JLG 80HX 80HX+6 Parts Manual (3120800) – PDF Download

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JLG 80HX 80HX+6 Parts Manual (3120800) – PDF Download

TABLE OF CONTENTS:

JLG 80HX 80HX+6 Parts Manual (3120800) – PDF Download

SECTION 1 - FRAME...............................................................................................  9
	FIGURE 1-1. FRAME, STEERING AND AXLE INSTALLATIONS - 2WD FIXED AXLE MACHINES................................ 10
	FIGURE 1-2. FRAME, STEERING AND AXLE INSTALLATIONS - 4WD FIXED AXLE MACHINES................................ 14
	FIGURE 1-3. FRAME, STEERING AND AXLE INSTALLATIONS - 2WD AND 4WD OSCILLATING AXLE MACHINES.................. 18
	FIGURE 1-4. REAR, STEERING AND AXLE INSTALLATIONS - 4WS MACHINES............................................ 22
	FIGURE 1-5. TIRE AND WHEEL DRIVE INSTALLATIONS - 80HX....................................................... 26
	FIGURE 1-6. DRIVE MOTOR ASSEMBLY - VICKERS (2WD/2WS FIXED FRONT AXLE MACHINES).............................. 32
	FIGURE 1-7. DRIVE MOTOR ASSEMBLY - SAUER-DANFOSS (2WD/2WS FIXED FRONT AXLE MACHINES)........................ 36
	FIGURE 1-8. DRIVE MOTOR ASSEMBLY - 2WD/4WS, 4WD/2WS AND 4WD/4WS FIXED FRONT AXLE MACHINES................... 38
	FIGURE 1-9. DRIVE MOTOR ASSEMBLY - 2WD/2WS, 2WD/4WS, 4WD/2WS AND 4WD/4WS OSCILLATING FRONT AXLE MACHINES.... 42
	FIGURE 1-10. BRAKE ASSEMBLY - AUSCO (2WD PRIOR TO JANUARY 1992)............................................. 44
	FIGURE 1-11. BRAKE ASSEMBLY - MICO (4WD PRIOR TO JULY 1991)................................................. 46
	FIGURE 1-12. BRAKE ASSEMBLY - MICO (2WD JANUARY 1992 TO PRESENT AND 4WD JULY 1991 TO PRESENT)............... 48
	FIGURE 1-13. GEAR REDUCER ASSEMBLY 2WD/2WS WITH FIXED FRONT AXLE AND ALL 2WD WITH OSCILLATING FRONT AXLE.... 52
	FIGURE 1-14. DRIVE HUB ASSEMBLIES........................................................................... 54
	FIGURE 1-15. VALVES AND SWITCHES INSTALLATIONS (FRAME MOUNTED).............................................. 58
	FIGURE 1-16. AXLE LIFT CYLINDER INSTALLATIONS............................................................... 62
	FIGURE 1-17. TOW PACKAGE INSTALLATION....................................................................... 66
SECTION 2 - TURNTABLE........................................................................................... 69
	FIGURE 2-1. BOOM, TURNTABLE AND BEARING LUBE INSTALLATION................................................... 70
	FIGURE 2-2. CONTROL VALVE INSTALLATION - VICKERS PROPORTIONAL............................................... 74
	FIGURE 2-3. CONTROL VALVE ASSEMBLY (VICKERS) (PRIOR TO OCTOBER 1994)........................................ 78
	FIGURE 2-4. CONTROL VALVE ASSEMBLY (VICKERS) (OCTOBER 1994 TO PRESENT)...................................... 82
	FIGURE 2-5. CONTROL VALVE ASSEMBLY - RACINE BANG-BANG WITH DUMP SECTION..................................... 86
	FIGURE 2-6. CONTROL VALVE ASSEMBLY - BANG-BANG WITH DUMP SECTION............................................ 90
	FIGURE 2-7. CONTROL VALVE ASSEMBLY - BANG-BANG WITH INLET RELIEF............................................ 94
	FIGURE 2-8. CONTROL VALVE ASSEMBLY - 1 SECTION BANG-BANG (80HX+6 ONLY)...................................... 96
	FIGURE 2-9. SWING DRIVE, BEARING AND LOCK INSTALLATIONS..................................................... 98
	FIGURE 2-10. SWING MOTOR ASSEMBLY - CHAR-LYNN...............................................................100
	FIGURE 2-11. SWING MOTOR ASSEMBLY - EATON...................................................................102
	FIGURE 2-12. SWING BRAKE ASSEMBLIES (PRIOR TO APRIL 1992)...................................................104
	FIGURE 2-13. SWING BRAKE ASSEMBLIES (APRIL 1992 TO PRESENT).................................................108
	FIGURE 2-14. SWING HUB ASSEMBLY.............................................................................112
	FIGURE 2-15. ROTARY COUPLING AND COLLECTOR RING ASSEMBLY AND INSTALLATION...................................114
	FIGURE 2-16. DEUTZ ENGINE INSTALLATION WITHOUT NOISE REDUCTION (BUILT PRIOR TO DECEMBER 1992)...............118
	FIGURE 2-17. DEUTZ ENGINE INSTALLATION WITH NOISE REDUCTION (BUILT DECEMBER 1992 TO PRESENT)................124
