Operation & Safety Manual 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 November 25, 2008 - A - Original Issue of Manual 31200148 a
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.
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Table of Contents Table of Contents TABLE OF CONTENTS Revision Log Read This First Operator Qualifications ...................................................... b Modifications ...................................................................... b Other Publications Available .............................................. c Table of Contents Section 1 - General Safety Practices 1.1 Hazard Classification system...............................................
Table of Contents Parking Procedure.......................................................... 3-9 Heater........................................................................... 3-10 3.3 Operator Seat.................................................................... 3-11 Seat Adjustments ......................................................... 3-11 Seat Belt ....................................................................... 3-13 3.4 Boom Angle and Extension Indicators .............................
Table of Contents Crane Hook...................................................................5-12 Bucket ...........................................................................5-14 Truss Boom...................................................................5-16 Boom Head-Mounted Winch.........................................5-18 6 ft (1,8 m) Mast with 48 or 72 in (1,2 & 1,8 m) Carriage ........................................................................
Table of Contents Dimensions.....................................................................
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. • DO NOT raise the load more than 11.8 in (300 mm) above ground surface or the boom more than 45°. • Weight of all rigging (slings, etc.) must be included as part of load. • Start, travel, turn and stop slowly to prevent load from swinging. • When driving with the boom raised, DO NOT exceed walking speed. • Beware of wind.
Section 1 - General Safety Practices Travel Hazard 4-Wheel Steer Pivot Steer OW0120 • Steering characteristics differ between 4-Wheel Steer & Pivot Steer telehandlers as shown above. Identify the telehandler you are operating & others on the jobsite. • Ensure that adequate clearance is provided between both rear tail swing and front fork swing. • Unlike a conventional 4-wheel steer telehandler the rear wheels of a pivot steer telehandler turn a wider circle than the front wheels.
Section 1 - General Safety Practices Load Falling Hazard OW0130 • Never suspend load from forks or other parts of carriage. • 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 a JLG 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, the rear of the machine is the “heavy end.” Drive with forks pointed downhill. • When loaded, the front of the machine is the “heavy end.” Drive with the forks pointed uphill. • For additional travel requirements, refer to the appropriate capacity chart.
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. • If spark arrestors are required, ensure they are in place and in good working order.
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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 & 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 2-8) 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. Model Year of Manufacture Serial Number Maximum Weight Without Attachments (lbs/kg) Maximim Capacity (lbs/kg)* As released from factory this truck meets design specifications in ASME B56.6-2002 Part III One or more of the following patents may apply to this truck: U.S. Nos.
Section 2 - Pre-Operation and Inspection EXHAUST SYSTEMS CAN BE HOT. KEEP AWAY FROM EXHAUST SYSTEM WHEN HOT. HOT EXHAUST COMPONENTS CAN CAUSE SEVERE BURNS.
Section 2 - Pre-Operation and Inspection Safety Decals 3 80603037 4105262 50 60 70 80 91143282 STAY CLEAR OF PINCH POINT AREA ANYTIME ENGINE IS RUNNING. BEING IN PINCH POINT AREA COULD CAUSE SERIOUS INJURY OR DEATH. PINCH POINT KEEP OUT 40 20 -10 0 10 30 9114-3282 REACHING INTO BOOM HOLES AND OTHER PINCH POINTS CAN CAUSE SERIOUS INJURY OR DEATH. 8060-3037-A B B 50° 60° 70° 80° A 40° 30° -10° 0° 10° 20° ATTACHMENT MUST BE SECURED TO MACHINE.
Section 2 - Pre-Operation and Inspection 2.3 WALK-AROUND INSPECTION 16 1 15 2 3 14 13 4 12 5 6 7 11 8 9 10 OY0181 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 4. Cab & Electrical • Check window glass is in place and clean; gauges, switches, joysticks, foot controls & horn operational. • General appearance; no visible damage; proper load charts and applicable Operator & Safety manual located in manual holder. • Make sure emergency escape hammer is in place (enclosed cabs only). • Check seat belt for damage, replace belt if frayed or cut webbing, damaged buckles or loose mounting hardware. 5.
