Operation and Safety Manual - JLG Industries

Operation and Safety ManualOriginal Instructions - Keep this manual with the machine at all times.

LIFTLUXModels210-25 & 245-25

S/N 20465 to Presentincluding S/N’s: 16563, 18190, 19542, 19543, 19933, 20020, 20242, & 20317

P/N - 3121330March 16, 2010

FOREWORD

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 andoperating 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 changeswithout prior notification. Contact JLG Industries, Inc. for updated information.

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FOREWORD

SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

DANGERINDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOTAVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECALWILL HAVE A RED BACKGROUND.

INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOTAVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. THISDECAL WILL HAVE AN ORANGE BACKGROUND.

CAUTIONINDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOTAVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY. IT MAYALSO ALERT AGAINST UNSAFE PRACTICES. THIS DECAL WILL HAVEA YELLOW BACKGROUND.

This is the Safety Alert Symbol. It is used to alert you to the potential personalinjury hazards. Obey all safety messages that follow this symbol to avoid possibleinjury or death

b – JLG Lift – 3121330

FOREWORD

THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE-TINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZEDJLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY-RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THISPRODUCT.

NOTICEJLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THEOWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES,INC. TO ENSURE THAT THE CURRENT OWNER RECORDS AREUPDATED AND ACCURATE.

NOTICEJLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALLINSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN ANACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNELOR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONALPROPERTY OR THE JLG PRODUCT.

Contact:

Product Safety and Reliability DepartmentJLG Industries, Inc.13224 Fountainhead PlazaHagerstown, MD 21742

or Your Local JLG Office(See addresses on manual rear cover)

In USA:

Toll Free: 877-JLG-SAFE (877-554-7233)

Outside USA:

Phone: 240-420-2661E-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

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FOREWORD

REVISION LOG

Original Issue . . . . . .. . . . . . . . . . . . . . . July 3, 2008

Revised . . . . . . . . . .. . . . . . . . . . . . . . . October 24, 2008

Revised . . . . . . . . . .. . . . . . . . . . . . . . . June 1, 2009

Revised. . . . . . . . . . .. . . . . . . . . . . . . . . March 16, 2010

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TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

SECTION - 1 - SAFETY PRECAUTIONS

1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11.2 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

Operator Training and Knowledge. . . . . . . . . . . 1-1Workplace Inspection. . . . . . . . . . . . . . . . . . . . . 1-2Machine Inspection . . . . . . . . . . . . . . . . . . . . . . 1-3

1.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3Trip and Fall Hazards . . . . . . . . . . . . . . . . . . . . . 1-4Electrocution Hazards . . . . . . . . . . . . . . . . . . . . 1-5Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . 1-7Crushing and Collision Hazards. . . . . . . . . . . . . 1-8

1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . .1-91.5 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10Maintenance Hazards. . . . . . . . . . . . . . . . . . . . 1-10Battery Hazards . . . . . . . . . . . . . . . . . . . . . . . . 1-11

SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPA-RATION AND INSPECTION

2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . .2-1Operator Training . . . . . . . . . . . . . . . . . . . . . . . . 2-1Training Supervision. . . . . . . . . . . . . . . . . . . . . . 2-1Operator Responsibility . . . . . . . . . . . . . . . . . . . 2-1

2.2 PREPARATION, INSPECTION, ANDMAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.3 PRE-START INSPECTION. . . . . . . . . . . . . . . . . . . . 2-4Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

SECTION - 3 - MACHINE CONTROLS AND INDICATORS

3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13.2 OPERATING CHARACTERISTICS AND

LIMITATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Placards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.3 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . 3-2Ground Control Stations . . . . . . . . . . . . . . . . . . . 3-2Engine Control. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Ground Control Console . . . . . . . . . . . . . . . . . . 3-6Platform Control Console . . . . . . . . . . . . . . . . . . 3-8

3.4 DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

SECTION - 4 - MACHINE OPERATION

4.1 DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14.2 STARTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14.3 LIFTING AND LOWERING . . . . . . . . . . . . . . . . . . . 4-2

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TABLE OF CONTENTS


Lifting:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Lowering: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Load Sensing System (LSS) . . . . . . . . . . . . . . . 4-3

4.4 AUTOMATIC SELF LEVELING. . . . . . . . . . . . . . . . . 4-4To retract the outriggers: . . . . . . . . . . . . . . . . . . 4-5

4.5 DRIVING THE MACHINE FROM THE PLATFORM . 4-54.6 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74.7 HYDRAULIC PLATFORM EXTENSION . . . . . . . . . . 4-74.8 EMERGENCY LOWERING - MANUAL DESCENT . 4-74.9 PARKING AND STOWING . . . . . . . . . . . . . . . . . . . . 4-74.10 TIE DOWN/LIFT LUGS. . . . . . . . . . . . . . . . . . . . . . . 4-8

Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4.11 TRANSPORT AND STORAGE OF THE MACHINE . 4-9Platform Rail Lowering Tool Procedure (245-25 Only) 4-10Main Platform Side Rails andExtension End Rail . . . . . . . . . . . . . . . . . . . . . . 4-11Main Platform End Rails/Gate andExtension Side Rails . . . . . . . . . . . . . . . . . . . . 4-14Rail Raising Procedure . . . . . . . . . . . . . . . . . . 4-15

SECTION - 5 - EMERGENCY PROCEDURES

5.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1Emergency Stop Switch . . . . . . . . . . . . . . . . . . 5-1

Platform Caught Overhead. . . . . . . . . . . . . . . . . 5-1Righting of Tipped Machine . . . . . . . . . . . . . . . . 5-1Post-Incident Inspection. . . . . . . . . . . . . . . . . . . 5-1

5.2 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . .5-2Operator Unable to Control Machine . . . . . . . . . 5-2Incident Notification . . . . . . . . . . . . . . . . . . . . . . 5-2

5.3 MANUAL PROCEDURES . . . . . . . . . . . . . . . . . . . . .5-3Manual Platform Deck Retraction. . . . . . . . . . . . 5-3Manual Descent . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.4 EMERGENCY TOWING . . . . . . . . . . . . . . . . . . . . . .5-6Prior to Towing . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

SECTION - 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

6.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16.2 OPERATING SPECIFICATIONS . . . . . . . . . . . . . . .6-2

Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . 6-3Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4Component Weights . . . . . . . . . . . . . . . . . . . . . 6-4Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . .6-86.4 TIRES AND WHEELS . . . . . . . . . . . . . . . . . . . . . . .6-16

Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-16

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TABLE OF CONTENTS


Wheel Replacement . . . . . . . . . . . . . . . . . . . . . 6-17Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . 6-17

6.5 LSS TESTING AND EVALUATION . . . . . . . . . . . . .6-186.6 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . .6-19

SECTION - 7 - INSPECTION AND REPAIR LOG

SECTION - 8 - APPENDIX

EC Declaration of Conformity forModel 210-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2EC Declaration of Conformity forModel 245-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3JLG Test Report for Model 210-25 . . . . . . . . . . . 8-4JLG Test Report for Model 245-25 . . . . . . . . . . . 8-5Transfer of Ownership Card . . . . . . . . . . . . . . . . 8-7

LIST OF FIGURES

2-1. Limit Switch Locations . . . . . . . . . . . . . . . . . . . . . . 2-72-2. Walk - Around Inspection Diagram. . . . . . . . . . . . . 2-82-3. Walk - Around Inspection Points (Sheet 1) . . . . . . 2-92-4. Walk - Around Inspection Points (Sheet 2) . . . . . 2-103-1. Ground Control Stations. . . . . . . . . . . . . . . . . . . . . 3-23-2. Engine Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33-3. Main Terminal Box . . . . . . . . . . . . . . . . . . . . . . . . . 3-43-4. Ground Control Console . . . . . . . . . . . . . . . . . . . . 3-63-5. Platform Control Console . . . . . . . . . . . . . . . . . . . . 3-83-6. Decal Location - (210-25) - Sheet 1 of 2. . . . . . . . 3-113-7. Decal Location - (210-25) - Sheet 2 of 2. . . . . . . . 3-123-8. Decal Location - (245-25) - Sheet 1 of 2. . . . . . . . 3-133-9. Decal Location - (245-25) - Sheet 2 of 2. . . . . . . . 3-144-1. Grade and Sideslope . . . . . . . . . . . . . . . . . . . . . . . 4-64-2. Lifting and Tie Down Location . . . . . . . . . . . . . . . . 4-84-3. Rail Lowering Tool (Optional) . . . . . . . . . . . . . . . . 4-105-1. Drive Disconnect Hub. . . . . . . . . . . . . . . . . . . . . . . 5-66-1. Engine Operating Temperature Specifications

(Deutz) - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . 6-56-2. Engine Operating Temperature Specifications

(Deutz) - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . 6-66-3. Operator Maintenance & Lubrication Diagram . . . 6-8

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TABLE OF CONTENTS


LIST OF TABLES

1-1 Minimum Approach Distances (M.A.D.) . . . . . . . . . 1-62-1 Inspection and Maintenance Table . . . . . . . . . . . . . 2-32-2 Cutout Switch Limits . . . . . . . . . . . . . . . . . . . . . . . . 2-63-1 Decal Legend. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-156-1 Operating Specifications . . . . . . . . . . . . . . . . . . . . . 6-26-2 Dimensional Data. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36-3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36-4 Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36-5 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . 6-46-6 Engine Battery Specifications . . . . . . . . . . . . . . . . . 6-46-7 Component Weights . . . . . . . . . . . . . . . . . . . . . . . . 6-46-8 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76-9 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . 6-77-1 Inspection and Repair Log . . . . . . . . . . . . . . . . . . . 7-1

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SECTION 1 - SAFETY PRECAUTIONS

SECTION 1. SAFETY PRECAUTIONS

1.1 GENERALThis section outlines the necessary precautions for properand safe machine usage and maintenance. In order to pro-mote proper machine usage, it is mandatory that a daily rou-tine is established based on the content of this manual. Amaintenance program, using the information provided in thismanual and the Service and Maintenance Manual, must alsobe established by a qualified person and must be followed toensure that the machine is safe to operate.

The owner/user/operator/lessor/lessee of the machineshould not accept operating responsibility until this manualhas been read, training is accomplished, and operation ofthe machine has been completed under the supervision ofan experienced and qualified operator.

These sections contain the responsibilities of the owner,user, operator, lessor, and lessee concerning safety, training,inspection, maintenance, application, and operation.If thereare any questions with regard to safety, training, inspection,maintenance, application, and operation, please contact JLGIndustries, Inc. (“JLG”).

FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED INTHIS MANUAL COULD RESULT IN MACHINE DAMAGE, PROPERTYDAMAGE, PERSONAL INJURY OR DEATH.