	FIGURE 2-18. ADECO THROTTLE COMPONENTS INSTALLATION - DEUTZ ENGINE MACHINES.................................130
	FIGURE 2-19. GENERATOR INSTALLATION - DEUTZ ENGINE MACHINES.................................................134
	FIGURE 2-20. FORD LSG-423 ENGINE INSTALLATIONS (PRIOR MARCH TO 1995)........................................136
	FIGURE 2-21. PRECISION GOVERNOR INSTALLATION - FORD ENGINE MACHINES BUILT PRIOR TO MARCH 1995...............142
	FIGURE 2-22. GENERATOR INSTALLATION - FORD ENGINE MACHINES BUILT PRIOR TO MARCH 1995 (OPTIONAL).............144
	FIGURE 2-23. FORD LRG423/LRG425 ENGINE INSTALLATION (MARCH 1995 TO PRESENT).................................148
	FIGURE 2-24. GENERATOR INSTALLATION - FORD MACHINES BUILT MARCH 1995 TO PRESENT.............................156
	FIGURE 2-25. DUAL FUEL INSTALLATION - FORD ENGINE MACHINES..................................................160
	FIGURE 2-26. PUMP COUPLING INSTALLATIONS....................................................................164
	FIGURE 2-27. MAIN PUMP ASSEMBLY.............................................................................168
	FIGURE 2-28. TANKS INSTALLATION.............................................................................170
	FIGURE 2-29. LP TANKS INSTALLATION..........................................................................174
	FIGURE 2-30. GROUND CONTROL COMPONENTS INSTALLATION (MACHINES BUILT PRIOR TO MAY 1994)......................176
	FIGURE 2-31. GROUND CONTROL COMPONENTS INSTALLATION (MACHINES BUILT MAY 1994 TO SN 25608)...................180
	FIGURE 2-32. GROUND CONTROL COMPONENTS INSTALLATION (MACHINE BUILT) (SN 25609 to Present)...................184
	FIGURE 2-33. ELECTRICAL COMPONENTS INSTALLATION (TURNTABLE MOUNTED).........................................188
	FIGURE 2-34. HOODS INSTALLATION (PRIOR TO DECEMBER 1992)....................................................192
	FIGURE 2-35. HOODS INSTALLATION (MACHINES BUILT DECEMBER 1992 TO PRESENT)...................................196
SECTION 3 - BOOM................................................................................................199
	FIGURE 3-1. BOOM ASSEMBLIES.................................................................................200
	FIGURE 3-2. BOOM WIPERS INSTALLATION........................................................................208
	FIGURE 3-3. EXTEND-A-REACH INSTALLATIONS....................................................................210
SECTION 4 - PLATFORMS...........................................................................................213
	FIGURE 4-1. STANDARD PLATFORM AND FOOTSWTICH INSTALLATION...................................................214
	FIGURE 4-2. LOW MOUNT PLATFORM AND FOOTSWITCH INSTALLATION..................................................220
	FIGURE 4-3. ROTATOR MOTOR ASSEMBLY..........................................................................224
	FIGURE 4-4. CONSOLE BOX ASSEMBLIES (PRIOR TO SEPTEMBER 1991)................................................226
	FIGURE 4-5. CONSOLE BOX ASSEMBLIES (SEPTEMBER 1991 TO PRESENT)..............................................230
	FIGURE 4-6. OPTIONAL COMMON PLATFORM MOUNTED COMPONENTS.....................................................236
SECTION 5 - CYLINDER............................................................................................239
	FIGURE 5-1. AXLE EXTENSION CYLINDER ASSEMBLIES - 80HX WITH FIXED AXLE.......................................240
	FIGURE 5-2. AXLE EXTENSION CYLINDER ASSEMBLIES - 80HX WITH OSCILLATING AXLE.................................242
	FIGURE 5-3. AXLE LIFT CYLINDER ASSEMBLY.....................................................................244
	FIGURE 5-4. AXLE LOCKOUT CYLINDER ASSEMBLY..................................................................246
	FIGURE 5-5. PLATFORM LEVEL CYLINDER ASSEMBLIES (MODEL 80HX BUILT PRIOR TO APRIL 1992).......................248
	FIGURE 5-6. PLATFORM LEVEL CYLINDER ASSEMBLIES (MODEL 80HX BUILT APRIL 1992 TO PRESENT).....................250
	FIGURE 5-7. SLAVE LEVEL CYLINDER ASSEMBLIES (80HX+6 EXTEND-A-REACH) (Prior to SN 29914).....................252
	FIGURE 5-8. SLAVE LEVEL CYLINDER ASSEMBLIES (80HX+6 EXTEND-A-REACH) (SN 29914 to Present)...................254
