Table of Contents
Related Manuals for JLG LIFTLUX 210-25
Summary of Contents for JLG LIFTLUX 210-25
- Page 1 Operation and Safety Manual Keep this manual with the machine at all times. LIFTLUX Models 210-25 & 245-25 Prior to S/N 20465 Excluding S/N’s: 16563, 18190, 19542, 19543, 19933, 20020, 20242, & 20317 P/N - 3121303 September 26, 2008...
- Page 3 The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and operating procedures essential for the safe and proper machine operation for its intended purpose. Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without prior notification. Contact JLG Industries, Inc. for updated information.
- Page 4 ALSO ALERT AGAINST UNSAFE PRACTICES. THIS DECAL WILL HAVE WILL HAVE A RED BACKGROUND. A YELLOW BACKGROUND. INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOT AVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE AN ORANGE BACKGROUND. – JLG Lift – 3121303...
- Page 5 • Accident Reporting • Standards and Regulations THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE- Compliance Information TINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED • Product Safety Publica- JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY- tions • Questions Regarding Spe-...
- Page 6 FOREWORD REVISION LOG Original Issue - May 5, 2005 Revised - May 23, 2005 Revised - July 31, 2006 Revised - July 3, 2008 Revised - September 26, 2008 – JLG Lift – 3121303...
-
Page 7: Table Of Contents
Platform Control Descriptions ....3-9 Operator Responsibility ....2-1 3121303 – JLG Lift –... - Page 8 OPERATOR MAINTENANCE ....6-8 TIRES AND WHEELS ..... . .6-13 – JLG Lift – 3121303...
- Page 9 (Deutz) - Sheet 2 of 2 ..... . 6-6 6-3. Operator Maintenance & Lubrication Diagram . . . 6-8 3121303 – JLG Lift –...
- Page 10 Lubrication Specifications ....6-7 Inspection and Repair Log ....7-1 – JLG Lift – 3121303...
-
Page 11: Section 1. Safety Precautions
JLG Industries, Inc. the machine has been completed under the supervision of an experienced and qualified operator. -
Page 12: Workplace Inspection
JLG. approved for that purpose by JLG. • All operating personnel must be familiar with the emer- • Ensure that the ground conditions are adequate to sup-... -
Page 13: Machine Inspection
• Avoid accumulation of debris on platform deck. Keep • When two or more persons are in the platform, the opera- mud, oil, grease, and other slippery substances from foot- tor shall be responsible for all machine operations. wear and platform deck. 3121303 – JLG Lift –... -
Page 14: Trip And Fall Hazards
• Always ensure that power tools are properly stowed and never left hanging by their cord from the platform work • JLG Industries, Inc. recommends that all persons in the area. platform wear a full body harness with a lanyard attached •... -
Page 15: Electrocution Hazards
Always maintain “three point contact” with the machine, using two hands and one foot or two feet and one hand at all times during entry and exit. • Keep oil, mud, and slippery substances cleaned from footwear and the platform floor. 3121303 – JLG Lift –... -
Page 16: Minimum Safe Approach Distances (M.s.a.d.)
• The minimum safe approach distance may be reduced if insulating barriers are installed to prevent contact, and the barriers are rated for the voltage of the line being guarded. These barriers shall not be part of (or attached to) the – JLG Lift – 3121303... -
Page 17: Tipping Hazards
• Never exceed the maximum work load as specified on the platform. Keep all loads within the confines of the plat- form, unless authorized by JLG. 3121303 – JLG Lift –... -
Page 18: Crushing And Collision Hazards
• Under all travel conditions, the operator must limit travel • Approved head gear must be worn by all operating and speed according to conditions of ground surface, conges- ground personnel. – JLG Lift – 3121303... -
Page 19: Towing, Lifting, And Hauling
Maintenance Manual. It is of utmost importance that maintenance personnel pay strict attention to these precautions to avoid possible injury to personnel or damage to the machine or property. A maintenance program must be established by a 3121303 – JLG Lift –... -
Page 20: Maintenance Hazards
Do not allow heavy objects to rest in an unstable position. Ensure adequate support is pro- • Do not contact tools or other metal objects across the bat- vided when raising components of the machine. tery terminals. 1-10 – JLG Lift – 3121303... - Page 21 AREA WITH CLEAN WATER AND SEEK MEDICAL ATTENTION. • Charge batteries only in a well ventilated area. • Avoid overfilling the battery fluid level. Add distilled water to batteries only after the batteries are fully charged. 3121303 – JLG Lift – 1-11...