1.2 PRE-OPERATION

Operator Training and Knowledge• The Operators and Safety Manual must be read in its

entirety before operating the machine. For clarification,questions, or additional information regarding any por-tions of this manual, contact JLG Industries, Inc.

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• An operator must not accept operating responsibilitiesuntil adequate training has been given by competent andauthorized persons.

• Allow only those authorized and qualified personnel tooperate the machine who have demonstrated that theyunderstand the safe and proper operation and mainte-nance of the unit.

• Read, understand, and obey all DANGERS, WARNINGS,CAUTIONS, and operating instructions on the machineand in this manual.

• Ensure that the machine is to be used in a manner whichis within the scope of its intended application as deter-mined by JLG.

• All operating personnel must be familiar with the emer-gency controls and emergency operation of the machineas specified in this manual.

• Read, understand, and obey all applicable employer,local, and governmental regulations as they pertain toyour utilization and application of the machine.

Workplace 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 ontrucks, trailers, railway cars, floating vessels, scaffolds orother equipment unless the application is approved inwriting by JLG.

• Before operation, check work area for overhead hazardssuch as electric lines, bridge cranes, and other potentialoverhead obstructions.

• Check floor surfaces for holes, bumps, drop-offs, obstruc-tions, debris, concealed holes, and other potential haz-ards.

• Check the work area for hazardous locations. Do notoperate the machine in hazardous environments unlessapproved for that purpose by JLG.

• Ensure that the ground conditions are adequate to sup-port the maximum tire load indicated on the tire loaddecals located on the chassis adjacent to each wheel.

• Do not operate the machine when wind conditions exceed12.5 m/s (28 mph).

• This machine can be operated in nominal ambient tem-peratures of -15°C to 45°C (5°F to 113°F). Consult JLG tooptimize operation outside of this temperature range.

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Machine Inspection • Do not operate this machine until the inspections and

functional checks have been performed as specified inSection 2 of this manual.

• Do not operate this machine until it has been serviced andmaintained according to the maintenance and inspectionrequirements as specified in the machine’s Service andMaintenance Manual.

• Ensure all safety devices are operating properly. Modifica-tion of these devices is a safety violation.

MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORMSHALL BE MADE ONLY WITH PRIOR WRITTEN PERMISSION FROM THEMANUFACTURER.

• Do not operate any machine on which the safety orinstruction placards or decals are missing or illegible.

• Check the machine for modifications to original compo-nents. Ensure that any modifications have been approvedby JLG.

• Avoid accumulation of debris on platform deck. Keepmud, 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, their tools, and equipment.

• Before operation, the user must be familiar with themachine capabilities and operating characteristics of allfunctions.

• Never operate a malfunctioning machine. If a malfunctionoccurs, shut down the machine. Remove the unit fromservice and notify the proper authorities.

• Do not remove, modify, or disable any safety devices.

• Never slam a control switch or lever through neutral to anopposite direction. Always return switch to neutral andstop before moving the switch to the next function. Oper-ate controls with slow and even pressure.

• Do not allow personnel to tamper with or operate themachine from the ground with personnel in the platform,except in an emergency.

• Do not carry materials directly on platform railing unlessapproved by JLG.

• When two or more persons are in the platform, the opera-tor shall be responsible for all machine operations.

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• Always ensure that power tools are properly stowed andnever left hanging by their cord from the platform workarea.

• Do not assist a stuck or disabled machine by pushing orpulling except by pulling at the chassis tie-down lugs.

• Stow scissor arm assembly and shut off all power beforeleaving machine.

Trip and Fall Hazards• JLG Industries, Inc. recommends that all persons in the

platform wear a full body harness with a lanyard attachedto an authorized lanyard anchorage point while operatingthis machine. For further information regarding fall protec-tion requirements on JLG products, contact JLG Indus-tries, Inc.

• Prior to operation, ensure all gates and rails are fastenedand secured in their proper position. Identify the desig-nated lanyard anchorage point(s) at the platform andsecurely attach the lanyard. Attach only one (1) lanyardper lanyard anchorage point.

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.

• Keep both feet firmly positioned on the platform floor at alltimes. Never position ladders, boxes, steps, planks, orsimilar items on unit to provide additional reach for anypurpose.

• Never use the scissor arm assembly to gain access to orleave the platform.

• Use extreme 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 machine,using two hands and one foot or two feet and one hand atall times during entry and exit.

• Keep oil, mud, and slippery substances cleaned from foot-wear and the platform floor.

Electrocution Hazards• This machine is not insulated and does not provide pro-

tection from contact or proximity to electrical current.

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• Maintain safe clearance from electrical lines, apparatus, orany energized (exposed or insulated) parts in accordancewith the Minimum Approach Distance (M.A.D.) as speci-fied in Table 1-1.

• Allow for machine movement and electrical line swaying.• Maintain a clearance of at least 10 ft (3 m) between any

part of the machine and its occupants, their tools, andtheir equipment from any electrical line or apparatus car-rying up to 50,000 volts. One foot additional clearance isrequired for every additional 30,000 volts or less.

• The minimum approach distance may be reduced if insu-lating barriers are installed to prevent contact, and thebarriers are rated for the voltage of the line being guarded.These barriers shall not be part of (or attached to) themachine. The minimum approach distance shall be

Table 1-1.Minimum Approach Distances (M.A.D.)

Voltage Range(Phase to Phase)

MINIMUM APPROACH DISTANCEin Feet (Meters)

0 to 50KV 10 (3)

Over 50 KV to 200 KV 15 (5)

Over 200 KV to 350 KV 20 (6)

Over 350 KV to 500 KV 25 (8)

Over 500 KV to 750 KV 35 (11)

Over 750 KV to 1000 KV 45 (14)

NOTE: This requirement shall apply except whereemployer, local or governmental regulations aremore stringent.

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reduced to a distance within the designed working dimen-sions of the insulating barrier. This determination shall bemade by a qualified person in accordance with theemployer, local, or governmental requirements for workpractices near energized equipment.

DANGERDO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITEDZONE (M.A.D.). ASSUME ALL ELECTRICAL PARTS AND WIRING AREENERGIZED UNLESS KNOWN OTHERWISE.

Tipping Hazards• Ensure that the ground conditions are adequate to sup-

port the maximum tire load indicated on the tire loaddecals located on the chassis adjacent to each wheel. Donot travel on unsupported surfaces.

• The user should be familiar with the driving surface beforedriving. Do not exceed the allowable sideslope and gradewhile driving.

.

• Do not elevate platform or drive with platform elevatedwhile on or near a sloping, uneven, or soft surface. Ensuremachine is positioned on a firm, level and uniformly sup-ported surface before elevating platform or driving withthe platform in the elevated position.

• Before driving on floors, bridges, trucks, and other sur-faces, check allowable capacity of the surfaces.

• Never exceed the maximum work load as specified on theplatform. Keep all loads within the confines of the plat-form, unless authorized by JLG.

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• Keep the chassis of the machine a minimum of 0.6 m (2 ft)from holes, bumps, drop-offs, obstructions, debris, con-cealed holes, and other potential hazards at the groundlevel.

• Never attempt to use the machine as a crane. Do not tie-off machine to any adjacent structure. Never attach wire,cable, or any similar items to platform.

• Do not operate the machine when wind conditions exceedthe maximum allowable wind speed.

• Do not cover the platform sides or carry large surface-areaitems in the platform when operating outdoors. The addi-tion of such items increases the exposed wind area of themachine.

• Do not increase the platform size with unauthorized deckextensions or attachments.

• If scissor arm assembly or platform is caught so that oneor more wheels are off the ground, all persons must beremoved before attempting to free the machine. Usecranes, forklift trucks, or other appropriate equipment tostabilize machine and remove personnel.

Crushing and Collision Hazards• Approved head gear must be worn by all operating and

ground personnel.

• Keep hands and limbs out of the scissor arm assemblyduring operation.

• Watch for obstructions around machine and overheadwhen driving. Check clearances above, on sides, and bot-tom of platform when lifting or lowering platform.

• During operation, keep all body parts inside platform rail-ing.

• Always post a lookout when driving in areas where visionis obstructed.

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• Keep non-operating personnel at least 1.8 m (6 ft) awayfrom machine during all driving operations.

• Under all travel conditions, the operator must limit travelspeed according to conditions of ground surface, conges-tion, visibility, slope, location of personnel, and other fac-tors causing hazards of collision or injury to personnel.

• Be aware of stopping distances in all drive speeds. Whendriving in high speed, switch to low speed before stop-ping. Travel grades in low speed only.

• Do not use high speed drive in restricted or close quartersor when driving in reverse.

• Exercise extreme caution at all times to prevent obstaclesfrom striking or interfering with operating controls and per-sons in the platform.

• Ensure that operators of other overhead and floor levelmachines are aware of the aerial work platform’s pres-ence. Disconnect power to overhead cranes. Barricadefloor area if necessary.

• Avoid operating over ground personnel. Warn personnelnot to work, stand, or walk under a raised platform. Posi-tion barricades on floor 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 ofemergency, malfunction, power failure, or loading/unload-ing. Refer to emergency towing procedures.

• Ensure platform is fully retracted and completely empty oftools prior to towing, lifting or hauling.

• When lifting machine with a forklift, position forks only atdesignated areas of the machine. Lift with a forklift of ade-quate capacity.

• Refer to Section 4 for lifting information.

3121330 – JLG Lift – 1-9


1.5 MAINTENANCE

GeneralThis section contains general safety precautions which mustbe observed during maintenance of this machine. Additionalprecautions to be observed during machine maintenanceare inserted at the appropriate points in this manual and inthe Service and Maintenance Manual. It is of utmost impor-tance that maintenance personnel pay strict attention tothese precautions to avoid possible injury to personnel ordamage to the machine or property. A maintenance programmust be established by a qualified person and must be fol-lowed to ensure the machine is safe.

Maintenance Hazards• Shut off power to all controls and ensure that all operating

systems are secured from inadvertent motion prior to per-forming any adjustments or repairs.

• Never work under an elevated platform until it has beenfully lowered to the full down position, if possible, or other-wise supported and restrained from movement withappropriate safety props, blocking, or overhead supports.

• Always relieve hydraulic pressure from all hydraulic cir-cuits before loosening or removing hydraulic compo-nents.

• Always disconnect batteries when servicing electricalcomponents or when performing welding on the machine.

• Shut down the engine (if equipped) while fuel tanks arebeing filled.

• Ensure replacement parts or components are identical orequivalent to original parts or components.

• Never attempt to move heavy parts without the aid of amechanical device. Do not allow heavy objects to rest inan unstable position. Ensure adequate support is pro-vided when raising components of the machine.

• Remove all rings, watches, and jewelry when performingany maintenance. Do not wear loose fitting clothing orlong hair unrestrained which may become caught orentangled in equipment.

• Use only clean approved non-flammable cleaning sol-vents.