	FIGURE 5-9. LIFT CYLINDER ASSEMBLIES - BOOM.................................................................256
	FIGURE 5-10. LIFT CYLINDER ASSEMBLY - EXTEND-A-REACH (80HX+6/86HX ONLY).....................................260
	FIGURE 5-11. MASTER CYLINDER ASSEMBLY.......................................................................262
	FIGURE 5-12. STEER CYLINDER ASSEMBLIES (WITH FIXED AXLE)....................................................264
	FIGURE 5-13. STEER CYLINDER ASSEMBLIES (WITH OSCILLATING AXLE)..............................................266
	FIGURE 5-14. TELESCOPE CYLINDER ASSEMBLIES..................................................................268
	FIGURE 5-15. TIE-ROD CYLINDER ASSEMBLY (WITH OSCILLATING AXLE ONLY).........................................272
	FIGURE 5-16. CYLINDER BELLOWS INSTALLATION..................................................................274
SECTION 6 - HYDRAULICS..........................................................................................277
	FIGURE 6-1. HYDRAULIC DIAGRAM LIST..........................................................................278
	FIGURE 6-2. HYDRAULIC DIAGRAM - AXLE EXTENSION AND STEER (2WS FIXED AXLE WITHOUT TOW PACKAGE)...............280
	FIGURE 6-3. HYDRAULIC DIAGRAM - AXLE EXTENSION AND STEER (2WS OSCILLATING AXLE WITHOUT TOW PACKAGE).........282
	FIGURE 6-4. HYDRAULIC DIAGRAM - BRAKE WITH PRESSURE REDUCING VALVE (USED WITH AUSCO DRIVE BRAKES)...........284
	FIGURE 6-5. HYDRAULIC DIAGRAM - DRIVE (2WD/2WS).............................................................286
	FIGURE 6-6. HYDRAULIC DIAGRAM - DRIVE (4WD/2WS).............................................................290
	FIGURE 6-7. HYDRAULIC DIAGRAM - LEVEL (80HX)................................................................294
	FIGURE 6-8. HYDRAULIC DIAGRAM - LEVEL (80HX+6)..............................................................296
	FIGURE 6-9. HYDRAULIC DIAGRAM - LIFT........................................................................298
	FIGURE 6-10. HYDRAULIC DIAGRAM - MANUAL DESCENT (Prior to SN 25609).........................................300
	FIGURE 6-11. HYDRAULIC DIAGRAM - MANUAL DESCENT (SN 25609 to Present).......................................302
	FIGURE 6-12. HYDRAULIC DIAGRAM - OSCILLATING AXLE (80HX/80HX+6).............................................304
	FIGURE 6-13. HYDRAULIC DIAGRAM - PUMP.......................................................................306
	FIGURE 6-14. HYDRAULIC DIAGRAM - ROTATE (80HX)..............................................................310
	FIGURE 6-15. HYDRAULIC DIAGRAM - SEQUENCE LINE..............................................................312
	FIGURE 6-16. HYDRAULIC DIAGRAM - SWING......................................................................314
	FIGURE 6-17. HYDRAULIC DIAGRAM - TELESCOPE..................................................................316
SECTION 7 - ELECTRICAL..........................................................................................319
	FIGURE 7-1. ELECTRICAL DIAGRAM LIST.........................................................................320
	FIGURE 7-2. ELECTRICAL SCHEMATIC - PLATFORM (SHEET 1 OF 2)..................................................328
	FIGURE 7-3. ELECTRICAL SCHEMATIC - GROUND (SHEET 1 OF 2)....................................................330
SECTION 8 - DECALS..............................................................................................333
	FIGURE 8-1. DECALS INSTALLATION.............................................................................334
SECTION 9 - RECOMMENDED SERVICE PARTS STOCK.....................................................................341
	FIGURE 9-1. MODELS 80HX/80HX+6 (WITH DEUTZ ENGINE) STANDARD PARTS...........................................342
	FIGURE 9-2. MODELS 80HX/80HX+6 (WITH DEUTZ ENGINE) VARIABLE PARTS...........................................346
SECTION 10 - SPECIAL OPTIONS....................................................................................347
	FIGURE 10-1. SPECIAL OPTIONS................................................................................348
PART NUMBER INDEX...............................................................................................351

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