Home

Operation 31200148

1. TT TT CIS Wr OX0160 Perform Shut Down Procedure on page 4 4 Open the engine cover When coolant is cool remove cap 1 Check coolant level in radiator Boc m If coolant is low add coolant 50 50 mixture of ethylene glycol and water as required Replace radiator cap 6 Close and secure the engine cover 7 18 31200148 Section 7 Lubrication and Maintenance Battery A Battery Check 50 Q Ore 0 0 8 amp 0 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 31200148 7 19 Section 7 Lubrication and Maintenance This Page Intentionally Left Blank 7 20 31200148 Section 8 Additional Checks SECTION 8 ADDITIONAL CHECKS This Page Intentionally Left Blank 31200148 8 1 Section 8 Additional Checks This Page Intentionally Left Blank 8 2 31200148 Section 9 Specifications SECTION 9 SPECIFICATIONS 9 1 PRODUCT SPECIFICATIONS Fluid and Lubrication Capacities Engine Crankcase Oil Capacity with Filter Change sese 15 5 quarts 14 7 liters Ri
2. 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 Use these indicators to determine boom extension when using the capacity chart see Use of the Capacity Chart on page 5 4 3 5 MIRROR Keep all windows and mirror s clean and unobstructed Adjust mirror s as required for maximum visibility before and during operation 3 14 31200148 Section 4 Operation SECTION 4 OPERATION 4 4 ENGINE Starting the Engine This machine can be operated under normal conditions in temperatures of O F to 104 F 20 C to 40 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 If engine fails to start within 20 seconds release key and allow starting motor to cool for a few minutes before trying again 3 After engine starts observe oil pressure gauge If gauge remains on zero for more than ten seconds stop engine and determine cause before restarting engine Reference engine manual
3. 2 10 Controls and Indicators Generale Sa nents 3 1 Controls rl eee pettiness re eee ai e te c 3 2 Transmission Control 3 3 Ignition Switch esssssseseeemeenenenn 3 4 JOYSTICK 3 5 Attachment Tilt and Frame Sway Lever 3 6 Auxiliary Control Joystick if equipped 3 7 Dash Controls and 3 8 Park Brake Switch 3 9 i Table of Contents Parking Procedure eese 3 9 Loci ERE e a inta ida 3 10 3 3 Operator Seat 3 11 Seat Adjustments sssssssssseseseeeenee 3 11 Seat beet eines 3 13 3 4 Boom Angle and Extension Indicators 3 14 3 5 IMIFTOT Ik ECHTE C C HER Tee tH ete ates 3 14 Section 4 Operation 4 1 Engine ecce tee eee pe ente ee tere 4 1 Starting the Engine 4 1 Cold Weather Starting Aids 4 2 Battery Boosted 4 3 Normal Engine Operation 4 4 Shut Down Procedure sssssssseseeeeneneees 4 4 4 2 Operating with a Load
4. 4 5 Lift Load 4 5 Picking Up a a e 4 5 Transporting the Load 4 6 Leveling Procedure eeeeee 4 6 Placing the Load seserinis inaasinta innin innn 4 7 Disengaging the 4 7 4 3 Operating with a Suspended 4 8 Lift Load 4 8 Picking Up a Suspended 4 8 Transporting a Suspended 4 9 Leveling Procedure eeseemee 4 9 Placing a Suspended 4 10 Disengaging a Suspended Load 4 10 4 4 Loading and Securing for 4 11 RO 4 11 Nune 4 12 Section 5 Attachments 5 1 Approved 5 1 5 2 Unapproved 5 2 5 3 Telehandler Attachment Fork 5 3 5 4 Use of the Capacity 5 4 Capacity Indicator Locations 5 4 Sample
5. 7 12 F Fall 1 12 Fork Positioner 5 11 Frame Sway 3 6 Fuel Level eese 7 8 Fuel 9 1 Fuel Water 7 9 G General Maintenance 7 2 H Hazard Classification System 1 1 3 10 Hydraulic Oil Level 7 13 Hydraulic Return Filter 7 17 Hydraulic System 9 1 a c 3 4 L Leveling Procedure 4 6 4 9 Lifting Personnel 1 8 Load Falling Hazard 1 7 Lubrication and Maintenance 7 1 1 Index Lubrication Schedule 7 6 250 Hour sincier 7 7 50 Flour eiue ctn 7 6 M Mast w Carriage 5 19 Operating with a Load 4 5 Operating with a Suspended Load nis encase anise 4 8 Operational 2 8 Operator 2 9 Operator Maintenance Instructions 5e e 7 8 Operator 3 11 P Park 3 9 Parking Procedure 3 9 Personnel W
6. 7 19 Battery Boosted Starting 4 3 Boom Angle Indicator 3 14 Boom Extension Indicator 3 14 Boom Head Mounted Winch 5 18 Boom 3 5 Bucket 5 14 C 9 1 Gapacity ooo D 5 3 Capacity 5 4 Exambple nte 5 6 Sample sese 5 5 Capacity Indicator Locations 5 4 Chemical Hazards 1 13 CONOIS tice tette feste 3 2 Coolant Level 7 18 Cooling System 9 1 5 12 Dash Controls and Indicators 3 8 Decals tate dene eed 2 3 Dimensions eese 9 3 Disengaging a Suspended eee RIA 4 10 Disengaging the Load 4 7 31200148 Driving Hazards on Slopes 1 9 E Electrical Hazards 1 2 Emergency Exit from 6 2 Emergency Lower of Boom 6 2 Emergency Procedures 6 1 Engine Rer 4 1 Normal Operation 4 4 Starting 4 1 Engine Crankcase 9 1 Engine Oil Level
7. 15 n 14 13 4 12 5 1 6 7 11 LJ 5 8 10 9 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 Inspect all structural members including attachment for cracks excessive corrosion and other damage 1 Boom Sections amp Lift Tilt Extend Retract Compensating Slave Cylinders e Check front top side amp rear slider pads for adequate grease e Pivot pins secure hydraulic hoses undamaged not leaking Check extend retract cables and adjustment blocks for adequate tension 2 Front Axle Pivot pins secure hydraulic hoses undamaged not leaking 3 Wheel Tire Assembly Properly inflated and secured no loose or missing lug nuts Inspect for worn tread cuts tears or other discrepancies 2 6 31200148 4 11 12 13 14 15 16 Section 2 Pre Operation and Inspection Cab amp Electrical Check window glass is in place and clean gauges switches joysticks foot controls amp horn operational General appearance no visible damage proper load charts and applicable Operator amp Safety manual located in manual holder Make sure emergency escape hamme
8. Separate attachment instructions must be kept in Manual Holder in cab with this Operation amp Safety Manual An additional copy must be kept with the attachment if it is equipped with a manual holder EQUIPMENT DAMAGE Some attachments may contact the front tires or machine structure when the boom is retracted and the attachment is rotated Improper use of attachment may result in attachment or machine structural damage EQUIPMENT DAMAGE Avoid contact with any structure or object when lifting a load Maintain clearance around boom structure and load Failure to maintain clearance may result in attachment or machine structural damage 5 10 31200148 Section 5 Attachments Carriage w Forks Description P N Carriage 48 in 91405073 Carriage 72 in scs emen edens 91405074 Carriage Drywall eene 91405077 Fork Cubing 2x2x48 in sessssseeesss 91403359 Fork 1 3 Ax4x48 in cesses 91403364 Fork Drywall 1 3 4x4x48 in 91403366 Fork 2 6 60 n 91403580 Fork 2 T AXbX4B Ihr ee ovest eens 91563141 Fork 2 1 4x6x60 in eese 91563142 Use Carriage Attachment Capacity Chart To determine maximum capacity refer to Telehandler Attachment Fork Capacity on page 5 3 OY0332 The joystick 1 controls lift lower and the extend retract movement of the boom The tilt lever 2 controls the f
