JLG 210-25, 245-25 Scissor Lift Service Manual
156 pages · Publication 3121304
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What's inside
From the manual's own table of contents: 255 sections, 299 entries. See sample pages (PDF, 528 KB)
General
Hydraulic System Safety
Maintenance6 topics
- Operating Specifications
- Dimensional Data
- Capacities
- Engine
- Tires
- Limit Switches
Minimum Height Limit Switch
High Drive Speed Cutout Limit Switch
Maximum Drive Height Limit Switch
Maximum Height Limit Switch
Tilt Sensor
Outrigger Sensors
Oscillating Axle Limit Switch6 topics
- Pressure Setting
- Major Component Weights
- Critical Stability Weights
- Lubrication
- Torque Charts
- 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
Show all 255 sections
Hydraulic System
Lubrication
Battery
Lubrication and Servicing1 topic
- Lubrication and Information
Hydraulic Oil
Changing Hydraulic Oil
Lubrication Specifications2 topics
- Operator Maintenance
- TABLE OF CONTENTS Cylinder Drift Test
Platform Drift2 topics
- Preventive Maintenance and Inspection Schedule
- Operating Characteristics
Leveling Jacks1 topic
- Torque Hub
Roll Test
Leak Test
Lubricant
Tire Replacement
Wheel Replacement
Wheel Installation1 topic
- Drive Motor
Motor Disassembly
Motor Assembly2 topics
- Steering Assembly
- Rear Axle
Limit Switches2 topics
- Outrigger Cylinder Removal
- 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 Filter4 topics
- Fuel Tank
- Ground Control Panel
- Battery Removal
- Platform
Platform Control Box
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 Removal2 topics
- Ladder Installation
- Scissor Arms
Arm Guards
Scissor Arm Assembly Removal
Lift Cylinder Removal
Scissor Arms Disassembly1 topic
- Cylinders - Theory of Operation
Deck Extension Cylinder
Lift Cylinder
Outrigger Cylinders
Steer Cylinder1 topic
- Valves - Theory of Operation
Solenoid Control Valves (Bang-Bang)
Relief Valves
Crossover Relief Valves
Proportional Valve2 topics
- Cylinder Checking Procedure
- Cylinder Repair
Disassembly
Cleaning and Inspection
Assembly1 topic
- Valves
Valve Compartment
Brake Valve
Drive Valve
Main Valve Bank
Hand Pump
Steer Valve
Load Holding Valve
Lift/Lower Valve Block
Outrigger Safety Valves
Pump Engage/Disengage Valve1 topic
- Operation and Technical Data on Control Card Complex 2
General Description of Components and Functions
Joystick Controller and Drive Mode
Joystick Controller and Drive/Lift/Lower
Platform Extension - Hydraulic1 topic
- Automatic Self Leveling Device - (NIVOLUX)
Introduction
Operation
Operating Instructions and Technical Details
Nivolux Board LED’s
Exchange and Adjustment of the NIVOLUX-Board1 topic
- Engine Control System (Circuit Board Code MC 536)
Functional Description1 topic
- Load Sensing System (LSS)
LSS Re-Calibration Procedure2 topics
- General
- Multimeter Basics
Grounding
Backprobing
Min/Max
Polarity
Scale
Continuity Measurement Over Long Distances
Requirements
Procedure2 topics
- Applying Silicone Dielectric Compound To Amp Connectors
- TABLE OF CONTENTS Assembly
Wedge Lock
Service - Voltage Reading1 topic
- Working With Deutsch Connectors
DT/DTP Series Assembly
DT/DTP Series Disassembly
HD30/HDP20 Series Assembly
HD30/HDP20 Series Disassembly
Limit Switch Locations
Engine Operating Temperature Specifications
Torque Chart (SAE Fasteners - Sheet 1 of 3)
Torque Chart (SAE Fasteners - Sheet 2 of 3))
Torque Chart (SAE Fasteners - Sheet 3 of 3)
Torque Chart (METRIC Fasteners - Sheet 1 of 3)
Torque Chart (METRIC Fasteners - Sheet 2 of 3))
Torque Chart (METRIC Fasteners - Sheet 3 of 3)
Lubrication Diagram
Torque Hub
Wheel Assembly Removal
Hub Torque Values
Torque Hub Assembly
Drive Motor (OMR 100)
Steering Assembly
Oscillating Axle Limit Switches
Outrigger Cylinder Removal - (Sheet 1 of 2)
Outrigger Cylinder Removal - (Sheet 2 of 2)
Engine Solenoid
Variable Displacement Axial Piston Pump
Hydraulic Tank Removal
Pressure Filter Removal
Fuel Tank Removal
Ground Control Panel Removal
Battery Removal
Platform Receptacle Box Removal
Extension End Rail Removal (210-25)
