Jlg 80SL Service Manual Bedienungsanleitung

Service & Maintenance ManualModel80SL3121325March 24, 2011

vi – JLG Lift – 3121325TABLE OF CONTENTS (Continued) 4-10. Spacer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 - HYDRAULICS4-20 – JLG Lift – 3121325Main Valve Block 1234106789PLATFORMDRIVE 2LIFTINGSTEERINGLEVELINGREAR RIGHTLEVELINGREAR LEFTLEVELINGFRO

SECTION 4 - HYDRAULICS3121325 – JLG Lift – 4-21Adjust main pressure on top of the Main Pressure Block • remove the cap and attach a pressure gauge t

SECTION 4 - HYDRAULICS4-22 – JLG Lift – 3121325Hand Pump 167928313171219171415124Pump AssemblyValveAssembly6511101111111031293527303428331932201923202

SECTION 4 - HYDRAULICS3121325 – JLG Lift – 4-23 Load Holding Valve BSVALVE SCHEMATICFigure 4-42. Hand Pump Valve Schematic12Axle LockoutCylinderFigur

SECTION 4 - HYDRAULICS4-24 – JLG Lift – 3121325Lift/Lower Valve Block Platform Lower Flow Valve Lift CylinderLift/LowerValve Block123SolenoidValvesChe

SECTION 4 - HYDRAULICS3121325 – JLG Lift – 4-25Outrigger Safety Valves Safety ValveOutriggerCylinderFront Outriggers:• Operating Pressure: 116 psi (8

SECTION 4 - HYDRAULICS4-26 – JLG Lift – 3121325NOTES:

SECTION 5 - JLG CONTROL SYSTEM3121325 – JLG Lift – 5-1SECTION 5. JLG CONTROL SYSTEM5.1 MAIN TERMINAL BOX CIRCUIT BOARDS C2 J1AC2 J1BC2 J2BC2 J2ACOMPL

SECTION 5 - JLG CONTROL SYSTEM5-2 – JLG Lift– 31213255.2 CONTROL CARD COMPLEX 2 General Description of Components and FunctionsThe Complex 2 Control c

SECTION 5 - JLG CONTROL SYSTEM3121325 – JLG Lift – 5-3Table 5-1. J1 ConnectorJ1 Connector1 Drive2 Drive Height LS3Lower4Ground5Lift6Joystick Analog S

3121325 – JLG Lift – vii TABLE OF CONTENTS6-19. Electrical Schematic - Sheet 2 of 15 . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 - JLG CONTROL SYSTEM5-4 – JLG Lift– 3121325Table 5-4. Complex 2 Circuit BoardINPUT SIGNALPlatform Select Lift Select Signal + VS Start (Swit

SECTION 5 - JLG CONTROL SYSTEM3121325 – JLG Lift – 5-55.3 NIVOLUX - AUTOMATIC SELF-LEVELING SYSTEM IntroductionNormally the operation of leveling the

SECTION 5 - JLG CONTROL SYSTEM5-6 – JLG Lift– 3121325• When the system completes the leveling process(sensed angle is within 0.5° of set point in both

SECTION 5 - JLG CONTROL SYSTEM3121325 – JLG Lift – 5-7* = This input is only necessary to establish output on J1/2. after the output J1/2 is establish

SECTION 5 - JLG CONTROL SYSTEM5-8 – JLG Lift– 31213255.4 PNP5 CIRCUIT BOARDSystemThe PNP5 circuit board is an electronic printed circuitboard mounted

SECTION 5 - JLG CONTROL SYSTEM3121325 – JLG Lift – 5-9Relay K31. Energized when there is a trigger output at 3.2. The analogue input signal 4 passes t

SECTION 5 - JLG CONTROL SYSTEM5-10 – JLG Lift– 3121325• When the platform is below the maximum height, thisswitch is closed. One contact passes a 24V

SECTION 5 - JLG CONTROL SYSTEM3121325 – JLG Lift – 5-115.7 ENGINE CONTROL SYSTEM Functional DescriptionNOTE: For desciptions in ( ), refer to Figure 6

SECTION 5 - JLG CONTROL SYSTEM5-12 – JLG Lift– 3121325remains on, even if the switch resets, until the igni-tion input X1/1 (15) is recycled.8. The mo

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121325 – JLG Lift – 6-1SECTION 6. GENERAL ELECTRICAL INFORMATION & SCHEMATICS6.1 GENE

viii – JLG Lift – 3121325TABLE OF CONTENTS (Continued) LIST OF TABLESTABLE NO. TITLE PAGE NO.1-1 Operating Specifications. . . . . . . . . . . .

