
Assembly 3-35
Final Test and Reinstallation 3-45
3 13 Drive Hub – Reggiana Riduttori (S/N 134389 to Present) 3-50
Symbol Nomenclature 3-50
Tools 3-50
Disassembly 3-55
Assembly 3-59
3 14 Swing Drive 3-65
Roll and Leak Testing 3-65
Tightening and Torquing Bolts 3-65
Motor Control Valve Disassembly 3-66
Motor and Brake Disassembly 3-67
Main Disassembly 3-68
Hub-Shaft Disassembly 3-69
Carrier Disassembly 3-70
SECTION NO TITLE PAGE NO
Hub-Shaft Sub-Assembly 3-71
Carrier Sub-Assembly 3-72
Main Assembly 3-74
Motor and Brake Assembly 3-76
Motor Control Valve Assembly 3-77
3 15 Swing Brake 3-78
Pre-Installation Checks 3-78
Installation 3-79
Maintenance 3-79
Disassembly 3-79
Examination 3-79
Assembly 3-79
3 16 Swing Motor 3-81
Disassembly and inspection 3-81
Assembly 3-88
One Piece Stator Construction 3-95
3 17 Procedure For Setting Gear Backlash 3-96
3 18 Swing Drive Lubrication 3-97
3 19 Swing Bearing 3-98
Turntable Bearing Mounting Bolt Condition Check 3-98
Wear Tolerance 3-101
Swing Bearing Removal 3-101
Swing Bearing Installation 3-103
Swing Bearing Torque Values 3-104
3 20 Swing Speed Proportioning 3-105
3 21 Chassis Tilt Indicator System 3-105
3 22 Rotary Coupling 3-106
3 23 Generator 3-110
Every 250 hours 3-110
Every 500 hours 3-110
Overload Protection 3-111
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings 3-111
3 24 Auxiliary Power System 3-113
3 25 Cold Weather Package 3-115
3 26 Engine 3-115
Glow Plugs 3-115
Checking Oil Level 3-115
Changing Engine Oil 3-115
Changing the Oil Filter 3-116
Replacing the Fuel Filter 3-117
Cleaning the Fuel Strainer 3-117
3 27 Deutz EMR 2 (S/N 87579 to Present) 3-118
3 28 Bio Fuel in Deutz Engines 3-131
General 3-131
Bio Fuel 3-131
Biological Contamination In Fuels 3-132
SECTION 4 – BOOM & PLATFORM
4 1 Boom Systems 4-1
Broken Cable Indicator System 4-1
Platform Control Enable System 4-1
Transport Position Sensing System 4-1
Beyond Transport – Drive Speed Cutback System 4-1
Drive/Steer – Boom Function Interlock System (CE ONLY) 4-2
Jib Stow System 4-2
Envelope Tracking System 4-2
Moment Control System 4-3
Boom Control System (BCS) Functional Check (Push to Test) System 4-3
Controlled Arc System 4-3
Controlled Boom Angle System 4-4
Envelope Tracking 4-4
Slow Down System 4-4
Dual Capacity System 4-5
Electronic Platform Leveling 4-5
Boom Control Select 4-6
4 2 Boom Assembly 4-7
Removal 4-7
Disassembly 4-16
Assembly 4-18
4 3 Jib Rotator Orientation 4-29
4 4 Jib Lift End of Stroke Dampening 4-29
4 5 Load Sensing Pin Removal and Installation 4-29
4 6 Hose Routing Procedure 4-44
4 7 Wire Rope 4-44
Inspection 4-44
Three Month Inspection 4-44
Seven Year Inspection 4-44
Replacement Criteria 4-44
Wire Rope Tensioning Procedure 4-45
4 8 Broken Boom Cable Proximity Switch 4-49
Adjusting the Proximity Switch 4-49
4 9 Electronic Platform Leveling 4-49
Description 4-49
Normal Operation 4-50
4 10 Rotary Actuator 4-51
Theory of Operation 4-51
Required Tools 4-51
Disassembly 4-54
Inspection 4-58
Assembly 4-58
Bleeding After Installation 4-63
SECTION 5 – HYDRAULICS
5 1 Lubricating O-Rings in the Hydraulic System 5-1
Cup and Brush 5-1
Dip Method 5-2
Spray Method 5-2
Brush-on Method 5-2
5 2 Cylinder Repair 5-3
Disassembly 5-3
Cleaning and Inspection 5-12
Assembly 5-14
5 3 Hydraulic Tank 5-24
5 4 Pressure Setting Procedure 5-24
SECTION NO TITLE PAGE NO
Set Up of the Function Pump 5-24
Adjustments made at the Main Valve Bank 5-25
Adjustments Made at the Frame Valve Bank 5-26
Adjustments Made at the Platform Valve Bank 5-30
5 5 Drive Pumps 5-31
Troubleshooting Procedure 5-31
Charge Pressure Relief Valve Adjustment 5-34
Mechanical Centering of Pump 5-35
Hydraulic Centering of Control Modules 5-35
High Pressure Relief Valve Adjustments 5-36
Removal and inspection of charge pump 5-36
Routine Maintenance 5-37
Removal and Installation of Shaft Seal 5-39
5 6 Function Pump 5-40
Spare Parts 5-40
Sealing the Drive Shaft 5-41
Disassembly and Assembly of the Complete Unit 5-42
Assembly 5-45
Adjustments 5-46
Tightening Torques 5-46
Pump Control Disassembly For Cleaning 5-48
5 7 Drive & Function Pump Start Up Procedures 5-50
Start-Up Procedure 5-50
SECTION 6 – JLG CONTROL SYSTEM
6 1 Introduction 6-1
6 2 CANbus Communications 6-2
6 3 Calibration Instructions 6-4
6 4 To Connect the JLG Control System Analyzer 6-14
6 5 Using the Analyzer 6-14
6 6 Changing the Access Level of the Hand Held Analyzer 6-15
6 7 Adjusting Parameters Using the Hand Held Analyzer 6-16
6 8 Machine Setup 6-16
6 9 Machine Personality Settings/Function Speeds 6-23
6 10 Machine Orientation When Setting Function Speeds 6-27
