JLG LIFTLUX 210-25, Operation And Safety Manual

Page 1: ...n 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...

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Page 3: ...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 improve...

Page 4: ...NOT AVOIDED COULD RESULT IN SERIOUS INJURY OR DEATH THIS DECAL WILL HAVE AN ORANGE BACKGROUND INDICATES A POTENTIALITY HAZARDOUS SITUATION IF NOT AVOIDED MAY RESULT IN MINOR OR MODERATE INJURY IT MAY...

Page 5: ...TANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROPERTY OR THE JLG PRODUCT Contact Produc...

Page 6: ...FOREWORD d JLG Lift 3121303 REVISION LOG Original Issue May 5 2005 Revised May 23 2005 Revised July 31 2006 Revised July 3 2008 Revised September 26 2008...

Page 7: ...CTION 2 USER RESPONSIBILITIES MACHINE PREPA RATION AND INSPECTION 2 1 PERSONNEL TRAINING 2 1 Operator Training 2 1 Training Supervision 2 1 Operator Responsibility 2 1 2 2 PREPARATION INSPECTION AND M...

Page 8: ...ERING MANUAL DESCENT 4 7 4 9 PARKING AND STOWING 4 8 4 10 LIMIT SWITCHES SAFETY DEVICES 4 8 4 11 TIE DOWN LIFT LUGS 4 9 Tie Down 4 9 Lifting 4 9 4 12 TRANSPORT AND STORAGE OF THE MACHINE 4 10 SECTION...

Page 9: ...d Inspection Points Sheet 2 2 9 3 1 Ground Control Stations 3 3 3 2 Engine Control 3 4 3 3 Platform Ground Control 3 5 3 4 Power Outriggers 3 7 3 5 Platform Control Station 3 8 3 6 Decal Location Shee...

Page 10: ...1 6 2 1 Inspection and Maintenance Table 2 3 3 1 Decal Legend 3 14 6 1 Operating Specifications 6 2 6 2 Dimensional Data 6 3 6 3 Capacities 6 3 6 4 Tire Specifications 6 3 6 5 Engine Specifications 6...

Page 11: ...been read training is accomplished and operation of the machine has been completed under the supervision of an experienced and qualified operator These sections contain the responsibilities of the ow...

Page 12: ...rkplace Inspection Precautions to avoid all hazards in the work area must be taken by the user before operation of the machine Do not operate or raise the platform from a position on trucks trailers r...

Page 13: ...s on platform deck Keep mud oil grease and other slippery substances from foot wear and platform deck 1 3 OPERATION General Do not use the machine for any purpose other than posi tioning personnel the...

Page 14: ...nd Fall Hazards JLG Industries Inc recommends that all persons in the platform wear a full body harness with a lanyard attached to an authorized lanyard anchorage point while operating this machine Fo...

Page 15: ...e caution when entering or leaving platform Ensure that the scissor arm assembly is fully lowered Face the machine when entering or leaving the platform Always maintain three point contact with the ma...

Page 16: ...lts One foot additional clearance is required for every additional 30 000 volts or less The minimum safe approach distance may be reduced if insulating barriers are installed to prevent contact and th...

Page 17: ...e maximum tire load indicated on the tire load decals located on the chassis adjacent to each wheel Do not travel on unsupported surfaces The user should be familiar with the driving surface before dr...

Page 18: ...scissor arm assembly or platform is caught so that one or more wheels are off the ground all persons must be removed before attempting to free the machine Use cranes forklift trucks or other appropria...

Page 19: ...or as necessary 1 4 TOWING LIFTING AND HAULING Never allow personnel in platform while towing lifting or hauling This machine should not be towed except in the event of emergency malfunction power fai...

Page 20: ...ttempt to move heavy parts without the aid of a mechanical device Do not allow heavy objects to rest in an unstable position Ensure adequate support is pro vided when raising components of the machine...

Page 21: ...contact with skin or clothing BATTERY FLUID IS HIGHLY CORROSIVE AVOID CONTACT WITH SKIN AND CLOTHING AT ALL TIMES IMMEDIATELY RINSE ANY CONTACTED AREA WITH CLEAN WATER AND SEEK MEDICAL ATTENTION Charg...

