Operation & Safety Manual Original Instructions Keep this manual with machine at all times.
CALIFORNIA PROPOSITION 65 BATTERY WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemical known to the State of California to cause cancer and reproductive harm. WASH HANDS AFTER HANDLING! CALIFORNIA PROPOSITION 65 EXHAUST WARNING Diesel Engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm.
Revision Log Revision Log REVISION LOG September 28, 2012 - A - Original Issue of Manual November 16, 2012 - B - Revised pages 3-6, 9-6 & 9-7. July 31, 2013 - C - Revised cover and pages 1-6, 1-7, 1-14, 1-15, 2-3, 2-4, 2-5, 2-6, 2-7, 3-2, 3-3, 3-4, 3-5, 3-14, 3-22, 3-24, 4-10, 5-2, 5-15, 6-2, 8-1, 8-2, 9-3, 9-4, 9-5 & 9-6. October 1, 2014 - D - Revised cover and pages 1-13, 2-4, 2-7, 3-2, 3-3, 3-4, 3-5, 3-22, 5-11, 8-1, 8-2, 9-1 & 9-3.
Read This First Read This First This manual is a very important tool! Keep it with the machine at all times. The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and operating procedures essential for the safe and proper machine operation for its intended purpose. Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without prior notification. Contact JLG Industries, Inc.
Read This First This product must comply with all safety related bulletins. Contact JLG Industries, Inc. or the local authorized JLG representative for information regarding safetyrelated bulletins which may have been issued for this product. JLG Industries, Inc. sends safety related bulletins to the owner of record of this machine. Contact JLG Industries, Inc. to ensure that the current owner records are updated and accurate. JLG Industries, Inc.
Read This First Other Publications Available Service Manual..........................................................................................31200792 Illustrated Parts Manual.............................................................................31200727 Note: The following standards may be referenced in this manual: ANSI is compliant to ANSI/ITSDF B56.6 AUS is compliant to AS 1418.
Table of Contents Table of Contents TABLE OF CONTENTS Revision Log Read This First Operator Qualifications ...................................................... b Modifications ...................................................................... b Other Publications Available .............................................. d Machine Configuration ....................................................... d Table of Contents Section 1 - General Safety Practices 1.1 Hazard Classification System ............
Table of Contents 3.3 3.4 3.5 3.6 G10-43A ......................................................................... 3-4 Dash Controls and Indicators ......................................... 3-6 Ignition ............................................................................ 3-7 Park Brake...................................................................... 3-8 Parking Procedure.......................................................... 3-8 Transmission Control Lever.................................
Table of Contents Section 5 - Attachments 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 Approved Attachments ........................................................5-1 Unapproved Attachments ....................................................5-1 JLG Supplied Attachments ..................................................5-2 Telehandler/Attachment/Fork Capacity................................5-4 Use of the Capacity Chart....................................................5-5 Capacity Indicator Locations ..........
Table of Contents Section 7 - Lubrication and Maintenance 7.1 Introduction.......................................................................... 7-1 Clothing and Safety Gear ............................................... 7-1 7.2 General Maintenance Instructions....................................... 7-2 7.3 Service and Maintenance Schedule.................................... 7-3 10, 1st 50 & 50 Hour Maintenance Schedule ................. 7-3 1st 250, 250 & 1st 500 Hour Maintenance Schedule .....
Section 1 - General Safety Practices SECTION 1 - GENERAL SAFETY PRACTICES 1.1 HAZARD CLASSIFICATION SYSTEM Safety Alert System and Safety Signal Words DANGER OW0010 DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING OW0021 WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Section 1 - General Safety Practices 1.3 OPERATION SAFETY Electrical Hazards 10 FT (3 M) OW0040 • This machine is not insulated and does not provide protection from contact or being near electrical current. • NEVER operate the telehandler in an area where overhead power lines, overhead or underground cables, or other power sources may exist without ensuring the appropriate power or utility company de-energizes the lines. • Always check for power lines before raising the boom.
Section 1 - General Safety Practices Tip Over Hazard General • For additional load requirements, refer to the appropriate capacity chart. OW0050 • Never use an attachment without the appropriate JLG approved capacity chart installed on the telehandler. • Understand how to properly use the capacity charts located in cab. • DO NOT exceed rated lift capacity. • Be sure that the ground conditions are able to support the machine.
Section 1 - General Safety Practices OH2291 • MAINTAIN proper tire pressure at all times. If proper tire pressures are not maintained, this machine could tip over. • Refer to manufacturer’s specifications for proper fill ratio and pressure requirements for tires equipped with ballast. OH20911 • Always wear the seat belt. • Keep head, arms, hands, legs and all other body parts inside operator’s cab at all times.
Section 1 - General Safety Practices Non-Suspended Load OW0060 • DO NOT drive with boom raised. Suspended Load OW0150 • Tether suspended loads to restrict movement. • Weight of all rigging (slings, etc.) must be included as part of load. • Beware of wind. Wind can cause a suspended load to swing and cause dangerous side loads - even with tag lines. • DO NOT attempt to use telehandler frame-leveling to compensate for load swing. • Keep heavy part of load closest to attachment.
Section 1 - General Safety Practices Travel Hazard 2-Wheel Front Steer 4-Wheel Circle Steer 4-Wheel Crab Steer OAL2030 • Steering characteristics differ between steer modes. Identify the steer mode settings of the telehandler being operated. • DO NOT change steer modes while traveling. Steer modes must be changed while telehandler is stationary. • Visually verify proper wheel alignment after each steer mode change.
Section 1 - General Safety Practices Load Falling Hazard OW0130 • Never suspend load from forks or other parts of carriage weldment. Use only JLG approved lift points. • DO NOT burn or drill holes in fork(s). • Forks must be centered under load and spaced apart as far as possible.
Section 1 - General Safety Practices Lifting Personnel OW0170 • When lifting personnel, USE ONLY an approved personnel work platform, with proper capacity chart displayed in the cab. OW0190 • DO NOT drive machine from cab when personnel are in platform.
Section 1 - General Safety Practices Driving Hazards On Slopes OW0200 To maintain sufficient traction and braking capabilities, travel on slopes as follows: • When unloaded, drive with forks pointed downhill. • When loaded, drive with the forks pointed uphill. • For additional travel requirements, refer to the appropriate capacity chart. • To avoid overspeeding the engine and drivetrain when driving down slopes, downshift to a lower gear and use the service brake as necessary to maintain a slow speed.
Section 1 - General Safety Practices Pinch Points and Crush Hazards Stay clear of pinch points and rotating parts on the telehandler. OW0210 • Stay clear of moving parts while engine is running. OW0220 • Keep clear of steering tires and frame or other objects. OW0230 • Keep clear from under boom.
Section 1 - General Safety Practices OW0240 • Keep clear of boom holes. OW0250 • Keep arms and hands clear of attachment tilt cylinder. OW0260 • Keep hands and fingers clear of carriage and forks. OW0960 • Keep others away while operating.
Section 1 - General Safety Practices Fall Hazard OW0280 • Enter using the proper hand holds and steps provided. Always maintain 3-point contact when mounting or dismounting. Never grab control levers or steering wheel when mounting or dismounting the machine. • DO NOT get off the machine until the shutdown procedure on page 4-4 has been performed. OW0290 • DO NOT carry riders. Riders could fall off machine causing death or serious injury.