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 mirror(s) for maximum visibility. WARNING CUT/CRUSH/BURN HAZARD. Keep engine cover closed while engine is running except when checking hydraulic filter condition indicator.
Section 2 - Pre-Operation and Inspection 2.5 OPERATOR CAB The telehandler is equipped with a standard open ROPS/FOPS cab. An optional enclosed ROPS/FOPS cab is available. WARNING Never operate telehandler unless the overhead guard and cab structure 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 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) 2 3 1 4 OAL0010 • During operation the window must either be latched open or closed. • Open the cab door window (1) and secure it in the latch. • Press the release button (2) inside the cab or pull on the lever (3) outside the cab to unlatch the window. • During operation the lower door (4) must be closed.
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. NOTICE EQUIPMENT DAMAGE. When a red light illuminates, immediately bring machine to a stop, lower boom and attachment to ground and stop the engine.
Section 3 - Controls and Indicators 3.2 CONTROLS 4 2 3 5 1 6 11 10 9 8 7 OY0023 1. Transmission Control Lever: See page 3-3. 2. Instrument Panel: See “Dash Controls and Indicators” on page 3-8. 3. Steering Wheel: Turning the steering wheel to the left or right steers the machine in the corresponding direction. 4. Frame Level Indicator: Enables the operator to determine the left to right level condition of the telehandler. 5. Boom Joystick: See page 3-5. 6.
Section 3 - Controls and Indicators Transmission Control Lever 15 F N R OX0081 Transmission control lever (15) 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’. • When traveling in REVERSE, the back-up alarm will automatically sound. • Drive in reverse and turn only at slow rates of speed.
Section 3 - Controls and Indicators Ignition Switch F N R ACC OFF RUN START OY0051 • 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 Boom Joystick 2 1 IF EQUIPPED OX0060 The boom joystick (1) controls the boom and attachment tilt (if equipped) 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. • The speed of boom functions depends upon the amount of joystick travel in corresponding direction. Increasing engine speed will also increase function speed.
Section 3 - Controls and Indicators Attachment Tilt and Frame Sway Lever FUEL QUARTZ TEMP 0 0 0 0 0 0 F 80 OIL E 0 240 16 VOLTS - 100 + 10 OFF ACC START RUN WORK TRAVEL IGNITION MACHINE MUST BE IN NEUTRAL AND PARK BRAKE ON TO START OY0143 4 This lever (4) controls the attachment tilt and the left to right frame sway. Attachment Tilt Function • Move lever forward to tilt attachment down; move lever back to tilt attachment up.
Section 3 - Controls and Indicators Auxiliary Control Joystick (if equipped) Auxiliary Hydraulics FUEL QUARTZ TEMP 0 0 0 0 0 0 F 80 OIL E 0 240 16 VOLTS - 100 + 10 OFF ACC START RUN WORK TRAVEL IGNITION MACHINE MUST BE IN NEUTRAL AND PARK BRAKE ON TO START Sway (optional) 1 Attachment Tilt (optional) OX0224 The auxiliary control joystick (1) controls the auxiliary hydraulic functions, left to right frame sway (if equipped), and attachment tilt (if equipped).
Section 3 - Controls and Indicators Dash Controls and Indicators . 1 FUEL QUARTZ TEMP F 80 3 OIL E 0 240 16 VOLTS - 100 + 10 WORK OFF OFF START ACC START ACC RUN WORK RUN 0 0 0 0 0 0 2 TRAVEL IGNITION MACHINE MUST BE IN NEUTRAL AND PARK BRAKE ON TO START TRAVEL IGNITION 6 5 4 OY0084 1. Hourmeter: Indicates total time of engine operation in hours and tenths of hours. 2. Park Brake Switch: See page 3-9. 3. 4-in-1 Gauge: a. Engine Coolant Temperature Gauge b.
Section 3 - Controls and Indicators Park Brake Switch F N R OY0122 1 2 Park brake switch controls the application and release of the park brake. Indicator light 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 Heater 3 4 3 6 5 2 1 OY0060 1. Heater 2. Access Cover/Heat Vent 3. Air Vents 4. 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. 5. Temperature Control Switch 6. Heater Fan Switch: On/Off switch.