Test Notes 6-27
6 11 System Test 6-28
Test from the Platform 6-28
Test from the Ground Station 6-31
6 12 Calibrating Steer 6-46
6 13 Calibrating Drive 6-49
6 14 Electronic Platform Leveling 6-52
Platform Leveling Fault Warning 6-52
Fault Response 6-52
CAN Errors 6-53
Additional Platform and Jib Valves 6-53
Platform Leveling Calibration Procedure 6-54
6 15 Calibrating Platform Level 6-55
STEP 1: SETTING THE PLATFORM VALVE MINIMUMS 6-55
STEP 2: CALIBRATING THE PLATFORM LEVEL SENSORS 6-56
STEP 3: BLEEDING THE PLATFORM VALVES 6-57
STEP 4: CALIBRATING THE PLATFORM LEVEL UP AND DOWN VALVE CRACKPOINTS 6-58
SECTION NO TITLE PAGE NO
6 16 Calibrating Lift Crack Point 6-59
6 17 Calibrating Telescope Crack point 6-62
6 18 Calibrating Tilt Sensor 6-65
6 19 Calibrating the Boom Sensors 6-67
Boom Control System Check Procedure 6-80
6 20 CANbus Troubleshooting 6-108
CANbus Communication Failure 6-115
Load Moment Pin Troubleshooting 6-128
SECTION 7 – BASIC ELECTRICAL INFORMATION & SCHEMATICS
7 1 General 7-1
7 2 Multimeter Basics 7-1
Grounding 7-1
Backprobing 7-1
Min/Max 7-1
Polarity 7-1
Scale 7-1
Voltage Measurement 7-1
Resistance Measurement 7-2
Continuity Measurement 7-2
Current Measurement 7-3
7 3 Applying Silicone Dielectric Compound to Electrical Connections 7-3
7 4 AMP Connector 7-4
Applying Silicone Dielectric Compound to AMP Connectors 7-4
Assembly 7-4
Disassembly 7-6
Wedge Lock 7-6
Service – Voltage Reading 7-6
7 5 Deutsch Connectors 7-8
DT/DTP Series Assembly 7-8
DT/DTP Series Disassembly 7-8
HD30/HDP20 Series Assembly 7-9
HD30/HDP20 Series Disassembly 7-9
FIGURE NO TITLE PAGE NO
1-1 Lubrication and Operator Maintenance Diagram 1-6
1-2 Torque Chart (SAE Fasteners – Sheet 1 of 3) 1-11
1-3 Torque Chart (SAE Fasteners – Sheet 2 of 3)) 1-12
1-4 Torque Chart (SAE Fasteners – Sheet 3 of 3) 1-13
1-5 Torque Chart (METRIC Fasteners – Sheet 1 of 3) 1-14
1-6 Torque Chart (METRIC Fasteners – Sheet 2 of 3) 1-15
1-7 Torque Chart (METRIC Fasteners – Sheet 3 of 3) 1-16
2-1 Engine Operating Temperature Specifications – Deutz 2-9
3-1 Axle Limit Switch Adjustment 3-2
3-2 Conventional Two Wheel Steer Mode 3-3
3-3 Crab Steer Mode 3-3
3-4 Coordinated Steer Mode 3-3
3-5 Chassis Component Location – Sheet 1 of 2 3-6
3-6 Chassis Component Location – Sheet 2 of 2 3-7
3-7 Turntable and Boom Component Location – Sheet 1 of 2 3-8
3-8 Turntable and Boom Component Location – Sheet 2 of 2 3-9
3-9 Oscillating Axle – Sheet 1 of 2 3-10
3-10 Oscillating Axle – Sheet 2 of 2 3-11
3-11 Axle Loctite Application 3-12
3-12 Steering Installation 3-13
3-13 Drive Hub – Sheet 1 of 2) 3-18
3-14 Drive Hub – Sheet 2 of 2 3-19
3-15 Drive Hub Identification Plate 3-20
3-16 Hub Assembly 3-22
3-17 Gearbox engaged 3-24
3-18 Gearbox Disengaged 3-25
3-19 Drive Hub S/N 100128 to Present 3-28
3-20 Drive Hub Special Tools – Sheet 1 of 4 3-46
3-21 Drive Hub Special Tools – Sheet 2 of 4 3-47
3-22 Drive Hub Special Tools – Sheet 3 of 4 3-48
3-23 Drive Hub Special Tools – Sheet 4 of 4 3-49
3-24 Bearing Track Spacer Mounting C016117 3-50
3-25 Oil Seal Spacer Mounting C125049 3-50
3-26 Bearing Spacer Mountng CO16117 3-51
3-27 Assembly Diagram 1 3-51
3-28 Wrench For Ring Nut 3-52
3-29 Anti-rotation Flange 3-52
3-30 Anti-rotation Block 3-52
3-31 Anti-rotation Pin 3-52
3-32 Assembly Diagram 2 3-53
3-33 Tools For Assembling Bearing 3rd Stage Planetary Gear Assembly Diagram 3-54
3-34 Reggiana Riduttori Hub – Sheet 1 of 2 3-56
3-35 Reggiana Riduttori Hub – Sheet 2 of 2 3-57
3-36 Swing System 3-64
3-37 Swing Drive – Motor Control Valve Disassembly 3-66
3-38 Swing Drive – Motor and Brake Disassembly 3-67
3-39 Swing Drive – Main Disassembly 3-68
3-40 Swing Drive – Hub Shaft Disassembly 3-69
3-41 Swing Drive – Carrier Disassembly 3-70
3-42 Swing Drive – Hub Shaft Sub-Assembly 3-71
3-43 Swing Drive – Carrier Sub-Assembly 3-73
3-44 Swing Drive – Main Assembly 3-75
3-45 Swing Drive – Motor and Brake Assembly 3-76
3-46 Swing Drive – Motor Control Valve Assembly 3-77
3-47 Swing Brake 3-78
3-48 Swing Brake Assembly 3-80
3-49 Swing Drive Motor 3-82
FIGURE NO TITLE PAGE NO
3-50 Swing Drive Ports 3-97
3-51 Swing Drive Lubrication 3-97
3-52 Swing Bearing Tolerance Boom Placement – Sheet 1 of 2 3-99
3-53 Swing Bearing Tolerance Boom Placement – Sheet 2 of 2 3-100
3-54 Swing Bolt Feeler Gauge Check 3-101
3-55 Swing Bearing Removal 3-102
3-56 Swing Bearing Torque Sequence 3-105
3-57 Rotary Coupling Seal Installation 3-106
3-58 Rotary Coupling Cutaway 3-107
3-59 Rotary Coupling Installation 3-108
3-60 Rotary Coupling Port Location 3-109
3-61 Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings 3-112