Section 1 - General Safety Practices Chemical Hazards Exhaust Fumes • DO NOT operate machine in an enclosed area without proper ventilation. • DO NOT operate the machine in hazardous environments unless approved for that purpose by JLG and site owner. Sparks from the electrical system and the engine exhaust can cause an explosion. Flammable Fuel OW0300 • DO NOT fill the fuel tank or service the fuel system near an open flame, sparks or smoking materials.
Section 1 - General Safety Practices 1.4 CLEARSKY (IF EQUIPPED) Federal Communications Commission (FCC) Information for Users FCC Statement Regarding Interference This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation.
Section 1 - General Safety Practices Antenna Installation A minimum separation distance of eight inches (20 centimeters) must be maintained between the antenna and all persons. The combined cable loss and antenna gain must not exceed +7.5 dBi (850 band). The combined cable loss and antenna gain must not exceed +2.5 dBi and total system output must not exceed 2.0W EIRP in the PCS (1900) band in order to comply with the EIRP limit of 24.232 (b).
Section 1 - General Safety Practices This Page Intentionally Left Blank 1-16 31200744
Section 2 - Pre-Operation and Inspection SECTION 2 - PRE-OPERATION AND INSPECTION 2.1 PRE-OPERATION CHECK AND INSPECTION Note: Complete all required maintenance before operating unit. WARNING FALL HAZARD. Use extreme caution when checking items beyond your normal reach. Use an approved ladder. The pre-operation check and inspection, performed at beginning of each work shift or at each change of operator, should include the following: 1.
Section 2 - Pre-Operation and Inspection 8. Operational Check - Once the walk-around inspection is complete, perform a warm-up and operational check (see page 2-12) of all systems in an area free of overhead and ground level obstructions. See Section 3 - Controls and Indicators for more specific operating instructions. WARNING If telehandler does not operate properly, immediately bring machine to a stop, lower boom and attachment to ground and stop the engine.
Section 2 - Pre-Operation and Inspection 2.2 SAFETY DECALS Ensure all DANGER, WARNING, CAUTION and instructional decals and proper capacity charts are legible and in place. Clean and replace as required. ANSI 1706768-ENGLISH 1706300-ENGLISH 1001163300-ENGLISH/FRENCH (ENCLOSED CAB) 1001163212-ENGLISH/FRENCH 1001160071-ENGLISH 1001160787-ENGLISH/FRENCH (IF EQUIPPED) DO NOT use Ether or other high energy starting aids. ENGINE EXPLOSION could result in death or serious injury.
Section 2 - Pre-Operation and Inspection 1001109459 (G6-42A & G9-43A, IF EQUIPPED) 1001109458 (G10-43A) (G9-43A, IF EQUIPPED) 1706851-ENGLISH 1001163321ENGLISH/FRENCH 1706303-ENGLISH 1001163273-ENGLISH/FRENCH Operator must be trained and must read and underst and all cap acity chart s, operator and safety manuals. 1706767-ENGLISH 1001163291ENGLISH/FRENCH 1706851A 1001131745A 1001109459C Fasten seat belt. 1001109458 1706767A 91163028 N R 91163028 REV.
Section 2 - Pre-Operation and Inspection 1706302-ENGLISH 1001163223-ENGLISH/FRENCH 50 60 70 80 4105262 40 20 -10 0 10 30 F G 50° 60° 70° 80° G 40° 30° -10° 0° 10° 20° 1706302-ENGLISH 1001163223-ENGLISH/FRENCH 91553072 F 1706302-ENGLISH 1001163223-ENGLISH/FRENCH 1706302-ENGLISH 1001163223-ENGLISH/FRENCH 1706298-ENGLISH 1001163206-ENGLISH/FRENCH 1706302-ENGLISH 1001163223-ENGLISH/FRENCH 1706298A VIEW F-F 31200744 VIEW G-G OY2111 2-5
Section 2 - Pre-Operation and Inspection ISO 1001092878 (ENCLOSED CAB) 1706098 1001160912 (IF EQUIPPED) 1 2 1001160912 Rev A 1001139654 (IF EQUIPPED FOR LS) 1706098 B S 15 mg/kg A 1001154575 D 1001139654 A A B C B C D D 9150-3112 REV - 91503112 (G9-43A IF EQUIPPED) (G10-43A) 1702300 1701640 1001092878 (OPEN CAB) 1701640 1706288 1702300 VIEW B-B (G6-42A & G9-43A) 1706284 1702300 1001092877 1702300 VIEW C-C (G10-43A) VIEW A-A 1702300 1702300 OY3151 VIEW D-D 2-6 31200744
Section 2 - Pre-Operation and Inspection 1001109459 (G6-42A & G9-43A, IF EQUIPPED) 1001131745 (G6-42A, IF EQUIPPED) 1001109458 (G10-43A) (G9-43A, IF EQUIPPED) 1706287 1706293 1706283 1001131745A 1001109459C 1706289 1001109458 91163028 N R 91163028 REV.
Section 2 - Pre-Operation and Inspection 1706292 50 60 70 80 4105262 40 20 -10 0 10 30 F G 50° 60° 70° 80° G 40° 30° -10° 0° 10° 20° 1706292 91553072 F 1706292 1706292 1706282 1706292 OY2140 VIEW F-F 2-8 VIEW G-G 31200744
Section 2 - Pre-Operation and Inspection This Page Intentionally Left Blank 31200744 2-9
Section 2 - Pre-Operation and Inspection 2.3 WALK-AROUND INSPECTION 18 1 2 3 17 16 4 15 14 13 5 6 12 7 8 11 9 10 OAL3491 Begin your walk-around inspection at item 1, as noted below. Continue to your right (counterclockwise when viewed from top) checking each item in sequence. INSPECTION NOTE: On all components, make sure there are no loose or missing parts, that they are securely fastened and no visible leaks or excessive wear exists in addition to any other criteria mentioned.
Section 2 - Pre-Operation and Inspection 5. Mirror - Clean and undamaged. 6. Cab and Electrical • General appearance; no visible damage. • Frame level indicator and window glass undamaged and clean. • Gauges, switches, joysticks, foot controls and horn operational. • Emergency escape hammer in place (enclosed cab only). • Check seat belt for damage, replace belt if frayed or cut webbing, damaged buckles or loose mounting hardware. 7.
Section 2 - Pre-Operation and Inspection 2.4 WARM-UP AND OPERATIONAL CHECKS Warm-Up Check During warm-up period, check: 1. Heater, defroster and windshield wiper (if equipped). 2. Check all lighting systems (if equipped) for proper operation. 3. Voltmeter should show 13.5 to 14 volts. 4. Adjust mirrors for maximum visibility. WARNING CUT/CRUSH/BURN HAZARD. Keep engine cover closed while engine is running except when checking transmission oil level.
Section 2 - Pre-Operation and Inspection 2.5 OPERATOR CAB The telehandler is equipped with an open or enclosed ROPS/FOPS cab. WARNING Never operate telehandler unless the overhead guard, cab structure and right side glass or screen are in good condition. Any modification to this machine must be approved by JLG to assure compliance with ROPS/FOPS certification for this cab/machine configuration. If the overhead guard or cab structure is damaged, the CAB CANNOT BE REPAIRED. It must be REPLACED.
Section 2 - Pre-Operation and Inspection 2.6 WINDOWS Keep all windows and mirrors clean and unobstructed. Cab Door Window (if equipped) 3 4 2 1 OAL0011 • Cab door (1) must be closed during operation. • During operation the cab door window (2) must either be latched open or closed. • Open the cab door window and secure it in the latch (3). • Press release button inside the cab or pull on lever (4) outside the cab to unlatch the window.
