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JLG 80HX Service Manual

JLG 80HX
176 pages
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Service and Maintenance Manual
ANSI
Model
80HX
80HX+6
80HXER
3120271
November 19, 2003

Table of Contents

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JLG 80HX Specifications

General IconGeneral
Platform Height80 ft
Gradeability45%
Working Height86 ft
Gradeability - 4WD45%
Overall Width8 ft 2 in
Wheelbase10 ft 6 in
Platform Capacity500 lbs
Platform Capacity - Unrestricted500 lbs
Ground Clearance1 ft

Summary

Section A: Introduction - Maintenance Safety Precautions

General Safety Precautions

Outlines general safety precautions to be observed during aerial platform maintenance.

Hydraulic System Safety

Details safety measures for operating and servicing high-pressure hydraulic systems.

General Maintenance Safety Rules

Covers essential safety rules and precautions applicable to all maintenance tasks.

Section 1: Specifications

Capacities

Lists fluid capacities for fuel, hydraulic oil, and torque hubs.

Component Data

Provides specifications for various engine models used in the machine.

Performance Data

Details key operational performance metrics like travel speed, boom speed, and weight.

Torque Requirements

Specifies torque values for critical fasteners in various assemblies.

Lubrication Specifications

Outlines lubrication types and intervals for machine components.

Pressure Settings

Lists hydraulic system pressure settings for different machine models and configurations.

Section 2: General

Machine Preparation, Inspection, and Maintenance

Covers procedures for preparing, inspecting, and maintaining the machine.

Service and Guidelines

Provides general service, safety, and workmanship guidelines for maintenance.

Lubrication and Information

Details hydraulic system contamination control and lubrication recommendations.

Cylinder Drift Test

Describes methods for measuring acceptable cylinder drift and testing procedures.

Preventive Maintenance and Inspection Schedule

Outlines a schedule for routine preventive maintenance and inspections.

Section 3: Chassis & Turntable

Torque Hub Procedures

Covers disassembly, cleaning, inspection, and assembly of the torque hub.

Drive Brake Maintenance

Details disassembly, cleaning, inspection, and assembly of drive brakes.

Governor Checks and Adjustments

Explains how to check and adjust engine governor settings for optimal performance.

Swing Bearing Maintenance

Covers swing bearing wear tolerance, replacement, and installation procedures.

Oscillating Axle Bleeding Procedure

Provides steps for bleeding the lockout cylinders in the oscillating axle system.

Section 4: Boom & Platform

Boom Maintenance Procedures

Outlines the steps for removing, disassembling, inspecting, assembling, and installing the boom.

Boom Chain Inspection and Adjustment

Details procedures for inspecting and adjusting boom chains for proper operation.

Capacity Indicator Calibration

Explains how to adjust the capacity indicator cable and replace decals for accurate readings.

Section 5: Hydraulics

Cylinder Checking Procedures

Describes how to check hydraulic cylinders for leaks and proper operation.

Cylinder Repair Procedures

Provides general steps for disassembling, cleaning, inspecting, and assembling hydraulic cylinders.

Cylinder Removal and Installation

Details the process for removing and installing telescope and boom lift cylinders.

Pressure Setting Procedures

Outlines procedures for setting pressure on various hydraulic valves and systems.

Section 6: Troubleshooting & Schematics

Hydraulic Circuit Checks

Guides troubleshooting of hydraulic circuits by systematically checking components.

Platform Assembly Troubleshooting

Lists common problems with the platform assembly and their probable causes and remedies.

Boom Assembly Troubleshooting

Covers troubleshooting for boom lift, extension, retraction, and swing systems.

Chassis Assembly Troubleshooting

Addresses issues related to the engine, power plant, drive system, and steering.

Hydraulic System Troubleshooting

Details common hydraulic system problems like pump noise, cavitation, and overheating.

Electrical System Troubleshooting

Covers troubleshooting for platform controls, starter system, and instruments.

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