Section 3 - Controls and Indicators 3.3 OPERATOR SEAT Seat Adjustments Before S/N 0160016100 2 1 OX0012 Prior to starting engine adjust seat for position and comfort as follows: 1. Use handle to move seat fore and aft 2. A two inch seat belt is standard equipment. If required, an optional three inch belt is available.
Section 3 - Controls and Indicators S/N 0160016100 & After 3 4 1 2 OX0520 Prior to starting engine adjust seat for position and comfort as follows: 1. Turn the knob on the front of seat to adjust the suspension. Turn the knob clockwise to increase stiffness. Turn the knob counterclockwise to reduce stiffness. 2. Pull up on handle to move seat fore and aft. 3. Arm rest can be moved up or down for comfort. 4. A two inch seat belt is standard equipment. If required, an optional three inch belt is available.
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. 4.
Section 3 - Controls and Indicators 3.4 BOOM ANGLE AND EXTENSION INDICATORS 1 50 ° 60° 70° 80° 2 ° 40 -10° 0° 10° 20° 30° OX0540 • 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 5-4). • The boom extension indicators (2) are located on the left side of the boom.
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. 1. Make sure all controls are in “Neutral” and all electrical components (lights, heater, defroster, etc.) are turned off. Set parking brake. 2. Turn ignition switch to “START” to engage starting motor. Release key immediately when engine starts.
Section 4 - Operation Cold Weather Starting Aids JLG approved starting aids employ ether. If your telehandler is equipped with an ether starting aid, the following applies: • Injection of ether is triggered by temperature sensor located on engine. • At start-up, temperature sensor on engine will detect if ether is needed. Follow normal start-up procedure. • Ether will be automatically injected if needed, to keep engine running. • A second battery is added for additional cold-cranking capacity.
Section 4 - Operation Battery Boosted Starting OW0530 If battery-boost starting (jump-start) is necessary, proceed as follows: • Never allow vehicles to touch. • 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 gauges frequently to be sure all engine 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 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 the 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. Move boom/attachment to 4 ft (1,2 m) off ground. 4.
Section 4 - Operation Placing the 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 5-4. • Align forks 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 4.3 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. See “Use of the Capacity Chart” on page 5-4. • 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 Tiedown Front Rear OX0381 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 tiedown points as shown in the figure. 5. Do not tiedown front of boom.
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 the lifting device and equipment to ensure the machine will be level when elevated. The machine must remain level at all times while being lifted.
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. Before S/N 0160037689 • The attachment model/option number on the attachment identification plate must match the attachment number 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 5.2 UNAPPROVED ATTACHMENTS Do not use unapproved attachments for the following reasons: • Range and capacity limitations for “will fit,” homemade, altered, or other non-approved attachments cannot be established. • An overextended or overloaded telehandler can tip over with little or no warning and cause serious injury or death to the operator and/or those working nearby. • The ability of a non-approved attachment to perform its intended function safely cannot be assured.
Section 5 - Attachments 5.3 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 5.4 USE OF THE CAPACITY CHART To properly use the capacity chart (see page 5-5), the operator must first determine and/or have the following: 1. A JLG 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 model of your telehandler is indicated on the boom or chassis. MODEL XXXXX DEDUCT 350 LBS FROM ALL CAPACITIES WHEN MACHINE IS EQUIPPED WITH WINCH 48' 69° 5 50° 36' 12' 10° 8' 3000 LBS 20° 16' 11 0 0 L B S 20' 2000 LBS 30° 4000 LBS 24' 9000 LB S 40° 7000 LB S 4 32' 28' Boom Angle 6 60° 40' 5000 LBS 6000 LBS 48" & 72" CARRIAGES RATED CAPACITY @ 2 FT.
Section 5 - Attachments Example A contractor owns a model xxxxx telehandler with a 48" Carriage. He knows this attachment may be used with his model since: • The attachment model/option number, matches the attachment number 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 5.5 ATTACHMENT INSTALLATION 1 2 3 5 4 OX0440 1. Attachment 2. Attachment Pivot Pin Recess 3. Quick Switch 4. Lock Pin 5. Retaining Pin This installation procedure is designed for one-person operation. 1. Retract Quick Switch™ to provide clearance. Check to be sure lock pin is secured in out position with retainer pin. OX0450 2. Align attachment pivot pin with recess in attachment. Raise boom slightly to engage attachment pivot pin in recess.