• Never alter, remove, or substitute any items such as coun-terweights, tires, batteries, platforms or other items thatmay reduce or affect the overall weight or stability of themachine.

• Reference the Service and Maintenance Manual for theweights of critical stability items.

1-10 – JLG Lift – 3121330


MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORMSHALL BE MADE ONLY WITH PRIOR WRITTEN PERMISSION FROM THEMANUFACTURER.

Battery Hazards• Always disconnect batteries when servicing electrical

components or when performing welding on the machine.

• Do not allow smoking, open flame, or sparks near batteryduring charging or servicing.

• Do not contact tools or other metal objects across the bat-tery terminals.

• Always wear hand, eye, and face protection when servic-ing batteries. Ensure that battery acid does not come incontact with skin or clothing.

BATTERY FLUID IS HIGHLY CORROSIVE. AVOID CONTACT WITH SKINAND CLOTHING AT ALL TIMES. IMMEDIATELY RINSE ANY CONTACTEDAREA WITH CLEAN WATER AND SEEK MEDICAL ATTENTION.

• Charge batteries only in a well ventilated area.

• Avoid overfilling the battery fluid level. Add distilled waterto batteries only after the batteries are fully charged.

3121330 – JLG Lift – 1-11


NOTES:

1-12 – JLG Lift – 3121330

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION

SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION

2.1 PERSONNEL TRAININGThe aerial platform is a personnel handling device; so it isnecessary that it be operated and maintained only by trainedpersonnel.

Persons under the influence of drugs or alcohol or who aresubject to seizures, dizziness or loss of physical control mustnot operate this machine.

Operator TrainingOperator training must cover:

1. Use and limitations of the controls in the platform and at the ground, emergency controls and safety systems.

2. Control labels, instructions, and warnings on the machine.

3. Rules of 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. The safest means to operate the machine where over-head obstructions, other moving equipment, and obsta-cles, depressions, holes, or drop-offs will not affect the safe operation.

7. Means to avoid the hazards of unprotected electrical conductors.

8. Specific job requirements or machine application.

Training SupervisionTraining must be done under the supervision of a qualifiedperson in an open area free of obstructions until the traineehas developed the ability to safely control and operate themachine.

Operator ResponsibilityThe operator must be instructed that he/she has the respon-sibility and authority to shut down the machine in case of amalfunction or other unsafe condition of either the machineor the job site.

3121330 – JLG Lift – 2-1


2.2 PREPARATION, INSPECTION, AND MAINTENANCE

The following table covers the periodic machine inspectionsand maintenance recommended by JLG Industries, Inc.Consult local regulations for further requirements for aerialwork platforms. The frequency of inspections and mainte-nance must be increased as necessary when the machine isused in a harsh or hostile environment, if the machine isused with increased frequency, or if the machine is used in asevere manner.

NOTICEJLG INDUSTRIES, INC. RECOGNIZES A FACTORY-CERTIFIED SERVICETECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETEDTHE JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PROD-UCT MODEL.

2-2 – JLG Lift – 3121330


Table 2-1.Inspection and Maintenance Table

Type FrequencyPrimary

ResponsibilityService

QualificationReference

Pre-Start InspectionBefore using each day; or whenever there’s an Operator change.

User or Operator User or Operator Operator and Safety Manual

Pre-Delivery Inspection (See Note)

Before each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG MechanicService and Maintenance Manual and applicable JLG inspection form

Frequent Inspection(See Note)

In service for 3 months or 150 hours, which-ever comes first; orOut of service for a period of more than 3 months; orPurchased used.

Owner, Dealer, or User Qualified JLG MechanicService and Maintenance Manual and applicable JLG inspection form

Load Sensing System Verification

Semi Annually Owner, Dealer, or UserFactory Certified Service Technician(Recommended)

Operator and Safety Manual

Annual Machine Inspection(See Note)

Annually, no later than 13 months from the date of prior inspection.

Owner, Dealer, or UserFactory Certified Service Technician(Recommended)

Service and Maintenance Manual and applicable JLG inspection form

Preventive Maintenance

At intervals as specified in the Service and Maintenance Manual.

Owner, Dealer, or User Qualified JLG MechanicService and Maintenance Manual

NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections.

3121330 – JLG Lift – 2-3


2.3 PRE-START INSPECTIONThe Pre-Start Inspection should include each of the follow-ing:

1. Cleanliness - Check all surfaces for leakage (oil, fuel, or battery fluid) or foreign objects. Report any leakage to the proper maintenance personnel.

2. Structure - Inspect the machine structure for dents, damage, weld or parent metal cracks or other discrep-encies.

3. Decals and Placards - Check all for cleanliness and legibility. Make sure none of the decals and placards are missing. Make sure all illegible decals and placards are cleaned or replaced.

4. Operators and Safety Manuals - Make sure a copy of the Operator and 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 proper fuel as necessary.

8. Engine Oil Supply - Ensure that the engine oil level is at the full mark on the dipstick and the filler cap is secure.

9. Fluid Levels - Be sure to check the engine oil and the hydraulic oil levels.

10. Accessories/Attachments - Reference the Operator and Safety Manual of each attachment or accessory installed upon the machine for specific inspection, oper-ation, and maintenance instructions.

11. Function Check - Once the “Walk-Around” Inspection is complete, perform a functional check of all systems in an area free of overhead and ground level obstructions. Refer to Section 4 for more specific instructions on the operation of each function.

Parent Metal Crack Weld Crack

2-4 – JLG Lift – 3121330


IF THE MACHINE DOES NOT OPERATE PROPERLY, TURN OFF THEMACHINE IMMEDIATELY! REPORT THE PROBLEM TO THE PROPERMAINTENANCE PERSONNEL. DO NOT OPERATE THE MACHINE UNTILIT IS DECLARED SAFE FOR OPERATION.

Function CheckPerform the Function Check as follows:

1. From the ground control panel with no load in the plat-form:

a. Check that all function control switches and locksare in place.

b. Operate all functions and check all limiting and cut-out switches.

c. Check for proper lifting and lowering of the plat-form.

d. If the platform extension is extended, check that theextension retracts.

NOTE: Be sure the platform extension is retracted before lower-ing.

e. Ensure that all machine functions are disabledwhen the Emergency Stop Button is activated.

f. Check manual descent.

g. Check for proper lifting and lowering of the plat-form.

h. Check the function of the protective scissor cage.

2. From the platform control console:

a. Ensure that the control console is firmly secured inthe proper location.

b. Check that all guards protecting the switches are inplace.

c. Operate all functions.

d. Ensure that all machine functions are disabledwhen the Emergency Stop Button is pushed in.

e. Ensure that all LED’s in the control box are workingproperly.

f. Check that the platform extension extends andretracts properly.

g. With the platform in the transport (stowed) positionand with outriggers not selected:

i. Drive the machine on a level grade and stop toensure the brakes hold.

ii. To ensure proper operation of the tilt sensor, drivethe machine onto a tilt greater than the preset 3°and attempt to lift. Platform should not lift beyond3.5 m (11.5 ft) on the 210-25 and 3.7 (12.1 ft) onthe 245-25.

3121330 – JLG Lift – 2-5


Limit Switches

Check that the following limit switches function properly byattempting to exceed the preset limits.

1. Lowered Limit Switch - Outriggers cannot be deployed beyond the height of 3 m (9.8 ft) on the 210-25 and 3.2 m (10.5 ft) on the 245-25.

2. Limit Switches for Drive Mode:

a. High Drive Speed Limit Switch - High drive speed ispossible up to a platform height of 3.5 m (11.5 ft) onthe 210-25 and 3.7 m (12.1 ft) on the 245-25. Oncethe platform exceeds this limit, only low drive speedis possible.

b. Maximum Drive Height Limit Switch - The maximumallowable drive height is 21 m (68.9 ft).

3. Maximum Height Switch - The Maximum Height Switchcuts out the lift function once the platform reaches 21 m(69 ft) on the 210-25 and 24.5 m (80 ft) on the 245-25.

4. Tilt Switch - If the machine is exceeding a tilt angle of 3°,the platform cannot be elevated beyond 3.5 m (11.5 ft)on the 210-25 and 3.7 m (12.1 ft) on the 245-25. If driv-ing while elevated, the drive function will be cut out.

5. Outrigger Interlocks - These switches allow the machineto be driven when all outriggers are completely

retracted. The switch also prevents the platform frombeing raised until the machine is level.

6. Oscillating Axle Limit Switch - When the platform israised above 3.5 m (11.5 ft) on the 210-25 and 3.7 m(12.1 ft) on the 245-25 and the axle inclination is >1°, thedrive function is cutout. When the platform is below thecutout height, the inclination of the axle is ignored anddriving is possible.

Table 2-2. Cutout Switch Limits

Limit and Cutout SwitchLimit

210-25 245-25

Lowered Position 3 m (9.8 ft) 3.2 m (10.5 ft)

High Drive Speed Cutout * 3.5 m (11.5 ft) 3.7 m (12.1 ft)

Maximum Drive Height * 21 m (69 ft)

Tilt * 3°

Maximum Height * 21 m (69 ft) 24.5 m (80 ft)

Outrigger Interlockdrive cut out when outriggers activated;

lift cut out when not level

Oscillating Axle >1° and 3.5 m (11.5 ft) >1° and 3.7 m (12.1 ft)

NOTE: * - these limit switches have corresponding LED’s onthe platform control console (refer to Figure 3-5., Plat-form Control Console). See page 3-11 and 3-12 for LEDfunctionality.

2-6 – JLG Lift – 3121330


51

23

4

6

71

2 4

245-25

210-25

Figure 2-1. Limit Switch Locations

1. Lowered Position Limit Switch

2. High Drive Speed Limit Switch

3. Maximum Drive Height Limit Switch

4. Maximum Height Switch

5. Tilt Sensor

6. Outrigger Interlocks (all 4 outriggers)

7. Oscillating Axle Limit Switches (rear axle)

3121330 – JLG Lift – 2-7


9

4 1112134 1415 1016

17

Figure 2-2. Walk - Around Inspection Diagram

2-8 – JLG Lift – 3121330


GeneralBegin the “Walk-Around Inspection” at Item 1, as noted onthe diagram. Continue to the left (clockwise viewed fromtop) checking each item in sequence for the conditionslisted in the “Walk-Around Inspection Checklist”.

TO AVOID POSSIBLE INJURY, BE SURE MACHINE POWER IS “OFF”DURING “WALK-AROUND INSPECTION”.

NOTICEDO NOT OVERLOOK VISUAL INSPECTION OF CHASSIS UNDERSIDE.CHECKING THIS AREA OFTEN RESULTS IN DISCOVERY OF CONDI-TIONS WHICH COULD CAUSE EXTENSIVE MACHINE DAMAGE.

NOTE: On each item, make sure there are no loose or missingparts, that they are securely fastened, and that no visi-ble damage exists in addition to any other criteria men-tioned.