9. MACHINE IS XXXXX EQUIPPED WITH WINCH m T T T T T RATED CAPACITY 2 FT LOAD CENTER 8 44 1 69 TUN C RD S S 4 Example 4 32 0 40 no 2 RI 2 e 24 30 o E 9 E 1 eor 5 Example 3 Example 2 16 2b 2 12 4 IS Example 1 2 USE WITH 8765 4321 1234 5678 48 CARRIAGE 72 CARRIAGE XXXX XXXX OWO660 Note This is a sample capacity chart only DO NOT use this chart use the one located in your operator cab 5 6 31200148 Section 5 Attachments 5 5 ATTACHMENT INSTALLATION OX0440 Attachment Attachment Pivot Pin Recess Quick Switch Lock Pin a A N 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 2 Align attachment pivot pin with recess in attachment Raise boom slightly to engage attachment pivot pin in recess OX0460 31200148 5 7 Section 5 Attachments 3 Engage Quick Switch OX0470 4 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 5 If equipped swing attachment saddles down and pin in place P OX0480 6 If equipped connect auxiliary hydraulic hoses 7 If equipped connect auxiliar
10. Bm OX0130 H fi 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 31200148 7 9 Section 7 Lubrication and Maintenance Air Intake System Ll A Air Filter Restriction Indicator Check 1 0 X aas a 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 Excessive access to check an element can lead to premature element failure 7 10 31200148 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 Remove outer primary element 6 and inspect for damage Damaged elements should not be reused Thoroughly clean the interior of the air cleaner canister and vacuato
11. 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 Note The user assumes all responsibility for choosing the proper method of transportation and tie down devices making sure the equipment used is capable of supporting the weight of the vehicle being transported and that all manufacturer s instructions and warnings regulations and safety rules of their employer the Department of Transportation and or any other state or federal laws are followed A WARNING TELEHANDLER SLIDE HAZARD Before loading telehandler for transport make sure deck ramps and telehandler wheels are free of mud snow and ice Failure to do so could cause telehandler to slide 31200148 4 11 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 Ensure that the lifting device and equipment is adequately rated and suitable for the intended purpose See Section 9 Specifications for machine weight Remove all loose items from machine prior to lifting Lift m
12. Inspection Maintenance and Repair Log iv 31200148 Section 1 General Safety Practices SECTION 1 GENERAL SAFETY PRACTICES 1 4 HAZARD CLASSIFICATION SYSTEM Safety Alert System and Safety Signal Words A DANGER fi DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING fA WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION po CAUTION indicates a potentiality hazardous situation which if not avoided may result in minor or moderate injury 1 2 GENERAL PRECAUTIONS A WARNING Before operation read and understand this manual Failure to comply with the safety precautions listed in this manual could result in machine damage property damage personal injury or death 31200148 1 1 Section 1 General Safety Practices 1 3 OPERATION SAFETY Electrical Hazards X LJ This machine is not insulated and does not provide protection from contact or being near electrical current OWo0040 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 Follow employer local and governmental regulations for clearance from powerlines 1 2
13. epa et ee ebbe certat 128 in 3 251 mm Length at Front 183 5 in 4 661 mm Overall Length less Forks 212 59 in 5 4 mm Ground 1 17 in 432 mm Turning Raduis Over 141 25 in 3 588 mm Turning Raduis at Forks 182 4 in 4 683 mm Gross Vehicle Weight with 20 400 Ib 9 253 kg Front Axle Weights ced eed cn ue 9 695 Ib 4 398 kg Rear Axle Weight diel adhe 10 705 Ib 4 856 kg Maximum Ground Bearing Pressure 13 00 x 24 Foam Filled 98 2 Ibs in 6 90 kg cm 15 50 X 25 Foam Filled redii c ees 70 8 Ibs in 4 98 kg cm 31200148 9 3 Section 9 Specifications This Page Intentionally Left Blank 9 4 31200148 A Additional Checks 8 1 Adjusting Moving Forks 5 9 Approved Attachments 5 1 Attachment Installation 5 7 Attachment Operation 5 10 Attachment Tilt Lever 3 6 Attachments 5 1 Auxiliary Control Joystick 3 7 AXI8S Do 9 1 B
14. 2 3 Section 2 Pre Operation and Inspection 91143280 BEFORE S N 0160026801 91143285 91143282 91143281 STAY CLEAR OF MOVING PARTE WHILE ENGINE IS RUNNING MOVING PARTS CAN CAUSE SERIOUS INJURY 91403573 91143282 91163028 FORWARD REVERSE 91413061 91403529 TRACTION LOCK i VIEW C C 2 4 91413024 Gi Mobiiflud 424 91143288 91143284 o CAPACITY CHARTS o 80603026 f 4 VIEW OY1071 VIEW OF HYDRAULIC TANK 31200148 Section 2 Pre Operation and Inspection 91143282 4105262 80603037 WARNING 91143290 91513210 Eee 91513210 91143282 PINCH POINT TA 91513210 91513210 OY1250 E VIEW A A VIEW B B 31200148 2 5 Section 2 Pre Operation and Inspection 2 3 WALK AROUND INSPECTION 16 1
15. Capacity 5 5 Example 4 nd enr OE tei 5 6 5 5 Attachment 5 7 5 6 Adjusting Moving Forks 5 9 5 7 Attachment Operation sss 5 10 Carriage w Forks 5 11 ii 31200148 Table of Contents Crane HOOK qun 5 12 ts 5 14 TRUSS BOOM erri dere se ER oe eiectus 5 16 Boom Head Mounted 5 18 6 ft 1 8 m Mast with 48 or 72 in 1 2 amp 1 8 m Cartiage i 5 19 6 ft 1 8 100 Swing Mast W Side Shift 5 21 Swing Carriage ssssssssseeeeeneeeneenes 5 23 Side Tilt Caria e nan ii 5 25 Personnel Work 5 27 Section 6 Emergency Procedures 6 1 Towing a Disabled 6 1 Moving Short 6 1 Moving Longer Distances 6 1 6 2 Emergency Lower of 6 2 6 3 Emergency Exit from Enclosed 6 2 Section 7 Lubrication and Maintenance FEM Introduction tone nota reel re
16. 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 31200148 5 17 Section 5 Attachments Boom Head Mounted Winch P N 91515036 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 7 1 SEO Ne dm S pee i OY0660 The joystick 1 controls lift lower and the extend retract movement of the boom Winch Control The auxiliary control joystick 2 controls the winch Move joystick up to lower cable Move joystick down to raise cable A 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 5 18 31200148 Section 5 Attachments 6 ft 1 8 m Mast with 48 or 72 in 1 2 amp 1 8 m Carriage e Description P N Mast 48 Ini ics etes to te Debe 91405060 NVES ETEA a 91405061 4 Use 6 ft Mast Attachment Capacity Chart OY0580 To determine maximum capacity refer to Telehandler Attachment Fork Capacity