Section 3 - Controls and Indicators SECTION 3 - CONTROLS AND INDICATORS 3.1 GENERAL This section provides the necessary information needed to understand control functions. Note: The manufacturer has no direct control over machine application and operation. The user and operator are responsible for conforming with good safety practices.
Section 3 - Controls and Indicators 3.
Section 3 - Controls and Indicators 1. Transmission Control Lever: See page 3-10. 2. Instrument Panel: See page 3-6. 3. Steering Wheel: Turning the steering wheel to the left or right steers the machine in the corresponding direction. Three steering modes are available. See “Steer Modes” on page 3-19. 4. Frame Level Indicator: Enables the operator to determine the left to right level condition of the telehandler. 5. Accessory Control Lever (if equipped): See page 3-18. 6. Right Hand Panel: See page 3-17. 7.
Section 3 - Controls and Indicators G10-43A 4 3 5 6 7 8 2 1 14 9 13 12 11 10 OY3180 3-4 31200744
Section 3 - Controls and Indicators 1. Transmission Control Lever: See page 3-10. 2. Instrument Panel: See page 3-6. 3. Steering Wheel: Turning the steering wheel to the left or right steers the machine in the corresponding direction. Three steering modes are available. See “Steer Modes” on page 3-19. 4. Frame Level Indicator: Enables the operator to determine the left to right level condition of the telehandler. 5. Accessory Control Lever (if equipped): See page 3-18. 6. Right Hand Panel: See page 3-17. 7.
Section 3 - Controls and Indicators Dash Controls and Indicators 1 OY3190 10 2 9 3 4 5 8 7 6 1. Transmission Temperature Indicator: Illuminates red when transmission temperature is too high. Immediately bring machine to a stop, retract and lower boom and stop the engine. Determine cause and correct before continued use. 2. Engine Pre-Heat Indicator: Illuminates yellow with ignition key in the “RUN” position. Indicator goes out when start temperature is reached. 3.
Section 3 - Controls and Indicators Ignition ACC OFF RUN START OY2760 • In "ACC" or "RUN" position, voltage is available for all electrical functions. • Full clockwise rotation to "START" engages starter motor. • Counter-clockwise rotation to "OFF" stops engine and removes voltage from all electrical functions.
Section 3 - Controls and Indicators Park Brake 2 1 OY2770 Park brake switch controls the application and release of the park brake. Indicator light on switch illuminates to indicate brake is applied. • With the engine running and the park brake switch in "OFF" position (1), park brakes are disengaged. • With switch in "ON" position (2), park brake is engaged and transmission will not engage forward or reverse. WARNING MACHINE ROLL-AWAY HAZARD.
Section 3 - Controls and Indicators This Page Intentionally Left Blank 31200744 3-9
Section 3 - Controls and Indicators Transmission Control Lever Direction of Travel Selection F N R 1 OY2780 Transmission control lever (1) engages forward or reverse travel. • Lift and push lever forward for forward travel; lift and pull lever rearward for reverse travel. Move lever to centered position for neutral. • Forward or reverse travel can be selected while in any gear. • When traveling in reverse, the back-up alarm will automatically sound.
Section 3 - Controls and Indicators Gear Selection 1st 2nd 3rd 4th OY2790 2 Gear selection is located on the twist grip handle (2) of transmission control lever. • Twist hand grip to select gear. • Select the appropriate gear for the task being performed. Use a lower gear when transporting a load. Use a higher gear only when driving unloaded for longer distances. • Slow down prior to downshifting. Do not downshift more than one gear at a time.
Section 3 - Controls and Indicators Boom Joystick WARNING TIP OVER/CRUSH HAZARD. Rapid, jerky operation of controls will cause rapid, jerky movement of the load. Such movements could cause the load to shift or fall or could cause the machine to tip over. G6-42A, G9-43A If Equipped 3 1 2 OY3200 The boom joystick (1) controls the boom and attachment tilt (if equipped) functions.
Section 3 - Controls and Indicators G9-43A If Equipped, G10-43A 1 4 5 OY3210 The boom joystick (1) controls the boom, attachment tilt and clutch lock functions. Boom Functions • Move the joystick back to lift boom; move joystick forward to lower boom; move joystick right to extend boom; move joystick left to retract boom. • Speed of boom functions depends upon amount of joystick travel in corresponding direction. Increasing engine speed will also increase function speed.
Section 3 - Controls and Indicators Frame Level and Attachment Tilt (if equipped) Joystick 1 OY3220 The middle joystick (1) controls the left to right frame level and attachment tilt (if equipped) functions. Frame Level • Move the joystick left to rotate frame left, move the joystick right to rotate frame right. • A level indicator is located above the front cab window to permit operator to determine whether the telehandler frame is level. WARNING TIP OVER HAZARD.
Section 3 - Controls and Indicators Auxiliary Hydraulic Joystick G6-42A, G9-43A IF EQUIPPED G9-43A IF EQUIPPED, G10-43A 1 1 (G10-43A) (G6-42A) 1 (G9-43A) 1(G9-43A) OY3240 The auxiliary hydraulic joystick (1) controls function of attachments that require hydraulic supply for operation. See Section 5 - Attachments for approved attachments and control instructions.
Section 3 - Controls and Indicators Outrigger Joysticks (G10-43A) 1 OY3230 The rear joysticks (1) control the outriggers. • The left joystick controls left outrigger and the right joystick controls right outrigger. • Push joysticks forward to lower outriggers; push joysticks back to raise outriggers. • Use outriggers to increase stability and/or load capacity and in leveling the telehandler. Study capacity charts to determine maximum load capacities, with and without outriggers. WARNING TIP OVER HAZARD.
Section 3 - Controls and Indicators Right Hand Panel 10 9 2 1 11 6 12 13 5 3 1 2 4 7 2 8 OAL0543 Heater and Air Conditioning Controls (if equipped) 1. Air Vent: Two individually adjustable round vents. 2. Air Louver: Three individually adjustable air louvers. 3. Defroster Fan: Two speed fan. Press fan switch down for slow speed; press switch up for fast speed. Return switch to middle position to turn off. 4. Temperature Control Switch: Adjustable rotary switch 5.
Section 3 - Controls and Indicators Accessory Control Lever (if equipped) The accessory control lever (1) operates the turn signals, parking lights and headlights. 2 5 7 1 4 3 6 OY1350 Turn Signal • Push the lever forward (2) to activate the left turn signal. • Pull the lever back (3) to activate the right turn signal. • The lever must be manually returned to the center position to deactivate either turn signal. The lever will not cancel automatically after a turn.
Section 3 - Controls and Indicators 3.3 STEER MODES Three steer modes are available for operator use. 2-Wheel Front Steer 4-Wheel Circle Steer 4-Wheel Crab Steer OAL2030 Note: 2-Wheel Front Steer mode is required for travel on public roads. Steer Mode Change 1 2 3 OY1491 1. Bring machine to a stop using service brake while either circle steer mode (1) or crab steer mode (3) is selected. 4 5 OAM2400 2.
Section 3 - Controls and Indicators 3.4 OPERATOR SEAT Adjustments Prior to starting engine adjust seat for position and comfort. 3 4 1 2 OW0480 1. Suspension: Use knob to adjust suspension to the appropriate setting. Turn clockwise to increase stiffness. Turn counterclockwise to reduce stiffness. 2. Fore/Aft: Pull up on handle to move seat fore and aft. 3. Arm Rest: Arm rest can be moved up or down for comfort. 4. Seat Belt: Always fasten seat belt during operation.