Section 5 - Attachments 3. Engage Quick Switch™. OX0470 4. Shut off engine. Exit cab and remove retainer pin and slide lock pin in fully. Secure lock pin in locked position using retainer pin. OX0470 5. If equipped, swing attachment saddles down and pin in place. OX0480 6. If equipped, connect auxiliary hydraulic hoses. 7. If equipped, connect auxiliary electric harness. WARNING CRUSH HAZARD.
Section 5 - Attachments 5.6 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. Refer to “Attachment Installation” on page 5-7. 2.
Section 5 - Attachments 5.7 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. NOTICE EQUIPMENT DAMAGE. Some attachments may contact the front tires or machine structure when the boom is retracted and the attachment is rotated.
Section 5 - Attachments Carriage w/Forks OY0690 Description P/N Carriage, 48 in .............................................................. 91405073 Carriage, 72 in .............................................................. 91405074 Carriage, Drywall .......................................................... 91405077 Fork, Cubing 2x2x48 in................................................. 91403359 Fork 1-3/4x4x48 in........................................................
Section 5 - Attachments Crane Hook Description P/N Crane Hook................................................................... 91565094 OY0640 Use Appropriate Carriage Attachment Capacity Chart To determine maximum capacity, refer to “Telehandler/Attachment/Fork Capacity” on page 5-3. Suspend loads in accordance with requirements set forth in Section 1 - General Safety Practices. 1 TILT SPEED CONTROL 2 The joystick (1) controls lift/lower and the extend/retract movement of the boom.
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 crane hook and rigging must be included as part of total load being lifted. • Do not use crane hook with attachments capable of rotating (i.e. side tilt and swing carriages) without disabling the rotation feature(s).
Section 5 - Attachments Bucket Description P/N Bucket 60 in - 3/4 yd3 ................................................... 91405054 Bucket 74 in - 1-1/4 yd3 ................................................ 91405055 Bucket 102 in - 1-1/4 yd3 .............................................. 91405071 OZ0730 Use Appropriate Bucket Capacity Chart To determine maximum capacity, refer to “Telehandler/Attachment/Fork Capacity” on page 5-3.
Section 5 - Attachments Equipment Damage Precautions • Drive into stockpile smoothly with boom fully retracted to load bucket. Loading bucket with boom extended could damage boom or extension chains/cables. Do not corner-load bucket. • Do not use bucket as a lever to pry material. Excessive prying forces could damage bucket. • Do not use bucket for "back dragging." This could cause severe damage to quick switch and retraction cables/chains.
Section 5 - Attachments Truss Boom Description P/N Truss Boom 10 ft w/winch .............................................91405081 Truss Boom 10 ft...........................................................91405083 Truss Boom 15 ft w/winch .............................................91405080 Truss Boom 15 ft...........................................................
Section 5 - Attachments Truss Boom W/Winch Control: The auxiliary joystick (3) controls the truss boom mounted winch. • Move joystick up to lower cable. • Move joystick down to raise cable. Installation Procedure: • Refer to “Attachment Installation” on page 5-7. WARNING CRUSH HAZARD. Maintain a minimum of three wraps of wire rope on the cable drum at all times. Failure to comply could cause object or load to fall.
Section 5 - Attachments Boom Head-Mounted Winch Description P/N Winch............................................................................91515036 OY0650 Use Carriage Attachment Capacity Chart To determine maximum capacity, refer to “Telehandler/Attachment/Fork Capacity” on page 5-3. Suspend loads in accordance with requirements set forth in Section 1 - General Safety Practices. 1 2 OY0660 The joystick (1) controls lift/lower and the extend/retract movement of the boom.