17. P N Bucket 60 in 3 4 yd 91405054 Bucket 74 in 1 1 4 yd sse 91405055 Bucket 102 in 1 1 4 yd 91405071 OZ0730 Use Appropriate Bucket Capacity Chart To determine maximum capacity refer to Telehandler Attachment Fork Capacity on page 5 3 278 a L 7 ma 17 12 a t pom lt gt p 4 2 4 PA 2 7 OY0342 The joystick 1 controls lift lower and the extend retract movement of the boom The tilt lever 2 controls bucket tilt Move joystick forward to tilt down Move joystick back to tilt up Installation Procedure Referto Attachment Installation on page 5 7 5 14 31200148 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 Operation Raise or lower boom to appropriate height for loading material from stockpile Align telehandler with face of stockpile and drive slowl
18. Section 2 2 1 2 2 2 3 2 4 2 5 2 6 Section 3 3 1 3 2 31200148 General Safety Practices Hazard Classification 1 1 Safety Alert System and Safety Signal Words 1 1 General Precautions sss 1 1 Operation 1 2 Electrical 2 1 2 Over nene 1 3 Travel Hazard 1 6 Load Falling 1 7 Lifting Personnel 1 8 Driving Hazards on Slopes 1 9 Pinch Points and Crush 1 10 Fall Hazard intet e ne 1 12 Chemical Hazards esses 1 13 Pre Operation and Inspection Pre Operation Check and 2 1 Safety D6Cals Lente eiae ee 2 3 Walk Around Inspection eeseeen 2 6 Warm Up and Operational 2 8 Warm Up Check ssssseseeeeeenneeenneeen nene 2 8 Operational Check ssssseeeeeeennes 2 8 Operator nennen nennen 2 9 WINGOWS ic titt d erret ei eate erg 2 10 Cab Door Window if
19. instructions Clothing and Safety Gear Wear all the protective clothing and personal safety devices issued to you or called for by job conditions DO NOT wear loose clothing or jewelry that can get caught on controls or moving parts 31200148 7 1 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 Apply a light coating of engine oil to all linkage pivot points ntervals shown are for normal usage and conditions Adjust intervals for abnormal usage and conditions Drain engine and gear cases after operating when oil is hot Check all lubricant levels when lubricant is cool For ease of filling hydraulic reservoir use a funnel with a hose or flexible tube for best results Note Be certain to check boom cable adjustment every 5 weeks or 250 hours and adjust as required Cable damage can occur if cable is not adjusted properly A WARNING CUT CRUSH BURN HAZARD Do not perform service or maintenance on the machine with the engine running with the exception of the transmission level and hyd
20. with auxiliary hydraulics and electrics If any of the above conditions are not met do not use the attachment The telehandler may not be equipped with the proper capacity chart or the attachment may not be approved for the model telehandler being used Contact JLG or a local distributor for further information 31200148 5 1 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 A WARNING Use only approved attachments Attachments which have not been approved for use with your telehandler could cause machine damage or an accident 5 2 31200148 Section 5 Attachments 5 3 TELEHANDLER ATTACHMENT FORK CAPACITY 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 cap
21. 0 THIS FAR TO GO With hands raised and open inward move hands laterally indicating distance to go TILT FORKS UP With one arm held at side extend other arm upward at about 45 degrees TILT FORKS DOWN With one arm held at side extend other arm downward at about 45 degrees Special Signals When signals for auxiliary equipment functions or conditions not covered are required they shall be agreed upon in advance by the operator and signalman 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 t 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 France SAS 2 1 de Baulieu 47400 Fauillet France Phone 33 0 5 53 88 31 70 Fax 33 0 5 53 88 31 79 JLG Industries Italia s r l Via Po 22 20010 Pregnana Milanese MI Italy Phone 39 029 359 5210 Fax 39 029 359 5845 JLG Industries Scotland Wright Business Centre 1 Lonmay Road Queenslie Glasgow G33 4EL Scotland Phone 44 0 141 781 6700 Fax 44 0 141 773 1907 JLG Latino Americana Ltda Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil Phone 55 193 295 0407 Fax 455 193 295 1025 JLG Deutschland GmbH Max Planck St
22. 31200148 Section 1 General Safety Practices Tip Over Hazard General For additional load requirements refer to the appropriate capacity chart 52 Be 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 e sure that the ground conditions are able to support the machine DO NOT raise boom unless frame is level 0 degrees unless otherwised noted on capacity chart Eu E E DO NOT level machine with boom attachment above 4 ft 1 2 m AUS DO NOT level machine with load more than 11 8 in 300 mm above ground surface 31200148 1 3 Section 1 General Safety Practices Ded OH2291 MAINTAIN proper tire pressure at all times If proper tire pressures are not maintained this machine could tip over Refer to manufacturers specifications for proper fill ratio and pressure requirements for tires equipped with ballast C y OH20911 Always wear the seat belt Keep head arms hands legs and all other body parts inside operator s cab at all times OH2221 DA If the telehandler starts to tip over DO NOT JUMP BRACE YOURSELF and STAY WITH THE MACHINE KEEP YOUR SEAT BELT FASTENED HOLD ON FIRMLY LEAN AWAY FROM THE POINT OF IMPACT 1 4 31200148 Section 1 General Safety Practices Non Su
23. DO NOT carry riders Riders could fall off machine causing death or serious injury OWo0290 1 12 31200148 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 f spark arrestors are required ensure they are in place and in good working order Flammable Fuel OW0300 DO NOT fill the fuel tank or service the fuel system near an open flame sparks or smoking materials Engine fuel is flammable and can cause a fire and or explosion Hydraulic Fluid 0950 DO NOT attempt to repair or tighten any hydraulic hoses or fittings while the engine is running or when the hydraulic system is under pressure Stop engine and relieve trapped pressure Fluid in the hydraulic system is under enough pressure that it can penetrate the skin DO NOT use your hand to check for leaks Use a piece of cardboard or paper to search for leaks Wear gloves to protect hands from spraying fluid 31200148 1 13 Section 1 General Safety Practices This Page Intentionally Left Blank 1 14 31200148 Section 2 Pre Operation and Inspection SECTION 2 PRE OPERATION AND INSPECTION 2 1 PRE OPERATION CHECK AND INSPECTION Note Comple