- Page 22 SECTION 1 - SAFETY PRECAUTIONS NOTES: 1-12 – JLG Lift – 3121303...
-
Page 23: Section 2. User Responsibilities, Machine Preparation And Inspection
4. Use of approved fall protection equipment. or the job site. 5. Enough knowledge of the mechanical operation of the machine to recognize a malfunction or potential mal- function. 3121303 – JLG Lift –... -
Page 24: Preparation, Inspection, And Maintenance
JLG INDUSTRIES, INC. RECOGNIZES A FACTORY-CERTIFIED SERVICE TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED The following table covers the periodic machine inspections THE JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PROD- and maintenance recommended by JLG Industries, Inc. UCT MODEL. -
Page 25: Inspection And Maintenance Table
At intervals as specified in the Service and Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Maintenance Maintenance Manual. Manual NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections. 3121303 – JLG Lift –... -
Page 26: Pre-Start Inspection
Refer to Section 4 for more specific instructions on the legibility. Make sure none of the decals and placards are operation of each function. missing. Make sure all illegible decals and placards are cleaned or replaced. – JLG Lift – 3121303... -
Page 27: Function Check
Check that the platform extension extends and retracts properly. NOTE: Be sure the platform extension is retracted before lower- ing. e. Ensure that all machine functions are disabled when the Emergency Stop Button is activated. 3121303 – JLG Lift –... - Page 28 Drive the machine on a level grade and stop to ensure the brakes hold. b. To ensure proper operation of the tilt sensor, drive the machine onto a tilt greater than the preset 3° and attempt to lift. – JLG Lift – 3121303...
-
Page 29: Walk - Around Inspection Diagram
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION 4 11 Figure 2-1. Walk - Around Inspection Diagram 3121303 – JLG Lift –... -
Page 30: Walk - Around Inspection Points (Sheet 1)
1. Steer Linkage - See Note. 2. Steer Cylinder - See Note Figure 2-2. Walk - Around Inspection Points (Sheet 1) – JLG Lift – 3121303... -
Page 31: Walk - Around Inspection Points (Sheet 2)
See Note 20. Platform/Handrail Installation (Not Shown) - See Note 17. Control Valve - No unsupported wires or hoses; no damaged or broken wires. Figure 2-3. Walk - Around Inspection Points (Sheet 2) 3121303 – JLG Lift –... - Page 32 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION NOTES: 2-10 – JLG Lift – 3121303...
-
Page 33: General
5. Sufficient knowledge of the mechanical operation of the sible for the operation and maintenance of the machine machine to recognize a malfunction or potential mal- undergo a thorough training program and check out period function. 3121303 – JLG Lift –... -
Page 34: Training Supervision
JLG Distributor before proceeding. – JLG Lift – 3121303... -
Page 35: Capacities
1. Machine is level and positioned on a firm supporting surface. 2. Load is within manufacturer’s rated capacity. 3. All machine systems are functioning properly. 1. Engine Control 3. Power Outrigger 2. Platform/Ground Control Figure 3-1. Ground Control Stations 3121303 – JLG Lift –... -
Page 36: Engine Control
FROM THE GROUND CONTROL STATION AS POSSIBLE. 3. Hourmeter - A meter used to measure the amount of time the machine is in use. ehbelectronics Vertragshandler Start 1. Start Assist 3. Hourmeter 2. Engine Start Figure 3-2. Engine Control – JLG Lift – 3121303... -
Page 37: Platform Ground Control
1. Platform/Ground Select (Key-switch) 2. Tilt Right LED 3. Tilt Left LED 4. Tilt Front LED 5. Tilt Rear LED 6. No Drive 7. Platform Extension Retract 8. Lift/Lower Switch Figure 3-3. Platform Ground Control 3121303 – JLG Lift –... - Page 38 6. Drive Cutout LED - This LED is illuminated when the out- riggers are used and the lift function is operated. 7. Platform Extension Retract - This push button switch is used to retract the platform deck extension if it is extended. – JLG Lift – 3121303...
