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 February 23, 2009 - A - Original Issue of Manual September 25, 2009 - B - Revised pages b, 1-5, 1-6, 2-3, 2-4, 3-3, 3-4, 3-5, 3-17, 3-19, 4-1, 4-2, 7-2, 7-5, 7-11, 7-14, 7-16, 7-17, 7-23, 7-24, 8-1, 8-2 & 9-1. December 21, 2010 - C - Revised pages 7-18, 9-2 & 9-4. September 30, 2014 - D - Revised pages 1-6, 1-7, 5-2, 5-14 thru 5-39 & 9-4.
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..........................................................................................31200079 Illustrated Parts Manual.............................................................................31200069 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 Table of Contents Section 1 - General Safety Practices 1.1 Hazard Classification System ..............................................
Table of Contents 3.3 3.4 3.5 3.6 3.7 3.8 Outrigger Joysticks ....................................................... 3-12 Frame Level Joystick.................................................... 3-13 Heater and Air Conditioning Controls (if equipped) ...... 3-14 Accessory Control Lever (if equipped) ......................... 3-15 Steer Modes ...................................................................... 3-16 Steer Mode Change .....................................................
Table of Contents 5.4 Telehandler/Attachment/Fork Capacity................................5-3 5.5 Use of the Capacity Chart....................................................5-4 Capacity Indicator Locations ...........................................5-4 Sample Capacity Chart ...................................................5-5 Example ..........................................................................5-7 5.6 Attachment Installation ........................................................
Table of Contents Engine Oil ..................................................................... 7-14 Hydraulic Oil ................................................................. 7-15 Engine Cooling System ................................................ 7-16 Tires.............................................................................. 7-18 Hydraulic Return Filter.................................................. 7-21 Transmission Oil...........................................................
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.
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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 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 2-8) 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.
Section 2 - Pre-Operation and Inspection 10438304 4 FT 10239617 RAISE LOAD 110 100 90 1 0 FT 30 20 C FORKLIFT SIGNALS STOP 3 FT 120 10 cm CAPACITY CHARTS 1001103932 C LOWER LOAD TILT FORKS RIGHT TILT FORKS LEFT TILT FORKS DOWN MOVE LOAD BACKWARD SERVICE/LUBRICATION SCHEDULE MODEL 1044C-54 SERIES II TILT FORKS UP SYSTEM CAPACITIES AND PRESSURES HYDRAULIC RESERVOIR 47 GALS HYDRAULIC SYSTEM & RESERVOIR 7 20 6 20 TIRES 14.
Section 2 - Pre-Operation and Inspection 50 60 70 80 4105262 40 20 -10 0 10 30 A B C D E F Q R S T U V 10239784 10267807 10116346 Do not disconnect or bypass proximity switches. Bypassing proximity switches may result in serious personal injury or death! See operators manual for instructions.
Section 2 - Pre-Operation and Inspection 2.3 WALK-AROUND INSPECTION 18 1 17 2 16 15 14 3 4 5 6 13 12 7 11 8 10 9 OV0080 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. 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. • Check seat belt for damage, replace belt if frayed or cut webbing, damaged buckles or loose mounting hardware. 6. Main Control Valve (under cab floor) - See Inspection Note. 7. Air Cleaner - Air cleaner element condition indicator, check for clogged condition.
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. Adjust mirror(s) for maximum visibility. WARNING CUT/CRUSH/BURN HAZARD. Keep engine cover closed while engine is running except when checking transmission oil level. Operational Check When engine warms, perform an operational check: 1.
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 2 4 1 OV0120 • 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). • Pull on knob (4) 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 3.2 CONTROLS 4 3 5 6 7 8 2 9 10 1 11 13 17 16 12 15 14 OV0130 1. Hourmeter: Records and indicates engine operating hours. 2. Transmission Control Lever: See page 3-8. 3. Horn: Depress button to sound horn. 4. 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 3-16. 5. Accessory Control Lever (if equipped): See page 3-15. 6.
Section 3 - Controls and Indicators 12. Frame Level Joystick: See page 3-13. 13. Park Brake: See page 3-7. 14. Steer Mode Selector: Three positions: 4-wheel circle steer, 4-wheel crab steer and 2-wheel steer. See page 3-16. 15. Accelerator Pedal: Pressing down the pedal increases engine and hydraulic speed. (Cummins Engine Only) Accelerator pedal also used to activate Cummins diagnostic system. See Service Manual for details. 16.