24. JL Operation amp Safety Manual Keep this manual with machine at all times Model G6 42P S N 0160004018 amp After 31200148 Original November 25 2008 SSS 3 E 509001 REGISTERED COMPANY Wha An Oshkosh Corporation Company 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 November 25 2008 A Original Issue of Manual 31200148 a 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 for updated information Operator Qualifications The operator of the machine must not operate the machine until this manual has been read training
25. JLG products Please return completed form to the JLG Product Safety amp Reliability Department via facsimile or mail to address as specified below Thank You Product Safety amp Reliability Department JLG Industries Inc 13224 Fountainhead Plaza Hagerstown MD 21742 USA Telephone 1 717 485 6591 Fax 1 301 745 3713 NOTE Leased or rented units should not be included on this form Mfg Model Serial Number Previous Owner Address Country Telephone Date of Transfer Current Owner Address Country Telephone Who in your organization should we notify Name Title Hand Signals OY1090 EMERGENCY STOP With both arms extended laterally hands open downward move arms back and forth OY1100 STOP With either arm extended laterally hand open downward move arm back and forth OY1110 STOP ENGINE Draw thumb or forefinger across throat RAISE BOOM With either arm extended horizontally fingers closed point thumb upward LOWER BOOM With either arm extended horizontally fingers closed point thumb downward OY1140 MOVE SLOWLY Place one hand motionless in front of hand giving motion signal Raise load slowly shown OY1150 EXTEND BOOM With both hands clenched point thumbs outward OY1160 RETRACT BOOM With both hands clenched point thumbs inward OY117
26. Page Intentionally Left Blank 5 28 31200148 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 DO NOT attempt to tow a telehandler that is loaded or the boom attachment is raised above 4 ft 1 2 m Moving Short Distances f it is only necessary to move telehandler a short distance less than 100 ft 30 m it is permissible to use a vehicle of sufficient capacity to tow the unit with no previous preparation Moving Longer Distances f the telehandler must be moved longer distances it must be loaded onto a trailer of sufficient capacity Contact your local Authorized Distributor for specific instructions if neither of these methods are applicable 31200148 6 1 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 us
27. RIAGE XXXX XXXX These numbers must match the model option OWO650 Note This is a sample capacity chart only DO NOT use this chart use the one located in your operator cab A WARNING TIP OVER HAZARD All loads shown on rated capacity chart are based on machine being on firm ground with frame level see page 4 6 the forks being positioned evenly on carriage the load being centered on forks proper size tires being properly inflated and the telehandler being in good operating condition 31200148 5 5 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 Load Weight Distance Height OK to Lift 1 2000 Ibs 907 kg 20ft 6 1 12ft 3 6 Yes 2 3000 Ibs 1361 kg 25ft 7 6 m 19ft 5 8 m NO 3 6000 Ibs 2722 kg 12ft 3 6 m 14 ft 4 3 m Yes 4 8000 Ibs 3629 kg 8 ft 2 4 m 30 ft 9 1 m NO DEDUCT 350 LBS M O D E L
28. achine must be leveled prior to lifting load Level machine with frame level joystick The telehandler is designed to permit leveling the main frame 8 to left or right to compensate for uneven ground conditions 31200148 4 9 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 Ensure that the guide men and operator remain in constant communication verbal or hand when placing the load Disengaging a Suspended Load Never place the guide men between the suspended load and the telehandler Once at the destination of the load ensure to bring the telehandler to a complete stop and apply the park brake prior to disengagement of the lifting devices and tethers 4 10 31200148 Section 4 Operation 4 4 LOADING AND SECURING FOR TRANSPORT 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
29. achine with smooth even motion Set machine down gently Avoid quick or sudden motions that could cause shock loads to machine and or lifting devices 4 12 31200148 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 The load center of the fork if equipped must match the load center as indicated on the capacity chart Hydraulically powered attachments must only be used on machines equipped with auxiliary hydraulics Hydraulically powered attachments that require auxiliary electrics must only be used on machines equipped with auxiliary hydraulics and electrics S N 0160037689 amp After 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 Hydraulically powered attachments must only be used on machines equipped with auxiliary hydraulics Hydraulically powered attachments that require auxiliary electrics must only be used on machines equipped
30. acities and load centers are stamped on the side of each fork 2 if equipped This rating specifies the maximum load capacity that the individual fork can safely carry at the maximum load center 3 Total attachment capacity is multiplied by the number of forks on the attachment if equipped up to the maximum capacity of the attachment Maximum capacity as indicated on the proper capacity chart See Approved Attachments on page 5 1 When the load rating of the telehandler differs from the capacity of the forks or attachment the lower value becomes the overall load capacity Use the proper capacity chart to determine maximum capacity at various machine configurations Lifting and placing a load may require use of more than one capacity chart based on machine configuration Other than block forks all forks should be used in matched pairs block forks used in matched sets A WARNING Never use an attachment without the appropriate JLG approved capacity chart installed on the telehandler 31200148 5 3 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 4 Weight of the load being lifted Load placement information a HEIGHT where the load is to be placed b DISTANCE from the fron
31. andler 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 5 26 31200148 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 7 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 Ensure the telehandler is on a firm surface and is level Engage the park brake Blocking the wheels is also recommended Level the platform both side to side frame sway and front to back attachment tilt Keep area under the platform free from personnel When personnel are on platform the operator must remain seated in cab with personnel in direct line of sight DO NOT lift or carry persons in the bucket or on forks Never tilt the platform forward rearward or sway the machine when the platform is occupied Serious injury or death could result 31200148 5 27 Section 5 Attachments This