3-62 Auxiliary Pump Installation 3-113
3-63 Cold Weather Package 3-114
3-64 Engine Oil Viscosity 3-116
3-65 EMR 2 Engine Side Equipment 3-119
3-66 Deutz EMR 2 Troubleshooting Flow Chart 3-120
3-67 Deutz EMR 2 Vehicle Side Connection Diagram 3-121
3-68 Deutz EMR 2 Engine Side Connection Diagram – Sheet 1 of 2 3-122
3-69 Deutz EMR 2 Engine Side Connection Diagram – Sheet 2 of 2 3-123
3-70 EMR 2 Engine Plug Pin Identification 3-124
3-71 EMR 2 Vehicle Plug Pin Identification 3-125
3-72 EMR2 Fault Codes – Sheet 1 of 5 3-126
3-73 EMR2 Fault Codes – Sheet 2 of 5 3-127
3-74 EMR2 Fault Codes – Sheet 3 of 5 3-128
3-75 EMR2 Fault Codes – Sheet 4 of 5 3-129
3-76 EMR2 Fault Codes – Sheet 5 of 5 3-130
4-1 Boom Assembly – Sheet 1 of 7 4-8
4-2 Boom Assembly – Sheet 2 of 7 4-9
4-3 Boom Assembly – Sheet 3 of 7 4-10
4-4 Boom Assembly – Sheet 4 of 7 4-11
4-5 Boom Assembly – Sheet 5 of 7 4-12
4-6 Boom Assembly – Sheet 6 of 7 4-13
4-7 Boom Assembly – Sheet 7 of 7 4-14
4-8 Boom Assembly Torque Values – Sheet 1 of 2 4-20
4-9 Boom Assembly Torque Values – Sheet 2 of 2 4-21
4-10 Locations for Loctite Application – Sheet 1 of 4 4-24
4-11 Locations for Loctite Application – Sheet 2 of 4 4-25
4-12 Locations for Loctite Application – Sheet 3 of 4 4-26
4-13 Locations for Loctite Application – Sheet 4 of 4 4-27
4-14 Jib Rotator Orientation 4-29
4-15 Load Pin Removal Tool, JLG P/N 4846765 4-31
4-16 Boom/Jib Sensors and Switches Installation – Sheet 1 of 4 4-32
4-17 Boom/Jib Sensors and Switches Installation – Sheet 2 of 4 4-33
4-18 Boom/Jib Sensors and Switches Installation – Sheet 3 of 4 4-34
4-19 Boom/Jib Sensors and Switches Installation – Sheet 4 of 4 4-35
4-20 Boom Wiper Installation 4-36
4-21 Pivot Pin Installation 4-37
4-22 Powertrack Installation – Sheet 1 of 4 4-38
4-23 Powertrack Installation – Sheet 2 of 4 4-39
4-24 Powertrack Installation – Sheet 3 of 6 4-40
4-25 Powertrack Installation – Sheet 4 of 6 4-41
4-26 Powertrack Installation – Sheet 5 of 6 4-42
4-27 Powertrack Installation – Sheet 6 of 6 4-43
4-28 Wire Rope Tensioning Figure A 4-46
4-29 Wire Rope Adjustment Tools (Optional) 4-48
4-30 Broken Boom Cable Proximity Switch Location 4-49
FIGURE NO TITLE PAGE NO
4-31 Rotary Actuator – Exploded View 4-52
4-32 Rotary Actuator – Assembly Drawing 4-53
4-33 Platform Support Torque Values 4-63
5-1 Cylinder Barrel Support 5-3
5-2 Cap Screw Removal 5-3
5-3 Axle Extension Cylinder 5-4
5-4 Axle Lockout Cylinder 5-5
5-5 Level Cylinder 5-6
5-6 Lift Cylinder 5-7
5-7 Jib Cylinder 5-8
5-8 Steer Cylinder – Prior to S/N 73367 5-9
5-9 Steer Cylinder – S/N 73367 to Present 5-10
5-10 Telescope Cylinder 5-11
5-11 Cylinder Rod Support 5-12
5-12 Tapered Bushing Removal 5-12
5-13 Composite Bearing Installation 5-13
5-14 Rod Seal Installation 5-14
5-15 Poly-Pak Piston Seal Installation 5-14
5-16 Wiper Seal Installation 5-14
5-17 Installation of Head Seal Kit 5-15
5-18 Piston Seal Kit Installation 5-15
5-19 Tapered Bushing Installation 5-16
5-20 Seating the Tapered Bearing 5-16
5-21 Rod Assembly Installation 5-17
5-22 Hydraulic Tank 5-18
5-23 Chassis Control Valve Locations 5-19
5-24 Platform Valve Identification – JLG P/N 4641266 5-20
5-25 Platform Valve Identification – JLG P/N 4641460 5-21
5-26 Main Valve Identification 5-22
5-27 Main Valve Cartridge Torque Values 5-23
5-27 Hydraulic Oil Level Gauge 5-24
5-28 Steer Pressure Adjustments 5-27
5-29 Function Pump – Sectional View 5-40
5-30 Function Pump, Pressure and Flow Control – Sheet 1 5-47
5-31 Function Pump, Pressure and Flow Control – Sheet 2 5-47
5-32 Function Pump, Pressure and Flow Control – Sheet 3 5-48
6-1 Hand Held Analyzer 6-1
6-2 Control System Block Diagram 6-3
6-3 Analyzer Flow Chart 6-5
6-4 Analyzer Flow Chart – Personalities (Software Version 7 X to Present) 6-6
6-5 Analyzer Flow Chart – Machine Setup (Software Version 7 X to Present) 6-7
6-6 Analyzer Flow Chart – Calibrations (Software Version 7 X to Present) 6-8
6-7 Analyzer Flow Chart – Diagnostics (Software Version 7 X to Present) – Sheet 1 of 3 6-9
6-8 Analyzer Flow Chart – Diagnostics (Software Version 7 X to Present) – Sheet 2 of 3 6-10
6-9 Analyzer Flow Chart – Diagnostics (Software Version 7 X to Present) – Sheet 3 of 3 6-11
6-10 Control Module Location 6-12
6-11 Analyzer Connecting Points 6-13
6-12 System Test Flow Chart – Platform Tests 6-30
6-13 System Test Flow Chart – Ground Station Tests 6-32
6-14 Boom Sensor Calibration Position 1 6-67
6-15 Boom Sensor Calibration Position 2 6-72
6-16 Boom Sensor Calibration Position 3 6-73
6-17 Boom Sensor Calibration Position 4 6-74
6-18 Boom Sensor Calibration Position 5 6-75