Section 5 - Attachments 6 ft (1,8 m) Mast with 48 or 72 in (1,2 & 1,8 m) Carriage Description P/N Mast 48 in ......................................................................91405060 Mast 72 in ......................................................................91405061 OY0580 Use 6 ft Mast Attachment Capacity Chart To determine maximum capacity, refer to “Telehandler/Attachment/Fork Capacity” on page 5-3.
Section 5 - Attachments Installation Procedure: • Refer to “Attachment Installation” on page 5-7. 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: • Lower forks fully in mast before engaging load. • Travel in accordance with requirements set forth in Section 1 - General Safety Practices. • Use a signal person to assist in positioning of load if necessary.
Section 5 - Attachments 6 ft (1,8 m) - 100° Swing Mast W/Side Shift Description P/N Mast w/ 48 in Fork .........................................................91405070 Mast w/ 60 in Fork .........................................................91415026 GNINRAW OY0590 Use 6 ft Swing Mast Attachment Capacity Chart To determine maximum capacity, refer to “Telehandler/Attachment/Fork Capacity” on page 5-3.
Section 5 - Attachments To Swing: • Pull Swing Switch (4) back, located on dash panel to activate Swing function. With Swing Switch activated, move the auxiliary control joystick (3) down to swing forks right or up to swing forks left. To Raise/Lower Mast: • Pull Forks Raise/Lower Switch (5) back, located on dash panel to activate Forks Raise/Lower function. With Forks Raise/Lower Switch activated, move the auxiliary control joystick (3) down to raise forks or up to lower forks.
Section 5 - Attachments Swing Carriage Description P/N 100° Swing Carriage .................................................... 91405075 100° Swing Drywall Carriage ....................................... 91405078 180° Swing Carriage .................................................... 91563146 OY0670 Use Swing Carriage Attachment Capacity Chart To determine maximum capacity, refer to “Telehandler/Attachment/Fork Capacity” on page 5-3.
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 Side Tilt Carriage Description P/N Side Tilt 48 in.................................................................91405101 Side Tilt 72 in.................................................................91405079 OY0690 Use Side Tilt Attachment Capacity Chart To determine maximum capacity, refer to “Telehandler/Attachment/Fork Capacity” on page 5-3. 1 TILT SPEED CONTROL 3 2 OY0380 The joystick (1) controls lift/lower and the extend/retract movement of the boom.
Section 5 - Attachments Installation Procedure: • Refer to “Attachment Installation” on page 5-7. Operation: • Approach load with forks centered on load and stop telehandler. • Level telehandler before side tilting carriage to engage load. • Side tilt carriage to left or right to align forks with load and engage load. • Raise load slightly and then level carriage side to side. • Travel in accordance with requirements set forth in Section 1 - General Safety Practices.
Section 5 - Attachments Personnel Work Platform The operator and personnel in platform must read and understand the separate personnel work platform manual prior to installing and using a platform. Preparation and Setup 1. Check to ensure the personnel platform is securely attached at the Quick Switch™ or is securely attached to the forks and/or carriage is using a fork mounted personnel work platform. Follow installation procedure on page 5-7 for JLG Quick Switch™ mounted personnel work platforms. 2.
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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. • The steering system permits manual steering if engine or power assist feature fails; however, steering will be slow and will require much greater force.
Section 6 - Emergency Procedures 6.2 EMERGENCY LOWER 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 your 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. Service intervals are based on machine usage of 1500 hours annually. Use of your product may vary significantly and you must adjust service frequency for your usage to obtain maximum service life. A A 1 VIEW A-A OX0370 The Service Instruction Plate (1) is located as indicated in figure.
