JLG LIFTLUX 210-25 Use and care manual

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

FOREWORD
3121303 – JLG Lift – a
FOREWORD
This manual is a very important tool! Keep it with the machine at all times.
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.

FOREWORD
b– JLG Lift – 3121303
SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT
AVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL
WILL HAVE A RED BACKGROUND.
INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF 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
ALSO ALERT AGAINST UNSAFE PRACTICES. THIS DECAL WILL HAVE
A YELLOW BACKGROUND.
This is the Safety Alert Symbol. It is used to alert you to the potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid possible
injury or death

FOREWORD
3121303 – JLG Lift – c
THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE-
TINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED
JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY-
RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS
PRODUCT.
NOTICE
JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE
OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES,
INC. TO ENSURE THAT THE CURRENT OWNER RECORDS ARE
UPDATED AND ACCURATE.
NOTICE
JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL
INSTANCES 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:
Product Safety and Reliability Department
JLG Industries, Inc.
13224 Fountainhead Plaza
Hagerstown, MD 21742
or Your Local JLG Office
(See addresses on rear cover)
In USA:
Toll Free: 877-JLG-SAFE (877-554-7233)
Outside USA:
Phone: [phone]
E-mail: [email protected]
For:
• Accident Reporting
• Product Safety Publica-
tions
• Current Owner Updates
• Questions Regarding
Product Safety
• Standards and Regulations
Compliance Information
• Questions Regarding Spe-
cial Product Applications
• Questions Regarding Prod-
uct Modifications

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

TABLE OF CONTENTS
3121303 – JLG Lift – i
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
SECTION - 1 - SAFETY PRECAUTIONS
1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.2 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Operator Training and Knowledge. . . . . . . . . . . 1-1
Workplace Inspection. . . . . . . . . . . . . . . . . . . . . 1-2
Machine Inspection . . . . . . . . . . . . . . . . . . . . . . 1-3
1.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Trip and Fall Hazards . . . . . . . . . . . . . . . . . . . . . 1-4
Electrocution Hazards . . . . . . . . . . . . . . . . . . . . 1-5
Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Crushing and Collision Hazards. . . . . . . . . . . . . 1-8
1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . .1-9
1.5 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Maintenance Hazards. . . . . . . . . . . . . . . . . . . . 1-10
Battery Hazards . . . . . . . . . . . . . . . . . . . . . . . . 1-10
SECTION - 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
MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3 PRE-START INSPECTION. . . . . . . . . . . . . . . . . . . . 2-4
Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
SECTION - 3 - USER RESPONSIBILITIES AND MACHINE CON-
TROL
3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . . 3-1
Operator Training . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Training Supervision . . . . . . . . . . . . . . . . . . . . . . 3-2
Operator Responsibility. . . . . . . . . . . . . . . . . . . . 3-2
3.3 OPERATING CHARACTERISTICS AND
LIMITATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Placards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.4 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . 3-3
Ground Control Stations . . . . . . . . . . . . . . . . . . . 3-3
Engine Control. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Power Outrigger . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.5 PLATFORM CONTROL STATION . . . . . . . . . . . . . 3-8
Platform Control Descriptions . . . . . . . . . . . . . . . 3-9

TABLE OF CONTENTS
ii – JLG Lift – 3121303
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
SECTION - 4 - MACHINE OPERATION
4.1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
General Description of the Functions and
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Tilt Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
High Drive Speed Cutout. . . . . . . . . . . . . . . . . . 4-3
Maximum Height Cutout . . . . . . . . . . . . . . . . . . 4-3
Maximum Drive Height Cutout. . . . . . . . . . . . . . 4-3
Oscillating Axle Limit Switch . . . . . . . . . . . . . . . 4-3
Platform Extend/Drive/Lift Select . . . . . . . . . . . . 4-3
Load Sensing System (LSS) . . . . . . . . . . . . . . . 4-4
4.2 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.3 LIFTING AND LOWERING . . . . . . . . . . . . . . . . . . . . 4-6
4.4 AUTOMATIC SELF LEVELING. . . . . . . . . . . . . . . . . 4-6
4.5 DRIVING THE MACHINE FROM THE PLATFORM . 4-7
4.6 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.7 HYDRAULIC PLATFORM EXTENSION . . . . . . . . . . 4-7
4.8 EMERGENCY LOWERING - 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 - 5 - EMERGENCY PROCEDURES
5.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Emergency Stop Switch . . . . . . . . . . . . . . . . . . . 5-1
Platform Caught Overhead. . . . . . . . . . . . . . . . . 5-1
Righting of Tipped Machine . . . . . . . . . . . . . . . . 5-1
Post-Incident Inspection . . . . . . . . . . . . . . . . . . . 5-1
5.2 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . .5-2
Operator Unable to Control Machine . . . . . . . . . 5-2
5.3 MANUAL DESCENT . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Manual Platform Deck Retraction. . . . . . . . . . . . 5-4
5.4 EMERGENCY TOWING . . . . . . . . . . . . . . . . . . . . . .5-5
Prior to Towing . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Incident Notification . . . . . . . . . . . . . . . . . . . . . . 5-6
SECTION - 6 - GENERAL SPECIFICATIONS AND OPERATOR
MAINTENANCE
6.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
6.2 OPERATING SPECIFICATIONS . . . . . . . . . . . . . . .6-2
Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . 6-3
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Component Weights . . . . . . . . . . . . . . . . . . . . . 6-4
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . .6-8
6.4 TIRES AND WHEELS . . . . . . . . . . . . . . . . . . . . . . .6-13

TABLE OF CONTENTS
3121303 – JLG Lift – iii
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-14
Wheel Replacement . . . . . . . . . . . . . . . . . . . . . 6-14
Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . 6-15
6.5 LSS TESTING AND EVALUATION . . . . . . . . . . . . .6-16
SECTION - 7 - INSPECTION AND REPAIR LOG
LIST OF FIGURES
2-1. Walk - Around Inspection Diagram. . . . . . . . . . . . . 2-7
2-2. Walk - Around Inspection Points (Sheet 1) . . . . . . 2-8
2-3. Walk - Around 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 - Sheet 1 of 3 . . . . . . . . . . . . . . . . 3-11
3-7. Decal Location - Sheet 2 of 3 . . . . . . . . . . . . . . . . 3-12
3-8. Decal Location - Sheet 3 of 3 . . . . . . . . . . . . . . . . 3-13
4-1. Grade and Sideslope . . . . . . . . . . . . . . . . . . . . . . . 4-2
4-2. Lifting and Tie Down Location . . . . . . . . . . . . . . . . 4-9
5-1. Drive Disconnect Hub. . . . . . . . . . . . . . . . . . . . . . . 5-5
6-1. Engine Operating Temperature Specifications
(Deutz) - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . 6-5
6-2. Engine Operating Temperature Specifications
(Deutz) - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . 6-6
6-3. Operator Maintenance & Lubrication Diagram . . . 6-8

TABLE OF CONTENTS
iv – JLG Lift – 3121303
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
LIST OF TABLES
1-1 Minimum Safe Approach Distances (M.S.A.D.) . . . 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 . . . . . . . . . . . . . . . . . . . . . . . 6-4
6-6 Engine Battery Specifications . . . . . . . . . . . . . . . . . 6-4
6-7 Component Weights . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6-8 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6-9 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . 6-7
7-1 Inspection and Repair Log . . . . . . . . . . . . . . . . . . .7-1