1. Steer Cylinder - See Note

2. Steer Linkage - See Note

3. Outrigger - (right front) - See Note

4. Wheel and Tire Assembly - Properly secured, no miss-ing lug nuts. Refer to Section 6. Inspect wheels for damage and corrosion.

5. Tie Rod and Spindle - (right front) - See Note

6. Ground Controls - Placard secure and legible, control switches return to neutral position, emergency stop switch functions properly.

7. Lift Cylinder - See Note

8. Drive Hub, Right Rear - See Note

9. Outrigger - (right rear) - See Note

10. Outrigger - (left rear) - See Note

11. Fuel Tank - See Note

12. Drive Hub, Left Rear - See Note

13. Motor and Hydraulic Pump Assembly - Check engine oil level. See Note

Figure 2-3. Walk - Around Inspection Points (Sheet 1)

3121330 – JLG Lift – 2-9


14. Hydraulic Reservoir - Recommended hydraulic fluid level on level indicator on tank. Breather cap secure and working.

15. Tie Rod and Spindle - (left front) - See Note

16. Outrigger - (left front) - See Note

17. Platform Control Console (mounted on platform rail) - Placard secure and legible, control lever and switches return to neutral, trigger switch and emergency stop switch function properly, operation and safety manual in storage box.

18. Scissor Arms and Sliding Wear Pads (Not Shown) - See Note

19. Control Valve (Not Shown) - No unsupported wires or hoses; no damaged or broken wires.

20. Platform/Handrail Installation (Not Shown) - See Note

Figure 2-4. Walk - Around Inspection Points (Sheet 2)

2-10 – JLG Lift – 3121330

SECTION 3 - MACHINE CONTROLS AND INDICATORS

SECTION 3. MACHINE CONTROLS AND INDICATORS

3.1 GENERAL

NOTICETHE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINEAPPLICATION AND OPERATION, THEREFORE, CONFORMANCE WITHGOOD SAFETY PRACTICES IN THESE AREAS IS THE RESPONSIBILITYOF THE USER AND HIS OPERATING PERSONNEL.

This section provides the necessary information needed tounderstand control functions. It is important that the userread and understand the proper procedures before operat-ing the machine. These procedures will aid in obtaining opti-mum service life and safe operation.

3.2 OPERATING CHARACTERISTICS AND LIMITATIONS

GeneralA thorough knowledge of the operating characteristics andlimitations of the machine is always the first requirement forany user, regardless of user’s experience with similar typesof equipment.

PlacardsImportant points to remember during operation are providedat the control stations by DANGER, WARNING, CAUTION,IMPORTANT and INSTRUCTION placards. This informationis placed at various locations for the express purpose ofalerting personnel of potential hazards constituted by theoperating characteristics and load limitations of the machine.See foreword for definitions of the above placards.

3121330 – JLG Lift – 3-1


CapacitiesRaising platform above the stowed position with or withoutany load 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 properly.

3.3 CONTROLS AND INDICATORS

Ground Control Stations

1 2 3

1. Engine Control Box

2. Main Terminal Box

3. Ground Control Console

Figure 3-1. Ground Control Stations

3-2 – JLG Lift – 3121330


Engine Control

DO NOT OPERATE FROM GROUND CONTROL STATION WITH PERSON-NEL IN THE PLATFORM EXCEPT IN AN EMERGENCY.PERFORM AS MANY PRE-OPERATIONAL CHECKS AND INSPECTIONSFROM THE GROUND CONTROL STATION AS POSSIBLE.

1. 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 depressed, will start the engine. (crank time limited to 6 seconds before power supply required recycling)

3. Hourmeter - A meter used to measure the amount of time the machine is in use.

4. Glow Plug LED - This LED is off under normal operating conditions. The LED is illuminated when the ignition is on and the temperature sensing requires pre-glow.

NOTE: Do not start machine when Glow Plug LED is illuminated.Once the LED goes out, machine starting is permitted.Vertragshandler

ehbelectronics

Start

1

23 Glow

Air

Oil

Alt.

OK

Temp.

4

Figure 3-2. Engine Control

1. Start Assist

2. Engine Start

3. Hourmeter

4. Glowplug LED

3121330 – JLG Lift – 3-3


Main Terminal Box

R

E900057 A

+X

-X

+Y

-Y

1

2

3

4

5

1. Tilt Right LED

2. Tilt Left LED

3. Tilt Front

4. Tilt Rear

5. Drive Cutout LED

Figure 3-3. Main Terminal Box

3-4 – JLG Lift – 3121330


NOTE: The following LED’s are part of the self leveling systemand illuminate as the machine self levels.

1. Tilt Right LED - This LED will illuminate any time the machine is tilted to the right.

2. Tilt Left LED - This LED will illuminate any time the machine is tilted to the left.

3. Tilt Front LED - This LED will illuminate any time the machine is tilted toward the machine front.

4. Tilt Rear LED - This LED will illuminate any time the machine is tilted toward the machine rear.

5. Drive Cutout LED - This LED is illuminated when the out-riggers are used and the lift function is operated.

3121330 – JLG Lift – 3-5


Ground Control Console

2

3

45

8

7

6

R

E900034A

1

1. Platform/ Ground Select (Key Switch)

2. Ignition/Engine Start Switch

3. Emergency Stop Button

4. Outrigger Select Switch

5. Platform Lift/Lower Switch

6. Deck Extend/Retract Switch

7. Glow Plug LED

8. Battery Disconnect Switch

Figure 3-4. Ground Control Console

3-6 – JLG Lift – 3121330


Ground Control Descriptions:

1. Platform/Ground Select - This three-way keyswitch is used to select between platform controls or ground con-trols. When in the center position, the machine is dis-abled.

2. Ignition/Engine Start Switch - Toggle Switch used to start engine. Up position starts the machine. Center position, ignition is on. Down position turns engine off.

3. Emergency Stop Button - Button, when depressed, will immediately shut the machine off. Cuts out all functions except emergency platform lowering.

4. Outrigger Select Switch - A 2 position switch used to select if outriggers auto leveling function is active or not.

5. Platform Lift/Lower Switch - Toggle switch used to raise and lower platform.

6. Deck Extend/Retract Switch - Toggle switch used to extend and retract platform deck extension.

NOTE: The platform deck extension should be retracted beforelowering the platform.

7. Glow Plug LED - This Yellow LED is off under normal operating conditions. The LED is illuminated when the ignition is on and the temperature sensing requires pre-glow.

NOTE: Do not start machine when Glow Plug LED is illuminated.Once the LED goes out, machine starting is permitted.

8. Battery Disconnect Switch - Disconnects ground control panel from the battery.

3121330 – JLG Lift – 3-7


Platform Control Console

12

34 56

7891011

E900030B

R

12

1. Ignition/Engine Start Switch

2. Emergency Stop Button

3. Deck Extension/Drive/Lift Select Switch

4. Drive Speed Switch

5. Lift/Drive/Deck/Steer Controller

6. Horn Button

7. Platform Overload LED

8. Drive Enabled LED

9. Glow Plug Active or Enabled LED

10. Lift Enabled LED

11. High Drive Speed Enabled LED

12. Tilt LED

Figure 3-5. Platform Control Console

3-8 – JLG Lift – 3121330


Platform Control Descriptions:

When platform/ground control select switch is switched toplatform, all movements and operations are controlled viathe platform control panel. The controls are activatedthrough either push-buttons or toggle switches, those ofwhich functions are marked with symbols and/or written text.

1. Ignition/Engine Start Switch - Toggle switch that turns the diesel engine on and off. Up position starts the machine. Center position, ignition is on. Down position turns engine off.

2. Emergency Stop Button - Button, when depressed, will immediately shut the machine off. Cuts out all functions except emergency platform lowering.

3. Deck Extension/Drive/Lift Select Switch - 3 position tog-gle switch that selects the functions of platform exten-sion, drive or lift. Up for platform extension, middle for drive, and down for lift. Works in conjunction with the joystick controller.

4. Drive Speed Switch - 3 position toggle switch that selects between fast drive, slow drive or posi-traction. Posi-traction evenly distributes the torque between all four wheels to provide better traction in situations that require it.

5. Lift/Drive/Deck/Steer Controller - The Controller works in conjunction with the platform extension, drive and the lift switch depending upon which function is selected. The button on the front of the joystick is the enable trigger. This trigger must be held in to work all joystick con-trolled functions. When the Drive function is selected, moving the joystick forward and backwards operates the forward and reverse movement of the machine. The switch on top of the joystick controls the steering of the machine when the Drive function is selected. When the Deck function is selected, moving the joystick forward and backward extends and retracts the platform deck extension. When the Lift function is selected, moving the joystick forward and backwards raises and lowers the platform.

6. Horn - Button, when depressed, activates the horn.

7. Platform Overload LED - This Red Flashing LED will illu-minate when the platform becomes overloaded.

8. Drive Enabled LED - This Green LED is illuminated when drive is enabled. The LED goes out when the platform is above the maximum drive height, or with outriggers selected and deployed.

3121330 – JLG Lift – 3-9


9. Glow Plug Enabled or Active LED - This Yellow LED is off under normal operating conditions. The LED is illumi-nated when the ignition is on and the temperature sens-ing requires pre-glow.

NOTE: Do not start machine when Glow Plug LED is illuminated.After the LED goes out, machine starting is permitted.

10. Lift Enabled LED - This Green LED is illuminated under normal driving conditions. The light goes out when tilted above fast drive height, or when at max height.

11. High Drive Speed Enabled LED - This Green LED is illu-minated under normal driving conditions. The light goes out when the platform is above the fast drive height.

12. Tilt (slope) LED - This Red LED will illuminate when the machine is driven on a slope greater than the allowable 3°. The LED remains off under normal operating condi-tions.

3-10 – JLG Lift – 3121330


3.4 DECALS

221 15

1011

4

22

623

518

2420

1516

11

2364

22947

13516

97

4

11

11

10 11

11 10

11

1011 3 19

17 15

Figure 3-6. Decal Location - (210-25) - Sheet 1 of 2

3121330 – JLG Lift – 3-11


4

7 149

1615

7 4 9

224 6

23

5

1516

24

236

224

298

12


3-12 – JLG Lift – 3121330


4

79

1613

7 4 9

24

46 23

11

16

2215

20 185

236

221 15

244

1011

3

1517

19111011

11

101111

10

11


3121330 – JLG Lift – 3-13


4

714 9

1615

7 4 9

24

4 623

5

1615

22

623

24

4

298

12


3-14 – JLG Lift – 3121330


Table 3-1. Decal Legend

Item #210-25

(1001099293-C)245-25

(1001099184-C)

1 -- --

2 1701505 1701505

3 1701640 1701640

4 1701785 1701785

5 1702773 1702773

6 1703687 1703687

7 1703811 1703811

8 1703812 1703812

9 1703814 1703814

10 1703819 1703819

11 1704277 1704277

12 1704412 1704412

13 1704885 1704885

14 1705515 1705515

15 1705671 1705671

16 1705673 1705673

17 1706473 1706474

18 1706482 1706482

19 1706485 1706485

20 1706487 1706487

21 1001103747 1001103747

22 1706562 1706498

23 1706563 1706507

24 1706564 1706508

25-28 -- --

29 1706098 1706098

Table 3-1. Decal Legend

Item #210-25

(1001099293-C)245-25

(1001099184-C)

3121330 – JLG Lift – 3-15


NOTES:

3-16 – JLG Lift – 3121330

SECTION 4 - MACHINE OPERATION

SECTION 4. MACHINE OPERATION

4.1 DESCRIPTIONThe normal location to operate the machine is on the plat-form. However, the control box can be disconnected fromthe platform location and plugged in (in emergencies) at thedistribution terminal inside the valve compartment of themachine.