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-2 – JLG Lift – 3121325 Voltage Measurement Resistance MeasurementFigure 6-1. Voltage M

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121325 – JLG Lift – 6-3 Continuity Measurement Current MeasurementFigure 6-3. Continuity

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-4 – JLG Lift – 3121325Continuity Measurement Over Long DistancesWhen trying to determine

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121325 – JLG Lift – 6-56.3 APPLYING SILICONE DIELECTRIC COMPOUND TO AMP CONNECTORSSilicone

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-6 – JLG Lift – 3121325AssemblyCheck to be sure the wedge lock is in the open, or as-shipp

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121325 – JLG Lift – 6-7Figure 6-8. Connector Assembly (3 of 4)Figure 6-9. Connector Asse

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-8 – JLG Lift – 3121325Disassembly5. Insert a 4.8 mm (3/16”) wide screwdriver blade betwee

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121325 – JLG Lift – 6-9Service - Voltage ReadingDO NOT PIERCE WIRE INSULATION TO TAKE VOLT

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-10 – JLG Lift – 31213256.4 WORKING WITH DEUTSCH CONNECTORSDT/DTP Series AssemblyFigure 6-

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121325 – JLG Lift – 6-1110. Push contact straight into connector grommet until a positive

SECTION 1 - SPECIFICATIONS3121325 – JLG Lift – 1-1SECTION 1. SPECIFICATIONS 1.1 OPERATING SPECIFICATIONS 1.2 DIMENSIONAL DATA 1.3 CAPACITIES Table 1

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-12 – JLG Lift – 3121325 Electrical Schematic 4321ABCDEFDiesel 80 SL / 67 SL7865GHI4321JC

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121325 – JLG Lift – 6-136JX1/57COMPLEX 2Circuit Board Complex 2X1/15J1/12DIFF LOCKCircuit

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-14 – JLG Lift – 3121325Page: 3SCHEMATIC ELECTRICAL7LIFTLUX8654321ABCDEFDiesel 80 SL / 67

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121325 – JLG Lift – 6-15HORNX1/25PNP5/J1/2T2GNDPNP5/J1/5X1/13BRAKEX1/GNDX1/GNDHORNPNP5/J1/

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-16 – JLG Lift – 31213254321ABCDEFDiesel 80 SL / 67 SL7865GHI4321JPage: 5SCHEMATIC ELECTRI

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121325 – JLG Lift – 6-17X2/7Deutz DieselV-BeltX2/11GND 2HDNOT1314X1/41X1/7X1/1123132414NIV

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-18 – JLG Lift – 3121325X1/44 X1/48X1/53X1/54X1/3X1/55ST2ST16J+24VJ5/1 J5/3 J5/2 J6/2J6/3J

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121325 – JLG Lift – 6-19Rev ASCHEMATIC ELECTRICALDiesel 80 SL / 67 SLX 1/24PUMP 2Page 5 (o

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-20 – JLG Lift – 3121325J2STARTOUTPSTARTINPDEADOUTPDEADINPSUPPLYTRIGGER INPUTSTART INPUTTR

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121325 – JLG Lift – 6-21Lower Imput K TC 11K VS /A1BAABBABAAB4321KD2 /11KD2 /21KD2 /A1FD 3

SECTION 1 - SPECIFICATIONS1-2 – JLG Lift – 31213251.4 ENGINE 1.5 TIRES 1.6 TORQUE REQUIREMENTSNOTE: JLG recommends that once any locknut is removedfro

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-22 – JLG Lift – 31213254321ABCDEFDiesel 80 SL / 67 SL7865GHI4321JTerminals5556K1 /13 PNOZ

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121325 – JLG Lift – 6-2313143+41+2B1B70 qmmS BATTERY DISCONNECTCONTROL PANELS KEYGROUND PA

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-24 – JLG Lift – 3121325M 12M 12 M 12 M 12M 12M 12M 12Oscillating axle valvesRev DGround P

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121325 – JLG Lift – 6-25Page: 147LIFTLUX8654Rev DSCHEMATIC ELECTRICALDiesel 80 SL / 67 SLS

