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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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JLG Liftlux 210-25 / 245-25 Scissor Lifts Service & Maintenance Manual (CE).pdf
Source : Sitelux.com