Liftlux Diesel Training

LIFTLUX SERVICE TRAINING
Series 2 (Excluding Electric Models)
European
Models
SL153-12
SL153-22
SL180-12
SL203-24
SL210-25
SL245-12
SL245-25
SL260-25
SL320-30
1 An Oshkosh Truck Corporation Company

Specification # 2

Handrails # 3
The hand rails on smaller models fold flat inwards onto the
scissor deck and are of steel construction.
On the larger scissor models the platform rails

Are made of Aluminium and fold outwards.
These hang over the side of the Platform.
The Steel deck extension rails fold inwards and
lay on the Platform

Main Terminal Board => Control Stations # 4
Ground Control
1 Emergency Stop 5
8
2 Key Switch
3 Battery Isolator
4 Start Switch
4
5 Glow Plug 1
6 6
6 Lift Switch
7
7 Outrigger Select Switch 8
7 8 Deck Extension Switch 3 2
Platform Control
5 Platform Control
1 1 Emergency Stop
2 Joystick
4 3 Steer
2
4 Start Switch
5 Glow Plug
6 Trigger Switch
3 7 Speed Select Switch
8 Function Select Switch
Ground Control
Main Terminal Box Control

Cable Connections # 7
See E Schematic for clearer

explanation of controls
To Main Terminal
Box
To Ground Control
To
24 Pin Connector
To Platform Control

Platform Control # 5
Take the Control Box lead

and plug it Into the plug
concealed under the floor

Basic Layout # 6
Deutz F4L 2011 Gear or Variable

Displacement Pump.
Depending on Model
To Pump
To Valve
Danfoss PVG 120 Drive Danfoss PVG 32 for
& Lift + Hoerbiger 260-
260-25 & 320-
320-30 Model
Traction Valve
To
And
OR Other Models

Emergency Stop # 8

Deutz Engine F4 or 3L2011 # 9
Data below for 4 cylinder version
Fill
Dipstick
Drain
3 & 4 Cylinder
Engines depend upon model
Please use this chart

for correct oil depending
upon ambient temperature.
Also see service manual
Engine Tray # 10
15 cm
15 cm
The Engine tray can be extended by

Approximately 15 cm to allow servicing
of the Alternator and Starter Motor
And is secured by the two clamping bolts

Engine Control Box # 11
Location
By-
By-Pass
Glow Indicator
1
2
3
4 Start
5
Hour Meter 6
N.B - Do not confuse terminal strips X1 & X2 in this

box with those in Main Terminal Box on schematic
2 3 1 4 6 5

Engine Control Box # 12
1. Engine Start Button for operating machine from under the

1 hood.
2. Holding this button in (Bleed) when starting will allow
cranking of the engine to continue longer when the engine
is cold.
3. If a failure occurs & all the LED’
LED’s are flashing, re-
re-starting
of the engine will not be allowed for 3 minutes.
4. Do not Jump Start machine as a result of a flat

battery as this will possibly damage this control
box.

Engine Control Box Wiring # 13

Engine Control Box Wiring # 14

Engine Control Box Wiring S2 # 15

Glow Plug Relays # 16
1
3 2 #1 Timer Relay N6
#2 Relay K3
3 #3 Fuse 30amp

Lift Cylinder # 17
To Brakes
From Lift Valve
To Descent Tap
LSS Manifold
Pressure Switch set @
e.g 210 bar – SL245-25
17
& Brake Valve An Oshkosh Truck Corporation Company
Ground Control Components # 18
Overload PNP Module

Module See P8
See P13
Mercury
Switch
See P7
Relay K1 Relay KD2 Engine

Stabilisers Torque
See P7
See P4
10A
Fuse Relay KVS
Voltage Drop
See P6
See P2
Terminal Jumpers &

Numbers X1/1 – X1/58
See P9A & P9B
Terminal Strip &
Cable Entry Schematic Page
numbers
Outriggers # 19
The activation of the outriggers with automatic self levelling can

can
be used optionally by way of a ON / OFF key switch located next
to the ground EMS. If selected operation of the jack function will
will
be automatically controlled by the lift function.
X1/43 Controls Key Off X1/39 Controls Key On
N.B Key has 3 positions.
From X1/43
From X1/39
Nivolux
Card

Leveling Process # 20
Outrigger
Pressure Switch

Leveling Process # 21
4 1
Front Steer Axle +

X
-
The levelling process begins with the lowest
3 -Y+ 2 corner of the frame. The LED’
LED’s will
reference which jack is operating.

