JLG 80HX, 80HX+6, 80HXER Boom Lift Service Manual
176 pages · Publication 3120271
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What's inside
From the manual's own table of contents: 214 sections, 270 entries. See sample pages (PDF, 592 KB)
General
Hydraulic System Safety
Maintenance2 topics
- Capacities
- Component Data
Engine - Ford LSG423
Engine - Deutz F4L912
Engine - Wisconsin V465D
Engine - Cummins 4B 3.9C
Engine - Ford LRG-423
Engine - Ford LRG-425
Drive System
Drive Motor Displacement Machines Built Prior to Jan. 1992
Drive Motor Displacement Machines Built from Jan. 1992 to Present
Drive Hub Ratios
Steer System
Swing System
Hydraulic Pump
Auxiliary Power Pump
Hydraulic Filter - Tank
Hydraulic Filter - Inline (Racine Valve Only)1 topic
- Performance Data
Travel Speed
Gradeability
Turning Radius (Outside)
Boom Speed (Telescope)
Boom Speed (Lift)
Show all 214 sections
Swing Speed 360°
Boom Elevation
Machine Weight
Machine Stowed Height
Machine Stowed Length
Machine Width
Maximum Tire Load
Wheelbase2 topics
- Torque Requirements
- Lubrication
Ford Engines
Deutz F4L912 Engine
Wisconsin V465D Engine
Cummins 4B 3.9C
Lubrication Specifications1 topic
- Pressure Settings
Prior to Mid 1987
80HX w/Hydraulic Controls
80HX w/Oscillating Axle3 topics
- Major Components Weights
- Cylinder Specifications
- Boom Tape
American Standard
Canadian Standard3 topics
- Critical Stability Weights
- Serial Number Location
- Machine Preparation, Inspection, and Maintenance
Preparation, Inspection, and Maintenance
Pre-Start Inspection
Pre-Delivery Inspection and Frequent Inspection
Annual Machine Inspection
Preventative Maintenance1 topic
- Service and Guidelines
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 Servicing1 topic
- Lubrication and Information
Hydraulic Oil
Changing Hydraulic Oil1 topic
- Cylinder Drift Test
Platform Drift
Cylinder Drift2 topics
- Pins and Composite Bearing Repair Guidelines
- Welding on JLG Equipment
Do the Following When Welding on JLG Equipment
Do NOT Do the Following When Welding on JLG Equipment3 topics
- Applying Silicone Dielectric Compound to Electrical Connections
- Preventive Maintenance and Inspection Schedule
- Torque Hub
Disassembly
Cleaning and Inspection
Repair
Input Shaft Assembly
Assembly2 topics
- Drive Brake, Ausco - Machines Built Prior to October 1987
- Drive Brake, Mico - Machines Built Prior to October 1987
Inspection
Bleeding3 topics
- Drive Brake, Ausco - Machines Built Prior to 1992
- Drive Brake, Mico - Machines Built From 1992 to Present
- Governor Checks and Adeco Adjustment, LRG423 & LRG425
Checks
Adjustments1 topic
- Throttle Checks and Precision Governor Adjustments, LSG-423 & LRG-425
Carburetor and Governor Adjustment1 topic
- E331 Precision Governor And Adjustments - Ford Engines
Quick-start Installations
Mounting-Actuator
Linkage
Mounting-Controller
Wiring
Power Distribution
Check-Out and Initial Start-Up Procedures
Troubleshooting
Automatic Choke Adjustment Procedure2 topics
- Automatic Choke Adjustment - Ford Engine
- Cold Weather Starting Difficulty
Checking the Carburetor
Checking the Ignition
Checking the Fuel2 topics
- Throttle Checks and Adjustments - Deutz Engine
- Swing Bearing
Turntable Bearing Mounting Bolt Condition Check
Wear Tolerance
Swing Bearing Torque Values1 topic
- Oscillating Axle Bleeding Procedure
Lockout Cylinder Bleeding (Without Holding Valves)
Lockout Cylinder Bleeding (With Holding Valves)2 topics