Page 22: ...SECTION 1 SAFETY PRECAUTIONS 1 12 JLG Lift 3121303 NOTES...

Page 23: ...the employer and government regulations 4 Use of approved fall protection equipment 5 Enough knowledge of the mechanical operation of the machine to recognize a malfunction or potential mal function 6...

Page 24: ...for further requirements for aerial work platforms The frequency of inspections and mainte nance must be increased as necessary when the machine is used in a harsh or hostile environment if the machin...

Page 25: ...Out ofservice for aperiod ofmorethan3 months or Purchased used Owner Dealer orUser QualifiedJLGMechanic ServiceandMaintenance Manual and applicableJLG inspection form Load Sensing System Verification...

Page 26: ...nd Safety Manual is enclosed in the weather resistant storage container 5 Walk Around Inspection Refer to Figure 2 1 6 Battery Charge as required 7 Fuel Combustion Engine Powered Machines Add the prop...

Page 27: ...ure the platform extension is retracted before lower ing e Ensure that all machine functions are disabled when the Emergency Stop Button is activated f Check manual descent g Check for proper lifting...

Page 28: ...6 JLG Lift 3121303 3 With the platform in the transport stowed position a Drive the machine on a level grade and stop to ensure the brakes hold b To ensure proper operation of the tilt sensor drive t...

Page 29: ...SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 3121303 JLG Lift 2 7 1 2 3 4 5 6 4 7 8 9 4 11 12 13 4 14 15 10 18 19 Figure 2 1 Walk Around Inspection Diagram...

Page 30: ...XTENSIVE MACHINE DAMAGE NOTE On each item make sure there are no loose or missing parts that they are securely fastened and that no visi ble damage exists in addition to any other criteria men tioned...

Page 31: ...e 17 Control Valve No unsupported wires or hoses no damaged or broken wires 18 Ground Controls Placard secure and legible control switches return to neutral position emergency stop switch functions pr...

Page 32: ...SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 2 10 JLG Lift 3121303 NOTES...

Page 33: ...ance of the machine It is important that all personnel who are assigned to and respon sible for the operation and maintenance of the machine undergo a thorough training program and check out period in...

Page 34: ...ibil ity and authority to shut down the machine in case of a mal function or other unsafe condition of either the machine or the job site and to request further information from his super visor or JLG...

Page 35: ...in platform is based on the following criteria 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 prope...

Page 36: ...Start Assist This push button is used to help assist starting the machine in cold temperatures overrides 6 second crank limit of Engine Start Button 2 Engine Start A push button switch that when depr...

Page 37: ...1303 JLG Lift 3 5 Platform Ground Control 2 3 4 8 7 6 5 1 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...

Page 38: ...his LED will illuminate any time the machine is tilted toward the machine front 5 Tilt Rear LED This LED will illuminate any time the machine is tilted toward the machine rear 6 Drive Cutout LED This...

Page 39: ...r selector switch positioned to ground fur nishes operating power to the ground control station In addition the switch can be used to turn off power to the function controls in the event of an emergen...

Page 40: ...STATION 1 Emergency Stop Button 2 Horn 3 Start Switch 4 Lift Drive Controller 5 Overload LED 6 Steer Switch 7 Drive Cutout LED 8 Platform Extension Drive Lift Select 9 Lift Indicator LED 10 Slow Drive...

Page 41: ...depending upon which switch is selected 5 Overload LED This LED will illuminate red when the platform becomes overloaded 6 Steer Switch Choose the direction of steering by acti vating the steer butto...

Page 42: ...rection you want to travel NOTE Tight turns are not possible while differential lock is acti vated NOTE Only slow drive is possible when the machine is in the elevated position When the platform reach...

Page 43: ...h Ends Both Ends Both Ends 5 7 18 1 2 5 3 8 30 3 1 2 6 16 Both Sides 15 5 19 1 23 11 12 14 28 10 5 22 12 11 23 1 19 6 Both Sides Both Sides Both Sides Both Sides Both Sides Both Sides Both Sides Exter...

Page 44: ...SER RESPONSIBILITIES AND MACHINE CONTROL 3 12 JLG Lift 3121303 4 Both Sides 20 4 Both Sides 13 20 Place Arrow to Left of Joystick on the Platform Control Box Each Corner 23 Figure 3 7 Decal Location S...