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-26 – JLG Lift – 3121325Page: 157LIFTLUX8654321ABCDEF7865GHI4321JNivolux-BoardIST XIST YJ6

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121325 – JLG Lift – 6-27Table 6-1. Main Terminal Box Wiring DescriptionWire NumberType Pos

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-28 – JLG Lift – 312132538 UL1569 18R K1/Y1 K1/Y2129 UL1569 18R K VS/Y1 K VS/Y239 UL1569 1

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121325 – JLG Lift – 6-29142 UL1569 18GR D16/A C2 J1B/1074 UL1569 18GR C2 J1B/11 X1/25-47

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-30 – JLG Lift – 3121325ader 3 X1/48-1ader 4 X1/49-2GGN 87 LIYYJZ5X0,5 UL OUTRIGGER 1 SWIT

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121325 – JLG Lift – 6-31ader 2 X1/37-1ader 3 X1/30-1ader 4 D24/AGGN98 LIYYJZ2X1 UL LOWERI

SECTION 1 - SPECIFICATIONS3121325 – JLG Lift – 1-31. Platform Stowed/Jacks Retract Limit Switch 5. Tilt Sensor2. High Drive Speed Cutout Limit Switch

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-32 – JLG Lift – 3121325105 LIYYJZ4X1 UL PLATFORM VALVEader 1 X1/22-1 1ader 2 X1/21B-1 2a

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121325 – JLG Lift – 6-33ader 9 X1/21B-2 PJader 10 X1/22-2 PKader 11 X1/56-2 PLader 12 X1/3

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-34 – JLG Lift – 3121325GGN NC NC121 LIYYJZ2X1 UL S. OSCILLATING AXLEader 1 PNP5 J2/3 Spl

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121325 – JLG Lift – 6-35130 UL 1569 18GR KTC/24 C2 J2B/8131 UL 1569 18GR X1/31-1 D17/A132

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-36 – JLG Lift – 3121325NOTE: Position 1 = Termination point in the Main Terminal Box (The

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121325 – JLG Lift – 6-37NOTES:

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-38 – JLG Lift – 3121325Electrical DiagramSTROBELIGHTSFigure 6-33. Electrical Diagram - P

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121325 – JLG Lift – 6-39PLATFORMCONSOLEBOXBATTERYDISCONNECTSWITCHFigure 6-34. Electrical

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-40 – JLG Lift – 3121325Hydraulic Diagram Figure 6-35. Hydraulic Components - H900067 Rev

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121325 – JLG Lift – 6-41Figure 6-36. Hydraulic Components - H900067 RevF - Sheet 2 of 2

SECTION 1 - SPECIFICATIONS1-4 – JLG Lift – 31213251.8 PRESSURE SETTINGCold temperatures have a significant impact on pressurereadings. JLG Industries

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-42 – JLG Lift – 3121325Hydraulic Schematic Figure 6-37. Hydraulic Schematic - 100109132

Corporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USA (717) 485-5161 (717) 485-6417JLG Worldwide LocationsJLG Industries (

SECTION 1 - SPECIFICATIONS3121325 – JLG Lift – 1-5Figure 1-2. Engine Operating Temperature Specifications

SECTION 1 - SPECIFICATIONS1-6 – JLG Lift – 31213251.12 TORQUE CHARTS Figure 1-3. Torque Chart (SAE Fasteners - Sheet 1 of 3)

SECTION 1 - SPECIFICATIONS3121325 – JLG Lift – 1-7Figure 1-4. Torque Chart (SAE Fasteners - Sheet 2 of 3))

SECTION 1 - SPECIFICATIONS1-8 – JLG Lift – 3121325Figure 1-5. Torque Chart (SAE Fasteners - Sheet 3 of 3)

SECTION 1 - SPECIFICATIONS3121325 – JLG Lift – 1-9Figure 1-6. Torque Chart (METRIC Fasteners - Sheet 1 of 3)

SECTION 1 - SPECIFICATIONS1-10 – JLG Lift – 3121325Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 2 of 3))

SECTION 1 - SPECIFICATIONS3121325 – JLG Lift – 1-11Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 3 of 3)

SECTION 1 - SPECIFICATIONS1-12 – JLG Lift – 3121325NOTES:

SECTION 2 - GENERAL3121325 – JLG Lift – 2-1SECTION 2. GENERAL2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCEGeneralThis section provides the nec