Section 3 - Controls and Indicators Seat Belt OH20912 Fasten seat belt as follows: 1. Grasp both free ends of the belt making certain that belt webbing is not twisted or entangled. 2. With back straight in the seat, couple the retractable end (male end) of the belt into the receptacle (buckle) end of the belt. 3. With belt buckle positioned as low on the body as possible, pull the retractable end of the belt away from the buckle until it is tight across the lap.
Section 3 - Controls and Indicators 3.5 REVERSE SENSOR SYSTEM (IF EQUIPPED) Reverse Sensor System provides audible indication of objects to rear of unit while in reverse gear. • Alarm sounds signaling machine is placed in reverse gear. Note: Reverse Sensing System detects objects larger than 36 square inches (232.25 square centimeters) area and is functional when machine is moving in reverse direction. • No alarm when detection zone is clear of objects.
Section 3 - Controls and Indicators 3.6 BOOM ANGLE AND EXTENSION INDICATORS 1 50 ° 60° 70° 80° 2 40 -10° 0° 10° 20° ° 30° OX0541 • The boom angle indicator (1) is located on the left side of the boom. Use this indicator to determine the boom angle when using the capacity chart (see “Use of the Capacity Chart” on page 5-5). • The boom extension indicators (2) are located on the left side of the boom.
Section 3 - Controls and Indicators This Page Intentionally Left Blank 3-24 31200744
Section 4 - Operation SECTION 4 - OPERATION 4.1 ENGINE Starting the Engine This machine can be operated under normal conditions in temperatures of 0°F to 104°F (-20°C to 40°C). Consult JLG for operation outside this range or under abnormal conditions. If equipped for extreme cold weather, -40°F to 0°F (-40°C to -20°C), see page 4-2 for starting procedure. 1. Make sure all controls are in “Neutral” and all electrical components (lights, heater, defroster, etc.) are turned off. Apply park brake. 2.
Section 4 - Operation Extreme Cold Weather Starting (if equipped) If equipped with extreme cold weather components, machine can be operated in temperatures of -40°F to 0°F (-40° C to -20° C). 1. Machine must be equipped with heating components and extreme cold weather fluids. See Section 9 - Specifications for fluid details. 2. Locate the two yellow extension cords stored behind seat in cab. 3.
Section 4 - Operation Battery Boosted Starting OW0530 If battery-boost starting (jump-start) is necessary, proceed as follows: • Never allow vehicles to touch. • Ensure boosting vehicle engine is running. • Connect the positive (+) jumper cable to positive (+) post of discharged battery. • Connect the opposite end of positive (+) jumper cable to positive (+) post of booster battery. • Connect the negative (-) jumper cable to negative (-) post on booster battery.
Section 4 - Operation Normal Engine Operation • Observe instrument panel frequently to be sure all systems are functioning properly. • Be alert for unusual noises or vibration. When an unusual condition is noticed, park machine in safe position and perform shut-down procedure. Report condition to your supervisor or maintenance personnel. • Avoid prolonged idling. If the engine is not being used, turn it off.
Section 4 - Operation 4.2 OPERATING WITH A NON-SUSPENDED LOAD Lift Load Safely • You must know the weight and load center of every load you lift. If you are not sure of the weight and load center, check with your supervisor or with the supplier of the material. WARNING TIP OVER HAZARD. Exceeding lift capacity of the telehandler could damage the equipment and/or cause tip over.
Section 4 - Operation Transporting a Load OW0540 After engaging the load and resting it against the backrest, tilt the load back to position it for travel. Travel in accordance with the requirements set forth in Section 1 - General Safety Practices and Section 5 - Attachments. Leveling Procedure 1. Position machine in best location to lift or place load. 2. Apply parking brake and move transmission control lever to NEUTRAL. 3.
Section 4 - Operation Placing a Load Before placing any load be sure that: • The landing point can safely support the weight of the load. • The landing point is level; front to back and side to side. • Use the capacity chart to determine safe boom extension range. See “Use of the Capacity Chart” on page 5-5. • Align forks at the level load is to be placed, then extend boom slowly until load is just above area where it is to be placed.
Section 4 - Operation 4.3 OPERATING WITH A SUSPENDED LOAD Lift Load Safely • You must know the weight and load center of every load you lift. If you are not sure of the weight and load center, check with your supervisor or with the supplier of the material. WARNING TIP OVER HAZARD. Exceeding lift capacity of the telehandler could damage the equipment and/or cause tip over.
Section 4 - Operation Transporting a Suspended Load OZ3160 OW0130 • Travel in accordance with the requirements set forth in Section 1 - General Safety Practices and Section 5 - Attachments. • For additional requirements, refer to the appropriate capacity chart in the operator cab. Important things to remember: • Ensure the boom is fully retracted. • Never raise the load more than 11.8 in (300 mm) above ground surface or the boom more than 45°.
Section 4 - Operation Placing a Suspended Load Before placing any load be sure that: • The landing point can safely support the weight of the load. • The landing point is level; front to back and side to side. • Use the capacity chart to determine safe boom extension range. “Use of the Capacity Chart” on page 5-5 • Align load at the level load is to be placed, then position boom slowly until load is just above area where it is to be placed.
Section 4 - Operation 4.4 LOADING AND SECURING FOR TRANSPORT G10-43A G6-42A & G9-43A OY1821 Tiedown 1. Level the telehandler prior to loading. 2. Using a spotter, load the telehandler with boom as low as possible. 3. Once loaded, apply parking brake and lower boom until boom or attachment is resting on deck. Move all controls to “Neutral,” stop engine and remove ignition key. 4. Secure machine to deck by passing chains through the designated tie down points as shown in the figure. 5.
Section 4 - Operation Lifting • When lifting machine, it is very important that the lifting device and equipment is attached only to designated lifting points. If machine is not equipped with lifting lugs contact JLG Product Safety for information. • Make adjustments to lifting device and equipment to ensure machine will be level when elevated. Machine must remain level at all times while being lifted. • Ensure that the lifting device and equipment is adequately rated and suitable for the intended purpose.
Section 5 - Attachments SECTION 5 - ATTACHMENTS 5.1 APPROVED ATTACHMENTS To determine if an attachment is approved for use on the specific telehandler you are using, perform the following prior to installation. • The attachment type, weight, dimensions and load center must be equal to or less than the data shown on a capacity chart located in the operator cab. • The model on the capacity chart must match the model telehandler being used.
Section 5 - Attachments 5.
Section 5 - Attachments This Page Intentionally Left Blank 31200744 5-3
Section 5 - Attachments 5.4 TELEHANDLER/ATTACHMENT/FORK CAPACITY 1 3 2 OW0550 Prior to installing the attachment verify it is approved and the telehandler is equipped with the proper capacity chart. See “Approved Attachments” on page 5-1. To determine the maximum capacity of the telehandler and attachment, use the smallest of the following capacities: • Capacity stamped on the attachment identification plate (1). • Fork capacities and load centers are stamped on the side of each fork (2) (if equipped).
Section 5 - Attachments 5.5 USE OF THE CAPACITY CHART To properly use the capacity chart (see page 5-6), the operator must first determine and/or have the following: 1. An approved attachment. See “Approved Attachments” on page 5-1. 2. The proper Capacity Chart(s). 3. Weight of the load being lifted. 4. Load placement information: a. HEIGHT where the load is to be placed. b. DISTANCE from the front tires of the telehandler where the load is to be placed. 5.
Section 5 - Attachments Sample Capacity Chart This Capacity Chart may be used with this model ONLY. The telehandler model is indicated on the boom or chassis. Model XXXXX is used for demonstration purposes only. XXXXX XX XX Attachment type, weight and dimensions must be equal to or less than the data shown.