4.2 STARTINGEnsure Battery Disconnect Switch is not cutting off the bat-tery power. On the Ground Control Console, select the oper-ating position (platform vs. ground).

NOTE: If Glow Plug LED illuminates, wait until the LED goes outbefore attempting to start the engine.

ENGINE EXPLOSION HAZARD. MACHINE IS EQUIPPED WITH A COLDSTART AID. DO NOT USE ADDITIONAL ETHER. FAILURE TO COMPLYCOULD RESULT IN DEATH OR SERIOUS INJURY.

On the selected Operating Console, press the Engine StartSwitch up and hold to start the engine. Release the switchonce engine starts. On the ground control console, selectOutriggers active or disabled.

The Engine Start Switch can also be used to shut the engineoff when the switch is pressed down.

NOTE: The Start Button on the Engine Control box can also beused to start the engine (refer to Figure 3-2.).

3121330 – JLG Lift – 4-1


4.3 LIFTING AND LOWERING

DO NOT RAISE PLATFORM EXCEPT ON A FIRM UNIFORM SURFACEFREE OF OBSTRUCTIONS AND HOLES.

CAUTIONENSURE SCISSOR ARM AREA IS FREE OF PERSONNEL PRIOR TOLOWERING PLATFORM.

DO NOT LOWER THE PLATFORM WITHOUT COMPLETELY RETRACT-ING THE PLATFORM EXTENSION.

Lifting:

1. If operating from the ground control console:

a. Lift up on the Platform Lift/Lower Switch to achievedesired elevation.

2. If operating from the platform control console:

a. Position the Drive/Lift Select Switch to the "Lift" posi-tion. Press and hold the enable trigger on the frontof the joystick while moving the joystick forward toraise the platform to desired elevation. Once the

trigger is released or the joystick is returned to theneutral position, the movement will stop.

Lowering:

3. If operating from the ground control console:

a. Press down on the Platform Lift/Lower Switch toachieve desired elevation.

4. If operating from the platform control console:

a. Position the Drive/Lift Select Switch to the "Lift" posi-tion. Press and hold the enable trigger on the frontof the joystick while moving the joystick backwardto lower the platform to desired elevation. Once thetrigger is released or the joystick is returned to theneutral position, the movement will stop.

NOTE: When the machine is in "Drive Mode," the lifting and low-ering functions are deactivated. Manual descent is theonly allowable platform movement when in "Drive Mode."

The machine is equipped with gravity descent. Theengine does not need to be running to lower the platform.

4-2 – JLG Lift – 3121330


Load Sensing System (LSS)

The Load Sensing System (LSS) senses pressure in themain lift cylinder. If this pressure exceeds a pre-set level, thefollowing will occur:

1. The Platform Overload LED on the platform console willflash (see the arrow below) and the audible alarm willsound.

2. All normal movement will be prevented from both theplatform console and the ground panel.

3. Platform descent is permitted for a period of 5 seconds(for situations where the platform may have contact withan obstacle when lifting).

4. Engaging the manual descent system, located in thevalve compartment, will allow further movement.

NOTICEIF ALL NORMAL MOVEMENT IS PREVENTED WITH NO AUDIBLE, ORVISUAL SIGNAL, THERE IS A FAULT IN THE SYSTEM.

If this situation occurs, proceed as follows:

1. Return the platform to the retracted and lowered posi-tion by means of the manual descent system located inthe valve compartment.

2. Disable the machine.

3. Have the fault assessed by a qualified JLG equipmentservice technician before returning to normal operation.

E900030B

R

3121330 – JLG Lift – 4-3


NOTICETHE LOAD SENSING SYSTEM MUST BE CALIBRATED WHEN ONE ORMORE OF THE FOLLOWING CONDITIONS OCCUR:

a. LSS component replacement

b. LSS Sensor removal or replacement

c. Platform is removed or replaced

NOTICETHE LOAD SENSING SYSTEM REQUIRES PERIODIC FUNCTION VERIFI-CATION NOT TO EXCEED 6 MONTHS FROM PREVIOUS VERIFICATION.REFER TOSECTION 6.5, LSS TESTING AND EVALUATION.

4.4 AUTOMATIC SELF LEVELINGThe machine is equipped with an auto leveling feature thatallows the operator to automatically level the machine. Whenthe machine is leveled, the lift function is automaticallyenabled. The indicator LED’s on the Main Terminal Box willalso indicate when the machine is level (See Figure 3-3.,Main Terminal Box for an explanation of the LED’s). Thisfunction can be turned on or off at the ground control station.

With the auto leveling (outrigger select switch) and lift func-tions selected:

1. Move the joystick controller forward to raise the plat-form. The drive function is disabled at this point and theDrive Enabled LED on the platform control console goesout.

NOTE: The engine remains at low idle speed and the outriggersbegin to extend.

2. When outriggers are deployed and machine is level, theengine speed increases and the platform begins to lift.

NOTICEALL OUTRIGGERS MUST BE EXTENDED AND IN CONTACT WITH THESUPPORT SURFACE AND THE MACHINE MUST BE LEVEL BEFORE THEPLATFORM IS LIFTED FROM THE STOWED POSITION. IF ONE OR MOREOUTRIGGERS, DESPITE BEING FULLY EXTENDED, IS NOT IN CONTACTWITH THE SUPPORTING SURFACE, THE OUTRIGGERS MUST BERETRACTED AND THE MACHINE MOVED TO A MORE APPROPRIATEPOSITION.

4-4 – JLG Lift – 3121330


To retract the outriggers:

3. Move the joystick controller backward to lower the plat-form.

NOTE: The engine remains at low idle speed while platform low-ers.

4. When the platform is fully lowered, engine speedincreases and the outriggers begin to retract.

5. When all outriggers are fully retracted, the drive functionis enabled and the Drive Enabled LED on the platformcontrol console will illuminate.

IF THE MACHINE BECOMES UNLEVEL, CAREFULLY LOWER THE PLAT-FORM AND REPOSITION THE MACHINE.

NOTICEALWAYS BE SURE THAT THE OPERATING SURFACE THE MACHINE ISTO BE USED ON IS FIRM AND FREE OF ANY VOIDS OR OBSTRUCTIONSTHAT MAY CAUSE THE OUTRIGGERS TO PERFORM IMPROPERLY.

4.5 DRIVING THE MACHINE FROM THE PLATFORM

With the lift/drive/extension switch in the drive position, themachine can be driven forward and in reverse. To activatethe drive of the machine, the controller (joystick) has to bemoved forward for forward-drive and back for reverse-drive.The controller has a neutral zone of about ± 7% of the totalpossible moving distance. After reaching the end of the neu-tral zone, the machine starts to move.

DO NOT DRIVE WITH PLATFORM RAISED EXCEPT ON A SMOOTH, FIRMAND LEVEL SURFACE FREE OF OBSTRUCTIONS AND HOLES.

TO AVOID LOSS OF TRAVEL CONTROL OR UPSET ON GRADES ANDSIDESLOPES, DO NOT DRIVE MACHINE ON GRADES OR SIDESLOPESEXCEEDING THOSE SPECIFIED. REFERENCE FIGURE 4-1., GRADE ANDSIDESLOPE.

3121330 – JLG Lift – 4-5


SIDESLOPEHORIZONTAL

GRADE

Figure 4-1. Grade and Sideslope

4-6 – JLG Lift – 3121330


4.6 STEERINGThe steer function is operated by depressing the two posi-tioned button on top of the joystick. Pressing and holding thebutton to the right will turn the wheels to the right. Releasethe button when desired direction is achieved. When the but-ton is released, the wheels will remain in the turned position.To straighten and/or turn to the left, the button must bepushed and held in the opposite direction (left in this case).The same procedure applies for straightening or turning rightwhen wheels are in left turn position.

4.7 HYDRAULIC PLATFORM EXTENSIONWith the lift/drive/extension switch in the extension position,the platform can be hydraulically extended. The function isactivated by moving the controller forward to extend andbackwards to retract.

4.8 EMERGENCY LOWERING - MANUAL DESCENT

All control switches have to be set to the neutral position.Next, the emergency lowering valve, which is located on thelifting ram, can be opened hydraulically by a hand pumplocated inside the hydraulic compartment. Once the loweringis completed all levers of the emergency lowering functionhave to be put into the neutral position. Refer to Section 5.3,Manual Procedures for instructions on manual descent.

4.9 PARKING AND STOWINGWhen machine use is completed, the machine has to be fullylowered and the battery isolator switch should be turned off.

NOTICETHE MACHINE SHOULD BE LOCKED BY THE KEYSWITCH ON THEGROUND CONTROL PANEL AND THE KEY REMOVED TO AVOID THEUSE BY ANY UNAUTHORIZED PERSONNEL.

In case the machine is not used for a longer period of time,the batteries should be charged once every two weeks dueto the self discharge and power consumption of the machineat rest.

3121330 – JLG Lift – 4-7


4.10 TIE DOWN/LIFT LUGS

Tie Down

When transporting the machine, the platform extension mustbe fully retracted and the platform fully lowered in the stowedposition with the machine securely tied down to the truck ortrailer deck. Refer to the tie down lugs in Figure 4-2., Liftingand Tie Down Location.

Lifting

If it becomes necessary to lift the machine, it is possible todo so from the lifting lugs located at the four corners of themachine. These lugs enable the machine to be lifted usingcranes or suitable lifting devices

NOTE: If lifting becomes necessary from the lifting lugs, JLGIndustries, Inc. recommends the use of a proper spreaderbar and straps/chains to avoid damage to the machine.

Cranes or other lifting devices must be capable of han-dling the weights listed in the Operating Specificationstable in section 6 of this manual.

Lift Lugs

Tie DownTie Down

Figure 4-2. Lifting and Tie Down Location

4-8 – JLG Lift – 3121330


4.11 TRANSPORT AND STORAGE OF THE MACHINE

NOTICEDURING TRANSPORT THE BATTERY DISCONNECT SWITCH ON THEGROUND CONTROL PANEL SHOULD BE SET TO THE DISCONNECTEDPOSITION.