6-19 Boom Sensor Calibration Position 6 6-76
6-20 Boom Sensor Calibration Position 7 6-76
6-21 Boom Sensor Calibration Position 8 6-77
FIGURE NO TITLE PAGE NO
6-22 Boom Sensor Calibration Position 9 6-78
6-23 Boom Sensor Calibration Position 10 6-79
6-24 Fault Code Light Location 6-81
6-25 CANbus Connections Diagram 6-108
6-26 CANbus Connections – Sheet 1 of 5 6-109
6-27 CANbus Connections – Sheet 2 of 5 6-110
6-28 CANbus Connections – Sheet 3 of 5 6-111
6-29 CANbus Connections – Sheet 4 of 5 6-112
6-30 CANbus Connections – Sheet 5 of 5 6-113
6-31 CANbus Circuit 6-114
6-32 Moment Chart 6-132
7-1 Voltage Measurement (DC) 7-1
7-2 Resistance Measurement 7-2
7-3 Continuity Measurement 7-2
7-4 Current Measurement (DC) 7-3
7-5 Connector Assembly Figure 1 7-4
7-6 AMP Connector 7-4
7-7 Connector Assembly Figure 2 7-5
7-8 Connector Assembly Figure 3 7-5
7-9 Connector Assembly Figure 4 7-5
7-10 Connector Disassembly 7-6
7-11 Connector Installation 7-7
7-12 DT/DTP Contact Installation 7-8
7-13 DT/DTP Contact Removal 7-8
7-14 HD/HDP Contact Installation 7-9
7-15 HD/HDP Locking Contacts Into Position 7-9
7-16 HD/HDP Contact Removal 7-9
7-17 HD/HDP Unlocking Contacts 7-9
7-18 Chassis Electrical Components – Sheet 1 of 2 7-10
7-19 Chassis Electrical Components – Sheet 2 of 2 7-11
7-20 Turntable Electrical Components – Prior to S/N 87579 – Sheet 1 of 2 7-12
7-21 Turntable Electrical Components – Prior to S/N 87579 – Sheet 2 of 2 7-13
7-22 Turntable Electrical Components – S/N 87579 to Present – Sheet 1 of 2 7-14
7-23 Turntable Electrical Components – S/N 87579 to Present – Sheet 2 of 2 7-15
7-24 Electrical Schematic – Sheet 1 of 6 7-16
7-25 Electrical Schematic – Sheet 2 of 6 7-17
7-26 Electrical Schematic – Sheet 3 of 6 7-18
7-27 Electrical Schematic – Sheet 4 of 6 7-19
7-28 Electrical Schematic – Sheet 5 of 6 7-20
7-29 Electrical Schematic – Sheet 6 of 6 7-21
7-30 Hydraulic Schematic – Boom Control – Sheet 1 of 2 7-22
7-31 Hydraulic Schematic – Boom Control – Sheet 2 of 2 7-23
7-32 Hydraulic Schematic – Pump Circuit – Sheet 1 of 2 7-24
7-33 Hydraulic Schematic – Pump Circuit – Sheet 2 of 2 7-25
7-34 Hydraulic Schematic – Platform Control – Sheet 1 of 2 7-26
7-35 Hydraulic Schematic – Platform Control – Sheet 2 of 2 7-27
7-36 Hydraulic Schematic – Axle Steer Control – Sheet 1 of 2 7-28
7-37 Hydraulic Schematic – Axle Steer Control – Sheet 2 of 2 7-29
7-38 Hydraulic Schematic – Traction Control – Sheet 1 of 2 7-30
7-39 Hydraulic Schematic – Traction Control – Sheet 2 of 2 7-31
TABLE NO TITLE PAGE NO
1-1 Capacities 1-1
1-2 Tire Specifications 1-1
1-3 Deutz BF4M2011 Specifications 1-1
1-4 Deutz TD2011L4 Specifications 1-1
1-5 Reach Specifications 1-2
1-6 Dimensional Data 1-2
1-7 Chassis Specifications 1-2
1-8 Torque Requirements 1-3
1-9 Engine Torque Requirements 1-3
1-10 Hydraulic Oil Specifications 1-3
1-11 Mobilfluid 424 Specs 1-3
1-12 Mobil DTE 13M Specs 1-4
1-13 UCon Hydrolube HP-5046 1-4
1-14 Mobil EAL H 46 Specs 1-4
1-15 Exxon Univis HVI 26 Specs 1-4
1-16 Component Weights 1-5
1-17 Pressure Settings 1-5
1-18 Lubrication Specifications 1-7
2-1 Inspection and Maintenance 2-2
2-2 Cylinder Drift 2-5
2-3 Inspection and Preventive Maintenance Schedule 2-6
3-1 Wheel Torque Chart 3-1
3-2 Steering Assembly Notes 3-13
3-2 Brake Technical Data 3-21
3-3 Suggested Lubricants According SAE 80W/90 and SAE 85W/140 API GL5 Grade 3-23
3-4 Drive Hub Maintenance Schedule 3-25
3-5 Troubleshooting 3-26
3-6 Coupling Port Information Table 3-110
4-1 Hose/Cable Pull Chart 4-42
4-1 Hose/Cable Pull Chart 4-42
5-1 Cylinder Head and Tapered Bushing Torque Specifications 5-17
5-2 Holding Valve Torque Specifications 5-17
5-3 Cartridge Torque Values 5-23
5-4 Torque Specs for Relief Valves into Port Block 5-36
5-5 Tightening Torques 5-46
6-1 Calibration Instructions 6-4
6-2 Machine Configuration Programming Information – Version P7 X to Present 6-17
6-3 Personality Ranges/Defaults 6-23
6-4 System Test Messages 6-33
6-5 Machine Diagnostics Parameters 6-36
6-6 Diagnostic Trouble Code Chart 6-82
6-7 Troubleshooting: Platform Can Communications Lost 6-117
6-8 Troubleshooting: BLAM Can Communications Lost 6-123
6-9 Troubleshooting: Chassis Can Communications Lost 6-127
6-10 Load Moment Pin Troubleshooting: Can Communications Lost 6-128
6-11 Load Moment Pin Troubleshooting: Moment Pin Horizontal Force Out of Range 6-129
6-12 Load Moment Pin Troubleshooting: Moment Pin Vertical Force Out of Range 6-130
6-13 Load Moment Pin Troubleshooting: Moment Pin Sensor Fault 6-131
6-14 Load Moment Pin Troubleshooting: New Moment Pin Detected Fault 6-131

