JLG 80H 80HX 86HX 80HX+6 Parts Manual (3120272) – PDF DOWNLOAD

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JLG 80H 80HX 86HX 80HX+6 Parts Manual (3120272) – PDF DOWNLOAD

TABLE OF CONTENTS:

JLG 80H 80HX 86HX 80HX+6 Parts Manual (3120272) – PDF DOWNLOAD

SECTION 1 - FRAME..........................................................................................................................  9
	FIGURE 1-1. FRAME, STEERING AND AXLE INSTALLATIONS - 80HX 2WD FIXED AXLE MACHINES...................................................... 10
	FIGURE 1-2. FRAME, STEERING AND AXLE INSTALLATIONS - 80HX 4WD FIXED AXLE MACHINES...................................................... 14
	FIGURE 1-3. FRAME, STEERING AND AXLE INSTALLATIONS - 80HX 2WD AND 4WD OSCILLATING AXLE MACHINES........................................ 18
	FIGURE 1-4. REAR, STEERING AND AXLE INSTALLATIONS - 80HX 4WS MACHINES.................................................................. 22
	FIGURE 1-5. FRAME, STEERING AND AXLE INSTALLATIONS - 80H MACHINES...................................................................... 26
	FIGURE 1-6. TIRE AND WHEEL DRIVE INSTALLATIONS......................................................................................... 30
	FIGURE 1-7. DRIVE MOTOR ASSEMBLY - VICKERS............................................................................................. 38
	FIGURE 1-8. DRIVE MOTOR ASSEMBLY - SAUER-DANFOSS....................................................................................... 42
	FIGURE 1-9. DRIVE MOTOR ASSEMBLY - CESSNA (TWO SPEED).................................................................................. 44
	FIGURE 1-10. DRIVE MOTOR ASSEMBLY - REXROTH............................................................................................ 50
	FIGURE 1-11. BRAKE ASSEMBLY - AUSCO AND MICO........................................................................................... 52
	FIGURE 1-12. BRAKE ASSEMBLY - AUSCO.................................................................................................... 56
	FIGURE 1-13. BRAKE ASSEMBLY - MICO..................................................................................................... 58
	FIGURE 1-14. BRAKE ASSEMBLY - MICO..................................................................................................... 60
	FIGURE 1-15. GEAR REDUCER ASSEMBLY..................................................................................................... 64
	FIGURE 1-16. DRIVE HUB ASSEMBLIES...................................................................................................... 66
	FIGURE 1-17. VALVES AND SWITCHES INSTALLATIONS (FRAME MOUNTED)......................................................................... 70
	FIGURE 1-18. AXLE LIFT CYLINDER INSTALLATIONS.......................................................................................... 74
	FIGURE 1-19. TOW PACKAGE INSTALLATION.................................................................................................. 78
SECTION 2 - TURNTABLE...................................................................................................................... 81
	FIGURE 2-1. BOOM, TURNTABLE AND BEARING LUBE INSTALLATION.............................................................................. 82
	FIGURE 2-2. CONTROL VALVES INSTALLATION - RACINE PROPORTIONAL.......................................................................... 86
	FIGURE 2-3. CONTROL VALVE ASSEMBLY - OUTLET SECTION (RACINE)........................................................................... 90
	FIGURE 2-4. CONTROL VALVE ASSEMBLY - WORKING SECTION (RACINE).......................................................................... 92
	FIGURE 2-5. CONTROL VALVE ASSEMBLY - INLET SECTION (RACINE)............................................................................ 94
	FIGURE 2-6. CONTROL VALVE ASSEMBLY - SERVO SECTION (RACINE)............................................................................ 98
	FIGURE 2-7. CONTROL VALVES ASSEMBLY - VICKERS VALVES...................................................................................102