Section 3 - Controls and Indicators Instrument Panel and Switches JOHN DEERE ENGINE 6 BOOM/ TRANSFER EXTEND LOCK 5 4 3 CHECK ENGINE P 240 WATER 190 160 130 100 °F F CUMMINS ENGINE FUEL 3/4 1/2 1/4 7 8 E PARK BRAKE BRAKE REAR OSC LOCK 2 20 1 TRANSMISSION DECLUTCH 16 80 60 40 15 0 OIL 16 BATT. 14 psi 14 12 10 13 V 12 9 10 11 17 5 BOOM/ TRANSFER EXTEND LOCK 4 3 2 P 80 60 40 REAR OSC LOCK 20 0 1 19 18 240 WATER 190 160 130 100 15 °F FUEL F 3/4 1/2 1/4 OIL BATT.
Section 3 - Controls and Indicators 13. Beacon Light Switch (if equipped): On/Off switch. Hazard Light Switch (if equipped): On/Off switch. 14. Work Light Switch (if equipped): On/Off switch. Roof Wiper Switch (if equipped): On/Off switch. 15. Transmission Declutch Switch: Depress top of switch to activate transmission declutch function and have transmission declutch while depressing service brake. Indicator illuminates to indicate transmission has declutched.
Section 3 - Controls and Indicators Ignition OFF RUN START OV0140 • In the "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 1 OV0150 Park brake knob (1) controls the application and release of the park brake. • Pull knob out to engage park brake. Push knob in to disengage park brake. • With the engine running and the park brake knob pushed in, park brakes are disengaged. • With knob pulled out, park brake is engaged and transmission will not engage forward or reverse. WARNING MACHINE ROLL-AWAY HAZARD.
Section 3 - Controls and Indicators Transmission Control Lever Direction of Travel Selection 1 F N R OV0160 Transmission control lever (1) engages forward or reverse travel. • Push lever forward for forward travel; 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. • Drive in reverse and turn only at slow rates of speed.
Section 3 - Controls and Indicators Gear Selection 1st 2nd 3rd 4th 2 OV0170 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 Front Joystick 2 1 OV0190 The front joystick (1) controls attachment tilt, transfer carriage and auxiliary hydraulic functions. Attachment Tilt Function • Move the joystick forward to tilt down, move the joystick back to tilt up. Transfer Carriage Function • Move the joystick right to extend transfer carriage; move joystick left to retract transfer carriage. • For two simultaneous functions, move the joystick between quadrants.
Section 3 - Controls and Indicators Middle Joystick 2 IF EQUIPPED 3 OV0200 The middle joystick (3) controls boom and second auxiliary hydraulic (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 Outrigger Joysticks 1 OV0210 The outrigger joysticks (1) control the outriggers. • The front joystick controls the right outrigger; the middle joystick controls the left outrigger. • Push the joysticks right to lower outriggers; push the joysticks left 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.
Section 3 - Controls and Indicators Frame Level Joystick 3 2 OV0220 The frame level joystick (2) controls the left to right frame level. • Lift detent ring (3) and move the joystick left to rotate frame left; lift detent ring and move the joystick right to rotate frame right. • A level indicator is located above the front cab window to permit the operator to determine whether the telehandler frame is level. WARNING TIP OVER HAZARD.
Section 3 - Controls and Indicators Heater and Air Conditioning Controls (if equipped) 1 2 3 4 5 OV0230 The heater and air conditioning controls are located on the left side of the cab dash. 1. Air Vent: Three individually adjustable air vents. 2. Heat/Air Conditioning Switch: Depress top of switch for air conditioning. Depress bottom of switch for heat. 3. Fan Switch: On/off switch. 4. Fan Speed Switch: Adjustable rotary switch. 5. Temperature Control Switch: Adjustable rotary switch.