Extension Side Rails Removal (210-25)
End Rails Removal (210-25)
Side Rails Removal (210-25)
Side Rails Removal (245-25)
End Rails Removal (245-25)
Extension Side Rails Removal (245-25)
Extension End Rail Removal (245-25)
Platform Removal - 1 of 2 - (Front of Platform)
Platform Removal - 2 of 2 (Rear of Platform)
Ladder Installation
Limit Switch Adjustment
Arm Guards Installation
Scissor Arm Removal (Left Side)
Scissor Arm Removal (Right Side)
Lift Cylinder Valve Block Removal
Load Check Valve Romoval
Safety Valve and Limit Switch Removal
Cylinder Barrel Support
Cylinder Head Removal
Cylinder Rod Support
Piston Setscrew Removal
Piston Removal
Piston Seals
Spacer Removal
Cylinder Head Seals
Bushing Installation
Rod Seal Installation
Cylinder Head Seal Installation
Cylinder Head Installation
Spacer Installation
Piston Seal Installation
Piston Installation
Piston Setscrew Installation
Rod Installation
Valve Block Installation
Load Check Valve Installation
Safety Valve and Limit Switch Installation
Lifting Cylinder Assembly
Steering Cylinder Assembly - Prior to S/N 1200009518
Steering Cylinder Assembly - S/N 1200009518 to Present
Outrigger Cylinder Assembly - Prior to S/N 01200008372
Outrigger Cylinder Assembly - S/N 01200008372 to Present
Axle Locking Cylinder Assembly - Prior to S/N 1200008372
Axle Locking Cylinder Assembly - S/N 1200008372 to Present
Deck Extension Cylinder Assembly (SL 210-25) - Prior to S/N 1200009518
Deck Extension Cylinder Assembly (SL210-25) - S/N 1200009518 to Present
Deck Extension Cylinder Assembly (245-25) - Prior to S/N 1200009518
Deck Extension Cylinder Assembly (SL245-25) - S/N 1200009518 to Present
Arms and Platform Positioning and Support
Main Valve Block
Main Valve Pressure Adjustment
Hand Pump Assembly
Hand Pump Schematic
Control Card Complex 2 Board
Platform Control Station
Nivolux Control Board
Voltage Measurement (DC)
Resistance Measurement
Continuity Measurement
Current Measurement (DC)
AMP Connector
Connector Assembly (1 of 4)
Connector Assembly (2 of 4)
Connector Assembly (3 of 4)
Connector Assembly (4 of 4)
Connector Disassembly
Connector Installation
DT/DTP Contact Installation
DT/DTP Contact Removal
HD/HDP Contact Installation
HD/HDP Locking Contacts Into Position
HD/HDP Contact Removal
HD/HDP Unlocking Contacts
Electrical Schematic - Sheet 1 of 14
Electrical Schematic - Sheet 2 of 14
Electrical Schematic - Sheet 3 of 14
Electrical Schematic - Sheet 4 of 14
Electrical Schematic - Sheet 5 of 14
Electrical Schematic - Sheet 6 of 14
Electrical Schematic - Sheet 7 of 14
Electrical Schematic - Sheet 8 of 14
Electrical Schematic - Sheet 9 of 14
Electrical Schematic - Sheet 10 of 14
Electrical Schematic - Sheet 11 of 14
Electrical Schematic - Sheet 12 of 14
Electrical Schematic - Sheet 13 of 14
Electrical Schematic - Sheet 14 of 14
Hydraulic Components Diagram - Page 1 of 2
Hydraulic Components Diagram - Sheet 2 of 2
Operating Specifications
Dimensional Data
Capacities
Engine Specifications
Engine Battery Specifications
Tire Specifications
Pressure Settings
Major Component Weights
Critical Stability Weights
Mobil Hydraulic Oil Specs
Inspection and Maintenance
Preventive Maintenance and Safety Inspection
Torque Hub Technical Specifications
Drive Motor Specs
Tightening Torques
Engine Technical Data
Variable Displacement Axial Piston Pump Specs
Steer Cylinder Specs
Outrigger Cylinder Specs
Axle Locking Cylinder Specs
Deck Extension Cylinder Specs (SL210-25)
Deck Extension Cylinder Specs (SL245-25)
Deutz Engine Control Board
LSS Load Height Chart
Inside this manual
Real pages from this service manual (156 pages). Open the sample pages (PDF, 527 KB)
- Specifications, page 13: SECTION 1 - SPECIFICATIONS
- Diagram, page 109: SECTION 4 - HYDRAULICS
- Troubleshooting, page 133: SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
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, 156 pages
Quantity one is the manual described above.
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Other editions and similar models
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