 

JLG Models 800A 800AJ Workshop Service and Maintenance Manual P/N – 3120740

Download JLG Models 800A 800AJ Workshop Service and Maintenance Manual P/N – 3120740 Manual.pdf

JLG Models 800A 800AJ Workshop Service and Maintenance Manual

This is the Most Practical Service Repair Manual for the JLG 800A, 800AJ Workshop Service Repair Manual Download ever compiled by mankind. This DOWNLOAD contains of high quality diagrams and instructions on how to service and repair your JLG.

Format:  PDF
File size: 37.6 MB (39,517,665 )

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The  Repair Manual Covers:

SECTION A. INTRODUCTION – MAINTENANCE SAFETY PRECAUTIONS

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.

SECTION 1 – SPECIFICATIONS

- SPECIFICATIONS
1.1 Operating specifications
Capacities
1.2 Component Data
Engine Data
Tires
Drive System
Swing System
Hydraulic Drive Pump
Variable Displacement Pump
Hydraulic Load Sense Pump
Auxiliary Power Pump
Hydraulic Filter – In-line
1.3 Performance Data
Function Speeds
1.4 Torque Requirements
1.5 Lubrication
Hydraulic Oil
1.6 Pressure Settings
1.7 Cylinder Specifications
1.8 Major Component Weights
Critical Stability Weights
1.9 Lubrication and Operator Maintenance
Draining Oil Build Up From The Propane Regulator
Propane Fuel Filter Replacement
Propane Fuel System Pressure Relief

SECTION 2 – GENERAL

2.1 Machine Preparation, Inspection, and Maintenance
General
Preparation, Inspection, and Maintenance
Pre-Start Inspection
Pre-Delivery Inspection and Frequent Inspection
Annual Machine Inspection
Preventative Maintenance
2.2 Service and Guidelines
General
Safety and Workmanship
Cleanliness
Components Removal and Installation
Component Disassembly and Reassembly
Pressure-Fit Parts
Bearings
Gaskets
Bolt Usage and Torque Application
Hydraulic Lines and Electrical Wiring
Hydraulic System
Lubrication
Battery
Lubrication and Servicing
2.3 Lubrication and Information
Hydraulic System
Hydraulic Oil
Changing Hydraulic Oil
Lubrication Specifications
2.4 Cylinder Drift Test
Platform Drift
Cylinder Drift
2.5 Pins and Composite Bearing Repair Guidelines
2.6 Welding on JLG Equipment
Do the Following When Welding on JLG Equipment
Do NOT Do the Following When Welding on JLG Equipment

SECTION 3 – CHASSIS & TURNTABLE

Tire Inflation The air pressure for pneumatic tires must be equal to the air pressure that is stenciled on the side of the JLG product or rim decal for safe and proper operational characteristics. Tire Damage For pneumatic tires, JLG Industries, Inc. recommends that when any cut, rip, or tear is discovered that exposes sidewall or tread area cords in the tire, measures must be taken to remove the JLG product from service immediately. Arrangements must be made for replacement of the tire or tire assembly. For polyurethane foam filled tires, JLG Industries, Inc. recommends that when any of the following are discovered, measures must be taken to remove the JLG product from service immediately and arrangements must be made for replacement of the tire or tire assembly. • a smooth, even cut through the cord plies which exceeds 3 inches (7.5 cm) in total length • any tears or rips (ragged edges) in the cord plies which exceeds 1 inch (2.5 cm) in any direction • any punctures which exceed 1 inch in diameter • any damage to the bead area cords of the tire If a tire is damaged but is within the above noted criteria, the tire must be inspected on a daily basis to insure the damage has not propagated beyond the allowable criteria. Tire Replacement JLG recommends a replacement tire be the same size, ply and brand as originally installed on the machine. Please refer to the JLG Parts Manual for the part number of the approved tires for a particular machine model. If not using a JLG approved replacement tire, we recommend that replacement tires have the following characteristics: • Equal or greater ply/load rating and size of original • Tire tread contact width equal or greater than original •Wheel diameter, width, and offset dimensions equal to the original Unless specifically approved by JLG Industries Inc. do not replace a foam filled or ballast filled tire assembly with a pneumatic tire. When selecting and installing a replacement tire, ensure that all tires are inflated to the pressure recommended by JLG. Due to size variations between tire brands, both tires on the same axle should be the same. Wheel Replacement The rims installed on each product model have been designed for stability requirements which consist of track width, tire pressure, and load capacity. Size changes such as rim width, center piece location, larger or smaller diameter, etc., without written factory recommendations, may result in an unsafe condition regarding stability. Wheel Installation It is extremely important to apply and maintain proper wheel mounting torque.
3.1 Tires & Wheels.
Tire Inflation
Tire Damage
Tire Replacement. .
Wheel Replacement.
Wheel Installation. .
3.2 Oscillating Axle Bleeding Procedure And Lockout Test.
Lockout Cylinder Bleeding .
Oscillating Axle Lockout Test
3.3 Free Wheeling Option
To Disengage Drive Motors and Brakes (Free Wheel) for Emergency Towing
To Engage Drive Motors and Brakes (Normal Operation)
3.4 Torque Hub, Drive
Disassembly.
Repair.
Assembly
3.5 Drive Brake – Ausco (Prior to S/N 56875) .
Disassembly.
Inspection
Assembly . 3-12
3.6 Drive Brake – Mico (S/N 56875 to 83332) .3-14
Disassembly. . . 3-14
Assembly . 3-14
Bleeding. . 3-16
3.7 Drive Brake (S/N 83332 to Present) .3-17
Disassembly. . . 3-17
Inspection 3-17
Assembly . 3-17
3.8 Drive Motor . . . .3-19
Description. . . . 3-19
Shaft Seal Replacement . 3-19
Loop Flushing Valve 3-20
Troubleshooting. . . . 3-21
Disassembly. . . 3-22
Inspection 3-26
Assembly . 3-28
Initial Start-up Procedures 3-33
SECTION NO. TITLE PAGE NO.
3.9 Swing Bearing . .3-34
Turntable Bearing Mounting Bolt Condition Check . . . 3-34
Wear Tolerance 3-37
Swing Bearing Replacement . . 3-37
Swing Bearing Torque Values . 3-39
3.10 Swing Hub installation. . . .3-40
3.11 Swing Hub (Prior to S/N 0300068040) . . .3-41
Disassembly. . . 3-41
Assembly . 3-41
Hub Shaft Sub-Assembly 3-44
Carrier Sub-Assembly . . . 3-47
3.12 Swing Brake – Ausco (Prior to S/N 0300068040) . .3-50
Disassembly. . . 3-50
Inspection 3-50
Assembly . 3-50
3.13 Swing Motor (Eaton) (Prior to S/N 0300068040) . .3-52
Disassembly. . . 3-52
Reassembly . . . 3-53
Motor Timing . . 3-54
3.14 Swing Hub (S/N 0300068040 to Present). . . . .3-56
Disassembly. . . 3-56
Main Assembly Procedure. . . . 3-56
Hub Shaft Sub-Assembly 3-59
Carrier Sub-Assembly . . . 3-61
3.15 Swing Brake (S/N 0300068040 to Present) . . .3-64
Disassembly. . . 3-64
Assembly . 3-64
3.16 Swing Motor (S/N 0300068040 to Present) . . .3-66
Disassembly. . . 3-66
Inspection and Cleaning . 3-68
Assembly . 3-68
Timing Procedure . . 3-70
3.17 Rotary Coupling. . . . .3-73
3.18 Tilt Alarm Switch (Prior to S/N 0300065534). . .3-77
Manual Adjustment . 3-77
3.19 Spark Arrester Cleaning Instructions . . . .3-77
3.20 Generator. .3-80
Every 250 hours 3-80
Every 500 hours 3-80
Overload Protection. 3-80
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings . . . 3-80
3.21 Dual Fuel System . . .3-82
Changing from Gasoline to LP Gas. 3-82
Changing from LP Gas to Gasoline. 3-82
3.22 EFI Engine .3-82
Performing Diagnostics . . 3-82
EFI Diagnostics (Prior to S/N 0300065534). . 3-83
ECM and Sensors . . 3-83
Fuel System . . . 3-89SECTION NO. TITLE PAGE NO.
3.23 Ford LPG System (S/N 0300077500 To Present). .3-93
Description. . . . 3-93
Regulator . 3-93
Megajector 3-93
Mixer. 3-93
Lockoff Solenoid
Megajector Diagnostic Code Descriptions
3.24 Electric Governor Installation And Adjustments – Ford LRG425 Engine
(Prior to S/N 0300065534)
General
Quick-start Installations
Mounting-Actuator
Wiring .
Power Distribution
Check-Out and Initial Start-Up Procedures.
Troubleshooting
Automatic Choke Adjustment Procedure
3.25 Throttle Checks And Adjustments – Deutz Engine (Prior to S/N 0300065534)
General
Procedure .
Controller Status
Failure Modes .
3.26 Deutz EMR 2 (S/N 85331 to Present)
3.27 GM Engine General Maintenance
Maintenance of the Drive Belt
Engine Electrical System Maintenance
Checking/Filling Engine Oil Level
Changing The Engine Oil
Coolant Fill Procedure – Dual Fuel Engine
3.28 GM Engine Dual Fuel System
Fuel Filter
Electric Lock Off
EPR Assembly
Low Pressure Regulator (LPR)
Air Fuel Mixer
Electronic Throttle Control (ETC)
Engine Control Module .
Heated Exhaust Gas Oxygen Sensor
Gasoline Multi Point Fuel Injection System (MPFI) .
Gasoline Fuel Pump .
Gasoline Pressure And Temperature Sensor Manifold.
Fuel Filter
Fuel Injector Rail
Fuel Injector
3.23 Ford LPG System (S/N 0300077500 To Present)
Description
Regulator
Megajector
Mixer.
Lockoff Solenoid
Megajector Diagnostic Code Descriptions
3.24 Electric Governor Installation And Adjustments – Ford LRG425 Engine
(Prior to S/N 0300065534)
General
Quick-start Installations
Mounting-Actuator
Linkage
Mounting-Controller
Wiring
Power Distribution
Check-Out and Initial Start-Up Procedures
Troubleshooting
Automatic Choke Adjustment Procedure
3.25 Throttle Checks And Adjustments – Deutz Engine (Prior to S/N 0300065534)
General
Procedure
Controller Status
Failure Modes
3.26 Deutz EMR 2 (S/N 85331 to Present)
3.27 GM Engine General Maintenance.
Maintenance of the Drive Belt
Engine Electrical System Maintenance.
Checking/Filling Engine Oil Level
Changing The Engine Oil
Coolant Fill Procedure – Dual Fuel Engine
3.28 GM Engine Dual Fuel System
Fuel Filter
Electric Lock Off.
EPR Assembly
Low Pressure Regulator (LPR)
Air Fuel Mixer
Electronic Throttle Control (ETC)
Engine Control Module
Heated Exhaust Gas Oxygen Sensor
Gasoline Multi Point Fuel Injection System (MPFI)
Gasoline Fuel Pump
Gasoline Pressure And Temperature Sensor Manifold
Fuel Filter
Fuel Injector Rail
Fuel Injector
3.29 GM Engine Fuel System Repair
Propane Fuel System Pressure Relief
Propane Fuel System Leak Test
Propane Fuel Filter Replacement
Electronic Pressure Regulator (EPR) Assembly Replacement
Temperature Manifold Absolute Pressure (TMAP) Sensor
Electronic Throttle Control Replacement
MIXER REPLACEMENT
Coolant Hose Replacement
Vapor Hose Replacement
Engine Control Module Replacement
Heated Exhaust Gas Oxygen Sensor Replacement
3.30 GM Engine LPG Fuel System Diagnosis
Fuel System Description
Diagnostic Aids