Section 3 - Controls and Indicators Accessory Control Lever (if equipped) 2 4 3 1 OV0460 The accessory control lever (1) operates the turn signals. • Push lever forward (2) to activate the left turn signal. • Pull lever back (3) to activate the right turn signal. • The lever must be manually returned to the center position (4) 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 ROUND STEER OBLIQUE STEER FRONT WHEEL STEER ROUND STEER OBLIQUE STEER FRONT WHEEL STEER ROUND STEER OBLIQUE STEER FRONT WHEEL STEER ROUND STEER OBLIQUE STEER FRONT WHEEL STEER 1 2 3 OV0240 1.
Section 3 - Controls and Indicators 3.4 REAR OSCILLATION LOCK SYSTEM 3 2 BOOM/ TRANSFER EXTEND LOCK 4 1 240 WATER 190 P REAR OSC LOCK 160 130 100 80 60 40 20 0 °F F FUEL 3/4 1/2 1/4 OIL E 16 BATT. 14 psi 12 10 V OV0261 Free Pivot Mode With boom below 20° (1), the system is in free pivot mode. • The rear axle pivots freely and frame level functions normally. • The Rear Oscillation Lock indicator (4) will be off.
Section 3 - Controls and Indicators 3.5 DRIVE LOCKOUT SYSTEM 3 2 1 5 OV0270 Normal Mode With boom below 20° (1), the drive system functions normally. Restricted Mode With boom between 20° and 40° (2), the system is in restricted mode. • The transmission is limited to first and second gear. Locked Mode With boom above 40° (3), the system is in locked mode. • The transmission is disengaged, stopping drive capabilities.
Section 3 - Controls and Indicators 3.6 BOOM/TRANSFER EXTEND LOCK SYSTEM The boom/transfer extend lock system limits boom/transfer carriage extension when outriggers are not engaged. 5 3 BOOM/ TRANSFER EXTEND LOCK 2 REAR OSC LOCK 240 WATER 190 P 160 130 100 80 60 40 20 0 °F F FUEL 3/4 1/2 1/4 OIL E 16 BATT.
Section 3 - Controls and Indicators 3.7 OPERATOR SEAT Adjustments Prior to starting engine adjust seat for position and comfort. 3 1 2 OAL1270 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. Seat Belt: Always fasten seat belt during operation. If required, a 3 in (76 mm) seat 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 3.8 INDICATORS Boom Angle and Extension Indicators 2 B C D 50 60 70 80 A 1 40 20 -10 0 10 30 OV0290 • 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). • 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. Apply parking brake. 2.
Section 4 - Operation Cold Weather Starting Aids John Deere Engine WARNING ENGINE EXPLOSION. If your telehandler is equipped with a cold start aid, do not spray additional ether into air cleaner. If machine is not equipped with cold start aid, follow instructions listed in the engine manual supplied with the telehandler. Cummins Engine Cummins engines are equipped with preheat for cold weather starting. Refer to “Starting the Engine” on page 4-1 for cold weather starting procedure.
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 and indicators 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 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 and fully retract transfer carriage. 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 and transfer carriage 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 and transfer carriage 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 and transfer carriage 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 OV0300 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. Do not tie down 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. • 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 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 5-5), 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 Load zones indicate the maximum weight that may be safely lifted. Boom Extension Indicator (arc) XX XX XX XX XX XX XX XX XX XX XX XX XXXX XXXX XX XXXX XX XX XXXX XX XXXX XXXX XX XX XX XX Boom Angle XXXX XX MAX XX X XX XX XX Load center must be equal to or less than value shown. XX OV0320 XX MAX XX XX XX XX XX XX XX XX XX XX XX XXXXXXX =XXXX XX MAX XXXXXXXXXX X This Capacity Chart may be used with this model ONLY.
Section 5 - Attachments To identify the proper capacity chart on telehandlers equipped with outriggers and/or transfer carriage, refer to the following icons which may be located on the load chart. • Use when lifting a load with outriggers up. OH4410 • Use when lifting a load with outriggers down. OH4420 80" 1" • Use for any forward movement (1 to 80 in) of the transfer carriage. OW0910 0" • Use for no forward movement (0 in) of the transfer carriage. Fully retracted position only.
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.
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Section 5 - Attachments 5.6 ATTACHMENT INSTALLATION 1 2 3 5 OY1540 4 6 1. Attachment 2. Attachment Pin Recess 3. Attachment Pin 4. Lock Pin 5. Retaining Pin 6. Quick Switch (attachment tilt control in cab, see page 3-10) WARNING CRUSH HAZARD. Always be certain that carriage or attachment is properly positioned on boom and is secured by lock pin and retainer pin. Failure to ensure proper installation could permit carriage/attachment/load to disengage.