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 50, 250 & 500 Hour Maintenance Schedule EVERY 50 Drain Fuel/ Water Separator Check Engine Coolant Level Check Battery Lubrication Schedule EVERY 250 Change Engine Oil and Filter* Check Front Axle Oil Level Check Front & Rear Wheel End Oil Levels Check Boom Cable Tension Check Boom Bearing Pads Check Rear Axle Stabilization Air Filter Vacuator Valve Check Fan Belt EVERY 500 LB/F T (N m) Change Fuel Filter Check Wheel Lug Nut Torque OX0530 Note: En
Section 7 - Lubrication and Maintenance 1000 & 1500 Hour Maintenance Schedule EVERY 1000 Change Front Axle Oil Change Front & Rear Wheel End Oil Change Hydraulic Tank Breather EVERY 1500 Change Engine Coolant Change Hydraulic Fluid & Filters OY1041 31200148 7-5
Section 7 - Lubrication and Maintenance 7.4 LUBRICATION SCHEDULES 50 Hour Lubrication Schedule EVERY Mystik Tetrimoly Grease (NLGI 2 GC-LB) 50 STAY CLEAR OF PINCH POINT AREA ANYTIME ENGINE IS RUNNING. BEING IN PINCH POINT AREA COULD CAUSE SERIOUS INJURY OR DEATH. 9114-3282 R ** unknown ** ** unknown ** 2 NO DIESEL FUEL IS FLAMMABLE EXTINGUISH ALL OPEN FLAME AND SMOKING MATERIALS WHEN REFUELING INJURY OR DEATH COULD RESULT FROM FIRE. 9114-3286 1 7733-3027 NO RIDERS PERMITTED ON HANDLER.
Section 7 - Lubrication and Maintenance 250 Hour Lubrication Schedule EVERY 250 Mystik Tetrimoly Grease (NLGI 2 GC-LB) STAY CLEAR OF PINCH POINT AREA ANYTIME ENGINE IS RUNNING. BEING IN PINCH POINT AREA COULD CAUSE SERIOUS INJURY OR DEATH. 9114-3282 R ** unknown ** ** unknown ** 2 NO 1 7733-3027 STAY CLEAR OF PINCH POINT AREA ANYTIME ENGINE IS RUNNING. BEING IN PINCH POINT AREA COULD CAUSE SERIOUS INJURY OR DEATH.
Section 7 - Lubrication and Maintenance 7.5 OPERATOR MAINTENANCE INSTRUCTIONS Fuel System 10 A. Fuel Level Check OW0970 OW0990 1 FUEL F 80 E 0 240 16 100 10 TEMP OIL VOLT 2 3 4 OY0070 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 3-5. 3. Locate fuel tank (2), turn fuel tank cap (3) and remove from filler neck (4). Add diesel fuel as needed. Replace fuel tank cap.
Section 7 - Lubrication and Maintenance 50 B. Drain Fuel/Water Separator 5 4 5-FRONT G OX0130 1. Perform “Shut-Down Procedure” on page 4-4. 2. Open the engine cover. 3. Loosen drain cock (4) on underside of fuel filter (5) and allow all water to drain into a glass until clear fuel is visible. Tighten drain cock. 4. Close and secure the engine cover.
Section 7 - Lubrication and Maintenance Air Intake System 10 A. Air Filter Restriction Indicator Check 4 1 6 3 7 5 2 OX0331 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. Unlock air cleaner cover (4), turn counterclockwise and remove from air cleaner canister (5). 2. Remove outer primary element (6) and inspect for damage. Damaged elements should not be reused. 3. Thoroughly clean the interior of the air cleaner canister and vacuator valve. 4. Replace inner safety element (7) after every third primary element change.
Section 7 - Lubrication and Maintenance Engine Oil 10 A. Engine Oil Level Check 4 AD D 2 3 1 OX0140 1. Perform “Shut-Down Procedure” on page 4-4. 2. 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. Replace dipstick. 3. If oil is low, open the engine cover, remove oil fill cap (4) and add motor oil to bring oil up to the full mark in the crosshatch area. 4. Replace oil fill cap. 5.
Section 7 - Lubrication and Maintenance Hydraulic Oil A. Hydraulic Oil Level Check 10 7 5 6 2-FRONT OX0180 1. Be sure all cylinders are fully retracted and machine is level. 2. Perform “Shut-Down Procedure” on page 4-4. 3. Check level of hydraulic oil in tank at the sight gauge (6) on the hydraulic tank (5). The oil level should be visible in the gauge window. 4. If hydraulic oil is low, open the tank cover and remove oil fill cap (7) from filler neck.