-
Page 39: Power Outrigger
3. Battery Isolator Switch - The battery isolator switch is located outside the battery compartment (chassis). Rotate handle counterclockwise to disconnect power rom the battery. 1. Outrigger Select Switch 3. Battery Isolator 2. Emergency Stop Switch Figure 3-4. Power Outriggers 3121303 – JLG Lift –... -
Page 40: Platform Control Station
5. Overload LED 6. Steer Switch 7. Drive Cutout LED 8. Platform Extension/Drive/Lift Select 9. Lift Indicator LED 10. Slow Drive LED 11. Lift/Lower Enable 12. Tilt (slope) LED 13. Speed Switch Figure 3-5. Platform Control Station – JLG Lift – 3121303... -
Page 41: Platform Control Descriptions
This switch must be held for the duration of steering. 7. Drive LED - This LED light remains illuminated when the machine is in a drivable configuration. 3121303 – JLG Lift –... - Page 42 High Drive 4x4 (race car symbol) After selecting the desired speed, move the controller forward or backward depending upon the direction you want to travel. NOTE: Tight turns are not possible while differential lock is acti- vated. 3-10 – JLG Lift – 3121303...
-
Page 43: Decal Location - Sheet 1 Of 3
Both Sides Both Sides Both Ends Both Both Ends Sides Both Sides Both Sides Both Sides Both Both Exterior Sides Sides Both Ends of Cover Figure 3-6. Decal Location - Sheet 1 of 3 3121303 – JLG Lift – 3-11... -
Page 44: Decal Location - Sheet 2 Of 3
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL 4 Both Sides Both Sides Each Corner Place Arrow to Left of Joystick on the Platform Control Box Figure 3-7. Decal Location - Sheet 2 of 3 3-12 – JLG Lift – 3121303... -
Page 45: Decal Location - Sheet 3 Of 3
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Place on the Inside of the Hood Figure 3-8. Decal Location - Sheet 3 of 3 3121303 – JLG Lift – 3-13... -
Page 46: Decal Legend
1703812 1705673 1705673 25 - 27 1706473 1706474 1702773 1702773 1706472 1706472 1704885 1704885 1706490 1706490 1705515 1705515 1706482 1706482 1706562 1706508 1706563 1706507 1706485 1706485 1706512 1706512 1706487 1706487 1706564 1706498 1701505 1701505 3-14 – JLG Lift – 3121303... -
Page 47: Section 4. Machine Operation
The tilt switch cuts out lifting, driving, and steering once the machine reaches a tilt angle (slope) beyond 3° and the plat- form is raised by 1 m (3.2 ft). At this point, lowering is the only function possible. 3121303 – JLG Lift –... -
Page 48: Grade And Sideslope
SECTION 4 - MACHINE OPERATION HORIZONTAL Figure 4-1. Grade and Sideslope – JLG Lift – 3121303... -
Page 49: High Drive Speed Cutout
(12.1 ft) on the 245-25, the inclination of the axle is ignored The steering (left/right) will be controlled by a separate and driving is possible. switch, which will be non active when the machine is in lift/ lower mode. 3121303 – JLG Lift –... -
Page 50: Load Sensing System (Lss)
1. Return the platform to the retracted and lowered posi- tion by means of the manual descent system located in the valve compartment. 2. Disable the machine. 3. Have the fault assessed by a qualified JLG equipment service technician before returning to normal operation. – JLG Lift – 3121303... -
Page 51: 4.2 Operation
• The machine is equipped with a horn, which can be acti- vated from the control box. While driving, a constant acoustic signal is activated as an additional motion alarm. 3121303 – JLG Lift –... -
Page 52: Lifting And Lowering
When the automatic leveling system is activated, the drive function is cutout, the control lamps on the Nivolux-box show the results of the measurement and the outriggers start to – JLG Lift – 3121303... -
Page 53: Driving The Machine From The Platform