SECTION 4 – BOOM & PLATFORM
4 1 Platform 4-1
Support Removal 4-1
Support Installation 4-2
Platform Sections Replacement 4-2
4 2 Rotator and Slave Cylinder 4-3
Removal 4-3
4 3 Upper Boom Powertrack 4-4
Removal 4-4
4 4 Upper Boom 4-4
Removal 4-4
Disassembly 4-6
Inspection 4-6
Assembly 4-6
Installation 4-7
4 5 Upright 4-8
Removal 4-8
Installation 4-9
4 6 Tower Boom Assembly 4-9
Removal 4-9
Inspection 4-10
Assembly 4-10
Installation 4-11
Tower Out of Sync 4-12
4 7 Articulating Jib 4-14
Removal 4-14
Disassembly 4-14
Inspection 4-14
Assembly 4-15
4 8 Sequence For Hose Replacement In The Tower Boom 4-15
4 9 Limit Switches Adjustment 4-15
Upper Boom Horizontal Limit Switch 4-15
Tower Boom Horizontal Limit Switch 4-15
Dual Capacity Angle Limit Switch (800A only) 4-23
Upper Boom Length Switch (800 A only) 4-23
4 10 Boom Valve Adjustment 4-23
4 11 Wear Pads 4-24
Tower Boom 4-24
Upper Boom 4-24
4 12 Rotator (prior to S/N 0300067538) 4-24
Disassembly 4-24
Inspection 4-25
Assembly 4-26
4 13 Rotator Assembly (S/N 0300067538 to Present) 4-28
Theory of Operation 4-28
Required Tools 4-28
Disassembly 4-31
Inspection 4-35
Assembly 4-35
4 14 Drive Card Setup Procedures 4-40
Lift, Swing, and Drive Cards 4-40
Flow Control Card 4-40
4 15 Foot Switch Adjustment 4-41
4 16 Upright Monitoring System 4-41
Re-Synchronizing Upright 4-41
Calibration – Pre ADE Machines 4-43
Calibration – ADE Equipped Machines 4-47
Calibration Faults 4-51
Function Check 4-52
Service Mode/Tower Boom Retrieval 4-53
4 17 UMS Troubleshooting and Fault Messages – Non-ADE Machines 4-59
Tower Lift Down Permanently closed 4-59
Backward Stability Concern Message 4-59
Forward Stability Concern Message 4-59
UMS Out of Usable Range Message 4-59
Battery voltage < 9 0 Volts 4-59
Battery voltage > 16 0 Volts 4-59
UMS Sensor Not Calibrated Message 4-60
UMS Sensor Faulted 4-60
Tower Lift Down Output Short to Ground or Open Circuit 4-60
Tower Lift Down Output Short to Battery 4-60
Platform Indicator Output Short to Ground or Open Circuit 4-60
Platform Indicator Output Short to Battery 4-60
Ground Indicator Output Short to Ground 4-60
Ground Indicator Output Short to Battery 4-60
Turntable Sensor Not Calibrated Message 4-60
Turntable Sensor Faulted 4-61
EEPROM checksums failure 4-61
4 18 UMS Troubleshooting and Fault Messages – ADE Machines 4-61
Backward Stability Concern Message 4-61
Forward Stability Concern Message 4-61
Auto Detection Input Low Message 4-61
UMS Sensor Communications lost 4-61
Out of Usable Range Message 4-62
UMS Sensor Not Calibrated Message 4-62
UMS Sensor Faulted Message 4-62
Incompatible Software Detected Message 4-62
Calibration Faults 4-62