The control box must be unplugged during transport of themachine. The socket at the platform must be closed, when-ever the control box is not plugged in. This is the best way toprevent any damages due to moisture and transport to theelectrical components of the machine.

• Ensure the control box is stored in a safe, dry location andthe main joystick controller is not affected by any harshforces.

1

R

E900034A

1. Battery Disconnect Switch

3121330 – JLG Lift – 4-9


Platform Rail Lowering Tool Procedure (245-25 Only)

NOTE: Prior to lowering/raising rails, ensure deck surface isclean, dry, and free of debris. Maintain good footing dur-ing procedure.

WHEN STANDING ON THE MAIN PLATFORM SURFACE LOWERING ORRAISING THE MAIN PLATFORM RAILS, JLG INDUSTRIES, INC. RECOM-MENDS THE USE OF A FALL RESTRAINT DEVICE ATTACHED TO THECENTER RAIL LANYARD ATTACH POINT ON THE PLATFORM EXTEN-SION RAIL ADJACENT TO THE MAIN RAIL YOU ARE LOWERING/RAIS-ING.

When transporting the machine, it may be necessary to lowerthe platform rails to meet traveling height requirements. A RailLowering Tool (Optional) is available to assist the operator withthis procedure.

1. Rope (Top)2. Rope (Bottom)

3. Rail Clamp4. Rubber Stopper

Figure 4-3. Rail Lowering Tool (Optional)

4-10 – JLG Lift – 3121330


Main Platform Side Rails and Extension End Rail

NOTE: The following procedures apply to the Main Platform SideRails and the Platform Extension End Rail. These rails foldoutward. Stow these rails prior to stowing the extensionside rails.

1. Remove the Rail/Platform Attach Pins from each rail leg(located on the sides of the platform where rails attachto platform).

a. Remove the Safety Pin.

b. Remove the Attach Pin.

3121330 – JLG Lift – 4-11


2. While standing on the platform, place the Rail LoweringTool on the Rail. (reference the illustration following)

a. Place the Rail Clamp on the underside of the top railnear the center post.

b. Lower the Tool handle so that the Rubber Stopperrests on the top of the rail locking the Tool in placeon the rail.

3. Let the Rail Lowering Tool rest on the rail.

4. Attach your fall restraint device to the extension platformrail - center lanyard attach point before lowering themain rails.

5. Remove the Rail Corner Pin where the side rail connectsto the end rail. While holding onto the side rail, removethe Safety Pin and pull out the Corner Pin.

6. While continuing to hold onto the rail, walk back to theRail Lowering Tool.

1. Rail Lowering Tool 1. Corner Pin2. Safety Pin

3. Top View of Side Rail

4-12 – JLG Lift – 3121330


7. Tightly grasp the top portion of the rope and begin toslowly lower the railing using hand-over-hand motions.

FALL HAZARD. EXERCISE EXTREME CAUTION WHEN LOWERINGRAILS, USER SHOULD STAND CLEAR OF THE PLATFORM EDGE ANDMAINTAIN A STABLE FOOTING DURING THE LOWERING PROCEDURE.

NOTE: The extension side rails, in the upright position, can beused for extra footing support.

8. When rail is fully lowered, pull the bottom portion of therope tight to release the Tool’s Rail Clamp from themachine.

9. Repeat the previous steps on the opposite side rail andplatform extension end rail.

10. Once the main platform side rails and platform extensionend rail are lowered, secure them in place by insertingall of the Pins into the lower holes of the Rail/PlatformAttach Brackets.

3121330 – JLG Lift – 4-13


11. Secure Pins in place with Safety Pins. Main Platform End Rails/Gate and Extension Side Rails

NOTE: The following procedures apply only to the Main PlatformEnd Rails/Gate and Extension Side Rails.

12. Remove the Rail/Platform Attach Pins from each rail leg(located on the sides of the platform where rails attachto platform).

a. Remove Safety Pin and pull out Main Pin.

1. Main Pin 2. Safety Pin

4-14 – JLG Lift – 3121330


2. Carefully lower rails inward to the platform deck.

3. Secure rails by inserting Main Pins back into bracketsand securing pin with Safety Pins.

Rail Raising Procedure

NOTE: Follow the Platform Rail Lowering Procedures in reverseorder to raise rails to the working positions. Make certainto secure all rails with all pins and all safety pins.

WHEN STANDING ON THE MAIN PLATFORM SURFACE LOWERING ORRAISING THE MAIN PLATFORM RAILS, JLG INDUSTRIES, INC. RECOM-MENDS THE USE OF A FALL RESTRAINT DEVICE ATTACHED TO THECENTER RAIL LANYARD ATTACH POINT ON THE PLATFORM EXTEN-SION RAIL ADJACENT TO THE MAIN RAIL YOU ARE LOWERING/RAIS-ING.

1. Safety Pin 2. Main Pin

3121330 – JLG Lift – 4-15


FALL HAZARD. FAILURE TO PROPERLY SECURE ALL RAIL SECTIONSWITH THEIR PROPER PINS AND PIN SAFETY PINS COULD RESULT INRAIL COLLAPSE RESULTING IN DEATH OR SERIOUS INJURY.

1. Raise Main Platform End Rails/Gate and Extension SideRails to the up-right position. Secure rails with all of thepins and all of the safety pins.

2. Attach the Rail Tool to raise Main Platform Side Rails tothe up-right position. Secure with pins and safety pins.

3. Before attempting to raise the main side rails, attachyour fall restraint device to the extension platform rail -center lanyard attach point.

4. Once main side rails are raised into place, secure SideRails to End Rails with all pins and secure all pins withsafety pins.

4-16 – JLG Lift – 3121330

SECTION 5 - EMERGENCY PROCEDURES

SECTION 5. EMERGENCY PROCEDURES

5.1 GENERALThis section provides information on the procedures to befollowed and on the systems and controls to be used in theevent an emergency situation is encountered duringmachine operation. Prior to operation of the machine andperiodically thereafter, the entire operating manual, includingthis section, should be reviewed by all personnel whoseresponsibilities include any work or contact with themachine.

Emergency Stop SwitchThese large red buttons, one located on the Ground ControlStation and one on the Platform Control Station, will immedi-ately stop the machine when depressed.

Platform Caught OverheadIf the platform becomes jammed or snagged in overheadstructures or equipment, do not continue operation of themachine from either the platform or the ground until theoperator and all personnel are safely moved to a securelocation. Only then should an attempt be made to free theplatform using any necessary equipment and personnel. Donot operate controls to cause one or more wheels to leavethe ground.

Righting of Tipped MachineA forktruck of suitable capacity or equivalent equipmentshould be placed under the elevated side of the chassis, witha crane or other suitable lifting equipment used to lift theplatform while the chassis is lowered by the forklift or otherequipment.

Post-Incident InspectionFollowing any incident, thoroughly inspect the machine andtest all functions first from the ground controls, and then fromthe platform controls. Do not lift above 3 m (10 ft) until it iscertain that all damage has been repaired, and that all con-trols are operating correctly.

3121330 – JLG Lift – 5-1


5.2 EMERGENCY OPERATIONUse of Ground Controls

NOTICEKNOW HOW TO USE THE GROUND CONTROLS IN AN EMERGENCY SIT-UATION.

Ground personnel must be thoroughly familiar with themachine operating characteristics and the ground controlfunctions. Training should include operation of the machine,review and understanding of this section and hands-on oper-ation of the controls in simulated emergencies.

Operator Unable to Control Machine1. Operate the machine from ground controls ONLY with

the 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 platform controls. DO NOT CONTINUE OPERATION IF CONTROLS DO NOT FUNCTION NORMALLY.

3. Cranes, forklift trucks or other equipment which may be available, should be used to stabilize motion of the machine in case machine controls are inadequate or malfunction when used prior to removing platform occu-pants.

Incident NotificationIt is imperative that JLG Industries, Inc. be notified immedi-ately of any incident involving a JLG product. Even if noinjury or property damage is evident, JLG should be con-tacted by telephone and provided with all necessary detailsat:

877-554-7233 or 240-420-2661

It should be noted that failure to notify the Manufacturer of anincident involving a JLG Industries product within 48 hours ofsuch an occurrence may void any warranty consideration onthat particular machine.

5-2 – JLG Lift – 3121330


5.3 MANUAL PROCEDURES

Manual Platform Deck Retraction

NOTE: The platform deck extension should be retracted beforethe platform lowering begins.

1. Locate the valve block and handpump inside the hydraulic cover on the right side of the machine.

2. Turn valve knob on the manual handpump clockwise until tight.

NOTE: Step 2 applies only to machines prior to S/N 1200021263.

3. Locate the lever at the end of the valve bank near the back. Push lever down to engage valve.

3121330 – JLG Lift – 5-3


4. Locate separate valve handle and place handle on the valve as shown (first section from the left).

NOTE: Valve handles are located in plastic storage bag withinvalve compartment.

5. Open valve by pulling handle down.

6. While continuing to hold the valve open, activate the manual pump by pumping back and forth.

7. After manual platform deck retraction is complete, release valve on the valve bank and remove handle from valve. Return the valve lever at the end of the valve bank near the back to it’s original position. Turn the valve on

the manual hand pump counterclockwise until fully open (if applicable). Push pump handle forward.

Manual Descent

NOTE: The manual descent system is provided as an emergencymeans to lower personnel from the platform.

1. Locate the valve block inside the hydraulic cover on the right side of the machine.

2. Turn valve knob on the manual handpump clockwise until tight.

NOTE: Step 2 applies only to machines prior to S/N 1200021263.

5-4 – JLG Lift – 3121330


3. Locate the lever at the end of the valve bank near the back. Lift lever to engage valve.

4. Locate valve handle and place it on the third valve from the left. Press handle downward while activating the manual pump.

NOTE: Valve handles are located in plastic storage bag withinvalve compartment.

.

PLATFORM WILL CONTINUE TO DESCEND ONCE MOVEMENT ISSTARTED. TO STOP PLATFORM DESCENT, RELEASE THE HANDLE ONTHE MAIN VALVE.

5. After manual lowering is complete, release valve on the valve bank and remove handle from valve. Return the valve lever at the end of the valve bank near the back to it’s original position. Turn the valve on the manual hand pump counterclockwise until fully open (if applicable). Push pump handle forward.

3121330 – JLG Lift – 5-5


5.4 EMERGENCY TOWING

RUNAWAY VEHICLE/MACHINE HAZARD. MACHINE HAS NO TOWINGBRAKES. TOWING VEHICLE MUST BE ABLE TO CONTROL MACHINE ATALL TIMES. ON-HIGHWAY TOWING NOT PERMITTED. FAILURE TO FOL-LOW INSTRUCTIONS COULD CAUSE SERIOUS INJURY OR DEATH.