Section 5 - Attachments To identify the proper capacity chart on telehandlers equipped with outriggers, refer to the following icons which may be located on the capacity chart. • Use when lifting a load with outriggers up. OAL1090 • Use when lifting a load with outriggers down.
Section 5 - Attachments Example A contractor owns a model xxxxx telehandler with a fork carriage. He knows this attachment may be used with his model since: • The attachment style, weight, dimensions and load center match the attachment data on the capacity chart. • The capacity chart is clearly marked for model xxxxx and corresponds with machine configuration being used. Below are examples with various conditions the contractor may encounter and whether or not the load may be lifted.
Section 5 - Attachments 5.6 ATTACHMENT INSTALLATION MECHANICAL HYDRAULIC 1 2 3 5 4 OY2851 3 6 4 6 1. Attachment 2. Attachment Pin Recess 3. Attachment Pin 4. Lock Pin 5. Retaining Pin (mechanical quick switch) 6. Quick Switch (attachment tilt control in cab, see page 3-12) WARNING CRUSH HAZARD. Always be certain that carriage or attachment is properly positioned on boom and is secured by lock pin and retainer pin.
Section 5 - Attachments Mechanical Quick Switch This installation procedure is designed for one-person operation. Prior to exiting cab, perform “Shut-Down Procedure” on page 4-4. 1. Tilt quick switch back to provide clearance. Check to be sure lock pin is removed. OY1550 2. Align attachment pin with recess in attachment. Raise boom slightly to engage attachment pin in recess. OY1560 3. Tilt quick switch forward to engage attachment. OY1570 4.
Section 5 - Attachments Hydraulic Quick Switch This installation procedure is designed for one-person operation. 1. Tilt quick switch back to provide clearance. OY3250 2. Align attachment pin with recess in attachment. Raise boom slightly to engage attachment pin in recess. OY3260 3. Check to be sure lock pin is disengaged. Tilt quick switch forward to engage attachment. OY3270 4. G6-42A - Press and hold the quick switch switch (1).
Section 5 - Attachments DISENGAGED 5. Raise boom to eye level and visually check that the lock pins protrude through the holes on both sides of the quick switch. If the lock pins do not protrude through the holes, place the attachment on the ground and return to step 2. ENGAGED OY3310 6. If attachment is equipped, connect auxiliary hydraulic hoses. See “Hydraulic Operated Attachment” on page 5-12. 5.7 HYDRAULIC OPERATED ATTACHMENT 2 1 OY3300 OY1720 1. Install attachment (see page 5-9). 2.
Section 5 - Attachments 5.8 ADJUSTING/MOVING FORKS Carriages may have different locations where forks can be positioned. Two different methods can be used for repositioning, depending upon the carriage structure. Note: Apply a light coating of appropriate lubricant to ease sliding of forks or fork bar. To slide forks: 1. Ensure attachment is properly installed. See “Attachment Installation” on page 5-9. 2.
Section 5 - Attachments 5.9 ATTACHMENT OPERATION • Capacities and range limits for the telehandler change depending on the attachment in use. • Separate attachment instructions must be kept in manual holder in cab with this Operation & Safety Manual. An additional copy must be kept with the attachment if it is equipped with a manual holder. Note: Operations described in this section reference the G9-43A & G10-43A with attachment tilt on the boom joystick. Refer to Section 3 for other configurations.
Section 5 - Attachments Carriage with Forks Use Carriage Attachment Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-4. OY0690 to “Telehandler/ Suspend loads in accordance with requirements set forth in Section 1 - General Safety Practices. 1 2 OY3320 The joystick (1) controls lift/lower and extend/retract movement of the boom. The tilt roller switch (2) controls fork tilt. • Press roller switch down to tilt up. • Press roller switch up to tilt down.
Section 5 - Attachments Side Shift Carriage Use Side Shift Carriage Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-4. to “Telehandler/ OAL1540 G10-43A 3 1 3 2 G9-43A OY3330 The joystick (1) controls lift/lower and extend/retract movement of the boom. The tilt roller switch (2) controls fork tilt. • Press roller switch down to tilt up. • Press roller switch up to tilt down. To Side Shift: The auxiliary hydraulic joystick (3) controls carriage side shift.
Section 5 - Attachments WARNING CRUSH HAZARD. Do not use side shift to push or pull objects or load. Failure to comply could cause object or load to fall. Equipment Damage Precautions: • Do not use forks as a lever to pry material. Excessive prying forces could damage forks or machine structure. • Do not attempt to lift loads that are attached or connected to another object.
Section 5 - Attachments Side Tilt Carriage Use Rotate/Side Tilt Carriage Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-4. to “Telehandler/ OAL1550 G10-43A 3 1 3 2 G9-43A OY3340 The joystick (1) controls lift/lower and extend/retract movement of the boom. The tilt roller switch (2) controls fork tilt. • Press roller switch down to tilt up. • Press roller switch up to tilt down. To Rotate: The auxiliary hydraulic joystick (3) controls carriage rotation.
Section 5 - Attachments WARNING CRUSH HAZARD. Do not use rotation to push or pull objects or load. Failure to comply could cause object or load to fall. Equipment Damage Precautions: • Do not use forks as a lever to pry material. Excessive prying forces could damage forks or machine structure. • Do not attempt to lift loads that are attached or connected to another object.
Section 5 - Attachments Swing Carriage Use Swing Carriage Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-4. to “Telehandler/ OU2150 G10-43A 3 1 3 2 G9-43A OY3350 The joystick (1) controls lift/lower and extend/retract movement of the boom. The tilt roller switch (2) controls fork tilt. • Press roller switch down to tilt up. • Press roller switch up to tilt down. To Swing: The auxiliary hydraulic joystick (3) controls carriage swing.
Section 5 - Attachments WARNING CRUSH HAZARD. Always level forks (horizontally) and telehandler frame before swinging load to side. Swinging unlevel forks could cause load to slide off forks. WARNING CRUSH HAZARD. Do not use swing carriage to push or pull objects or load. Failure to comply could cause object or load to fall. WARNING CRUSH HAZARD. Use retaining pin (if equipped) for locking swing frame to fixed frame when carrying loads greater than 5000 lb.
Section 5 - Attachments Dual Fork Positioning Carriage Use Dual Fork Positioning Carriage Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-4. to “Telehandler/ OZ3670 G10-43A 3 1 3 2 G9-43A OY3360 The joystick (1) controls lift/lower and extend/retract movement of the boom. The tilt roller switch (3) controls fork tilt. • Press roller switch down to tilt up. • Press roller switch up to tilt down.
Section 5 - Attachments WARNING CRUSH HAZARD. Do not use fork positioning to push or pull objects or load. Failure to comply could cause object or load to fall. Operation: • Travel in accordance with the requirements set forth in Section 1 - General Safety Practices. Equipment Damage Precautions: • Do not use forks as a lever to pry material. Excessive prying forces could damage forks or machine structure. • Do not attempt to lift loads that are attached or connected to another object.
Section 5 - Attachments Mast Carriage Use Mast Carriage Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-4. to “Telehandler/ OY0580 G10-43A 3 1 3 2 G9-43A OY3370 The joystick (1) controls lift/lower and extend/retract movement of the boom. The tilt roller switch (3) controls fork tilt. • Press roller switch down to tilt up. • Press roller switch up to tilt down.
