JLG Liftlux 210-25 / 245-25 Scissor Lifts Service & Maintenance Manual (CE)

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This service manual PDF download for the 210-25 / 245-25 JLG Liftlux Scissor Lifts 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. 


APPLICABLE MODELS :

JLG Liftlux 210-25
JLG Liftlux 245-25

S/N 20465 to Present
including S/N’s: 16563, 18190, 19542, 19543, 19933, 20020, 20242 & 20317


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 Specifications
    1.3 Capacities
    1.4 Engine
    1.5 Tires
    1.6 Limit Switches
    1.7 Pressure Setting
    1.8 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 (Circuit Board Code MC 716)
    5.8 Load Sensing System (LSS)
        
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 : 3121331
Total Pages : 172


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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 Specifications
    1.3 Capacities
    1.4 Engine
    1.5 Tires
    1.6 Limit Switches
        Platform Stowed/Jacks Retract Limit Switch
        High Drive Speed Cutout Limit Switch
        Maximum Drive Height Limit Switch
        Maximum Height Limit Switch
        Tilt Sensor
        Outrigger Sensors
        Oscillating Axle Limit Switch
    1.7 Pressure Setting
    1.8 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
        Torque Hub
        Roll Test
        Leak Test
        Lubricant
        Hub
        Tire Replacement
        Wheel Replacement
        Wheel Installation
    3.3 Drive Motor
        Motor Disassembly
        Motor Assembly
    3.4 Steering Assembly
    3.5 Rear Axle
        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
        Platform Extension End Rail (210-25)
        Platform Extension Side Rails (210-25)
        Main Platform End Rails (210-25)
        Main Platform Side Rails (210-25)
        Main Platform Side Rails (245-25)
        Main Platform End Rails (245-25)
        Platform Extension Side Rails (245-25)
        Platform Extension End Rail
        Platform Removal
    3.12 Ladder Installation
    3.13 Beacon Installation (Option)
    3.14 Scissor Arms
        Limit Switches
        Arm Guards
        Scissor Arm Assembly Removal
        Lift Cylinder Removal
        Scissor Arms Disassembly
        
Section 4. Hydraulics
    4.1 Cylinders - Theory of Operation
        Pump Flow
        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 Bank
        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 (Circuit Board Code MC 716)
        Functional Description
    5.8 Load Sensing System (LSS)
        LSS Re-Calibration Procedure
        
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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