JLG 80SL Scissor Lift Service & Maintenance Manual (ANSI)

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This service manual PDF download for the 80SL JLG Scissor Lift has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

TABLE OF CONTENTS :

Section A. Introduction – Maintenance Safety Precautions
A. General
B. Hydraulic System Safety
C. Maintenance

Section 1. Specifications
1.1 Operating Specifications
1.2 Dimensional Data
1.3 Capacities
1.4 Engine
1.5 Tires
1.6 Torque Requirements
1.7 Sensors
1.8 Pressure Setting
1.9 Major Component Weights
1.10 Critical Stability Weights
1.11 Lubrication
1.12 Torque Charts

Section 2. General
2.1 Machine Preparation, Inspection, and Maintenance
2.2 Service and Guidelines
2.3 Lubrication and Information
2.4 Operator Maintenance
2.5 Cylinder Drift Test
2.6 Preventive Maintenance and Inspection Schedule

Section 3. Chassis, Platform & Scissor Arms
3.1 Operating Characteristics
3.2 Wheel Assembly
3.3 Drive Motor
3.4 Steering Assembly
3.5 Rear Axle
3.6 Outrigger Cylinder Removal
3.7 Engine Compartment
3.8 Fuel Tank
3.9 Ground Control Panel
3.10 Battery Removal
3.11 Platform
3.12 Ladder Installation
3.13 Beacon Installation (Option)
3.14 Scissor Arms

Section 4. Hydraulics
4.1 Cylinders – Theory of Operation
4.2 Valves – Theory of Operation
4.3 Cylinder Checking Procedure
4.4 Cylinder Repair
4.5 Valves

Section 5. JLG Control System
5.1 Main Terminal Box Circuit Boards
5.2 Control Card Complex 2
5.3 Nivolux – Automatic Self-Leveling System
5.4 PNP5 Circuit Board
5.5 Trigger Control Circuit Card
5.6 Limit Switch & Sensor Operation
5.7 Engine Control System

Section 6. General Electrical Information & Schematics
6.1 General
6.2 Multimeter Basics
6.3 Applying Silicone Dielectric Compound To Amp Connectors
6.4 Working With Deutsch Connectors

LIST OF FIGURES
LIST OF TABLES

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : 3121325
Total Pages : 162

This service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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Section A. Introduction – Maintenance Safety Precautions
A. General
B. Hydraulic System Safety
C. Maintenance

Section 1. Specifications
1.1 Operating Specifications
1.2 Dimensional Data
1.3 Capacities
1.4 Engine
1.5 Tires
1.6 Torque Requirements
1.7 Sensors
Platform Stowed/Jacks Retract Limit Switch
High Drive Speed Cutout Limit Switch
Maximum Drive Height/Maximum Height without Outriggers Limit Switch
Maximum Height Limit Switch
Tilt Sensor
Outrigger Sensors
Oscillating Axle Limit Switch
1.8 Pressure Setting
1.9 Major Component Weights
1.10 Critical Stability Weights
1.11 Lubrication
1.12 Torque Charts

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 Operator Maintenance
2.5 Cylinder Drift Test
Platform Drift
2.6 Preventive Maintenance and Inspection Schedule

Section 3. Chassis, Platform & Scissor Arms
3.1 Operating Characteristics
Leveling Jacks
3.2 Wheel Assembly
Drive System
Drive Hub
Roll Test
Leak Test
Lubricant
Tire Replacement
Wheel Replacement
Wheel Installation
3.3 Drive Motor
Motor Disassembly
Motor Assembly
3.4 Steering Assembly
3.5 Rear Axle
Limit Switches
3.6 Outrigger Cylinder Removal
3.7 Engine Compartment
Hood Assembly
Deutz Engine
Engine Tray Slide
Glow Plugs
Engine Solenoid Fuse
Hydraulic Pump Assembly
Hydraulic Pump
Exhaust Pipe Assembly
Air Filter Assembly
Engine Removal
Hydraulic Tank
Pressure Filter
3.8 Fuel Tank
3.9 Ground Control Panel
3.10 Battery Removal
3.11 Platform
Platform Control Box
Joystick Controller
Receptacles
Main Platform Side Rails
Main Platform End Rails
Platform Extension Side Rails
Platform Extension End Rail
Platform Removal
3.12 Ladder Installation
3.13 Beacon Installation (Option)
3.14 Scissor Arms
Limit Switches
Scissor Arm Assembly Removal
Lift Cylinder Removal
Scissor Arms Disassembly

Section 4. Hydraulics
4.1 Cylinders – Theory of Operation
Deck Extension Cylinder:
Lift Cylinder:
Outrigger Cylinders:
Steer Cylinder:
4.2 Valves – Theory of Operation
Solenoid Control Valves (Bang-Bang)
Relief Valves
Crossover Relief Valves
Proportional Valve
4.3 Cylinder Checking Procedure
4.4 Cylinder Repair
Disassembly
Cleaning and Inspection
Assembly
4.5 Valves
Valve Compartment
Pressure Switch, Drive Enable
Brake Valve
Drive Valve
Main Valve Block
Pump Engage/Disengage Valve
Hand Pump
Load Holding Valve
Lift/Lower Valve Block
Platform Lower Flow Valve
Outrigger Safety Valves

Section 5. JLG Control System
5.1 Main Terminal Box Circuit Boards
5.2 Control Card Complex 2
General Description of Components and Functions
5.3 Nivolux – Automatic Self-Leveling System
Introduction
The System
Operation
NIVOLUX Board LED’s
Setting and Adjustment of the NIVOLUX Board
5.4 PNP5 Circuit Board
System
Operation
Adjustment
5.5 Trigger Control Circuit Card
Relay K1
Relay K2
Relay K3
5.6 Limit Switch & Sensor Operation
Height Limit Switches
Tilt Switch
Oscillating Axle Limit Switches
Outrigger Limit Switches
Pressure Switch
5.7 Engine Control System
Functional Description

Section 6. General Electrical Information & Schematics
6.1 General
6.2 Multimeter Basics
Grounding
Backprobing
Min/Max
Polarity
Scale
Continuity Measurement Over Long Distances
Requirements:
Procedure
6.3 Applying Silicone Dielectric Compound To Amp Connectors
Assembly
Disassembly
Wedge Lock
Service – Voltage Reading
6.4 Working With Deutsch Connectors
DT/DTP Series Assembly
DT/DTP Series Disassembly
HD30/HDP20 Series Assembly
HD30/HDP20 Series Disassembly

 

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JLG 80SL Scissor Lift Service & Maintenance Manual (ANSI).pdf

Source : Sitelux.com

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