Oscillating Axle # 22
Two Limit Switches connected in series monitor

the Oscillating Axle angle.
A tripped switch will prevent the drive function
When 50cm of scissor opening is reached.
Once the platform is raised & triggers
the 2,5m Limit Switch the signal to the cylinder
solenoids is cut & locks the axle out.

Steer Cylinder # 23
Steering Control Panel

Cylinder & Steering Switch
See Hydraulic &

Electrical Schematics
For further explanation

Main Pump:
Models 265-25 + 320-30 # 24
Pump 1 Pump 2
High Speed Controlled

By L/S S2,5 &
P3 P2 P1
• P1 is the Main Function Pump

• P2 is the High Speed Pump
• P3 is the Steering Pump

Main Pump Variable Displacement:
Models 210-25 245-25 & 245-12 # 25
2
1
N.B.
This Pump is factory set for flow, pressure & Horse Power
Control & should not normally require any adjustment.
However should this require adjustment #1 Standby
#2 Max Pressure
{See slide 28 for procedure}

Danfoss PVG 32 & 120
Models 265-25 & 320-30 # 26
PVG 120 PVG 32
Drive 1 Lift
1 2 3 4 5 6 7
Also to Oscillating Axle See schematic
#1 Main Pressure & Tank Block

#2 Drive 2 - Proportional
#3 Extending Deck – Bang/Bang
#4 R/R Outrigger – Bang/Bang
#5 R/L Outrigger – Bang/Bang
#6 F/L Outrigger – Bang/Bang
#7 F/R Outrigger – Bang/Bang

Danfoss PVG32 Models Except
Previous Slide # 27
# 1 Main Pressure/Tank Inlet

# 2 Extending Deck
# 3 Drive 2
# 4 Lift
# 5 Steering
# 6 R/R Outrigger
# 7 R/L Outrigger
# 8 F/L Outrigger 10
# 9 F/R Outrigger 9
# 10 Drive 1 8
7
6
5
4
3
2
1
This valve layout is a general view & may vary

from model-model

Models with Remote Steer
Valve # 28
Models:
153-22, 203-24, 260-25 & 320-30
Adjust Pressure to 175 bar

Dead Head steering to attain
pressure

Main Pressure Adjustment # 29
Adjust main pressure:

SL 153-12 185 bar
SL153-22 190 bar
SL180-12 195 bar
SL203-24 210 bar
SL245-12 210 bar
SL210-25 185 bar
SL245-12 185 bar
SL245-25 210 bar
SL 260-25 195 bar
SL320-30 195 bar (See Next Slide)

Main Pressure Adjustment Cont … # 30
Procedure Models:
265-25 & 320-30
Adjustment PVG 120:

Install a gauge at point indicated (inset).
Operate Deck retract & adjust at point
indicated (inset)
1
Extending Deck # 31

Extending Deck Cylinders # 32
2 Cylinders are used for

Extending the Deck on:
SL245-25
SL260-25
SL320-30

Drive Motors # 33
4
3 2
3
1
1
4
#1Case Drain Line
#2 Fwd Direction
#3 Rev Direction Brevini Torque Hubs
Torque wheel nuts to
#4 Brake Line 480nm

Torque Hubs (Brevini) # 34
Hub Disengaged other

models
12.00 O'clock Filler
Oil Level
Hub Shown above from 32-30
Dis-engage Brakes on
Manual Descent Valve
Oil Level

Lug Nut Torque Settings # 35
Settings in Nm
Model Qty Front Axle Rear Axle

153-12 24 480 "
153-22 24 480 "
180-12 24 480 "
203-24 24 480 "
210-25 24 480 "
245-25 24 480 "
245-12 24 480 "
260-25 32 680 "
320-25 48 930 "