Section 5 - Attachments WARNING CRUSH HAZARD. Do not use mast to push or pull objects or load. Failure to comply could cause object or load to fall. Operation: • Always lower forks fully in mast before engaging load. • To drive with a load, lower forks fully in mast and travel in accordance with the requirements set forth in Section 1 - General Safety Practices. • Use a signal person to assist in positioning of load if necessary.
Section 5 - Attachments Mast Carriage w/Side Tilt Use Mast Carriage Capacity Chart GNINRAW To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-4. to “Telehandler/ OY0590 4 3 1 5 6 2 + 3 + OY3380 The joystick (1) controls lift/lower and extend/retract movement of the boom. The tilt roller switch (3) controls fork tilt. • Press roller switch down to tilt up. • Press roller switch up to tilt down.
Section 5 - Attachments To Raise/Lower Mast: Press Forks Raise/Lower Switch (6) located on dash panel to activate Forks Raise/ Lower function. The auxiliary hydraulic joystick controls the mast raise/lower function. • Move joystick left to lower. • Move joystick right to raise. Installation Procedure: • Refer to “Attachment Installation” on page 5-9. WARNING CRUSH HAZARD. Do not use mast to push or pull objects or load. Failure to comply could cause object or load to fall. WARNING CRUSH HAZARD.
Section 5 - Attachments Fork Extension Use Appropriate Carriage Attachment Capacity Chart OZ0750 To determine maximum capacity, refer to “Telehandler/Attachment/Fork Capacity” on page 5-4. The maximum capacity of the carriage when equipped with fork extensions may be reduced to the capacity indicated on the fork extensions. If the load exceeds the capacity of the fork extension contact JLG to obtain forks and/or fork extensions of the proper load rating and length.
Section 5 - Attachments Installation Procedure: • Ensure carriage is properly installed. Refer to “Attachment Installation” on page 5-9. • Ensure length and cross section of the parent fork arm is equal to or exceeds the parent fork arm blade length stamped into the fork extension. • Secure the fork extensions to the forks by sliding the fork extensions onto the parent forks and install the retaining pin behind the vertical shank of the fork.
Section 5 - Attachments Fork Mounted Hook Use Appropriate Carriage Attachment Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-4. to “Telehandler/ OY0640 Suspend loads in accordance with requirements set forth in Section 1 - General Safety Practices. 1 2 OY3320 The joystick (1) controls lift/lower and extend/retract movement of the boom. The tilt roller switch (3) controls fork tilt. • Press roller switch down to tilt up. • Press roller switch up to tilt down.
Section 5 - Attachments Operation: • Pallet or lumber forks of an appropriate load rating must be used. Do not use with cubing or block forks. • Weight of fork mounted hook and rigging must be included as part of total load being lifted. • Do not use with mast carriage attachment. • Do not use fork mounted hook with attachments capable of rotating (i.e. side tilt and swing carriages) without disabling the rotation feature(s).
Section 5 - Attachments Bucket Use Bucket Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-4. to “Telehandler/ OZ0730 1 2 OY3390 The joystick (1) controls lift/lower and extend/retract movement of the boom. The tilt roller switch (2) controls bucket tilt. • Press roller switch down to tilt up. • Press roller switch up to tilt down. Installation Procedure: • Refer to “Attachment Installation” on page 5-9.
Section 5 - Attachments Operation: • Raise or lower boom to appropriate height for loading material from stockpile. • Align telehandler with face of stockpile and drive slowly and smoothly into pile to load bucket. • Tilt bucket up far enough to retain load and back away from pile. • Travel in accordance with requirements set forth in Section 1 - General Safety Practices. • Tilt bucket down to dump load.
Section 5 - Attachments Grapple Bucket Use Grapple Bucket Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-4. to “Telehandler/ OZ1450 G10-43A 3 1 3 2 G9-43A OY3400 The joystick (1) controls lift/lower and extend/retract movement of the boom. The tilt roller switch (2) controls bucket tilt. • Press roller switch down to tilt up. • Press roller switch up to tilt down.
Section 5 - Attachments Operation: • Raise or lower boom to appropriate height and open grapple for loading material from stockpile. • Align telehandler with face of stockpile and drive slowly and smoothly into pile to load bucket. • Tilt bucket up far enough to retain load, close grapple and back away from pile. • Travel in accordance with requirements set forth in Section 1 - General Safety Practices. • Open grapple and tilt bucket down to dump load.
Section 5 - Attachments Truss Boom Use Appropriate Truss Boom Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-4. OY0570 to “Telehandler/ Suspend loads in accordance with requirements set forth in Section 1 - General Safety Practices. G10-43A 3 1 3 2 G9-43A OY3410 The joystick (1) controls lift/lower and extend/retract movement of the boom. The tilt roller switch (2) controls truss boom tilt. • Press roller switch down to tilt up.
Section 5 - Attachments Installation Procedure: • Refer to “Attachment Installation” on page 5-9. Operation: • Weight of rigging must be included as part of total load being lifted.
Section 5 - Attachments Personnel Work Platform - Fork Mounted Use Appropriate Carriage Attachment Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-4. to “Telehandler/ OY1610 The operator and personnel in platform must read and understand the separate personnel work platform manual prior to installing and using a platform. 1 2 OY3420 The joystick (1) controls lift/lower and extend/retract movement of the boom. The tilt roller switch (3) controls platform tilt.
Section 5 - Attachments Preparation and Setup: 1. Ensure the telehandler is on a firm surface and is level. 2. Engage the park brake. Blocking the wheels is also recommended. 3. Level the platform, both side to side (frame level) and front to back (attachment tilt). 4. Keep area under platform free from personnel. 5. When personnel are on platform, the operator must remain seated in cab with personnel in direct line of sight. 6. DO NOT lift or carry persons in a bucket or on forks. WARNING FALL HAZARD.
Section 5 - Attachments This Page Intentionally Left Blank 5-40 31200744
Section 6 - Emergency Procedures SECTION 6 - EMERGENCY PROCEDURES 6.1 TOWING A DISABLED PRODUCT The following information assumes the telehandler cannot be moved under its own power. • Before moving the telehandler, read all of the following information to understand options available. Then select the appropriate method. • Machine mounted retrieval devices provide suitable means to attach a tow rope, chain or tow bar only in the event the telehandler becomes stuck or disabled.
Section 6 - Emergency Procedures 6.2 EMERGENCY LOWERING OF BOOM In the event of total loss of engine power or hydraulic pump failure with an elevated load, the situation must be properly evaluated and dealt with on an individual basis. Contact a local Authorized Distributor for specific instructions. Secure the telehandler using the following procedures: 1. Clear the area around telehandler of all personnel. 2. Engage the parking brake. Place the transmission control lever in “NEUTRAL”. 3.
Section 7 - Lubrication and Maintenance SECTION 7 - LUBRICATION AND MAINTENANCE 7.1 INTRODUCTION Service the product in accordance with the maintenance schedule on the following pages. 1 OY2970 The lubrication and maintenance (2) charts contain instructions that must be followed to keep this product in good operating condition. The Operation & Safety Manual and Service Manual contain more detailed service information with specific instructions.
Section 7 - Lubrication and Maintenance 7.2 GENERAL MAINTENANCE INSTRUCTIONS Prior to performing any service or maintenance on the telehandler, follow the shut-down procedure on page 4-4 unless otherwise instructed. Ensure telehandler is level, for proper fluid readings. • Clean lubrication fittings before lubricating. • After greasing telehandler, cycle all functions several times to distribute lubricants. Perform this maintenance procedure without attachment installed.
Section 7 - Lubrication and Maintenance 7.