32. bar 60016 272 kg Fodtn emet Es 58 psi 4 0 bar 15 50 x 25 G 3 L 3 Bias Ply Rock 12 Ply PneufTatic nin et tht E A dtd etre 65 psi 4 5 bar 600 Ib 272 Kg Foam intere ott t tele A dante ie goa 65 psi 4 5 bar 15 50 x 25 G 2 L 2 Radial 1 Star Pne umatiCw 2 Sei adie Aes ies pb ER EE EG 70 psi 4 8 bar 600 1b 272 kg FOAM is ere recte fete trier 70 psi 4 8 bar Wheel Lug Nut TOELQUG im ch ea o ecce i te ud 350 400 Ib ft 475 542 Nm Performance Maximum Lift Capacity sssesseeeeeeeenenes 6 600 Ib 2 994 kg Maximum Lift Height 42 79 ft 13 04 m Capacity at Maximum 6 000 Ib 2 722 kg Maximum Forward 28 14 ft 8 58 m Capacity at Maximum Forward 1 000 Ib 454 kg Reach at Maximum Height 5 05 ft 1 54 m Carriage Rotation eet ee ree teet ce 128 degrees Maximum Travel Speed sssseeeee 20 5 mph 33 0 kmph Towing Capacity in dh eL epus 18 000 8 165 kg Frame Leveling uei Pria b A Ree aie 8 degrees 9 2 31200148 Section 9 Specifications Dimensions Overall Height tote teas aie 95 40 in 2 423 mm Overall Width iss 54 di ae ING edu 96 23 in 2 444 mm Gab Width eee teer ia aed ea aie 37 in 940 mm Track Widths ii eminet RES 82 24 in 2 089 mm Wheelbase
33. cause unexpected machine movement A WARNING TIP OVER CRUSH HAZARD Bring telehandler to a complete stop before shifting transmission control lever A sudden change in direction of travel could reduce stability and or cause load to shift or fall 31200148 3 3 Section 3 Controls and Indicators Ignition Switch OY0051 In ACC 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 3 4 31200148 Section 3 Controls and Indicators Boom Joystick AE A Pa 7 S 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 e For two simultaneous boom functions move the joystick between quadrants For example moving the joystick forward and to the left will lower and retract boom simultaneously Attachment Functions if equipped Tilt control is actuated by the switch 2 Depress the rear of the switch t
34. d eet tot 7 1 Clothing and Safety 7 1 7 2 General Maintenance 7 2 7 3 Service and Maintenance Schedules 7 3 10 amp 1st 50 Hour Maintenance Schedule 7 3 50 250 amp 500 Hour Maintenance Schedule 7 4 1000 amp 1500 Hour Maintenance Schedule 7 5 7 4 Lubrication Schedules sesssseeeeeeee 7 6 50 Hour Lubrication 7 6 250 Hour Lubrication 7 7 7 5 Operator Maintenance 7 8 Fuel System e iet p 7 8 Air Intake System 7 10 Engine Oil re ee 7 12 Hydraulic Oils 7 13 Hr EE 7 14 Hydraulic Return Filter 7 17 Engine Cooling System ssssessesss 7 18 Battery e t aei aget me vl Le o ete 7 19 Section 8 Additional Checks Section 9 Specifications 9 1 Product Specifications 9 1 Fluid and Lubrication Capacities 9 1 NIME 9 2 Performance oen n mer cae 9 2 31200148 lii Table of Contents DIMENSIONS ia tun 9 3 Index
35. d has been placed safely at the landing point proceed as follows 1 With the forks free from the weight of the load the boom can be retracted and or the telehandler can be backed away from under the load if surface will not change level condition of telehandler 2 Lower the carriage 3 The telehandler can now be driven from the landing location to continue work 31200148 4 7 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 A WARNING TIP OVER HAZARD Exceeding lift capacity of the telehandler could damage the equipment and or cause tip over Know the rated load capacities refer to Section 5 of the telehandler to determine the operating range in which you can safely lift transport and place a load Picking Up a Suspended Load Note the conditions of the terrain Adjust travel speed and reduce amount of load if conditions warrant Avoid lifting double tiered loads Make sure load is clear of any adjacent obstacles NEVER operate telehandler without a proper and legible capacity chart in the operator cab for the telehandler attachment combination you are using Only use approved lifting devices rated for the lifting of the load Identify the proper lifting points of the load taking int
36. e Level Indicator Enables the operator to determine the left to right level condition of the telehandler Boom Joystick See page 3 5 Heater Control if equipped See page 3 10 Accelerator Pedal Pressing down the pedal increases engine and hydraulic speed Traction Lock Pedal Operates traction lock valve which functions to restore 10 11 traction when a wheel spins Service Brake Pedal Inching Travel Pedal Operates the service brakes on the front axle Permits slow travel speed while engine speed is kept high for other handler functions The further the pedal is depressed the slower the travel speed Ignition Switch Key activated See page 3 4 Attachment Tilt and Frame Sway Lever See page 3 6 Auxiliary Control Joystick if equipped See page 3 7 31200148 Section 3 Controls and Indicators Transmission Control Lever 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 Donotincrease engine speed with the transmission in forward or reverse and the service brake depressed in an attempt to get quicker hydraulic performances This could
37. e at low idle for 3 to 5 minutes DO NOT over rev engine Shut off engine and remove ignition key Exit telehandler properly NO a onm Block wheels if necessary 4 4 31200148 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 A WARNING TIP OVER HAZARD Exceeding lift capacity of the telehandler could damage the equipment and or cause tip over e Know the rated load capacities refer to Section 5 of the telehandler to determine the operating range in which you can safely lift transport and place a load Picking Up a Load Note the conditions of the terrain Adjust travel speed and reduce amount of load if conditions warrant Avoid lifting double tiered loads Make sure load is clear of any adjacent obstacles Adjust spacing of forks so they engage the pallet or load at maximum width See Adjusting Moving Forks on page 5 9 Approach load slowly and squarely with fork tips straight and level NEVER attempt to lift a load with just one fork NEVER operate telehandler without a proper and legible Capacity Chart in the operators cab for the telehandler attachment combination you are using 31200148 4 5 Section 4 Operation Transporting the Load After engaging the load and re
38. eration and Safety Manual of each attachment or accessory installed for specific inspection operation and maintenance instructions 31200148 2 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 A WARNING If telehandler does not operate properly immediately bring machine to a stop lower boom and attachment to ground and stop the engine Determine cause and correct before continued use 2 2 31200148 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 91143283 91143286 91143282 1705881 1705882 After S N Before S N 0160022389 0160022389 A CAUTION 91 323030 91343016 90553028 91503102 80603022 A DANGER VIEW A A OY1061 31200148