Section 5 - Attachments 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. Lift retaining pin and insert lock pin completely through quick switch.
Section 5 - Attachments Hydraulic Operated Attachment 1. Install attachment (see page 5-9). 2. Lower attachment to ground and perform “Shut-Down Procedure” on page 4-4. 1 2 OV0330 3. Connect attachment hoses to both auxiliary fittings (1). 4. If equipped, connect attachment hoses to both second auxiliary fittings (2).
Section 5 - Attachments 5.7 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 5.8 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 Use Carriage Attachment Capacity Chart OY0690 To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-3. to “Telehandler/ Suspend loads in accordance with requirements set forth in Section 1 - General Safety Practices. 2 1 OV0340 The middle joystick (1) controls lift/lower and extend/retract movement of the boom. The front joystick (2) controls fork tilt. • Move joystick back to tilt up. • Move joystick forward to tilt down.
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Section 5 - Attachments Side Tilt Carriage Use Side Tilt Carriage Attachment Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-3. to “Telehandler/ OAL1550 3 2 1 OV0350 The middle joystick (1) controls lift/lower and extend/retract movement of the boom. The front joystick (2) controls fork tilt. • Move joystick back to tilt up. • Move joystick forward to tilt down. To Side Tilt: The auxiliary hydraulic button (3) on the front joystick enables carriage side tilt.
Section 5 - Attachments Installation Procedure: • Refer to “Attachment Installation” on page 5-9. WARNING CRUSH HAZARD. Do not use side tilt to push or pull objects or load. Failure to comply could cause object or load to fall. 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 level carriage side to side.
Section 5 - Attachments Side Shift Carriage Use Side Shift Carriage Attachment Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-3. to “Telehandler/ OV0670 The middle joystick (1) controls lift/lower and extend/retract movement of the boom. The front joystick (2) controls fork tilt. • Move joystick back to tilt up. • Move joystick forward to tilt down. To Side Shift: The auxiliary hydraulic button (3) on the front joystick enables carriage side shift.
Section 5 - Attachments Installation Procedure: • Refer to “Attachment Installation” on page 5-9. 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. Operation: • Approach load with forks centered on load and stop telehandler. • Level telehandler before side shifting carriage to engage load. • Side shift carriage to left or right to align forks with load and engage load. • Raise load slightly and level carriage side to side.
Section 5 - Attachments Dual Fork Positioning Carriage Use Carriage Load Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-3. to “Telehandler/ OZ3670 OV0680 The middle joystick (1) controls lift/lower and extend/retract movement of the boom. The front joystick (2) controls fork tilt. • Move joystick back to tilt up • Move joystick forward to tilt down. To Fork Position: The auxiliary hydraulic button (3) controls fork position.
Section 5 - Attachments Installation Procedure: • Refer to “Attachment Installation” on page 5-9. 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.
Section 5 - Attachments Fork Extension Use Appropriate Carriage Attachment Capacity Chart OZ0750 To determine maximum capacity, refer to “Telehandler/Attachment/Fork Capacity” on page 5-3. 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 Swing Carriage Use Swing Carriage Attachment Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-3. to “Telehandler/ OU2150 3 2 1 OV0360 The middle joystick (1) controls lift/lower and extend/retract movement of the boom. The front joystick (2) controls fork tilt. • Move joystick back to tilt up. • Move joystick forward to tilt down. To Swing: The auxiliary hydraulic button (3) on the front joystick enables the swing function.
Section 5 - Attachments Installation Procedure: • Refer to “Attachment Installation” on page 5-9. 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.
Section 5 - Attachments Mast Carriage Use Mast Carriage Attachment Capacity Chart OY0580 To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-3. to “Telehandler/ 3 2 1 OV0370 The middle joystick (1) controls lift/lower and extend/retract movement of the boom. The front joystick (2) controls fork tilt. • Move joystick back to tilt up. • Move joystick forward to tilt down.
Section 5 - Attachments 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. 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 Attachment Capacity Chart GNINRAW To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-3. to “Telehandler/ OY0590 OV0381 The middle joystick (1) controls lift/lower and extend/retract movement of the boom. The front joystick (2) controls fork tilt. • Move joystick back to tilt up. • Move joystick forward to tilt down.