SECTION 5 – HYDRAULICS
5 1 Lubricating O-Rings in the Hydraulic System 5-1
Cup and Brush 5-1
Dip Method 5-2
Spray Method 5-2
Brush-on Method 5-2
5 2 Valves – Theory Of Operation 5-3
Solenoid Control Valve – Rexroth 5-3
Relief Valves 5-3
5 3 Holding Valve Checks 5-3
5 4 Cylinders – Theory Of Operation 5-4
Systems Incorporating Double Acting Cylinders 5-4
Systems Incorporating Holding Valves 5-4
5 5 Cylinder Checking Procedure 5-5
Cylinders Without Counterbalance Valves – Master Cylinder and Steer Cylinders 5-5
Cylinders With Single Counterbalance Valve 5-5
Cylinders With Dual Counterbalance Valves 5-6
5 6 Cylinder Repair 5-7
Disassembly 5-7
Cleaning and Inspection 5-19
Assembly 5-20
5 7 Cylinder Removal And Installation 5-24
Upper Boom Telescope Cylinder Removal 5-24
Upper Boom Telescope Cylinder Installation 5-25
Upper Lift Cylinder Removal 5-25
Upper Boom Lift Cylinder Installation 5-26
Upright Level Cylinder Removal 5-26
Upright Level Cylinder Installation 5-27
Tower Boom Lift Cylinder Removal 5-27
Tower Lift Cylinder Installation 5-28
Tower Telescope Cylinder Removal 5-28
Tower Telescope Cylinder Installation 5-28
Slave Cylinder Removal 5-28
Slave Cylinder Installation 5-29
5 8 Hydraulic Pump W/hayes Pump drive Coupling Lubrication 5-29
5 9 Pressure Setting Procedures 5-29
FIRST: Set Up the Function Pump 5-29
SECOND: Adjustments Made at the Main Valve Block 5-36
5 10 Hydraulic oil change-out procedure 5-37
5 11 Hydraulic Component Start-Up Procedures and Recommendations 5-38
5 12 Rexroth Variable Displacement Pump Prior to S/N 0300121643 5-40
5 13 Sauer Piston Pump S/N 0300121643 to Present 5-42
Initial start-up procedures 5-43
Troubleshooting 5-43
Shaft Seal Replacement 5-47
Control Assembly 5-47
Plug and Fitting Sizes and Torques 5-49

SECTION 6 – JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)
6 1 Introduction 6-1
6 2 CANbus Communications 6-14
6 3 To Connect the JLG Control System Analyzer 6-14
6 4 Using the Analyzer 6-14
6 5 Changing the Access Level of the Hand Held Analyzer 6-15
6 6 Adjusting Parameters Using the Hand Held Analyzer 6-16
6 7 Machine Setup 6-17
6 8 Level Vehicle Description 6-17
6 9 Machine Personality Settings 6-33
Analyzer Diagnostics Menu Structure 6-50
SECTION 7 – BASIC ELECTRICAL INFORMATION & SCHEMATICS
7 1 General 7-1
7 2 Multimeter Basics 7-1
Grounding 7-1
Backprobing 7-1
Min/Max 7-1
Polarity 7-1
Scale 7-1
Voltage Measurement 7-1
Resistance Measurement 7-2
Continuity Measurement 7-2
Current Measurement 7-3
7 3 Applying Silicone Dielectric Compound to Electrical Connections 7-3
7 4 AMP Connector 7-4
Applying Silicone Dielectric Compound to AMP Connectors 7-4
Assembly 7-4
Disassembly 7-6
Wedge Lock 7-6
Service – Voltage Reading 7-6
7 5 Deutsch Connectors 7-8
DT/DTP Series Assembly 7-8
DT/DTP Series Disassembly 7-8
HD30/HDP20 Series Assembly 7-9
HD30/HDP20 Series Disassembly 7-9

and more

JLG Model 80HX 80HX+6 80HXER Service and Maintenance Manual 3120271

Download JLG Model 80HX 80HX+6 80HXER Repair Service and Maintenance Manual.PDF

This can be the Almost all Functional Services Repair Guide for that JLG 80HX, 80HX+6, 80HXER Working area Services Repair Guide Acquire previously compiled by mankind. This kind of OBTAIN contains of good quality diagrams along with guidance on how to be able to services along with restoration ones JLG.

JLG80HX

Format:  PDF
File size: 9.95 MB (10,435,022 )

Instant Download

Repair Manual Covers:

1.SECTION A. INTRODUCTION – MAINTENANCE SAFETY PRECAUTIONS

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.

TABLE OF CONTENTS

SECTION 1 – SPECIFICATIONS

  • 1.1 Capacities
  • 1.2 Component Data
  • Engine – Ford LSG423
  • Engine – Deutz F4L912
  • Engine – Wisconsin V465D
  • Engine – Cummins 4B 3.9C
  • Engine – Ford LRG-423
  • Engine – Ford LRG-425
  • Drive System
  • Drive Motor Displacement Machines Built Prior to Jan. 1992
  • Drive Motor Displacement Machines Built from Jan. 1992 to Present
  • Drive Hub Ratios
  • Steer System
  • Swing System
  • Hydraulic Pump
  • Auxiliary Power Pump
  • Hydraulic Filter – Tank.
  • Hydraulic Filter – Inline (Racine Valve Only)
  • 1.3 Performance Data
  • Travel Speed
  • Gradeability
  • Turning Radius (Outside)
  • Boom Speed (Telescope)
  • Boom Speed (Lift)
  • Swing Speed 360°
  • Boom Elevation
  • Machine Weight
  • Machine Stowed Height
  • Machine Stowed Length
  • Machine Width
  • Maximum Tire Load
  • Wheelbase
  • 1.4 Torque Requirements
  • 1.5 Lubrication
  • Ford Engines
  • Deutz F4L912 Engine
  • Wisconsin V465D Engine
  • Cummins 4B 3.9C.
  • Lubrication Specifications
  • 1.6 Pressure Settings
  • Prior to Mid 1987
  • 80 HX
  • 80HX w/Hydraulic Controls
  • 80HX w/Oscillating Axle
  • 1.7 Major Components Weights
  • 1.8 Cylinder Specifications
  • AND MORE…

SECTION 2 – GENERAL

This section provides the necessary information needed by those personnel that are responsible to place the machine in operation readiness and maintain its safe operating condition. For maximum service life and safe operation, ensure that all the necessary inspections and maintenance have been completed before placing the machine into service.