39. for minimum pressure at operating temperature 4 Warm up engine at approximately 1 2 throttle Note Engine will not start unless transmission control lever is in Neutral and park brake switch is applied A WARNING UNEXPECTED MOVEMENT HAZARD Always ensure that transmission control lever is in neutral and the service brake is applied before releasing park brake Releasing park brake in either forward or reverse could cause the machine to move abruptly causing an accident 31200148 4 1 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 A 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 4 2 31200148 Section 4 Operation NS OW0530 Battery Boosted Starting If battery boost starting jump start is necessary proceed as follows Never allow ve
40. hicles 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 Connect opposite end of negative jumper cable to ground point on machine away from discharged battery Follow standard starting procedures Remove cables in reverse order after machine has started A WARNING BATTERY EXPLOSION HAZARD Never jump start or charge a frozen battery as it could explode Keep sparks flames and lighted smoking materials away from the battery Lead acid batteries generate explosive gases when charging Wear safety glasses 31200148 4 3 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 Shut Down Procedure When parking the telehandler park in a safe location on flat level ground and away from other equipment and or traffic lanes 1 Apply the park brake Shift the transmission to Neutral Lower forks or attachment to the ground Operate engin
41. ing down slopes downshift to a lower gear and use the service brake as necessary to maintain a slow speed DO NOT shift into neutral and coast downhill Avoid excessively steep slopes or unstable surfaces To avoid tip over DO NOT drive across excessively steep slopes under any circumstances Avoid turning on a slope Never engage inching or shift to Neutral when going downhill DO NOT park on a slope 31200148 1 9 Section 1 General Safety Practices Pinch Points and Crush Hazards Stay clear of pinch points and rotating parts on the telehandler OWO0210 Stay clear of moving parts while engine is running OW0220 Keep clear of steering tires and frame or other objects oy OW0230 Keep clear from under boom 1 10 31200148 Section 1 General Safety Practices Y OW0240 Keep clear of boom holes i OWO0250 Keep arms and hands clear of attachment tilt cylinder OWO0260 Keep hands and fingers clear of carriage and forks 4 p 0960 Keep others away while operating 31200148 1 11 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 mats ear
42. ing 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 Block all four wheels 4 Section off a large area under the boom with string or tape to restrict any personnel from entering this area 6 3 EMERGENCY EXIT FROM ENCLOSED CAB an emergency an escape hammer located directly below the rear window in an enclosed cab can be used to exit the telehandler ANGUS PALM 005413 OWO740 6 2 31200148 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 AJl a BN te AR um VIEW A A OX0370 o The Service Instruction Plate 1 is located as indicated in figure It contains general service instructions that must be followed to keep this product in good operating condition The Operation amp Safety Manual and Service Manual contain more detailed service information with specific
43. ipped Auxiliary Hydraulics Function Controls function of attachments that require hydraulic supply for operation See Section 5 Attachments for approved attachments and control instructions Frame Sway if equipped Move the joystick left to sway frame left move the joystick right to sway frame right A level indicator is located in the upper front window frame to permit operator to determine whether the telehandler frame is level Attachment Tilt if equipped Move joystick up to tilt down move joystick down to tilt up 31200148 3 7 Section 3 Controls and Indicators Dash Controls and Indicators 654 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 Engine Oil Pressure Gauge c Fuel Gauge d Voltmeter indicates alternator output and battery condition 4 Horn Button Depress button to sound horn 5 Ignition Switch See page 3 6 4X2 4X4 Switch Engages and disengages rear wheel drive motors Rear drive motors are engaged for four wheel drive Indicator light on switch glows amber to indicate four wheel drive is engaged When park brake is applied light will not glow 3 8 31200148 Section 3 Controls and Indicators Park Brake Switch OY0122 Park brake sw
44. is accomplished and operation of the machine has been completed under the supervision of an experienced and qualified operator Operation within the U S A requires training per OSHA 1910 178 Operators of this equipment must possess a valid applicable driver s license be in good physical and mental condition have normal reflexes and reaction time good vision and depth perception and normal hearing Operator must not be using medication which could impair abilities nor be under the influence of alcohol or any other intoxicant during the work shift In addition the operator must read understand and comply with instructions contained in the following material furnished with the material handler This Operation amp Safety Manual Telehandler Safety Manual as required All instructional decals and plates Any optional equipment instructions furnished The operator must also read understand and comply with all applicable Employer Industry and Governmental rules standards and regulations Modifications Any modification to this machine must be approved by JLG b 31200148 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 safety related 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 Indus
45. itch 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 A WARNING MACHINE ROLL AWAY HAZARD Always move park brake switch to ON position lower boom to ground and stop engine before leaving cab A WARNING CRUSH HAZARD Turning engine off applies the park brake Applying park brake or turning engine off while traveling will cause unit to stop abruptly and could cause load loss Either may be used in an emergency situation Parking Procedure 1 Using service brake stop telehandler in an appropriate parking area 2 Follow Shut Down Procedure on page 4 4 31200148 3 9 Section 3 Controls and Indicators Heater 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 3 10 31200148 Section 3 Controls and Indicators 3 3 OPERATOR SEAT Seat Adjustments Before S N 0160016100 Ox0012 Prior to starting engine adjust seat for position and comfort as follows 1 Use handle to move sea