MAXIMUM TOWING SPEED 5 M.P.H. (8 K.M.H.) FOR NO LONGER THAN45 MINUTES.

MAXIMUM TOWING GRADE 25%.

Prior to TowingPrior to towing the machine, complete the following:

NOTICEDO NOT TOW MACHINE WITH ENGINE OPERATING OR DRIVE HUBSENGAGED.

1. Completely lower platform.

2. Disconnect drive hubs by inverting disconnect cap.(See Figure 5-1.) After towing the machine, complete thefollowing:

a. Reconnect drive hubs by inverting disconnect cap.(See Figure 5-1.)

1

2

3

Figure 5-1. Drive Disconnect Hub

1. Hub Connected

2. Disconnect Cap

3. Hub Disconnected

5-6 – JLG Lift – 3121330

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

SECTION 6. GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

6.1 INTRODUCTIONThis section of the manual provides additional necessaryinformation to the operator for proper 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 replace the more thoroughPreventive Maintenance and Inspection Schedule includedin the Service and Maintenance Manual.

Other Publications Available Specific to this Machine:

Service and Maintenance Manual ..................... 3121331

Illustrated Parts Manual ..................................... 3121332

3121330 – JLG Lift – 6-1


6.2 OPERATING SPECIFICATIONS Table 6-1. Operating Specifications

Description 210-25 245-25

Maximum Working Height 23 m (75 ft) 26.5 m (87 ft)

Maximum Platform Height 21 m (69 ft) 24.5 m (80 ft)

Turning Radius: Inside Outside

1.5 m (4.9 ft)6.2 m (20.3 ft)

Wheelbase 3.9 m (12.8 ft)

Maximum Work Load (Capacity): Main Platform Platform Extension

1000 kg (2205 lbs)800 kg (1764 lbs)

750 kg (1650 lbs)750 kg (1650 lbs)

Maximum Platform Occupants 5 2

Tools and Equipment: Main Platform Platform Extension

600 (1323 lbs)400 kg (882 lbs)

590 kg (1300 lbs)590 kg (1300 lbs)

Maximum Horizontal Manual Side Force

400 N (90 Lbf)

Tilt Sensor Setting 3°

Maximum Operating Wind Speed 12.5 m/s (28mph)

Gross Machine Weight (Approximate)

15,000 kg (33,069 lbs)

16,800 kg (36,960 lbs)

Drive Speed (creep)0.14 m/sec(0.46 ft/sec)

Drive Speed (slow) 0.4 m/sec (1.4 ft/sec)

Drive Speed (fast) 0.6 m/sec (2.1 ft/sec)

Lift Speed (platform empty) 95 sec 105 sec

Lowering Speed 70 sec 80 sec

Maximum Operating Hydraulic Pressure

210 bar (3046 psi)

Power Supply Diesel Engine

Maximum Ground Bearing Pressure: Outriggers Tires

7 kg/cm² (100 psi)5 kg/cm² (71 psi)

9 kg/cm² (128 psi)6 kg/cm² (85 psi)

Maximum Outrigger Pad Load5915 kg

(13,040 lb)7720 kg

(17,020 lb)

Maximum Tire Load Rating5950 kg

(13,118 lbs)6620 kg

(14,595 lbs)

Electrical System Voltage 24V

Sideslope (fully stowed) 5°

Gradeability (fully stowed) 35% 25%

Ground Clearance 0.26 m (0.85 ft)

Table 6-1. Operating Specifications


6-2 – JLG Lift – 3121330


Dimensional Data Capacities

Tires

Table 6-2. Dimensional Data


Machine Height: rails up rails down

4.1 m (13.5 ft)3.2 m (10.5 ft)

4.24 m (13.9 ft)3.24 m (10.6 ft)

Platform Dimensions : extension retracted (W x L)

extension extended (W x L)

2.5 x 5.35 m(8.2 x 17.6 ft)2.5 x 7.6 m(8.2 x 25 ft)

2.5 x 5.35 m(8.2 x 17.6 ft)2.5 x 7.8 m

(8.2 x 25.6 ft)

Transport Dimensions: rails up (L x W x H)

rails down (L x W x H)

5.35 x 2.5 x 4.1 m(17.6 x 8.2 x 13.5 ft)5.35 x 2.5 x 3.2 m

(17.6 x 8.2 x 10.5 ft)

5.35 x 2.5 x 4.24 m(17.6 x 8.2 x 13.9 ft)5.35 x 2.5 x 3.24 m(17.6 x 8.2 x 10.6 ft)

Table 6-3. Capacities


Fuel Tank 90 L (23.8 gal)

Hydraulic Tank 260 L (68.7 gal)

Engine Crankcase: with Filter without Filter

10.5 L (11 qt)10 L (10.6 qt)

Table 6-4. Tire Specifications


Size 315/80R 22.5

Ply Rating 18

Tire Pressure 7.5 bar (108.8 psi)

3121330 – JLG Lift – 6-3


Engine Component Weights

Table 6-5. Engine Specifications

Type Deutz D2011 L04 i

Displacement 3108 cm³

Bore 94 mm

Stroke 112 mm

Fuel Type Diesel

Table 6-6. Engine Battery Specifications

Voltage 12V

Cranking Performance 100Ah

Reserve Capacity 880A

Table 6-7. Component Weights


Platform Assembly (including extension)

572 kg(1261 lbs)

731 kg(1612 lbs)

Platform Extension188 kg

(415 lbs)278 kg

(613 lbs)

Chassis2359 kg

(5200 lbs)

Arm Assembly6388 kg

(14,083 lbs)7789 kg

(17,172 lbs)

Lift Cylinder826 kg

(1821 lbs)

6-4 – JLG Lift – 3121330


NO OPERATION ABOVE THISAMBIENT TEMPERATURE

ENGINESPECIFICATIONS

SUMMER GRADE FUEL

WINTERGRADE FUEL

WINTER GRADE FUEL WITHKEROSENE ADDED

ENGINE WILL START AND OPERATE UNAIDED AT THISTEMPERATURE WITH THE RECOMMENDED FLUIDS AND AFULLY CHARGED BATTERY

ENGINE WILL START AND OPERATE AT THIS TEMPERATUREWITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERYAND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHERPACKAGE (IE. ENGINE BLOCK HEATER, ETHER INJECTION OR GLOWPLUGS, BATTERY WARMER AND HYDRAULIC OIL TANK HEATER)

NO OPERATION BELOW THISAMBIENT TEMPERATURE

AMBIENT AIRTEMPERATURE

SA

E O

W-3

0

SA

E O

W-4

0

SA

E 5

W-3

0

SA

E 5

W-4

0

SA

E 1

0W-3

0

SA

E 1

0W-4

0

SA

E 1

5W-4

0

SA

E 2

0W-5

0

120°F (49°C)

110°F (43°C)

100°F (38°C)

90°F (32°C)

80°F (27°C)

70°F (21°C)

60°F (16°C)

50°F (10°C)

40°F (4°C)

30°F (-1°C)

20°F (-7°C)

10°F (-12°C)

0°F (-18°C)

-10°F (-23°C)

-20°F (-29°C)

-30°F (-34°C)

-40°F (-40°C)

4150548 C

Figure 6-1. Engine Operating Temperature Specifications (Deutz) - Sheet 1 of 2

3121330 – JLG Lift – 6-5


NOTE:

1) RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES CONSISTANTLY WITHIN SHOWN LIMITS

2) ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL

SUMMER - GRADEFUEL

WINTER - GRADEFUEL

% OF ADDED KEROSENE

+32 0

+23 -5

+14 -10

+5 -15

-4 -20

-13 -25

-22 -30

0 10 20 30 40 50 60

°F °C

AM

BIE

NT

TE

MP

ER

ATU

RE

120°F (49°C)

110°F (43°C)

100°F (38°C)

90°F (32°C)

80°F (27°C)

70°F (21°C)

60°F (16°C)

50°F (10°C)

40°F (4°C)

30°F (-1°C)

20°F (-7°C)

10°F (-12°C)

0°F (-18°C)

-10°F (-23°C)

-20°F (-29°C)

-30°F (-34°C)

-40°F (-40°C)

AMBIENT AIRTEMPERATURE

180°F (82°C)(HYD. OIL TANK TEMP.

NO OPERATION BELOW THISAMBIENT TEMPERATURE

DO NOT START UP HYDRAULIC SYSTEMWITHOUT HEATING AIDS AND COLD WEATHERHYDRAULIC OIL BELOW THIS TEMPERATURE

DO NOT START UP HYDRAULIC SYSTEMWITHOUT HEATING AIDS WITH MOBILE 424HYDRAULIC OIL BELOW THIS TEMPERATURE

HYDRAULICSPECIFICATIONS

NO OPERATION ABOVE THISAMBIENT TEMPERATURE PROLONGED OPERATION IN

AMBIENT AIR TEMPERATURESOF 100°F (38°C) OR ABOVE

IF EITHER OR BOTH CONDITIONSEXIST JLG HIGHLY RECOMMENDSTHE ADDITION OF A HYDRAULICOIL COOLER (CONSULT JLG SERVICE)

EXTENDED DRIVING WITHHYDRAULIC OIL TANKTEMPERATURES OF 180°F(82°C) OR ABOVE

MO

BIL

424

10W

-30

EX

XO

N U

NIV

IS H

VI

26

MOBILDTE 13

Figure 6-2. Engine Operating Temperature Specifications (Deutz) - Sheet 2 of 2

6-6 – JLG Lift – 3121330


Lubrication

Hydraulic Oil

NOTE: Hydraulic oils must have anti-wear qualities at least to APIService Classification GL-3, and sufficient chemical stabil-ity for mobile hydraulic system service. JLG Industriesrecommends Mobilfluid 424 hydraulic oil, which has anSAE viscosity index of 152.

When temperatures remain below -7°C (20°F), JLG Indus-tries recommends the use of Mobil DTE13.

NOTE: Aside from JLG recommendations, it is not advisable tomix oils of different brands or types, as they may not con-tain the same required additives or be of comparable vis-cosities. If use of hydraulic oil other than Mobilfluid 424 isdesired, contact JLG Industries for proper recommenda-tions.

Lubrication Specifications

Table 6-8. Hydraulic Oil

HYDRAULIC SYSTEM OPERATING TEMPERATURE RANGE

SAE VISCOSITY GRADE

-18° to -5°C (0° to +23°F)

10W

-18° to +100°C (0° to +210°F)

10W-20, 10W-30

+10° to +100°C (+50° to +210°F)

20W-20

Table 6-9. Lubrication Specifications

KEY SPECIFICATIONS

MPG

Multipurpose Grease having a minimum dripping point of 177°C (350°F). Excellent water resistance and adhesive

qualities, and being of extreme pressure type. (Timken OK 40 pounds minimum.)