  • 2.1 Machine Preparation, Inspection, and Maintenance
  • General
  • Preparation, Inspection, and Maintenance
  • Pre-Start Inspection
  • Pre-Delivery Inspection and Frequent Inspection
  • Annual Machine Inspection
  • Preventative Maintenance
  • 2.2 Service and Guidelines
  • General
  • Safety and Workmanship
  • Cleanliness.
  • Components Removal and Installation
  • Component Disassembly and Reassembly
  • Pressure-Fit Parts
  • Bearings
  • Gaskets
  • Bolt Usage and Torque Application
  • Hydraulic Lines and Electrical Wiring
  • Hydraulic System.
  • Lubrication
  • Battery
  • Lubrication and Servicing
  • 2.3 Lubrication and Information
  • Hydraulic System.
  • Hydraulic Oil
  • Changing Hydraulic Oil
  • Lubrication Specifications
  • 2.4 Cylinder Drift Test
  • Platform Drift.
  • Cylinder Drift
  • 2.5 Pins and Composite Bearing Repair Guidelines
  • 2.6 Welding on JLG Equipment
  • Do the Following When Welding on JLG Equipment
  • Do NOT Do the Following When Welding on JLG Equipment
  • 2.7 Applying Silicone Dielectric Compound to Electrical Connections
  • 2.8 Preventive Maintenance and Inspection Schedule
  • SECTION 3 – CHASSIS & TURNTABLE
  • 3.1 Torque Hub .
  • Disassembly.
  • Cleaning and Inspection .
  • Repair
  • Input Shaft Assembly
  • Assembly
  • SUBJECT – SECTION, PARAGRAPH PAGE NO.
  • 3.2 Drive Brake, Ausco – Machines Built Prior to October 1987
  • Disassembly.
  • Cleaning and Inspection
  • Assembly
  • 3.3 Drive Brake, Mico – Machines Built Prior to October 1987
  • Disassembly
  • Inspection
  • Assembly
  • Bleeding
  • 3.4 Drive Brake, Ausco – Machines Built Prior to 1992
  • Disassembly
  • Cleaning and Inspection
  • Assembly
  • 3.5 Drive Brake, Mico – Machines Built From 1992 to Present .
  • Disassembl
  • Inspection
  • Assembly
  • 3.6 Governor Checks and Adeco Adjustment, LRG423 & LRG425
  • Checks
  • Adjustments
  • 3.7 Throttle Checks and Precision Governor Adjustments, LSG-423 & LRG-425
  • Checks
  • Carburetor and Governor Adjustment
  • 3.8 E331 Precision Governor And Adjustments – Ford Engines
  • General.
  • Quick-start Installations
  • Mounting-Actuator
  • Linkage.
  • Mounting-Controller
  • Wiring
  • Power Distribution
  • Check-Out and Initial Start-Up Procedures.
  • Troubleshooting
  • Automatic Choke Adjustment Procedure
  • 3.9 Automatic Choke Adjustment – Ford Engine
  • 3.10 Cold Weather Starting Difficulty
  • Checking the Carburetor
  • Checking the Ignition
  • Checking the Fuel
  • 3.11 Throttle Checks and Adjustments – Deutz Engine
  • 3.12 Swing Bearing
  • Turntable Bearing Mounting Bolt Condition Check .
  • Wear Tolerance
  • Replacement and Devcon Application Procedures on Machines Built Prior to Mid 1991 . . 3-35
  • Swing Bearing Torque Values
  • 3.13 Oscillating Axle Bleeding Procedure.
  • Lockout Cylinder Bleeding (Without Holding Valves)
  • Lockout Cylinder Bleeding (With Holding Valves)
  • 3.14 Oscillating Axle Lockout Test
  • 3.15 Free Wheeling Option
  • To Disengage Drive Motors and Brakes (Free Wheel) for Towing, etc.
  • To Engage Drive Motors and Brakes (Normal Operation)
  • 3.16 Spark Arrestor Mufflers
  • 3.17 Footswitch Adjustment
  • SUBJECT – SECTION, PARAGRAPH PAGE NO.
  • 3.18 Hydraulic Pump W/Hayes Pump Drive Coupling Lubrication
  • 3.19 Dual Fuel System
  • Changing from gasoline to LP-Gas
  • Changing from LP Gas to Gasoline.

SECTION 4 – BOOM & PLATFORM

  • 4.1 Boom Maintenance
  • Removal
  • Disassembly.
  • Inspection
  • Assembly
  • Installation
  • 4.2 Boom Chains
  • Adjusting Procedures
  • Inspection Procedures
  • 4.3 Wear Pads .
  • 4.4 Telescope Cylinder Eccentric Bushing.
  • 4.5 Horizontal High Speed Cutout Switch Adjustment Procedure.
  • 4.6 Controllers
  • PQ .
  • OEM.
  • VICKERS (All Hydraulic)
  • 4.7 Capacity Indicator
  • Capacity Indicator Cable Adjustment .
  • Capacity Indicator Boom Tape Replacement
  • Installation Procedure
  • Capacity Indicator Dial Decal Replacement
  • Indicator Decal Installation
  • 4.8 Basket Rotator Brake

SECTION 5 – HYDRAULICS

  • 5.1 Cylinders – Theory Of Operation
  • Double Acting Cylinders
  • 5.2 Valves – Theory Of Operation
  • Holding Valves.
  • Solenoid Control Valves (Bang-Bang)
  • Proportional Control Valve – Vickers
  • Main Relief Valves
  • Relief Valves
  • 5.3 Cylinder Checking Procedure.
  • Cylinders Without Counterbalance Valves
  • Cylinders With Single Counterbalance Valve
  • Cylinders With Dual Counterbalance Valves
  • 5.4 Cylinder Repair
  • Disassembly.
  • Cleaning and Inspection
  • Assembly .
  • 5.5 Cylinder Removal and Installation
  • Telescope Cylinder Removal
  • Telescope Cylinder Installation
  • Boom Lift Cylinder Removal .
  • Boom Lift Cylinder Installation

AND MORE

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