46. ll A WARNING CRUSH HAZARD Use retaining pin if equipped for locking swing frame to fixed frame when carrying loads greater than 5000 Ib Failure to comply could cause object or load to fall Operation To drive with a load keep forks pointed forward and travel in accordance with the requirements set forth in Section 1 General Safety Practices 5 24 31200148 Section 5 Attachments Side Tilt Carriage Description P N Side Tilt 48 ipasi 91405101 mentes 91405079 Use Side Tilt Attachment Capacity Chart To determine maximum capacity refer to Telehandler Attachment Fork Capacity on page 5 3 re 85 Eo J OY0380 The joystick 1 controls lift lower and the extend retract movement of the boom The rear joystick 2 controls the mast tilt Move joystick forward to tilt down Move joystick back to tilt up To Side Tilt The auxiliary control joystick 3 controls the carriage side tilt Move joystick up to side tilt carriage left Move joystick down to side tilt carriage right 31200148 5 25 Section 5 Attachments Installation Procedure Refer to Attachment Installation on page 5 7 Operation Approach load with forks centered on load and stop teleh
47. nformation 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 Wheel diameter width and offset dimensions equal to the original Approved for the application by the tire manufacturer including inflation pressure and maximum tire load Unless specifically approved by JLG do not replace a foam filled or ballast filled tire assembly with a pneumatic tire Due to size variations between tire brands when selecting and installing a replacement tire ensure both tires on the axle are the same The rims installed have been designed for stability requirements which consist of track width tire pressure and load capacity Size changes such as rim width center piece location larger or smaller diameter etc without written factory recommendations may result in unsafe condition regarding stability 31200148 7 15 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 al
48. o consideration the center of gravity and load stability Ensure to always properly tether loads to restrict movement Referto See Use of the Capacity Chart on page 5 4 for proper lifting guidelines in addition to the appropriate capacity chart in the operator cab 4 8 31200148 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 The combination of frame leveling and load could cause the telehandler to tip over The guide men and operator must remain in constant communication verbal or hand and be in visual contact with the operator at all times Never place the guide men between the suspended load and the telehandler Only transport the load at walking speed 0 9 mph 0 4 m s or less Leveling Procedure Position machine in best location to lift or place load Apply parking brake and move transmission control lever to NEUTRAL Move boom so load is no more than 11 8 in 300 mm above ground surface and boom or boom is raised no more than 45 Observe level indicator to determine whether m
49. o tilt up depress the front of switch to tilt down A WARNING TIP OVER CRUSH HAZARD Rapid jerky operation of controls will cause rapid jerky movement of the load Such movements could cause the load to shift or fall or could cause the machine to tip over 31200148 3 5 Section 3 Controls and Indicators Attachment Tilt and Frame Sway Lever 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 Sway Function Move the lever left to sway frame left move the lever right to sway frame right A level indicator is located in the upper front window frame to permit operator to determine whether the telehandler frame is level A WARNING TIP OVER HAZARD Always move boom as low as possible while allowing for best visibility of right hand mirror before leveling frame Attempting to level machine with boom raised could cause it to tip over 3 6 31200148 Section 3 Controls and Indicators Auxiliary Control Joystick if equipped Hydraulics UEET DOWN Auxiliary 1 AUXILIARY Sway optional B 8 Attachment T Tilt e optional OX0224 The auxiliary control joystick 1 controls the auxiliary hydraulic functions left to right frame sway if equipped and attachment tilt if equ
50. on page 5 3 OY0360 The joystick 1 controls lift lower and the extend retract movement of the boom The rear joystick 2 controls the mast tilt Move joystick forward to tilt down Move joystick back to tilt up To Raise Lower Mast The auxiliary control joystick 3 controls the lift lower movement of the mast Move joystick up to lower forks Move joystick down to raise forks 31200148 5 19 Section 5 Attachments Installation Procedure Referto Attachment Installation on page 5 7 A 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 5 20 31200148 Section 5 Attachments 6 ft 1 8 m 100 Swing Mast W Side Shift Description P N Mast w 48 in Fork sssseseeeeeenn e 91405070 Mast w 60 in 91415026 OY0590 Use 6 ft Swing Mast Attachment Capacity Chart To determine maximum capacity refer to Telehandler Attachment Fork Capacity on page 5 3 E m OY0371 The j
51. ork Platform 5 27 Picking Up a Load 4 5 Picking Up a Suspended Load 4 8 Pinch Points and Crush Hazards 1 10 Placing a Suspended Load 4 10 Placing the Load 4 7 Pre Operation Check and Inspection 2 1 R Restriction 7 10 S Safety Decals 2 3 Safety 1 1 Safety Signal Words 1 1 Seat Belt ss ees 3 13 Service and Maintenance Schedule 2 ees 7 3 TO HOUE ient 7 3 1000 7 5 1500 7 5 2 15150 Hour 7 3 250 HOUM Rene 7 4 5O HOUE ii 7 4 5OO ElOUi etos 7 4 Shut Down Procedure 4 4 Side Tilt Carriage 5 25 9 1 Swing 5 23 Swing Mast w Side Shift 5 21 T Tip Over 1 3 Ep 7 14 Air 55 7 14 Damage 7 14 POSSUO ote hae 9 2 Replacement 7 15 TOWing x i idee 6 1 Transmission Control Lever 3 3 TranspoOrt nct deca
52. ork tilt Move joystick forward to tilt down Move joystick back to tilt up Installation Procedure Refer to Attachment Installation on page 5 7 31200148 5 11 Section 5 Attachments Crane Hook gt Description P N ESS Gratne lHoO0K cette treten eee te ever 91565094 RES 5 2 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 The joystick 1 controls lift lower and the extend retract movement of the boom The tilt lever 2 controls the crane hook tilt Move lever forward to tilt down Move lever back to tilt up Installation Procedure Referto Attachment Installation on page 5 7 Secure the crane hook to the forks by sliding the crane hook onto the parent forks and install the retaining pin behind the vertical shank of the fork 5 12 31200148 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 31200148 5 13 Section 5 Attachments Bucket Description