	FIGURE 2-8. CONTROL VALVE ASSEMBLY - VICKERS (PRIOR TO OCTOBER 1994)...................................................................108
	FIGURE 2-9. CONTROL VALVE ASSEMBLY - VICKERS (OCTOBER 1994 TO PRESENT).................................................................112
	FIGURE 2-10. VICKERS VALVE ASSEMBLY - HYDRAULIC CONTROLS (OCTOBER 1994 TO PRESENT).....................................................116
	FIGURE 2-11. CONTROL VALVE ASSEMBLY - RACINE BANG-BANG WITH DUMP SECTION...............................................................120
	FIGURE 2-12. CONTROL VALVE ASSEMBLY - BANG-BANG WITH DUMP SECTION......................................................................124
	FIGURE 2-13. CONTROL VALVE ASSEMBLY - BANG-BANG WITH INLET RELIEF......................................................................128
	FIGURE 2-14. CONTROL VALVE ASSEMBLY - 1 SECTION BANG-BANG (80HX+6/86HX)................................................................130
	FIGURE 2-15. ACCESSORY VALVE ASSEMBLY (MILLER) (HYDRAULIC CONTROLS MACHINES BUILT THROUGH 1989)........................................132
	FIGURE 2-16. ACCESSORY VALVE ASSEMBLY..................................................................................................134
	FIGURE 2-17. SWING DRIVE, BEARING AND LOCK INSTALLATIONS...............................................................................136
	FIGURE 2-18. SWING MOTOR ASSEMBLY - WHITE..............................................................................................140
	FIGURE 2-19. SWING MOTOR ASSEMBLY - CHAR-LYNN..........................................................................................142
	FIGURE 2-20. SWING MOTOR ASSEMBLY - EATON..............................................................................................144
	FIGURE 2-21. SWING BRAKE ASSEMBLIES (PRIOR TO APRIL 1992)..............................................................................146
	FIGURE 2-22. SWING BRAKE ASSEMBLIES (APRIL 1992 TO PRESENT)............................................................................150
	FIGURE 2-23. SWING HUB ASSEMBLY........................................................................................................154
	FIGURE 2-24. ROTARY COUPLING AND COLLECTOR RING ASSEMBLY AND INSTALLATION..............................................................156
	FIGURE 2-25. DEUTZ ENGINE INSTALLATION WITHOUT NOISE REDUCTION (BUILT PRIOR TO FEBRUARY 1995)..........................................160
	FIGURE 2-26. DEUTZ ENGINE INSTALLATION WITH NOISE REDUCTION (BUILT FEBRUARY 1995 TO PRESENT)...........................................168
	FIGURE 2-27. ADECO THROTTLE COMPONENTS INSTALLATION - DEUTZ ENGINE MACHINES............................................................174
	FIGURE 2-28. GENERATOR INSTALLATION - DEUTZ ENGINE MACHINES............................................................................178
	FIGURE 2-29. FORD LSG-423 ENGINE INSTALLATIONS - (PRIOR TO MARCH 1995).................................................................182
	FIGURE 2-30. ADECO THROTTLE INSTALLATIONS - FORD ENGINE MACHINES BUILT PRIOR TO MID 1987...............................................192
	FIGURE 2-31. PRECISION GOVERNOR INSTALLATIONS - FORD ENGINE MACHINES BUILT MID 1987 TO MARCH 1995......................................194
	FIGURE 2-32. GENERATOR INSTALLATION - FORD ENGINE MACHINES BUILT PRIOR TO MARCH 1995 (OPTIONAL)........................................196
	FIGURE 2-33. FORD LRG423/LRG425 ENGINE INSTALLATION (MARCH 1995 TO PRESENT)............................................................200
	FIGURE 2-34. GENERATOR INSTALLATION - FORD MACHINES BUILT MARCH 1995 TO PRESENT........................................................208
	FIGURE 2-35. DUAL FUEL INSTALLATION - FORD ENGINE MACHINES.............................................................................212
	FIGURE 2-36. WISCONSIN ENGINE INSTALLATION.............................................................................................216
	FIGURE 2-37. PUMP COUPLING INSTALLATIONS...............................................................................................222
	FIGURE 2-38. MAIN PUMP ASSEMBLY (MACHINES WITH RACINE PROPORTIONAL VALVES).............................................................226