Section 5 - Attachments 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. 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.
Section 5 - Attachments Fork Mounted Hook Use Appropriate Carriage Attachment Capacity Chart OY0640 To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-3. to “Telehandler/ Suspend loads in accordance with requirements set forth in Section 1 - General Safety Practices. 2 1 OV0390 The middle joystick (1) controls lift/lower and extend/retract movement of the boom. The front joystick (2) controls fork tilt. • Move joystick back to tilt up. • Move joystick forward to tilt down.
Section 5 - Attachments Installation Procedure: • Ensure carriage is properly installed. Refer to “Attachment Installation” on page 5-9. • Secure the fork mounted hook to the forks by sliding the fork mounted hook onto the parent forks and install the retaining pin behind the vertical shank of the fork. Operation: • Pallet or lumber forks of an appropriate load rating must be used. Do not use with cubing or block forks. • Weight of rigging must be included as part of total load being lifted.
Section 5 - Attachments Truss Boom Use Appropriate Truss Boom Attachment Capacity Chart OY0570 To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-3. to “Telehandler/ Suspend loads in accordance with requirements set forth in Section 1 - General Safety Practices. 3 2 1 OV0400 The middle joystick (1) controls lift/lower and extend/retract movement of the boom. The front joystick (2) controls truss boom tilt. • Move joystick back to tilt up. • Move joystick forward to tilt down.
Section 5 - Attachments Installation Procedure: • Refer to “Attachment Installation” on page 5-9. 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 Bucket Use Appropriate Bucket Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-3. to “Telehandler/ OZ0730 2 1 OV0410 The middle joystick (1) controls lift/lower and extend/retract movement of the boom. The front joystick (2) controls bucket tilt. • Move joystick back to tilt up. • Move joystick forward to tilt down.
Section 5 - Attachments Installation Procedure: • Refer to “Attachment Installation” on page 5-9. 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 OZ1450 To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-3. to “Telehandler/ 3 2 1 OV0420 The middle joystick (1) controls lift/lower and extend/retract movement of the boom. The front joystick (2) controls grapple bucket tilt. • Move joystick back to tilt up. • Move joystick forward to tilt down.
Section 5 - Attachments Installation Procedure: • Refer to “Attachment Installation” on page 5-9 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.
Section 5 - Attachments Personnel Work Platform Use Personnel Work Platform Capacity Chart OY1610 To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-3. to “Telehandler/ The operator and personnel in platform must read and understand the separate personnel work platform manual prior to installing and using a platform. 2 1 OV0430 The middle joystick (1) controls lift/lower and extend/retract movement of the boom. The front joystick (2) controls platform tilt.
Section 5 - Attachments Installation Procedure: • Ensure carriage is properly installed. Refer to “Attachment Installation” on page 5-9. • Secure the personnel work platform to the forks by sliding the personnel work platform onto the parent forks and install the retaining pin behind the vertical shank of the fork. 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.
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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. • 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 OV0450 The Lubrication and Maintenance chart (1) contains 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 50, 250 & 1st 500 Hour Maintenance Schedule EVERY 50 Check Battery Check Washer Fluid Level (if equipped) Lubrication Schedule EVERY 250 Change Engine Oil and Filter* Check Axle Oil Level Check Wheel End Oil Levels Check Boom Chain & Tension Check Boom Wear Pads Lubrication Schedule 1st 500 Change Axle Oil Change Wheel End Oil OV0480 Note: Engine oil and filter service interval can be extended, see page 7-14 for details.
Section 7 - Lubrication and Maintenance 500, 1000 & 2000 Hour Maintenance Schedule EVERY 500 LB/F T (N m) Change Fuel Filter & Strainer Check Wheel Lug Nut Torque Change Air Filter Elements Change Hydraulic Tank Breather EVERY 1000 Change Transmission Oil & Filter Change Hydraulic Fluid & Filters Change Axle Oil Change Wheel End Oil Check Fan Belt Check Air Intake System EVERY 2000 Change Engine Coolant OV0490 31200608 7-5
Section 7 - Lubrication and Maintenance 7.