Section 7 - Lubrication and Maintenance 1st 250, 250 & 1st 500 Hour Maintenance Schedule 1st 250 Change Axle Oil Change Wheel End Oil Change Transmission Oil & Filter Change Transfer Case Oil EVERY 250 Change Engine Oil and Filter Check Axle Oil Level Check Wheel End Oil Levels Air Filter Vacuator Valve Check Boom Wear Pads Check Transfer Case Oil Level Check Rear Axle Stabilization Lubrication Schedule Check Fan Belt EVERY 500 LB/F T (N m) Change Fuel Filters Check Wheel Lug Nut Torqu
Section 7 - Lubrication and Maintenance 500, 1000 & 1500 Hour Maintenance Schedule EVERY 1000 Change Transmission Oil & Filter Change Transfer Case Oil Check Boom Chains Lubrication Schedule Change Axle Oil Change Wheel End Oil Check Air Intake System EVERY 1500 Change Hydraulic Fluid & Filters Change Hydraulic Tank Breather EVERY 2000 Change Crankcase Vent Filter (if equipped for ULS) Engine Valve Lash Adjustment Change Engine Coolant OY3440 31200744 7-5
Section 7 - Lubrication and Maintenance 7.
Section 7 - Lubrication and Maintenance 250 Hour Lubrication Schedule EVERY 250 2 B 2 B B 2 B 2 2 B B 2 B B 2 2 A A A 2 A A A A A A 2 2 2 A G10-43A OY2560 31200744 7-7
Section 7 - Lubrication and Maintenance 1000 Hour Lubrication Schedule EVERY 1000 B B G10-43A OY2570 7-8 31200744
Section 7 - Lubrication and Maintenance This Page Intentionally Left Blank 31200744 7-9
Section 7 - Lubrication and Maintenance 7.5 OPERATOR MAINTENANCE INSTRUCTIONS Fuel System 10 A. Fuel Level Check OW0970 OW0990 1 2 OY2990 1. Check fuel gauge (1) located on instrument panel in cab. 2. If fuel is low, proceed to fuel source and perform “Shut-Down Procedure” on page 4-4. 3. Turn fuel tank cap (2) and remove from filler neck. 4. Add diesel fuel as needed. 5. Replace and secure fuel tank cap. Note: Replenish diesel fuel at end of each work shift to minimize condensation.
Section 7 - Lubrication and Maintenance B. Fuel/Water Separator Check 50 OW0980 OW1000 IF EQUIPPED FOR ULS 4 3 OY3450 IF EQUIPPED FOR LS 4 3 OY3500 1. Perform “Shut-Down Procedure” on page 4-4. 2. Open the engine cover. 3. Loosen drain cock (3) on underside of fuel filter (4) and allow all water to drain into a glass until clear fuel is visible. 4. Tighten drain cock. 5. Close and secure the engine cover.
Section 7 - Lubrication and Maintenance Air Intake System If Equipped for ULS 10 A. Air Filter Restriction Indicator Check OW0970 OW1010 1 2 6 7 4 5 3 OY3000 1. Perform “Shut-Down Procedure” on page 4-4. 2. Locate air cleaner (1) and check restriction indicator (2). If red band is visible, filter(s) must be replaced. 3. Remove dust from vacuator valve (3) by squeezing bottom of valve to allow loose particles to fall out.
Section 7 - Lubrication and Maintenance B. Element Change (as restriction indicator indicates) 1. Perform “Shut-Down Procedure” on page 4-4. 2. Unlock air cleaner cover (4) and remove from air cleaner canister. 3. Lightly remove any loose dirt from cover and precleaner (5). 4. Remove outer primary element (6) and inspect for damage. Damaged elements should not be reused. 5. Thoroughly clean the interior of the air cleaner canister and vacuator valve. 6.
Section 7 - Lubrication and Maintenance If Equipped for LS 10 A. Air Filter Restriction Indicator Check OW0970 OW1010 1 4 2 5 3 6 OY3010 1. Perform “Shut-Down Procedure” on page 4-4. 2. Locate air cleaner (1) and check restriction indicator (2). If red band is visible, filter(s) must be replaced. 3. Remove dust from vacuator valve (3) by squeezing bottom of valve to allow loose particles to fall out. Note: Only remove canister cover to service the elements as restriction indicator indicates.
Section 7 - Lubrication and Maintenance B. Element Change (as restriction indicator indicates) 1. Perform “Shut-Down Procedure” on page 4-4. 2. Unlock air cleaner cover (4) and remove from air cleaner canister. 3. Remove outer primary element (5) and inspect for damage. Damaged elements should not be reused. 4. Thoroughly clean the interior of the air cleaner canister and vacuator valve. 5. Replace inner safety element (6) after every third primary element change.
Section 7 - Lubrication and Maintenance Engine Oil 10 A. Engine Oil Level Check OW0970 OW1020 IF EQUIPPED FOR ULS 4 1 2 AD D 3 OY3490 IF EQUIPPED FOR LS 4 AD D 2 3 1 OY3510 1. Perform “Shut-Down Procedure” on page 4-4. 2. Open the engine cover. 3. Remove dipstick (1) and check oil mark. The oil should be between the full (2) and add (3) marks within the crosshatched area of the dipstick. 4.
Section 7 - Lubrication and Maintenance Hydraulic Oil 10 A. Hydraulic Oil Level Check OW0970 OW1030 5 6 OAL3531 1. Be sure all cylinders are fully retracted and machine is level. 2. Perform “Shut-Down Procedure” on page 4-4. 3. Open the engine cover. 4. Check level of hydraulic oil at the sight gauge (5) on the hydraulic tank. The oil level should be between the marks on the sight gauge. 5. If hydraulic oil is low, remove oil fill cap (6) from filler neck.
Section 7 - Lubrication and Maintenance Tires A. Tire Air Pressure Check 10 OW0970 OW1040 1. Perform “Shut-Down Procedure” on page 4-4. 2. Remove valve stem cap. 3. Check tire pressure. 4. Add air if required. See page 9-5 for tire pressures. 5. Replace valve stem cap. B. Tire Damage For pneumatic tires, when any cut, rip or tear is discovered that exposes sidewall or tread area cords in the tire, measures be taken to remove the product from service immediately.
Section 7 - Lubrication and Maintenance C. Tire and Wheel Replacement It is recommended that a replacement tire to be the same size, ply and brand as originally installed. Refer to the appropriate parts manual for ordering information. If not using an approved replacement tire, the replacement tires must have the following characteristics: • Equal or greater ply/load rating and size of original. • Tire tread contact width equal or greater than original.
Section 7 - Lubrication and Maintenance E. Wheel Installation Torque lug nuts after first 50 hours and after each wheel installation. Note: If machine is equipped with directional tire assemblies, the wheel and tire assemblies must be installed with the directional tread pattern “arrows” facing in the direction of forward travel. 1. Start all nuts by hand to prevent cross threading. DO NOT use a lubricant on threads or nuts. 2. Tighten lug nuts in an alternating pattern as indicated in figure.
Section 7 - Lubrication and Maintenance Transmission Oil 10 A. Transmission Oil Level Check OW0970 OW1050 1 2 T HO LD CO MIN OY3460 1. Check transmission oil level with engine at idle and oil at normal operating temperature. 2. Apply park brake, shift transmission to "Neutral" and lower forks or attachment to the ground. 3. Open the engine cover. 4. Remove the transmission dipstick (1) and check oil level. The oil level should be within the HOT zone. 5. Replace transmission dipstick. 6.