	FIGURE 2-39. MAIN PUMP ASSEMBLY (MACHINES WITH VICKERS PROPORTIONAL VALVES BUILT PRIOR TO MID 1987 - HAS ONE OUTLET IN END COVER)......230
	FIGURE 2-40. MAIN PUMP ASSEMBLY (MACHINES WITH VICKERS PROPORTIONAL VALVES BUILT MID 1987 TO PRESENT- HAS TWO OUTLETS IN END COVER)....232
	FIGURE 2-41. TANKS INSTALLATION........................................................................................................234
	FIGURE 2-42. LP TANKS INSTALLATION.....................................................................................................238
	FIGURE 2-43. GROUND CONTROL COMPONENTS INSTALLATION (MACHINES WITH RACINE PROPORTIONAL VALVES).........................................240
	FIGURE 2-44. GROUND CONTROL INSTALLATION (MACHINES WITH VICKERS PROPORTIONAL VALVES AND STANDARD CONTROLS).............................244
	FIGURE 2-45. GROUND CONTROLS INSTALLATION (MACHINES WITH VICKERS PROPORTIONAL VALVES AND HYDRAULIC CONTROLS)...........................250
	FIGURE 2-46. ELECTRICAL COMPONENTS INSTALLATION (TURNTABLE MOUNTED)....................................................................256
	FIGURE 2-47. HOODS INSTALLATION (PRIOR TO DECEMBER 1992)...............................................................................260
	FIGURE 2-48. HOODS INSTALLATION (MACHINES BUILT DECEMBER 1992 TO PRESENT)..............................................................264
SECTION 3 - BOOM...........................................................................................................................267
	FIGURE 3-1. BOOM ASSEMBLIES............................................................................................................268
	FIGURE 3-2. BOOM WIPERS INSTALLATION...................................................................................................278
	FIGURE 3-3. EXTEND-A-REACH INSTALLATION................................................................................................280
SECTION 4 - PLATFORMS......................................................................................................................283
	FIGURE 4-1. STANDARD PLATFORM AND FOOTSWITCH INSTALLATION..............................................................................284
	FIGURE 4-2. LOW MOUNT PLATFORM AND FOOTSWITCH INSTALLATION.............................................................................290
	FIGURE 4-3. ROTATOR MOTOR ASSEMBLY.....................................................................................................296
	FIGURE 4-4. CONSOLE BOX ASSEMBLIES - PQ CONTROLLERS WITHOUT PROP TELE (MACHINES BUILT PRIOR TO SEPTEMBER 1991).........................298
	FIGURE 4-5. CONSOLE BOX ASSEMBLIES - PQ CONTROLLERS WITH PROP TELE (MACHINES BUILT PRIOR TO SEPTEMBER 1991)............................302
	FIGURE 4-6. CONSOLE BOX ASSEMBLIES - PQ CONTROLLERS WITH PROP VALVE MACHINES BUILT SEPTEMBER 1991 TO PRESENT...........................306
	FIGURE 4-7. CONSOLE BOX ASSEMBLY - OEM CONTROLLERS.....................................................................................310
	FIGURE 4-8. CONSOLE BOX ASSEMBLY - HYDRAULIC CONTROLS..................................................................................314
	FIGURE 4-9. CAPACITY INDICATOR INSTALLATION (OPTIONAL).................................................................................318
	FIGURE 4-10. OPTIONAL COMMON PLATFORM MOUNTED COMPONENTS...............................................................................322
SECTION 5 - CYLINDER.......................................................................................................................325
	FIGURE 5-1. AXLE EXTENSION CYLINDER ASSEMBLIES - 80HX WITH FIXED AXLE..................................................................326
	FIGURE 5-2. AXLE EXTENSION CYLINDER ASSEMBLIES - 80HX WITH OSCILLATING AXLE............................................................328
	FIGURE 5-3. AXLE LIFT CYLINDER ASSEMBLY................................................................................................330
	FIGURE 5-4. AXLE LOCKOUT CYLINDER ASSEMBLY.............................................................................................332