SECTION 2 - GENERAL2-2 – JLG Lift – 31213252.2 SERVICE AND GUIDELINESGeneralThe following information is provided to assist you in theuse and applicat

SECTION 2 - GENERAL3121325 – JLG Lift – 2-3Component Disassembly and ReassemblyWhen disassembling or reassembling a component, com-plete the procedura

SECTION 2 - GENERAL2-4 – JLG Lift – 31213252.3 LUBRICATION AND INFORMATIONHydraulic System1. The primary enemy of a hydraulic system is contam-ination

SECTION 2 - GENERAL3121325 – JLG Lift – 2-52.4 OPERATOR MAINTENANCETO AVOID PERSONAL INJURY, USE SAFETY PROPS FOR ALL MAINTENANCE REQUIRING PLATFORM T

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS3121325 – JLG Lift – aSECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSA. GENERALThis section con

SECTION 2 - GENERAL2-6 – JLG Lift – 3121325NOTE: The following numbers correspond with those inFigure 2-1., Lubrication Diagram.1. Arm Pins• Lube Poin

SECTION 2 - GENERAL3121325 – JLG Lift – 2-7b. Oil Filter• Maintenance - Replaceable Element (JLG P/N 7016331)• Interval - Change every 500 hours or 6

SECTION 2 - GENERAL2-8 – JLG Lift – 31213254. Tie Rod Ends• Lube Points - 2 Grease Fittings• Capacity - As Required•Lube - MPG• Interval - As Required

SECTION 2 - GENERAL3121325 – JLG Lift – 2-98. Fuel Tank (Opposite Engine Compartment)• Capacity - 23.8 gal (90 L)• Lube - Diesel Fuel• Interval - Chec

SECTION 2 - GENERAL2-10 – JLG Lift – 31213252.5 CYLINDER DRIFT TESTMaximum acceptable cylinder drift is to be measuredusing the following method.Platf

SECTION 2 - GENERAL3121325 – JLG Lift – 2-11Table 2-3. Preventive Maintenance and Safety InspectionAREA INTERVALDaily Weekly100 Hours(3 Months)200 Hou

SECTION 2 - GENERAL2-12 – JLG Lift – 3121325NOTES:

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3121325 – JLG Lift – 3-1SECTION 3. CHASSIS, PLATFORM & SCISSOR ARMS3.1 OPERATING CHARACTERISTICSA

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3-2 – JLG Lift – 3121325Drive HubDRIVE HUB UNITS SHOULD ALWAYS BE ROLL AND LEAKTESTED BEFORE DISASSEMB

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3121325 – JLG Lift – 3-3Tire ReplacementJLG recommends a replacement tire be the same size, plyand bra

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSb – JLG Lift – 3121325REVISION LOGOriginal Issue - February 6, 2007Revised - March 5, 2007Revised - June

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3-4 – JLG Lift – 3121325SECURE MACHINE WITH JACKS AND CHALK BLOCKS WHENREMOVING AND/OR INSTALLING WHEE

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3121325 – JLG Lift – 3-51. Torque to 354 lb ft Dry (480 Nm)2. Torque to 230.9 lb ft Dry (313 Nm)3. Tor

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3-6 – JLG Lift – 31213251124112102313231227222567171839383637151648 2 3521463140452842 3247 4149342023

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3121325 – JLG Lift – 3-73.3 DRIVE MOTOR 1234567888910111213Figure 3-5. Drive Motor (OMR 100)1. Dust S

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3-8 – JLG Lift – 3121325Motor DisassemblyNOTE: For numbers in ( ), refer to Figure 3-5., Drive Motor(O

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3121325 – JLG Lift – 3-93.4 STEERING ASSEMBLY NOTE: * = not used on later machines.Remove wheel and ti

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3-10 – JLG Lift – 31213253.5 REAR AXLELimit Switches NOTE: Limit switches are located on the front sid

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3121325 – JLG Lift – 3-113.6 OUTRIGGER CYLINDER REMOVAL NOTE: Refer to Figure 3-8., Outrigger Cylinder

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3-12 – JLG Lift – 3121325Installation:1. Carefully insert Outrigger Cylinder (16) back into theframe a

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3121325 – JLG Lift – 3-133.7 ENGINE COMPARTMENTHood Assembly NOTE: Removing the hoods will allow for e