Page 45: ...SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3121303 JLG Lift 3 13 29 28 24 21 9 Place on the Inside of the Hood 17 Figure 3 8 Decal Location Sheet 3 of 3...

Page 46: ...1706473 1706474 8 1706472 1706472 9 1706490 1706490 10 1706482 1706482 11 1706562 1706508 12 1706563 1706507 13 1706485 1706485 14 1706512 1706512 15 1706487 1706487 16 1706564 1706498 17 1701505 1701...

Page 47: ...cated on the control panel The machine is also equipped with an audible alarm which is automati cally activated when the machine driven The allowable operation of the machine is within the follow ing...

Page 48: ...SECTION 4 MACHINE OPERATION 4 2 JLG Lift 3121303 SIDESLOPE HORIZONTAL GRADE Figure 4 1 Grade and Sideslope...

Page 49: ...red and driving is possible AS THE PROPER FUNCTIONING OF THE LIMIT SWITCHES IS VERY IMPORTANT FOR A SAFE USE OF THE MACHINE THEIR FUNCTIONING HAS TO BE CHECKED DAILY BEFORE THE START OF THE OPERATION...

Page 50: ...rom both the platform control box and the ground control box 4 Engaging the manual descent system located in the valve compartment will allow further movement NOTICE IF ALL NORMAL MOVEMENT IS PREVENTE...

Page 51: ...vated the signals of the control board will be cut off instantly and all functions will be stopped except the functions emergency descent and emergency lifting at ground level These will still work if...

Page 52: ...s not need to be running to lower the platform 4 4 AUTOMATIC SELF LEVELING The machine is equipped with an auto leveling feature that allows the operator to automatically level the machine This functi...

Page 53: ...ble moving distance After reaching the end of the neutral zone the valves drive brake and motion alarm will be activated The machine starts to move 4 6 STEERING The steer function is operated by acti...

Page 54: ...hen the platform is lowered When the platform is raised by 3 5 m 11 5 ft 210 25 and 3 7 12 1 ft 245 25 or greater only low drive is possible 2 Outrigger Interlock This switch allows the machine to be...

Page 55: ...ry to lift the machine it is possible to do so from the lifting lugs located at the four corners of the machine These lugs enable the machine to be lifted using cranes or suitable lifting devices NOTE...

Page 56: ...ged during the transport of the machine The socket at the platform must be closed whenever the control box is not plugged in This is the best way to prevent any damages due to moisture and transport t...

Page 57: ...latform Caught Overhead If the platform becomes jammed or snagged in overhead structures or equipment do not continue operation of the machine from either the platform or the ground until the operator...

Page 58: ...assistance of other personnel and equipment cranes overhead hoists etc as may be required to safely remove the danger or emergency condition 2 Other qualified personnel on the platform may use the pl...

Page 59: ...downward while activating the manual pump PLATFORM WILL CONTINUE TO DESCEND ONCE MOVEMENT IS STARTED TO STOP PLATFORM DESCENT TURN VALVE KNOB COUN TERCLOCKWISE 5 After manual lowering is complete rele...

Page 60: ...and place on the valve as shown first section from the left 3 Open valve by pulling handle down 4 While continuing to hold the valve open activate the manual pump by pumping back and fourth as shown...

Page 61: ...SPEED 5 M P H 8 K M H FOR NO LONGER THAN 30 45 MINUTES MAXIMUM TOWING GRADE 25 Prior to Towing Prior to towing the machine complete the following DO NOT TOW MACHINE WITH ENGINE OPERATING OR DRIVE HUBS...

Page 62: ...if no injury or property damage is evident JLG should be con tacted by telephone and provided with all necessary details at USA 877 JLG SAFE 877 554 7233 Europe 240 420 2661 It should be noted that f...

Page 63: ...per operation and mainte nance of this machine The maintenance portion of this section is intended as infor mation to assist the machine operator to perform daily main tenance tasks only and does not...

Page 64: ...Force 400N 90Lbf MaximumInclination 3 MaximumOperating WindSpeed 12 5m s 28mph GrossMachineWeight Approximate 15 000kg 33 069lbs 16 800kg 37 038lb Drive Speed slow 0 2 m s 0 4mph 0 2m s 0 4mph Drive...

