JLG 210-25, 245-25 Scissor Lift Service Manual
172 pages · Publication 3121331
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What's inside
From the manual's own table of contents: 287 sections, 336 entries. See sample pages (PDF, 553 KB)
General
Hydraulic System Safety
Maintenance6 topics
- Operating Specifications
- Dimensional Specifications
- Capacities
- Engine
- Tires
- 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 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 287 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
- Wheel Assembly
Drive System
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
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
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 Removal3 topics
- Ladder Installation
- Beacon Installation (Option)
- Scissor Arms
Limit Switches
Arm Guards1 topic
- TABLE OF CONTENTS Scissor Arm Assembly Removal
Lift Cylinder Removal
Scissor Arms Disassembly1 topic
- Cylinders - Theory of Operation
Pump Flow
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
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 Valves2 topics
- Main Terminal Box Circuit Boards
- Control Card Complex 2
General Description of Components and Functions1 topic
- NIVOLUX - Automatic Self-Leveling System
Introduction
The System
Operation
NIVOLUX Board LED’s
Setting and Adjustment of the NIVOLUX Board1 topic
- PNP5 Circuit Board
System
Adjustment1 topic
- Trigger Control Circuit Card
Relay K1
Relay K2
Relay K31 topic
- Limit Switch & Sensor Operation
Height Limit Switches
Tilt Switch
Oscillating Axle Limit Switches
Outrigger Limit Switches
Pressure Switch1 topic
- TABLE OF CONTENTS Engine Control System (Circuit Board Code MC 716)
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
Procedure1 topic
- Applying Silicone Dielectric Compound To Amp Connectors
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
Wheel Assembly Removal
Hub Torque Values
Torque Hub Assembly
Drive Motor
Steering Assembly
Oscillating Axle
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
Joystick
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
Beacon 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
Outrigger Cylinder Assembly
Axle Locking Cylinder Assembly
Deck Extension Cylinder Assembly (SL210-25)
Deck Extension Cylinder Assembly (SL245-25)
Arms and Platform Positioning and Support
Pressure Switch Adjustment
Brake Valve Adjustment
Main Valve Block
Pressure Test Port
Main Valve Pressure Adjustment
Hand Pump Assembly
Hand Pump Schematic
Main Terminal Box
Control Card Complex 2 Board
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 18
Electrical Schematic - Sheet 2 of 18
Electrical Schematic - Sheet 3 of 18
Electrical Schematic - Sheet 4 of 18
Electrical Schematic - Sheet 5 of 18
Electrical Schematic - Sheet 6 of 18
Electrical Schematic - Sheet 7 of 18
Electrical Schematic - Sheet 8 of 18
Electrical Schematic - Sheet 9 of 18
Electrical Schematic - Sheet 10 of 18
Electrical Schematic - Sheet 11 of 18
Electrical Schematic - Sheet 12 of 18
Electrical Schematic - Sheet 13 of 18
Electrical Schematic - Sheet 14 of 18
Electrical Schematic - Sheet 15 of 18
Electrical Schematic - Sheet 16 of 18
Electrical Schematic - Sheet 17 of 18
Electrical Schematic - Sheet 18 of 18
Electrical Components - (Sheet 1 of 2)
Electrical Components - (Sheet 2 of 2)
Hydraulic Components Diagram - H900067 RevE - Page 1 of 2
Hydraulic Components Diagram - H900067 RevE - Sheet 2 of 2
Hydraulic Schematic - 1001091321 RevC
Operating Specifications
Dimensional Specifications
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
Torque Specs
Engine Technical Data
Variable Displacement Axial Piston Pump Specs
Joystick Specifications
Plug Loading Chart
Beacon Harness MTB Connections
Steer Cylinder Specs
Outrigger Cylinder Specs
Axle Locking Cylinder Specs
Deck Extension Cylinder Specs (SL210-25)
Deck Extension Cylinder Specs (SL245-25)
J1 Connector
J2 Connector
J3 Connector
Complex 2 Circuit Board
NIVOLUX Circuit Board
PNP Circuit Board - I/O
Connector J1
Connector J2
Connector CON1
Trigger Control Circuit Board
Deutz Engine Control Board
LSS Load Height Chart
Main Terminal Box Wiring Description
Inside this manual
Real pages from this service manual (172 pages). Open the sample pages (PDF, 551 KB)
- Specifications, page 13: SECTION 1 - SPECIFICATIONS
- Troubleshooting, page 137: SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
- Diagram, page 147: 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, 172 pages
Quantity one is the manual described above.
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Other editions and similar models
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