	FIGURE 5-5. PLATFORM LEVEL CYLINDER ASSEMBLIES (MODEL 80HX/80H BUILT THROUGH 1986).....................................................334
	FIGURE 5-6. PLATFORM LEVEL CYLINDER ASSEMBLIES (MODEL 80HX/80H BUILT 1987 TO APRIL 1992)...............................................336
	FIGURE 5-7. PLATFORM LEVEL CYLINDER ASSEMBLIES (MODEL 80HX/80H BUILT APRIL 1992 TO PRESENT)............................................338
	FIGURE 5-8. SLAVE LEVEL CYLINDER ASSEMBLIES (80HX+6/86HX EXTEND-A-REACH) (Prior to SN 29914)...........................................340
	FIGURE 5-9. SLAVE LEVEL CYLINDER ASSEMBLIES (80HX+6/86HX EXTEND-A-REACH) (SN 29914 to Present).........................................342
	FIGURE 5-10. LIFT CYLINDER ASSEMBLIES - BOOM...........................................................................................344
	FIGURE 5-11. LIFT CYLINDER ASSEMBLY - EXTEND-A-REACH (80HX+6/86HX ONLY)................................................................346
	FIGURE 5-12. MASTER CYLINDER ASSEMBLY..................................................................................................348
	FIGURE 5-13. STEER CYLINDER ASSEMBLIES (80HX/80HX+6 WITH FIXED FRONT AXLE).............................................................350
	FIGURE 5-14. STEER CYLINDER ASSEMBLIES (80HX/80HX+6 WITH OSCILLATING FRONT AXLE).......................................................352
	FIGURE 5-15. STEER CYLINDER ASSEMBLY (80H 2WD).........................................................................................354
	FIGURE 5-16. STEER CYLINDER ASSEMBLIES (80H 4WD).......................................................................................356
	FIGURE 5-17. TELESCOPE CYLINDER ASSEMBLIES.............................................................................................358
	FIGURE 5-18. TIE-ROD CYLINDER ASSEMBLY (80HX/80HX+6 WITH OSCILLATING AXLE ONLY)........................................................362
	FIGURE 5-19. CYLINDER BELLOWS INSTALLATION.............................................................................................364
SECTION 6 - HYDRAULICS.....................................................................................................................367
	FIGURE 6-1. HYDRAULIC DIAGRAM LIST - 80HX/80HX+6/86HX..................................................................................368
	FIGURE 6-2. HYDRAULIC DIAGRAM LIST - 80HX/80HX+6/86HX..................................................................................370
	FIGURE 6-3. HYDRAULIC DIAGRAM - AXLE EXTENSION AND STEER (80HX/80HX+6 2WS FIXED AXLE WITHOUT TOW PACKAGE)..............................372
	FIGURE 6-4. HYDRAULIC DIAGRAM - AXLE EXTENSION AND STEER (80HX/80HX+6 2WS OSCILLATING AXLE WITHOUT TOW PACKAGE)........................374
	FIGURE 6-5. HYDRAULIC DIAGRAM - BRAKE WITH PRESSURE REDUCING VALVE (USED WITH AUSCO DRIVE BRAKES)......................................376
	FIGURE 6-6. HYDRAULIC DIAGRAM - DRIVE (2WD/2WS) - 80H-80HX-80HX+6......................................................................378
	FIGURE 6-7. HYDRAULIC DIAGRAM - DRIVE (4WD/2WS) - 80H-80HX-80HX+6......................................................................382
	FIGURE 6-8. HYDRAULIC DIAGRAM - LEVEL (80HX AND 80H)...................................................................................386
	FIGURE 6-9. HYDRAULIC DIAGRAM - LEVEL (80HX+6).........................................................................................388
	FIGURE 6-10. HYDRAULIC DIAGRAM - LIFT - 80H-80HX-80HX+6................................................................................390
	FIGURE 6-11. HYDRAULIC DIAGRAM - MANUAL DESCENT........................................................................................392
	FIGURE 6-12. HYDRAULIC DIAGRAM - OSCILLATING AXLE (80HX/80HX+6)........................................................................394
	FIGURE 6-13. HYDRAULIC DIAGRAM - PUMP (STANDARD CONTROLS)..............................................................................396
	FIGURE 6-14. HYDRAULIC DIAGRAM - PUMP (HYDRAULIC CONTROLS).............................................................................400