3121325 – JLG Lift – i TABLE OF CONTENTSTABLE OF CONTENTSSUBJECT - SECTION, PARAGRAPH PAGE NO.SECTION A - INTRODUCTION - MAINTENANCE SA

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3-14 – JLG Lift – 3121325Deutz Engine 12341. Diesel Engine2. Air Filter3. Air Intake4. Hydraulic Oil T

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3121325 – JLG Lift – 3-15Engine Tray Slide The engine tray can slide outward approximately 5.9 in.(15

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3-16 – JLG Lift – 3121325Glow Plugs Engine Solenoid Fuse 1. 30 amp Fuses2. Timer Relay N63. Relay K3Fi

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3121325 – JLG Lift – 3-17Hydraulic Pump Assembly REMOVAL:1. Disconnect any hoses and/or wires on the H

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3-18 – JLG Lift – 3121325Hydraulic Pump Pump Flow• Flow from the pump to the control valve is protect

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3121325 – JLG Lift – 3-19Exhaust Pipe Assembly NOTE: In the event any or all exhaust piping needs repa

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3-20 – JLG Lift – 3121325Air Filter Assembly NOTE: Refer to Figure 3-18. when dismantling the Air Filt

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3121325 – JLG Lift – 3-21Engine Removal NOTE: Refer to Figure 3-19. when removing engine fromengine co

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3-22 – JLG Lift – 3121325Hydraulic Tank Removal:1. Close shutoff valve lever (5) to turn off flow ofhy

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3121325 – JLG Lift – 3-23Pressure Filter Removal:1. Disconnect hose(s) from the Pressure Filter (1).2.

ii – JLG Lift – 3121325TABLE OF CONTENTS (Continued) 2.5 Cylinder Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3-24 – JLG Lift – 31213253.8 FUEL TANK Removal:NOTE: Drain Fuel Tank (1) before removing. Store diesel

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3121325 – JLG Lift – 3-253.9 GROUND CONTROL PANEL Removal:DISCONNECT GROUND CONTROL PANEL (1) FROM BAT

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3-26 – JLG Lift – 31213253.10 BATTERY REMOVAL Removal:1. Disconnect and remove the Battery Cables (2,

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3121325 – JLG Lift – 3-273.11 PLATFORMPlatform Control Box For access to the inside of the platform co

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3-28 – JLG Lift – 3121325Joystick Controller Figure 3-26. JoystickTable 3-6. Joystick Specifications

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3121325 – JLG Lift – 3-29Receptacles DISCONNECT BATTERY SUPPLY ON GROUND CONTROL PANELBEFORE REMOVING

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3-30 – JLG Lift – 3121325Main Platform Side Rails NOTE: Before rails can be lowered, loosen the bolt o

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3121325 – JLG Lift – 3-31Main Platform End Rails Removal:1. If applicable, disconnect end rails (1,2,3

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3-32 – JLG Lift – 3121325Platform Extension Side Rails THE EXTENSION SIDE RAILS WEIGH APPROXIMATELY 58

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3121325 – JLG Lift – 3-33Platform Extension End Rail Removal1. If applicable, detach the end rail (1)

3121325 – JLG Lift – iii TABLE OF CONTENTSDeck Extension Cylinder: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3-34 – JLG Lift – 3121325Platform Removal Machine Stabilization:The arm stack can be supported by usin

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3121325 – JLG Lift – 3-35Platform Removal:NOTE: Procedures apply to both left and right sides.1. Suppo

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3-36 – JLG Lift – 31213253.12 LADDER INSTALLATION Removal:1. The ladder can easily be removed from th

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3121325 – JLG Lift – 3-373.13 BEACON INSTALLATION (OPTION) Removal:NOTE: Procedures apply to both the

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3-38 – JLG Lift – 31213253.14 SCISSOR ARMSLimit Switches Cam Adjustment:1. Adjust Cam 1 (5) to activat

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3121325 – JLG Lift – 3-39Scissor Arm Assembly Removal EXTREME CAUTION MUST BE USED WHILE REMOVING ANYL

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3-40 – JLG Lift – 31213254. Remove one pin from the steering linkage to gainaccess to the scissor arms

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3121325 – JLG Lift – 3-4111. Lift the arm stack up and to the front. The lift cylinder(1) is still att

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3-42 – JLG Lift – 3121325Lift Cylinder RemovalUSE CAUTION WHEN REMOVING AND MOVING THE LIFT CYLIN-DER.