Section 7 - Lubrication and Maintenance 50 Hour Lubrication Schedule EVERY 50 OV0510 31200608 7-7
Section 7 - Lubrication and Maintenance 250 Hour Lubrication Schedule EVERY 250 OV0610 7-8 31200608
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Section 7 - Lubrication and Maintenance 7.5 OPERATOR MAINTENANCE INSTRUCTIONS Fuel System 10 A. Fuel Level Check OW0970 F 3/4 1/2 1/4 FUEL OW0990 1 3 E 2 VIEW OF FUEL TANK FROM TOP OF MACHINE OV0520 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. Locate fuel tank (3), turn fuel tank cap (2) and remove from filler neck. 4. Add diesel fuel as needed. 5. Replace and secure fuel tank cap.
Section 7 - Lubrication and Maintenance 10 B. Drain Fuel/Water Separator OW0970 OW1000 JOHN DEERE ENGINE 4 5 OV0530 CUMMINS ENGINE 4 5 OV0640 1. Perform “Shut-Down Procedure” on page 4-4. 2. If equipped, open engine access door. 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. 4. Tighten drain cock. 5. If equipped, close and secure engine access door.
Section 7 - Lubrication and Maintenance Air Intake System 10 A. Air Filter Restriction Indicator Check OW0970 OW1010 1 2 5 7 6 4 3 OV0540 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 OW0970 JOHN DEERE ENGINE OW1020 CUMMINS ENGINE 4 4 2 3 1 1 OV0551 1. Perform “Shut-Down Procedure” on page 4-4. 2. If equipped, open engine access door. 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. If oil is low, remove oil fill cap (4) and add motor oil to bring oil up to the full mark in the crosshatch area. 5.
Section 7 - Lubrication and Maintenance Hydraulic Oil 10 A. Hydraulic Oil Level Check OW0970 OW1030 7 9 10 5 8 6 H I G H L O W OV0560 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 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 remove hex cap (7) from the hydraulic return filter (8). 5.
Section 7 - Lubrication and Maintenance Engine Cooling System A. Engine Coolant Level Check 10 OW0970 OW1070 John Deere Engine 1 OV0580 1. Perform “Shut-Down Procedure” on page 4-4. 2. If equipped, open engine access door. 3. When coolant is cool, remove cap (1). Check coolant level in radiator. 4. If coolant is low, add coolant as required. 5. Replace cap. 6. If equipped, close and secure engine access door.
Section 7 - Lubrication and Maintenance Cummins Engine 1 2 OV0650 1. Perform “Shut-Down Procedure” on page 4-4. 2. Check coolant level in sight gauge (2). 3. If coolant is low, remove cap (1) and add coolant as required. 4. Replace cap. Note: When filling with coolant, the maximum fill rate is 2.5 gallon (9,5 liter) per minute.
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. 14.00 x 24, G-2/L-2 Bias-Ply Traction - 12 Ply Water and Calcium Chloride ....................................................70 psi (4,8 bar) Foam........................................................................................62 psi (4,3 bar) 14.00 x 24, G-2/L-2 Radial - 1 Star Water and Calcium Chloride ......
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 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. Install wheel lug washers. 2. Start all nuts by hand to prevent cross threading. DO NOT use a lubricant on threads or nuts. 3.
Section 7 - Lubrication and Maintenance Hydraulic Return Filter A. Hydraulic Return Filter Indicator Check 10 OW0970 OW1060 1 H I G H L O W 2 OV0600 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. With an assistant observing the indicator (2) located on the hydraulic return filter (1), extend and retract the boom 10 to 12 ft (3,0 to 3,7 m).
Section 7 - Lubrication and Maintenance Transmission Oil 10 A. Transmission Oil Level Check OW0970 OW1050 3 4 T HO LD CO MIN OV0570 1. Apply park brake, shift transmission to "Neutral" and lower forks or attachment to the ground. 2. Check transmission oil level with engine at idle and oil at normal operating temperature. 3. If equipped, open engine access door. 4. Remove the transmission dipstick (3) and check oil level. The oil level should be within the "HOT" zone (4). 5.
Section 7 - Lubrication and Maintenance Battery 50 A. Battery Check OW0980 OW1080 John Deere Engine 1 2 OV0590 1. Perform “Shut-Down Procedure” on page 4-4. 2. Open rear access door. 3. Remove strap (1) and battery box cover (2). 4. Wearing eye protection, visually inspect the battery. Check terminals for corrosion. Replace battery if it has a cracked, melted or damaged case. 5. Replace battery box cover and secure with strap. 6. Close and secure rear access door.