Page 65: ...3 14m Platformdimensions extensionretracted 2 45x5 4m 8x18ft 2 45x5 4m 8x18ft Platformdimensions extensionextended 2 45x7 8m 8 26ft 2 45x7 8m 8 26ft TransportDimensions 5 77x 2 51x2 85m 19x8 2x9 3ft...

Page 66: ...DeutzD2011L04i Displacement 3108cm3 Bore 94mm Stroke 112mm FuelType Diesel Table 6 6 Engine Battery Specifications Voltage 12V Amp Hour 100 Amp 880 Table 6 7 Component Weights Description 210 25 245 2...

Page 67: ...NDED FLUIDS A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER PACKAGE IE ENGINE BLOCK HEATER ETHER INJECTION OR GLOW PLUGS BATTERY WARMER AND HYDRAULIC OIL TANK HEATER NO OP...

Page 68: ...F 82 C HYD OIL TANK TEMP NO OPERATION BELOW THIS AMBIENT TEMPERATURE DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS AND COLD WEATHER HYDRAULIC OIL BELOW THIS TEMPERATURE DO NOT START UP HYDRAUL...

Page 69: ...e of comparable vis cosities If use of hydraulic oil other than Mobilfluid 424 is desired contact JLG Industries for proper recommenda tions Lubrication Specifications Table 6 8 Hydraulic Oil HYDRAULI...

Page 70: ...TIONS AND OPERATOR MAINTENANCE 6 8 JLG Lift 3121303 6 3 OPERATOR MAINTENANCE Figure 6 3 Operator Maintenance Lubrication Diagram 1 Arm Pins 2 Outrigger Cylinders 3 Engine Compartment 4 Tie Rod End 5 S...

Page 71: ...ose in Figure 6 3 Operator Maintenance Lubrication Diagram NOTE Be sure to grease all like items on the opposite side of machine 1 Arm Pin Lube Points 36 Grease Fittings Capacity As Required Lube MPG...

Page 72: ...121303 3 Engine Compartment a Engine Oil Check Fill Lube Points Fill Cap Dip Stick Capacity See Engine Manual Lube EO SAE 20W20 Interval Every 3 months or 150 hours of operation b Air Filter Lube Poin...

Page 73: ...3 JLG Lift 6 11 c Hydraulic Oil Check Fill Lube Points Fill Cap Site Gage Capacity 260 ltr 68 7 gal Lube HO Interval Check oil daily change every 1200 hours of operation 4 Tie RodEnd Lube Points 2 Gre...

Page 74: ...OPERATOR MAINTENANCE 6 12 JLG Lift 3121303 5 Spindles Lube Points 2 Grease Fittings Capacity As Required Lube MPG Interval As required 6 Oscillating Axle Lube Points 3 Grease Fittings Capacity As Req...

Page 75: ...r tire assembly 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 ate...

Page 76: ...al Wheel diameter width and offset dimensions equal to the original Unless specifically approved by JLG Industries Inc do not replace a foam filled tire assembly with a pneumatic tire When selecting a...

Page 77: ...immediately have a service garage or dealer tighten the lug nuts to the proper torque Over tightening will result in breaking the studs or permanently deforming the mounting stud holes in the wheels T...

Page 78: ...rom Ground Control and place the platform in the fully stowed position for safety Place 120 of the machines rated load in the center of the platform and ensure that the overload visual and audible war...

Page 79: ...SECTION 7 INSPECTION AND REPAIR LOG 3121303 JLG Lift 7 1 SECTION 7 INSPECTION AND REPAIR LOG Table 7 1 Inspection and Repair Log Date Comments...

Page 80: ...SECTION 7 INSPECTION AND REPAIR LOG 7 2 JLG Lift 3121303 Table 7 1 Inspection and Repair Log Date Comments...

Page 81: ...rented units should not be included on this form Mfg Model _______________________________________________________________ Serial Number ____________________________________________________________ P...

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Page 84: ...Ihlpohl Germany 49 0 421 69 350 20 49 0 421 69 350 45 JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong 852 2639 5783 852 2639 5797 JLG Industries Italia...