Refer to Section 5, ble moving distance. After reaching the end of the neutral zone, Emergency Procedures, for instructions on manual lowering. the valves "drive, brake and motion alarm" will be activated. The machine starts to move. 3121303 – JLG Lift –... -
Page 54: Parking And Stowing
21m (69 ft). 5. Scissor Protection Cage - To avoid jamming of objects in the scissor device a protective cage is designed, which by means of struts will automatically be raised, once the platform elevates. – JLG Lift – 3121303... -
Page 55: 4.11 Tie Down/Lift Lugs
These lugs enable the machine to be lifted using cranes or suitable lifting devices NOTE: If lifting becomes necessary from the lifting lugs, JLG Lift Lugs Industries Inc. recommends the use of a proper spreader Figure 4-2. -
Page 56: Transport And Storage Of The Machine
DURING TRANSPORT THE BATTERY ISOLATOR SWITCH SHOULD BE • Assure that the control box is stored in a safe and dry DISCONNECTED. location and the main joystick controller is not affected by any harsh forces. 1. Battery Isolator 4-10 – JLG Lift – 3121303... -
Page 57: Section 5. Emergency Procedures
Do not lift above 3 m (10 ft) until you are secure that all damage has been repaired, if required, and that all controls are operating correctly. 3121303 – JLG Lift –... -
Page 58: Emergency Operation
2. Other qualified personnel on the platform may use the platform controls. DO NOT CONTINUE OPERATION IF CONTROLS DO NOT FUNCTION NORMALLY. 3. Cranes, forklift trucks or other equipment which may be available are to be used to remove platform occupants – JLG Lift – 3121303... - Page 59 Turn the valve on the hand pump counterclockwise to open and push pump handle forward. Push the lever at the end of the valve bank back to the original position. 3121303 – JLG Lift –...
-
Page 60: Manual Platform Deck Retraction
2. Locate separate valve handle and place on the valve as valve. Turn the valve on the hand pump counterclock- shown (first section from the left). wise to open and push pump handle forward 3. Open valve by pulling handle down. – JLG Lift – 3121303... -
Page 61: Emergency Towing
1. Hub Connected 1. Completely lower platform. 2. Disconnect Cap 2. Disconnect drive hubs by inverting disconnect cap. (See 3. Hub Disconnected Figure 5-1.) After towing the machine, complete the fol- lowing: Figure 5-1. Drive Disconnect Hub 3121303 – JLG Lift –... -
Page 62: Incident Notification
Incident Notification It is imperative that JLG Industries, Inc. be notified immedi- ately of any incident involving a JLG product. Even if no injury or property damage is evident, JLG should be con- tacted by telephone and provided with all necessary details... -
Page 63: Section 6. General Specifications And Operator Maintenance
Preventive Maintenance and Inspection Schedule included in the Service and Maintenance Manual. Other Publications Available Specific to this Machine: Service and Maintenance Manual ..... 3121304 Illustrated Parts Manual ........3121305 3121303 – JLG Lift –... -
Page 64: Operating Specifications
(90 Lbf) Gradeability Maximum Inclination 3° Ground Clearance 0.27 m (0.9 ft) 0.27 m (0.9 ft) Maximum Operating Wind Speed 12.5 m/s (28mph) Gross Machine Weight 15,000 kg 16,800 kg (Approximate) (33,069 lbs) (37,038 lb) – JLG Lift – 3121303... -
Page 65: Dimensional Data
(8 - 26 ft) Description 210-25 245-25 Transport Dimensions 5.77 x 2.51 x 2.85 m 5.77 x 2.51 x 3.14 m Size 315/80R 22.5 (19 x 8.2 x 9.3 ft) (19 x 8.2 x 10.3 ft) 3121303 – JLG Lift –... -
Page 66: Engine
5,800 kg 5,800 kg Tires (12,787 lb) (12,787 lb) Bore 94 mm Arm Assembly 6,400 kg 7,100 kg Stroke 112 mm (14,110 lb) (15,653 lb) Fuel Type Diesel Table 6-6. Engine Battery Specifications Voltage Amp Hour – JLG Lift – 3121303... -