Section 7 - Lubrication and Maintenance Cummins Engine 3 OV0660 1. Perform “Shut-Down Procedure” on page 4-4. 2. Open battery box (3). 3. Wearing eye protection, visually inspect the batteries. Check terminals for corrosion. Replace battery if it has a cracked, melted or damaged case. 4. Close and secure battery box.
Section 8 - Additional Checks SECTION 8 - ADDITIONAL CHECKS 8.1 REAR OSCILLATION LOCK SYSTEM 10 A. Rear Oscillation Lock System Test OW0970 With boom raised above 20° the indicator illuminates. If indicator does not illuminate the test was not performed properly or rear oscillation lock system is not functioning correctly and the test should be stopped immediately. To check the indicator, perform the following: 2 6 3 4 REAR OSC LOCK 1 5 OV0621 1.
Section 8 - Additional Checks 8.2 BOOM/TRANSFER EXTEND LOCK SYSTEM 10 A. Boom/Transfer Extend Lock System Test OW0970 Boom/transfer extend lock system operates in two modes. In locked mode, with outriggers raised, the indicator illuminates and a sensor in the boom will stop boom from extending past a point between the “N” and “O” extension indicators. In unlocked mode, with outriggers lowered, the boom will extend fully.
Section 9 - Specifications SECTION 9 - SPECIFICATIONS 9.1 PRODUCT SPECIFICATIONS Capacities Engine Crankcase Oil Capacity with Filter Change John Deere ..............................................................................14 quart (13,2 liter) Cummins ..............................................................................13.7 quart (13,0 liter) Type of Oil ................................................................................................ 15W-40 CH Fuel Tank Capacity .........
Section 9 - Specifications Tires 14.00 x 24, G-2/L-2 Bias Ply Traction - 12 ply Water and Calcium Chloride ............................................. Approx 623 lb (283 kg) Foam................................................................................. Approx 720 lb (327 kg) 14.00 x 24, G-3/L-3 Bias Ply Rock - 12 Ply Water and Calcium Chloride ............................................. Approx 623 lb (283 kg) Foam.................................................................................
Section 9 - Specifications Performance Maximum Lift Capacity Outriggers Engaged ............................................................... 10,000 lb (4536 kg) Outriggers Not Engaged Transfer Carriage Fully Retracted..................................... 10,000 lb (4536 kg) Transfer Carriage Extended................................................ 5,000 lb (2268 kg) Maximum Lift Height Outriggers Engaged .........................................................................
Section 9 - Specifications Dimensions Overall Height....................................................................................97 in (2464 mm) Overall Width ...................................................................................101 in (2565 mm) Track Width ....................................................................................81.5 in (2070 mm) Wheelbase.......................................................................................
Index Index A Driving Hazards on Slopes ...............1-9 Additional Checks............................. 8-1 Dual Fork Positioning Carriage .......5-20 Adjusting/Moving Forks .................. 5-12 Air Conditioning .............................. 3-14 Approved Attachments ..................... 5-1 Attachment Installation ..................... 5-9 Attachment Operation .................... 5-13 Attachment Tilt Function................. 3-10 E Electrical Hazards .............................
Index L Restriction Indicator ........................7-12 Leveling Procedure.................... 4-6, 4-9 Return Filter Indicator......................7-21 Lifting Personnel............................... 1-8 Load Falling Hazard ......................... 1-7 Lubrication and Maintenance ........... 7-1 Lubrication Schedule 10 Hour ....................................... 7-6 250 Hour ..................................... 7-8 50 Hour ....................................... 7-7 M Mast Carriage ...........
Index Transporting a Load ......................... 4-6 Transporting a Suspended Load ...... 4-9 Travel Hazard................................... 1-6 Truss Boom .................................... 5-32 W Walk-Around Inspection ................... 2-6 Warm-Up Check............................... 2-8 Wheel Installation ........................... 7-20 Wheel Lug Nut.................................. 9-2 Wheel Replacement ....................... 7-19 Windows.........................................
Index 4 31200608
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.
31200608 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.