Scissor Pack # 36
Each Pin is secured in place with a

Threaded Locking Ring and Tab
Washer.
Grease Nipples are located

At each end of the Pin and should be
Lubricated every 6 months

Hoerbiger Drive Valve # 37
Some models may use only

3 Solenoid valves + the layout will be slightly different but the principal is the same
Section # 3 Drive 2
Section # 10 Drive 1
Front Rear
2 3 4
1
D1
10
9 6
8 5
7
D2 6
5
4
3 Hoerbiger Valve Block
2
1

Hoerbiger Drive Valve Cont …
…..##38
36
1
Hoerbiger Drive Valve Cont … # 39
Fast Drive From Drive 1

Drive 2 Passive

Hoerbiger Drive Valve Cont … # 40
From Drive 2 From Drive 1

Differential Drive

Limit Switch Installation # 41
# 1 Will automatically retract the jacks if

they have been deployed
# 2 Will Cut out High speed drive (Height varies on models)
Set to trip at 50cm of scissor opening
# 3 Drive cut out switch
(Not Used on models with full drive height)
# 4 Cuts lift up function just before end of
cylinder stroke. (No false LSS pressure)
Typical
Installation
1 2 3 4
1
Model Drive c/o heights # 42
SL153-12 7m
SL153-22 Full Height
SL180-12 7m 1 2 3 4
SL203-24 18m
SL245-12 18m
SL245-25 21m
SL320-30 20m
Drive C/O
Not used on
some models
see chart
opposite
1
Manual Descent # 43
SL 153-22
STEERING
LIFT
Ext Deck
BRAKE

Manual Descent # 44
With the Two levers in SL 153-22

The vertical position
Oil will free flow
Through the drive valve
Hand Pump
1. Close the tap on the hand pump.

2. Position the levers in the various
direction as identified by the decals or in
the operating manual
3. Pump the handle until function movement
is complete.
4. Return handles to vertical position undo
the tap to relieve pressure.
Manual Descent # 45
SL 203-24 SL245-25

Manual Descent # 46
SL 260-25 SL320-30
Rotate Red Knobs to
activate

Tilt Sensor # 47
The Tilt Sensor is mounted next to the

Deutz Engine control module above
the PVG32 Valve Block
Should the frame inclination angle go

Beyond 3 Degrees the platform will not
Elevate above 50cm of scissor arm opening
An elevated and tilted platform beyond

50cm of scissor arm opening will result in
the pump solenoid being cut,
therefore only lowering is Possible.
Red Wire input X1/34

from S2,5 L/S
Output X1/29 to Light
at Platform Box
Light goes out when tilted
Beyond 3 deg (ser1)

Platform Control Box # 48
5
6 7 8 5
1
1 2 3 4
1 2 3 4 5
1. Drive Speed Select

2. Lift Lower Select (with Jumper Complex) 4 3 2 1
3. Drive/Deck Extend/Lift Select
4. Steer Direction
2
5. Joystick 3 4
6. Emergency Stop
7. Horn
8. Start 1. 24v
2. Switched 24v
1 Tilt Indication (Direction Indicated) 3. Analogue Signal (“
(“S”)
2 Drive Speed Cut 4. Ground
4
3 Lift Up Cut 2
4 Drive Cut 3
5 SWL L.S.S Active 1
Switched Off Series 1 & On Series 2
Platform Control Box # 49
24v Ground Analogue

Complex Circuit Board # 50
J2 J3 J1


Two Potentiometers are

Found on the ‘Complex’
Circuit Board.
TP1
Will adjust the elevated drive
Speed above heights of Complex Nivolux
2.5m
TP2
Will adjust the ramp speed:
Set at approx 2 secs
Jumper 1
Not used
Jumper 2
(Pins Closed)
Required for CE to enable
Lift Button

Complex Board T/T # 53

Complex – Board T/T # 54

Complex – Board T/T # 55

Complex – Board Connector Table # 56

Nivolux Card # 57

Nivolux Card T/T # 58

Nivolux Card Adjustments # 59
For the Nivolux Automatic Levelling system set the Scissor

frame at true Zero degrees, then Nivolux card must be set at
zero volts.