Section 7 - Lubrication and Maintenance Engine Cooling System A. Engine Coolant Level Check 50 OW0980 OW1070 1 2 OY3470 1. Perform “Shut-Down Procedure” on page 4-4. 2. Open the engine cover. 3. Check coolant level in surge tank (1). 4. If coolant is low, allow fluid to cool. 5. Remove surge tank cap (2) slowly. Add coolant as required. 6. Replace surge tank cap. 7. Close and secure the engine cover.
Section 7 - Lubrication and Maintenance Battery 50 A. Battery Check OW0980 1 OW1080 OY3480 1. Perform “Shut-Down Procedure” on page 4-4. 2. Open the engine cover. 3. Wearing eye protection, visually inspect the battery (1). Check terminals for corrosion. Replace battery if it has a cracked, melted or damaged case. 4. Close and secure the engine cover.
Section 7 - Lubrication and Maintenance Windshield Washer System (if equipped) A. Windshield Washer Fluid Level Check 50 OW0980 OAL2040 2 OAL2300 1. Perform “Shut-Down Procedure” on page 4-4. 2. The windshield washer fluid should be visible in the reservoir (2). 3. If washer fluid level is low, add fluid as needed.
Section 8 - Additional Checks SECTION 8 - ADDITIONAL CHECKS 8.1 GENERAL If any of the following test results cannot be achieved, the system is not functioning properly and the machine must be removed from service and repaired before continued operation. 8.2 REVERSE SENSOR SYSTEM (IF EQUIPPED) A. Reverse Sensor System Check Reverse Sensor System provides audible indication of objects to rear of unit while in reverse gear. 1.
Section 8 - Additional Checks 4. Verify operation with no objects in detection zone. No audible alarm. 5. Verify operation when object is in range of approximately 9 to 15 ft (2.7 to 4.5 m). Produces pulsing audible alarm at a frequency of one per second (1 Hz). 6. Verify operation when object is in range of approximately 7 to 9 ft (2.1 to 2.7 m). Produces pulsing audible alarm. Produces pulsing audible alarm at a frequency of two per second (2 Hz). 7.
Section 9 - Specifications SECTION 9 - SPECIFICATIONS 9.
Section 9 - Specifications Compartment or System Fuel Type and Classification Viscosities Ambient Temperature Range °F °C Min Max Min Max #2 Diesel B5 Biodiesel Blend of #1 diesel and Ultra Low Sulfur #2 diesel fuels (S ≤ 15 mg/kg) ("winterized" #2) B5 Biodiesel with Winter Conditioner Standard Cold Weather Note: Friction Modifier may be added to front axle differential.
Section 9 - Specifications If Equipped for LS Compartment or System Type and Classification Engine Crankcase API CI-4 Multigrade Transmission and Transfer Case Axle Differential and Wheel End Hydraulic System Viscosities Ambient Temperature Range °F °C Min Max Min Max 5 120 -15 49 -40 0 -40 -20 0 104 -20 40 Mobilfluid 424 SAE 15W-40 SAE 0W-40 10W-30 Mobilfluid LT 75W-80 -40 0 -40 -20 Mobilfluid 424* Mobilfluid LT* 10W-30 75W-80 SAE140 80W-140 85W-140 SAE90 SAE90LS 80W-90 85W-90 75W-90 75W
Section 9 - Specifications Capacities Engine Crankcase Oil Capacity with Filter Change.................................................................... 8.0 qt (7,6 L) Fuel Tank Capacity.................................................................................................38 gal (144 L) Cooling System System Capacity.................................................................................... 15 qt (14,2 L) Hydraulic System System Capacity G6-42A ..........................................
Section 9 - Specifications Tires G6-42A 13.00 x 24, G-2/L-2 Bias-Ply Traction - 12 Ply Pneumatic......................................................................................65 psi (4,5 bar) Foam .................................................................................Approx 542 lb (246 kg) 15.50 x 25, G-2/L-2 Bias-Ply Traction - 12 Ply Pneumatic......................................................................................58 psi (4,0 bar) Foam ........................................
Section 9 - Specifications Performance Note: Values shown are per machine as originally manufactured. Reference capacity charts in operator cab for specific model and attachment configuration values. Maximum Lift Capacity G6-42A .....................................................................................6,600 lb (2994 kg) G9-43A .....................................................................................9,000 lb (4082 kg) G10-43A ............................................................
Section 9 - Specifications Dimensions Overall Height G6-42A .....................................................................................95.4 in (2423 mm) G9-43A & G10-43A ..................................................................95.5 in (2426 mm) Overall Width.....................................................................................99 in (2515 mm) Cab Width............................................................................................37 in (940 mm) Track Width ......
Section 9 - Specifications Maximum Ground Bearing Pressure G6-42A 13.00 x 24 Air Filled ..................................................................136 lb/in² (9,6 kg/cm²) Foam Filled ...........................................................178 lb/in² (12,5 kg/cm²) 15.50 x 25 Air Filled ..................................................................136 lb/in² (9,6 kg/cm²) Foam Filled ...........................................................183 lb/in² (12,9 kg/cm²) 370/75-28 Air Filled .........
Index Index A Accessory Control Lever ................ 3-18 Additional Checks............................. 8-1 Adjusting/Moving Forks .................. 5-13 Air Conditioning Controls..................................... 3-17 Attachment Installation ..................... 5-9 Hydraulic Quick Switch ............. 5-11 Mechanical Quick Switch .......... 5-10 Attachment Tilt Control................... 3-13 Attachments Approved..................................... 5-1 JLG Supplied ..............................
Index H P Hazard Classification System........... 1-1 Park Brake ........................................3-8 Headlights....................................... 3-18 Parking Lights .................................3-18 Heater Controls .............................. 3-17 Parking Procedure ............................3-8 Hydraulic Oil Level.......................... 7-17 Performance......................................9-6 Hydraulic Operated Attachment .....
Index T Tip Over Hazard ............................... 1-3 Tires ........................................ 7-18, 9-5 Air Pressure .............................. 7-18 Damage .................................... 7-18 Replacement............................. 7-19 Towing.............................................. 6-1 Transmission Control Lever Direction of Travel..................... 3-10 Gear Selection .......................... 3-11 Transmission Oil Level ................... 7-21 Transport Lifting ........
Index 4 31200744
Inspection, Maintenance and Repair Log Inspection, Maintenance and Repair Log Serial Number ______________________________ Date Comments
Inspection, Maintenance and Repair Log Date Comments
TRANSFER OF OWNERSHIP An Oshkosh Corporation Company To Product Owner: If you now own but ARE NOT the original purchaser of the product covered by this manual, we would like to know who you are. For the purpose of receiving safety-related bulletins, it is very important to keep JLG Industries, Inc. updated with the current ownership of all JLG products. JLG maintains owner information for each JLG product and uses this information in cases where owner notification is necessary.
Hand Signals OY1090 EMERGENCY STOP - With both arms extended laterally, hands open downward, move arms back and forth. OY1120 RAISE BOOM - With either arm extended horizontally, fingers closed, point thumb upward. OY1150 EXTEND BOOM - With both hands clenched, point thumbs outward. OY1180 TILT FORKS UP - With one arm held at side, extend other arm upward at about 45 degrees. OY1100 STOP - With either arm extended laterally, hand open downward, move arm back and forth.
31200744 An Oshkosh Corporation Company JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA Phone: +1-717-485-5161 Customer Support Toll Free: 1-877-554-5438 Fax: +1-717-485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia Phone: +61 2 65811111 Fax: +61 2 65813058 JLG Latino Americana Ltda.