EPGLExtreme Pressure Gear Lube (oil) meeting API service classi-

fication GL-5 or MIL-Spec MIL-L-2105.

EOEngine (crankcase) Oil. Gas - API SF/SG class, MIL-L-2104.

Diesel - API CC/CD class, MIL-L-2104B/MIL-L-2104C.

HO Hydraulic Oil. API service classification GL-3, e.g. Mobil 424.

3121330 – JLG Lift – 6-7


6.3 OPERATOR MAINTENANCE

Figure 6-3. Operator Maintenance & Lubrication Diagram

1. Arm Pins

2. Outrigger Cylinders

3. Tie Rod Ends

4. Spindles

5. Lower Slide Pads

6. Upper Slide Pads

7. Lift Cylinder

8. Oscillating Axle

9. Engine Compartment

10. Fuel Tank

6-8 – JLG Lift – 3121330


NOTE: The following numbers correspond with those in Figure 6-3., Operator Maintenance & Lubrication Diagram.

Be sure to grease all like items on the opposite side ofmachine.

1. Arm Pin

• Lube Points - 30 & 36 Grease Fittings

• Capacity - As Required

• Lube - MPG

• Interval - As Required

2. Outrigger Cylinders

• Lube Points - 4 Grease Fittings


• Lube - MPG


3121330 – JLG Lift – 6-9


3. Tie Rod End



• Lube - MPG


4. Spindles



• Lube - MPG

• Interval - As required

6-10 – JLG Lift – 3121330


5. Lower Slide Pads



• Lube - MPG


6. Upper Slide Pads



• Lube - MPG


3121330 – JLG Lift – 6-11


7. Lift Cylinder



• Lube - MPG


8. Oscillating Axle



• Lube - MPG


6-12 – JLG Lift – 3121330


9. Engine Compartment

a. Engine Oil Check/Fill

• Lube Points - Fill Cap & Dip Stick

• Capacity - See Engine Manual

• Lube - EO SAE 20W20

• Interval - Check daily. Change every 1000 hours ofoperation.

b. Oil Filter

• Maintenance - Replaceable Element (JLG P/N 7016331)

• Interval - Change every 1000 hours of operation.Change filter every time engine oil is changed.

3121330 – JLG Lift – 6-13


c. Fuel Filter

• Maintenance - Replaceable Element (JLG P/N 7020023)

• Interval - Change every year or 1000 hours of opera-tion.

d. Air Filter

• Maintenance - Replaceable Element

• Interval - Check every 1000 hours of operation.Replace every 2 years.

6-14 – JLG Lift – 3121330


e. 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 ofoperation.

10. Fuel Tank

• Capacity - 90 ltr (23.8 gal)

• Type - Diesel Fuel

• Interval - Check fuel periodically during each use.

3121330 – JLG Lift – 6-15


6.4 TIRES AND WHEELS

Tire DamageFor pneumatic tires, JLG Industries, Inc. recommends thatwhen any cut, rip, or tear is discovered that exposes sidewallor tread area cords in the tire, measures must be taken toremove the JLG product from service immediately. Arrange-ments must be made for replacement of the tire or tireassembly.

For polyurethane foam filled tires, JLG Industries, Inc. recom-mends that when any of the following are discovered, mea-sures must be taken to remove the JLG product from serviceimmediately and arrangements must be made for replace-ment of the tire or tire assembly.

• a smooth, even cut through the cord plies whichexceeds 7.5 cm (3 inches) in total length

• any tears or rips (ragged edges) in the cord plieswhich exceeds 2.5 cm (1 inch) in any direction

• any punctures which exceed 2.5cm in diameter

• any damage to the bead area cords of the tire

If a tire is damaged but is within the above noted criteria, thetire must be inspected on a daily basis to insure the damagehas not propagated beyond the allowable criteria.

Tire ReplacementJLG recommends a replacement tire be the same size, plyand brand as originally installed on the machine. Refer to theJLG Parts Manual for the part number of the approved tiresfor a particular machine and model. If not using a JLGapproved replacement tire, we recommend that replacementtires have the following characteristics:

• Equal or greater ply/load rating and size of original

• Tire tread contact width equal or greater than original

• Wheel diameter, width, and offset dimensions equal tothe original

Unless specifically approved by JLG Industries Inc. do notreplace a foam filled tire assembly with a pneumatic tire.When selecting and installing a replacement tire, ensure thatall tires are inflated to the pressure recommended by JLG.Due to size variations between tire brands, both tires on thesame axle should be the same.

6-16 – JLG Lift – 3121330


Wheel ReplacementThe rims installed on each product model have beendesigned for stability requirements which consist of trackwidth, tire pressure, and load capacity. Size changes such asrim width, center piece location, larger or smaller diameter,etc., without written factory recommendations, may result inan unsafe condition regarding stability.

Wheel InstallationIt is extremely important to apply and maintain proper wheelmounting torque.

WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPERTORQUE TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSI-BLE DANGEROUS SEPARATION OF WHEEL FROM THE AXLE.

Tighten the lug nuts to the proper torque to prevent wheelsfrom coming loose. Use a torque wrench to tighten the fas-teners. If you do not have a torque wrench, tighten the fas-teners with a lug wrench, then immediately have a servicegarage or dealer tighten the lug nuts to the proper torque.Over-tightening will result in breaking the studs or perma-nently deforming the mounting stud holes in the wheels. Theproper procedure for attaching wheels is as follows:

1. Start all nuts by hand to prevent cross threading. DO NOT use a lubricant on threads or nuts.

2. Tighten nuts in the following sequence:

1

2

3 4

5

6

6 LUG PATTERN

3121330 – JLG Lift – 6-17


3. The tightening of the nuts should be done in stages. Fol-lowing the recommended sequence, tighten the nuts perwheel torque chart.

4. Wheel nuts should be torqued after the first 50 hours ofoperation and after each wheel removal. Check torqueevery 3 months or 150 hours of operation.

6.5 LSS TESTING AND EVALUATIONConfirm Load Sensing System Performance with CalibratedWeights:

1. Operate the vehicle from 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 warnings are active. 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.

TORQUE SEQUENCE

1st Stage 2nd Stage 3rd Stage

150-190 ft lbs(210 - 270 Nm)

230 - 270 ft lbs(320-380 Nm)

305 - 343 ft lbs( 440 - 480 Nm)

6-18 – JLG Lift – 3121330


6.6 SUPPLEMENTAL INFORMATIONThe following information is provided in accordance with therequirements of the European Machinery Directive 2006/42/EC and is only applicable to CE machines.

For electric powered machines, the equivalent continuous A-Weighted sound pressure level at the work platform is lessthan 70dB(A)

For combustion engine powered machines, guaranteedSound Power Level (LWA) per European Directive 2000/ 14/EC (Noise Emission in the Environment by Equipment forUse Outdoors) based on test methods in accordance withAnnex III, Part B, Method 1 and 0 of the directive, is 109 dB.

The vibration total value to which the hand-arm system issubjected does not exceed 2,5 m/s2. The highest root meansquare value of weighted acceleration to which the wholebody is subjected does not exceed 0,5 m/s2.

3121330 – JLG Lift – 6-19


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6-20 – JLG Lift – 3121330

SECTION 7 - INSPECTION AND REPAIR LOG

SECTION 7. INSPECTION AND REPAIR LOG

Table 7-1. Inspection and Repair Log

Date Comments

3121330 – JLG Lift – 7-1

SECTION 7 - INSPECTION AND REPAIR LOG

Table 7-1. Inspection and Repair Log

Date Comments

7-2 – JLG Lift – 3121330

SECTION 8 - APPENDIX

SECTION 8. APPENDIX

This Appendix includes the following documents that pertain to this machine:

EC Declaration of Conformity for 210-25 and 245-25

JLG - Test Report for 210-25 and 245-25

Transfer of Ownership

3121330 – JLG Lift – 8-1


EC

Dec

lara

tion

of

Co

nfo

rmity

fo

r M

od

el 2

10-2

5

8-2 – JLG Lift – 3121330


EC

Dec

lara

tion

of

Co

nfo

rmity

fo

r M

od

el 2

45-2

5

3121330 – JLG Lift – 8-3


JLG

Tes

t R

epo

rt f

or

Mo

del

210

-25

8-4 – JLG Lift – 3121330


JL

G T

est

Rep

ort

fo

r M

od

el 2

45-2

5

3121330 – JLG Lift – 8-5


This page intentionally left blank.

8-6 – JLG Lift – 3121330

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8-8 – JLG Lift – 3121330

Corporate Office

JLG Industries, Inc.

1 JLG Drive

McConnellsburg PA. 17233-9533

USA

(717) 485-5161

(717) 485-6417

JLG Worldwide LocationsJLG Industries (Australia)P.O. Box 511911 Bolwarra RoadPort MacquarieN.S.W. 2444Australia

+61 2 65 811111

+61 2 65 810122

JLG Latino Americana Ltda.Rua Eng. Carlos Stevenson,80-Suite 7113092-310 Campinas-SPBrazil

+55 19 3295 0407

+55 19 3295 1025

JLG Industries (UK) LtdBentley HouseBentley AvenueMiddletonGreater ManchesterM24 2GP - England

+44 (0)161 654 1000

+44 (0)161 654 1001

JLG France SASZ.I. de Baulieu47400 FauilletFrance

+33 (0)5 53 88 31 70

+33 (0)5 53 88 31 79

JLG Deutschland GmbHMax-Planck-Str. 21D - 27721 Ritterhude - IhlpohlGermany

+49 (0)421 69 350 20

+49 (0)421 69 350 45

JLG Equipment Services Ltd.Rm 1107 Landmark North39 Lung Sum AvenueSheung Shui N. T.Hong Kong

(852) 2639 5783

(852) 2639 5797

JLG Industries (Italia) s.r.l.Via Po. 2220010 Pregnana Milanese - MIItaly

+39 029 359 5210

+39 029 359 5845

JLG Europe B.V.Polaris Avenue 632132 JH HoofddorpThe Netherlands

+31 (0)23 565 5665

+31 (0)23 557 2493

JLG PolskaUI. Krolewska00-060 WarsawaPoland

+48 (0)914 320 245

+48 (0)914 358 200

JLG Industries (Scotland)Wright Business Centre1 Lonmay RoadQueenslie, Glasgow G33 4ELScotland

+44 (0)141 781 6700

+44 (0)141 773 1907

Plataformas Elevadoras JLG Iberica, S.L.Trapadella, 2P.I. Castellbisbal Sur08755 Castellbisbal, BarcelonaSpain

+34 93 772 4700

+34 93 771 1762

JLG Sverige ABEnkopingsvagen 150Box 704SE - 176 27 JarfallaSweden

+46 (0)850 659 500

+46 (0)850 659 534

www.jlg.com

3121330

Documents

Operation and Safety Manual - JLG Industries