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3121325 – JLG Lift – 3-43Scissor Arms DisassemblyINDIVIDUAL SCISSOR ARMS ARE HEAVY. USE CAUTION WHENRE

iv – JLG Lift – 3121325TABLE OF CONTENTS (Continued) Backprobing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS3-44 – JLG Lift – 3121325NOTES:

SECTION 4 - HYDRAULICS3121325 – JLG Lift – 4-1SECTION 4. HYDRAULICS4.1 CYLINDERS - THEORY OF OPERATIONDeck Extension Cylinder:The deck is extended an

SECTION 4 - HYDRAULICS4-2 – JLG Lift – 31213254.3 CYLINDER CHECKING PROCEDURENOTE: Cylinder check must be performed anytime a systemcomponent is repla

SECTION 4 - HYDRAULICS3121325 – JLG Lift – 4-3NOTE: Step 3 applies only to the Axle Lockout Cylinder.3. To prevent damage, remove the load check valve

SECTION 4 - HYDRAULICS4-4 – JLG Lift – 31213259. Using a spanner wrench, loosen and remove thecylinder head from the barrel. EXTREME CARE SHOULD BE TA

SECTION 4 - HYDRAULICS3121325 – JLG Lift – 4-514. Remove and discard the piston o-rings, seal rings,and, if applicable, the snap ring.15. If applicabl

SECTION 4 - HYDRAULICS4-6 – JLG Lift – 3121325Cleaning and Inspection1. Clean all parts thoroughly in an approved cleaningsolvent.2. Inspect the cylin

SECTION 4 - HYDRAULICS3121325 – JLG Lift – 4-7AssemblyNOTE: Prior to cylinder assembly, ensure that the propercylinder seal kit is used. See your JLG

SECTION 4 - HYDRAULICS4-8 – JLG Lift – 31213255. Carefully slide the piston spacer onto the cylinder-rod.6. If applicable, correctly install new o-rin

SECTION 4 - HYDRAULICS3121325 – JLG Lift – 4-9EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THECYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE RODOFF

3121325 – JLG Lift – v TABLE OF CONTENTSLIST OF FIGURESFIGURE NO. TITLE PAGE NO.1-1. Limit Switch Locations. . . . . . . . . . . . . . .

SECTION 4 - HYDRAULICS4-10 – JLG Lift – 3121325NOTE: Refer to Figure 1-3., Torque Chart (SAE Fasteners -Sheet 1 of 3) to Figure 1-8., Torque Chart (ME

SECTION 4 - HYDRAULICS3121325 – JLG Lift – 4-11221987105364112218131417161315121. Piston Rod2. Bushing3. Piston4. Piston Seal5. O-Ring6. Setscre

SECTION 4 - HYDRAULICS4-12 – JLG Lift – 312132512345678111091221. Barrel2. Bushing3. Piston4. Piston Seal5. Setscrew6. Spacer7. Head8. Head Se

SECTION 4 - HYDRAULICS3121325 – JLG Lift – 4-131234567891011121314151617181. Barrel2. O-Ring3. Cap4. Mounting Flange5. Stop6. Piston7. Snap Rin

SECTION 4 - HYDRAULICS4-14 – JLG Lift – 312132512234567891011121413221. Barrel2. Bushing3. Load Check Valve4. Piston5. Piston Seal6. Setscrew7.

SECTION 4 - HYDRAULICS3121325 – JLG Lift – 4-15123456789101112131. Barrel2. Piston3. Setscrew4. Piston Seal5. Spacer6. Head7. O-Ring8. Wiper9. O-Ring1

SECTION 4 - HYDRAULICS4-16 – JLG Lift – 3121325STRAPREMOVE ANY LOAD FROM PLATFORM. NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL IT HAS BEEN RESTRAINED

SECTION 4 - HYDRAULICS3121325 – JLG Lift – 4-174.5 VALVESValve Compartment Pressure Switch, Drive Enable 12341. Pressure Switch, Drive Enable& Br

SECTION 4 - HYDRAULICS4-18 – JLG Lift – 3121325Brake Valve Brake Valve Adjustment:12VALVE SCHEMATICAPTFigure 4-34. Brake Valve1. Torque to 5 ft lbs

SECTION 4 - HYDRAULICS3121325 – JLG Lift – 4-19Drive Valve • With no power activating the Valve Coils (1 thru 4), themachine is in 4 wheel drive low s