Section 7 - Lubrication and Maintenance Tires A. Tire Air Pressure Check 10 1. Perform “Shut-Down Procedure” on page 4-4. 2. Remove valve stem cap. 3. Check tire pressure using a good quality gauge. 4. Add air if required. 13.00 x 24, G-2/L-2 Bias-Ply Traction - 12 Ply ............................ 65 psi (4.5 bar) 13.00 x 24, G-3/L-3 Bias Ply Rock - 12 Ply ................................. 65 psi (4.5 bar) 13.00 x 24, G-2/L-2 Radial - 1 Star ............................................. 70 psi (4.
Section 7 - Lubrication and Maintenance C. Tire and Wheel Replacement JLG recommends 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 a JLG approved replacement tire, JLG recommends that replacement tires 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 before first use and after each wheel removal. 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 Hydraulic Return Filter 10 A. Hydraulic Return Filter Indicator Check 1 OX0170 2 1. Apply park brake, shift transmission to "Neutral" and lower forks or attachment to horizontal position. 2. Check hydraulic return filter indicator with engine at normal operating temperature. 3. Have an assistant open the tank cover. 4.
Section 7 - Lubrication and Maintenance Engine Cooling System 50 A. Engine Coolant Level Check 1 OX0160 1. Perform “Shut-Down Procedure” on page 4-4. 2. Open the engine cover. 3. When coolant is cool, remove cap (1). Check coolant level in radiator. 4. If coolant is low, add coolant (50/50 mixture of ethylene glycol and water) as required. 5. Replace radiator cap. 6. Close and secure the engine cover.
Section 7 - Lubrication and Maintenance Battery 50 A. Battery Check 2 - + 2-FRONT CLM 05-09-97 4 YES . . 1 . 9114-9206 . OX0150 1. Perform “Shut-Down Procedure” on page 4-4. 2. Remove the front cover. 3. Wearing eye protection, visually inspect the battery (2). Check terminals for corrosion. Replace battery if it has a cracked, melted or damaged case. 4. Replace the front cover.
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Section 8 - Additional Checks SECTION 8 - ADDITIONAL CHECKS This Page Intentionally Left Blank 31200148 8-1
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Section 9 - Specifications SECTION 9 - SPECIFICATIONS 9.1 PRODUCT SPECIFICATIONS Fluid and Lubrication Capacities Engine Crankcase Oil Capacity with Filter Change ...................................................15.5 quarts (14,7 liters) Type of Oil ................................................................................................ 15W-40 CD Fuel Tank Capacity .................................................................................38 gallons (143,8 liters) Type of Fuel............
Section 9 - Specifications Tires Pressure 13.00 x 24, G-2/L-2 Bias-Ply Traction - 12 Ply Pneumatic ......................................................................................65 psi (4.5 bar) 542 lb (246 kg) Foam .....................................................................60 psi (4.1 bar) 13.00 x 24, G-3/L-3 Bias Ply Rock - 12 Ply Pneumatic ......................................................................................65 psi (4.5 bar) 542 lb (246 kg) Foam ..........................
Section 9 - Specifications Dimensions Overall Height..............................................................................95.40 in (2.423 mm) Overall Width...............................................................................96.23 in (2.444 mm) Cab Width............................................................................................37 in (940 mm) Track Width..................................................................................82.24 in (2.089 mm) Wheelbase ...........
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Index Index A Additional Checks............................. 8-1 Adjusting/Moving Forks .................... 5-9 Approved Attachments ..................... 5-1 Driving Hazards on Slopes ...............1-9 E Electrical Hazards .............................1-2 Attachment Installation ..................... 5-7 Emergency Exit from Enclosed Cab....................................6-2 Attachment Operation .................... 5-10 Emergency Lower of Boom...............6-2 Attachment Tilt Lever ............
Index Lubrication Schedule ........................ 7-6 250 Hour ..................................... 7-7 50 Hour ....................................... 7-6 1st 50 Hour ..................................7-3 250 Hour ......................................7-4 50 Hour ........................................7-4 500 Hour ......................................7-4 M Shut-Down Procedure.......................4-4 Mast w/ Carriage ............................ 5-19 Side Tilt Carriage ..........................
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.
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: +61 265 811 111 Fax: +61 265 810 122 JLG Latino Americana Ltda. Rua Eng.