	FIGURE 6-15. HYDRAULIC DIAGRAM - ROTATE - 80H-80HX.....................................................................................404
	FIGURE 6-16. HYDRAULIC DIAGRAM - SEQUENCE LINE.........................................................................................406
	FIGURE 6-17. HYDRAULIC DIAGRAM - STEER (80H ONLY)......................................................................................408
	FIGURE 6-18. HYDRAULIC DIAGRAM - SWING.................................................................................................410
	FIGURE 6-19. HYDRAULIC DIAGRAM - TELESCOPE.............................................................................................412
SECTION 7 - ELECTRICAL.....................................................................................................................415
	FIGURE 7-1. ELECTRICAL DIAGRAM LIST....................................................................................................416
	FIGURE 7-2. WIRING DIAGRAM - DUAL FUEL.................................................................................................428
	FIGURE 7-3. WIRING DIAGRAM - GENERATOR (DEUTZ ENGINES).................................................................................430
	FIGURE 7-4. WIRING DIAGRAM - GENERATOR (FORD ENGINES)..................................................................................432
	FIGURE 7-5. WIRING DIAGRAM - PLATFORM CONSOLE STANDARD CONTROLS (SHEET 1 OF 2).........................................................434
	FIGURE 7-6. WIRING DIAGRAM - PLATFORM CONSOLE HYDRAULIC CONTROLS.......................................................................436
	FIGURE 7-7. WIRING DIAGRAM - STANDARD (DEUTZ ENGINE/FIXED AXLE/STANDARD CONTROLS) (SHEET 1 OF 2).......................................438
	FIGURE 7-8. WIRING DIAGRAM - STANDARD (DEUTZ ENGINE/OSCILLATING AXLE/STANDARD CONTROLS) (SHEET 1 OF 2).................................440
	FIGURE 7-9. WIRING DIAGRAM - STANDARD (DEUTZ ENGINE/HYDRAULIC CONTROLS) (SHEET 1 OF 2).................................................442
	FIGURE 7-10. WIRING DIAGRAM - STANDARD (FORD ENGINE/FIXED AXLE/STANDARD CONTROLS) (SHEET 1 OF 2).......................................444
	FIGURE 7-11. WIRING DIAGRAM - STANDARD (FORD ENGINE/OSCILLATING AXLE/STANDARD CONTROLS) (SHEET 1 OF 2).................................446
	FIGURE 7-12. WIRING DIAGRAM - STANDARD (FORD ENGINE/HYDRAULIC CONTROLS) (SHEET 1 OF 2).................................................448
SECTION 8 - DECALS.........................................................................................................................451
	FIGURE 8-1. DECALS INSTALLATION - DOMESTIC BROWN DECALS................................................................................452
	FIGURE 8-2. DECALS INSTALLATION - DOMESTIC BLACK DECALS................................................................................458
	FIGURE 8-3. DECALS INSTALLATION - COUNTRY SPEC BROWN DECALS............................................................................462
	FIGURE 8-4. DECALS INSTALLATION - COUNTRY SPEC BLACK DECALS............................................................................468
SECTION 9 - RECOMMENDED SERVICE PARTS STOCK................................................................................................471
	FIGURE 9-1. MODELS 80HX/80HX+6 (STANDARD CONTROLS) STANDARD PARTS......................................................................472
	FIGURE 9-2. MODELS 80HX/80HX+6 (STANDARD CONTROLS) VARIABLE PARTS......................................................................474
SECTION 10 - SPECIAL OPTIONS...............................................................................................................475
	FIGURE 10-1. SPECIAL OPTIONS...........................................................................................................476
	FIGURE 10-2. JAPANESE SPEC COMPONENTS..................................................................................................482
PART NUMBER INDEX..........................................................................................................................485

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