Page 67: Engine Operating Temperature Specifications
ENGINE WILL START AND OPERATE AT THIS TEMPERATURE GRADE WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY FUEL -20°F (-29°C) AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER WITH PACKAGE (IE. ENGINE BLOCK HEATER, ETHER INJECTION OR GLOW KEROSENE -30°F (-34°C) -
Page 68: Engine Operating Temperature Specifications
180°F (82°C) (HYD. OIL TANK TEMP. IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS THE ADDITION OF A HYDRAULIC AMBIENT AIR OIL COOLER (CONSULT JLG SERVICE) TEMPERATURE 120°F (49°C) NOTE: NO OPERATION ABOVE THIS AMBIENT TEMPERATURE PROLONGED OPERATION IN 110°F (43°C) -
Page 69: Lubrication
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Lubrication NOTE: Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not con- tain the same required additives or be of comparable vis- Hydraulic Oil cosities. -
Page 70: Operator Maintenance
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE OPERATOR MAINTENANCE 1. Arm Pins 2. Outrigger Cylinders 3. Engine Compartment 4. Tie Rod End 5. Spindles 6. Oscillating Axle Figure 6-3. Operator Maintenance & Lubrication Diagram – JLG Lift – 3121303... - Page 71 • Capacity - As Required • Lube - MPG • Lube Points - 36 Grease Fittings • Interval - As Required • Capacity - As Required • Lube - MPG • Interval - As Required 3121303 – JLG Lift –...
- Page 72 • Interval - Every 6 months or 300 hours of operation. • Capacity - See Engine Manual • Lube - EO SAE 20W20 • Interval - Every 3 months or 150 hours of operation. 6-10 – JLG Lift – 3121303...
- Page 73 • Capacity - 260 ltr (68.7 gal) • Capacity - As Required • Lube - HO • Lube - MPG • Interval - Check oil daily, change every 1200 hours of operation. • Interval - As Required 3121303 – JLG Lift – 6-11...
- Page 74 • Lube Points - 3 Grease Fittings • Capacity - As Required • Capacity - As Required • Lube - MPG • Lube - MPG • Interval - As required • Interval - As Required 6-12 – JLG Lift – 3121303...
-
Page 75: Tires And Wheels
For polyurethane foam filled tires, JLG Industries, Inc. recom- mends that when any of the following are discovered, measures must be taken to remove the JLG product from service immedi- ately and arrangements must be made for replacement of the tire or tire assembly. -
Page 76: Tire Replacement
Size changes such as JLG Parts Manual for the part number of the approved tires for a rim width, center piece location, larger or smaller diameter, particular machine and model. -
Page 77: Wheel Installation
2. Tighten nuts in the following sequence: 4. Wheel nuts should be torqued after the first 50 hours of operation and after each wheel removal. Check torque every 3 months or 150 hours of operation. 3121303 – JLG Lift – 6-15... -
Page 78: Lss Testing And Evaluation
Reduce the platform load to 100% rated load and ensure that the warnings are not active. For vehicles with multiple capacities, evaluate each operating mode with the proper rated load. 6-16 – JLG Lift – 3121303... -
Page 79: Section 7 - Inspection And Repair Log
SECTION 7 - INSPECTION AND REPAIR LOG SECTION 7. INSPECTION AND REPAIR LOG Table 7-1. Inspection and Repair Log Date Comments 3121303 – JLG Lift –... - Page 80 SECTION 7 - INSPECTION AND REPAIR LOG Table 7-1. Inspection and Repair Log Date Comments – JLG Lift – 3121303...
- Page 84 1 JLG Drive McConnellsburg PA. 17233-9533 3121303 (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) Ltd JLG France SAS P.O. Box 5119 Rua Eng. Carlos Stevenson, Bentley House Z.I. de Baulieu...
Need help?
Do you have a question about the LIFTLUX 210-25 and is the answer not in the manual?
Questions and answers