Nivolux Card Adjustments # 60
Place the machine on a true

zero degrees surface and
adjust the x & y trim pots
until zero volts can be
measured from the two
poles on the card. X Y

Nivolux Card Schematic # 61
61 J7 J5 J6 J1 J8 J10 An Oshkosh Truck Corporation Company

Nivolux Card Schematic # 62

PNP Module Time Delay # 63
J1 J2
Potentiometer
Module
Location

Relay K1 P Nozz # 64
K1
This relay K1 P Nozz is to sense contact with the

ground of the outriggers.
If this is lost lift will not be allowed

Relay KVS # 65
KVS
KVS Relay
To allow for voltage drop
From Platform to Ground

Relay KD2 # 66
KD2
KD2 Switches when

Engine speed & torque
are sufficient

Cable Layout # 67

Main Terminal Board Wiring Explanation # 68 MTB
TOP 4
Top Terminals M.T.B

2
1
3
1 = Terminal Bridge
2 = X1/? Terminal Number e.g X1/15
3. Wire connection description
4 = Position within Schematics – e.g 6J
5 Page 6 Column J.
5 = Terminal Bridge as in 1 Ref same
terminal
LSS Module Wiring (No Overload) # 69

LSS Module Wiring (Overloaded) # 70

LSS Setup Procedure # 71




Load Setup Chart for LSS

LSS Relay # 76

LSS Relay # 76
This
Concludes
This Session
of the Training
Thank you

Liftlux Diesel Training

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LIFTLUX SERVICE TRAINING

Series 2 (Excluding Electric Models)

1 An Oshkosh Truck Corporation Company

2 An Oshkosh Truck Corporation Company

On the larger scissor models the platform rails

3 An Oshkosh Truck Corporation Company

4 An Oshkosh Truck Corporation Company

See E Schematic for clearer

5 An Oshkosh Truck Corporation Company

Take the Control Box lead

6 An Oshkosh Truck Corporation Company

Deutz F4L 2011 Gear or Variable

7 An Oshkosh Truck Corporation Company

8 An Oshkosh Truck Corporation Company

Data below for 4 cylinder version

Please use this chart

The Engine tray can be extended by

10 An Oshkosh Truck Corporation Company

N.B - Do not confuse terminal strips X1 & X2 in this

11 An Oshkosh Truck Corporation Company

1. Engine Start Button for operating machine from under the

4. Do not Jump Start machine as a result of a flat

12 An Oshkosh Truck Corporation Company

13 An Oshkosh Truck Corporation Company

14 An Oshkosh Truck Corporation Company

15 An Oshkosh Truck Corporation Company

16 An Oshkosh Truck Corporation Company

Overload PNP Module

Relay K1 Relay KD2 Engine

Terminal Jumpers &

The activation of the outriggers with automatic self levelling can

19 An Oshkosh Truck Corporation Company

20 An Oshkosh Truck Corporation Company

Front Steer Axle +

21 An Oshkosh Truck Corporation Company

Two Limit Switches connected in series monitor

22 An Oshkosh Truck Corporation Company

Steering Control Panel

See Hydraulic &

23 An Oshkosh Truck Corporation Company

High Speed Controlled

• P1 is the Main Function Pump

24 An Oshkosh Truck Corporation Company

25 An Oshkosh Truck Corporation Company

PVG 120 PVG 32

Also to Oscillating Axle See schematic

#1 Main Pressure & Tank Block

26 An Oshkosh Truck Corporation Company

# 1 Main Pressure/Tank Inlet

This valve layout is a general view & may vary

27 An Oshkosh Truck Corporation Company

Adjust Pressure to 175 bar

28 An Oshkosh Truck Corporation Company

Adjust main pressure:

29 An Oshkosh Truck Corporation Company

Adjustment PVG 120:

31 An Oshkosh Truck Corporation Company

2 Cylinders are used for

32 An Oshkosh Truck Corporation Company

33 An Oshkosh Truck Corporation Company

Hub Disengaged other

34 An Oshkosh Truck Corporation Company

Model Qty Front Axle Rear Axle

35 An Oshkosh Truck Corporation Company