- Oscillating Axle Lockout Test
- Free Wheeling Option
To Disengage Drive Motors and Brakes (Free Wheel) for Towing, etc
To Engage Drive Motors and Brakes (Normal Operation)4 topics
- Spark Arrestor Mufflers
- Footswitch Adjustment
- Hydraulic Pump W/Hayes Pump Drive Coupling Lubrication
- Dual Fuel System
Changing from gasoline to LP-Gas
Changing from LP Gas to Gasoline1 topic
- Boom Maintenance
Removal
Installation1 topic
- Boom Chains
Adjusting Procedures
Inspection Procedures4 topics
- Wear Pads
- Telescope Cylinder Eccentric Bushing
- Horizontal High Speed Cutout Switch Adjustment Procedure
- Controllers
VICKERS (All Hydraulic)1 topic
- Capacity Indicator
Capacity Indicator Cable Adjustment
Capacity Indicator Boom Tape Replacement
Installation Procedure
Capacity Indicator Dial Decal Replacement
Indicator Decal Installation2 topics
- Basket Rotator Brake
- Cylinders - Theory Of Operation
Double Acting Cylinders1 topic
- Valves - Theory Of Operation
Holding Valves
Solenoid Control Valves (Bang-Bang)
Proportional Control Valve - Vickers
Main Relief Valves
Relief Valves1 topic
- Cylinder Checking Procedure
Cylinders Without Counterbalance Valves
Cylinders With Single Counterbalance Valve
Cylinders With Dual Counterbalance Valves2 topics
- Cylinder Repair
- Cylinder Removal and Installation
Telescope Cylinder Removal
Telescope Cylinder Installation
Boom Lift Cylinder Removal
Boom Lift Cylinder Installation5 topics
- Racine Proportional Air Gap Adjustment
- Pressure Setting Procedures
- General
- Troubleshooting Information
- Hydraulic Circuit Checks
Lubrication Diagram
Serial Number Locations
Torque Chart - (In/Lb - Ft/Lb). (For ASTM Fasteners)
Torque Chart (Metric Conversion) - (For ASTM Fasteners)
Torque Chart - (N, m) - (For Metric Class Fasteners)
Torque Hub Assembly
Drive Brake, Ausco - Machines Built Prior to October 1987
Drive Brake, Mico - Machines Built Prior to October 1987
Drive Brake, Ausco - Machines Built Prior to 1992
Drive Brake, Mico - Machines Built from 1992 to Present
Spring Loading
Governor Adjustment, LRG-423 & LRG-425 with Adeco
Adeco Adjustment, LRG-423 & LRG-425
Precision Governor Adjustment - LRG-423 & LRG-425 (Sheet 1 of 2)
Precision Governor Adjustment - LRG-423 & LRG-425 (Sheet 2 of 2)
Adeco Actuator Adjustments - F4L912
Swing Bearing Bolt Feeler Gauge Check
Swing Bearing Tolerance Measuring Point
Swing Bearing Tolerance Boom Placement
Swing Bearing Torquing Sequence
Boom Assembly (Sheet 1 of 2)
Boom Assembly (Sheet 2 of 2)
Typical Boom Assembly
Telescope Cylinder Eccentric Bushing
Boom Tape Replacement
Capacity Indicator Dial
Belleville Washers
Proportional Control Valve
Boom Positioning and Support - Cylinder Repair
Typical Hydraulic Cylinders (Sheet 1 of 4)
Typical Hydraulic Cylinders (Sheet 2 of 4)
Typical Hydraulic Cylinders (Sheet 3 of 4)
Typical Hydraulic Cylinders (Sheet 4 of 4)
Cylinder Barrel Support
Cylinder Rod Support
Poly-Pak Seal Installation
Racine Proportional Air Gap Adjustment, Machines Built Prior to Mid 1987
Racine Proportional Valve Pressure Setting - Prior to Mid 1987 (Sheet 1 of 2)
Racine Proportional Valve Pressure Setting - Prior to Mid 1987 (Sheet 2 of 2)
Solenoid Valve Pressure Settings - Prior to Mid 1992 with Steering Wheel
Pressure and Flow Settings - Machines Prior to Mid 1992 with Steering Wheel
Vickers Proportional Valve Pressure Setting - Mid 1992 to Present (Sheet 1 of 4)
Vickers Proportional Valve Pressure Setting - Mid 1992 to Present (Sheet 2 of 4)
Vickers Proportional Valve Pressure Setting - Mid 1992 to Present (Sheet 3 of 4)
Vickers Proportional Valve Pressure Setting - Mid 1992 to Present (Sheet 4 of 4)
Pressure Setting - All Hydraulic Machines (Sheet 1 of 4)
Pressure Setting - All Hydraulic Machines (Sheet 2 of 4)
Pressure Setting - All Hydraulic Machines (Sheet 3 of 4)
Pressure Setting - All Hydraulic Machines (Sheet 4 of 4)
Solenoid Valve Pressure Settings - Machines Built to Present
Solenoid Valve Pressure Settings - 4 Wheel Steer
Extend-A-Reach Valve Pressure and Speed Settings
Wiring Schematic Dual Fuel
Wiring Diagram - Generator (Deutz Engines)
Wiring Diagram - Generator (Ford Engine)
Wiring Diagram - Platform Console Standard Controls (Sheet 1 of 2)
Wiring Diagram - Platform Console Standard Controls (Sheet 2 of 2)
Wiring Diagram - Platform Console Hydraulic Controls
Wiring Diagram - Standard (Deutz Engine/Fixed Axle/Standard Controls) (Sheet 1 of 2)
Wiring Diagram - Standard (Deutz Engine/Fixed Axle/Standard Controls)(Sheet 2 of 2)
Wiring Diagram - Standard (Deutz Engine/Oscillating Axle/Standard Controls)(Sheet 1 of 2)
Wiring Diagram - Standard (Deutz Engine/Oscillating Axle/Standard Controls)(Sheet 2 of 2)
Wiring Diagram - Standard (Deutz Engine/Hydraulic Controls)(Sheet 1 of 2)
Wiring Diagram - Standard (Deutz Engine/Hydraulic Controls)(Sheet 2 of 2)
Wiring Diagram - Standard (Ford Engine/Fixed Axle/Standard Controls)(Sheet 1 of 2)
Wiring Diagram - Standard (Ford Engine/Fixed Axle/Standard Controls)(Sheet 2 of 2)
Wiring Diagram - Standard (Ford Engine/Oscillating Axle/Standard Controls)(Sheet 1 of 2)
Wiring Diagram - Standard (Ford Engine/Oscillating Axle/Standard Controls)(Sheet 2 of 2)
Wiring Diagram - Standard (Ford Engine/Hydraulic Controls)(Sheet 1 of 2)
Wiring Diagram - Standard (Ford Engine/Hydraulic Controls)(Sheet 2 of 2)
Hydraulic Schematic (Sheet 1 of 6)
Hydraulic Schematic (Sheet 2 of 6)
Hydraulic Schematic (Sheet 3 of 6)
Hydraulic Schematic (Sheet 4 of 6)
Hydraulic Schematic (Sheet 5 of 6)
Hydraulic Schematic (Sheet 6 of 6)
Torque Requirements
Lubrication Chart
Mobil EAL 224 H Specs
Mobil DTE 13M Specs
Major Component Weights
Cylinder Specifications
Critical Stability Weights
Inspection and Maintenance
Preventive Maintenance and Inspection Schedule
Chain Stretch Tolerance
Cylinder Piston Nut Torque Specifications
Holding Valve Torque Specification
Platform Assembly - Troubleshooting
Boom Assembly - Troubleshooting
Turntable Assembly - Troubleshooting
Chassis Assembly - Troubleshooting
Hydraulic System - Troubleshooting
Electrical System - Troubleshooting
Inside this manual
Real pages from this service manual (176 pages). Open the sample pages (PDF, 591 KB)
- Specifications, page 14: SECTION 1 - SPECIFICATIONS
- Troubleshooting, page 146: Table 6-6.Electrical System - Troubleshooting
- Diagram, page 170: Figure 6-21. Hydraulic Schematic (Sheet 3 of 6)
- Color page, page 70: SECTION 3 - CHASSIS & TURNTABLE
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the 80HX, 80HX+6 are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.
This manual: Service Manual 3120271$69.81
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This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 176 pages
Quantity one is the manual described above.
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Other editions and similar models
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