53. ower forks fully in mast keep forks pointed forward and travel in accordance with the requirements set forth in Section 1 General Safety Practices Use a signal person to assist in positioning load if necessary 5 22 31200148 Section 5 Attachments Swing Carriage Description P N 100 Swing Carriage sess 91405075 100 Swing Drywall Carriage 91405078 180 Swing Carriage sss 91563146 OY0670 Use Swing Carriage Attachment Capacity Chart To determine maximum capacity refer to Telehandler Attachment Fork Capacity on page 5 3 7 i 2T AO gt Ab lt ree Y H 2 1 7 2 OY0680 The joystick 1 controls lift lower and the extend retract movement of the boom The rear joystick 2 controls the carriage tilt Move joystick forward to tilt down Move joystick back to tilt up To Swing The auxiliary control joystick 3 controls the Swing function Move joystick up to swing left Move joystick down to swing right 31200148 5 23 Section 5 Attachments A 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 A WARNING CRUSH HAZARD Do not use swing carriage to push or pull objects or load Failure to comply could cause object or load to fa
54. oystick 1 controls lift lower and the extend retract movement of the boom The rear joystick 2 controls the mast tilt Move joystick forward to tilt down Move joystick back to tilt up 31200148 5 21 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 To Side Shift Press Side Shift Switch 6 forward located on dash panel to activate Side Shift function With Side Shift Switch activated move the auxiliary control joystick 3 down to shift forks right or up to shift forks left Installation Procedure Referto Attachment Installation on page 5 7 A 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 A 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 e Always lower forks fully in mast and position forks straight ahead before engaging load e To drive with a load l
55. r 21 D 27721 Ritterhude Ihlpohl Germany Phone 49 0 421 69 350 20 Fax 49 0 421 69 350 45 JLG Europe B V Polaris Avenue 63 2132 JH Hoofddorp The Netherlands Phone 31 0 23 565 5665 Fax 31 0 23 557 2493 Plataformas Elevadoras JLG Iberica S L Trapadella 2 P I Castellbisbal Sur 08755Castellbisbal Barcelona Spain Phone 34 93 772 4 700 Fax 34 93 771 1762 JLG Industries UK Ltd Bentley House Bentley Avenue Middleton Greater Manchester M24 2GP England Phone 44 0 161 654 1000 Fax 44 0 161 654 1001 JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong Phone 852 2639 5783 Fax 4852 2639 5797 JLG Polska UI Krolewska 00 060 Warsawa Poland Phone 48 0 914 320 245 Fax 48 0 914 358 200 JLG Sverige AB Enkopingsvagen 150 Box 704 SE 176 27 Jarfalla Sweden Phone 46 0 850 659 500 Fax 46 0 850 659 534
56. r is in place enclosed cabs only Check seat belt for damage replace belt if frayed or cut webbing damaged buckles or loose mounting hardware Fuel Tank Check fluid level refill as required filler cap is securely fastened Air Cleaner Air cleaner element condition indicator check for clogged condition Replace element as required Wheel Tire Assembly Properly inflated and secured no loose or missing lug nuts Inspect for worn tread cuts tears or other discrepancies Main Control Valve See Inspection Note Back up Alarm See Inspection Note Rear Axle Steer cylinders undamaged not leaking pivot pins secure hydraulic hoses undamaged not leaking Wheel Tire Assembly Properly inflated and secured no loose or missing lug nuts Inspect for worn tread cuts tears or other discrepancies Engine Compartment Engine Crankcase and Radiator check level amp refill as required Drive belts check condition amp replace as required Hydraulic pump amp reservoir recommended fluid level on sight gauge lubricant must be cool breather cap secure and working Engine cover properly secured Mirrors Clean and undamaged Wheel Tire Assembly Properly inflated and secured no loose or missing lug nuts Inspect for worn tread cuts tears or other discrepancies Sway Cylinder Pins secure hydraulic hoses undamaged not leaking Attachment Properly installed
57. r valve Replace inner safety element 7 after every third primary element change If replacing the inner safety element at this time carefully slide the element out and replace with new element Slide the new primary element over the inner element making sure the sealing edge is flush with the base of the air cleaner Position air cleaner cover in place turn clockwise and lock into position Depress button on restriction indicator to reset Note An inner safety element should never be washed or reused Always install a new element 31200148 7 11 Section 7 Lubrication and Maintenance Engine Oil A Engine Oil Level Check 1 0 x b 4 y Hri o i Buda 9 B 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 Close and secure the engine cover Note The standard service interval for engine oil and filter is 250 hours maximum If an e
58. raulic return filter indicator checks 7 2 31200148 Section 7 Lubrication and Maintenance 7 3 SERVICE AND MAINTENANCE SCHEDULES 10 amp 1st 50 Hour Maintenance Schedule Et bE O n Check Fuel Check Tire Air Filter Check Engine Check Hydraulic Level Pressure Restriction Oil Level Oil Level Indicator Check Hydraulic Return Filter Indicator Change Change Wheel Change Engine Check Wheel Check Boom Axle Oil End Oil Oil amp Filter Lug Nut Cable Tension Torque OX0201 31200148 7 3 Section 7 Lubrication and Maintenance 50 250 amp 500 Hour Maintenance Schedule EVERY 50z be Drain Fuel Check Engine Check Lubrication Water Coolant Level Battery Schedule Separator Change Engine Check Front Check Front amp Air Filter Oil and Axle Rear Wheel Vacuator Filter Oil Level End Oil Levels Valve Check Boom Check Boom Cable Bearing Rear Axle Tension Pads Stabilization Change Fuel Check Wheel Filter Lug Nut Torque OX0530 Note Engine oil amp filter service interval can be extended see page 7 12 for details 7 4 31200148 Section 7 Lubrication and Maintenance 1000 amp 1500 Hour Maintenance Schedule Change Front Change Front amp Change Axle Oil Rear Wheel Hydraulic Tank End Oil Breather g Change Engine Coolant Hydraulic Fluid amp Filters OY1041 31200148 7 5 Section 7 Lubrication and Maintenance 7 4 LUBRICATION SCHEDULES 50 Hour L
59. re moving be sure of a clear path and sound horn When driving retract boom and keep boom attachment as low as possible while maintaining visibility of mirrors and maximum visibility of path of travel Always look in the direction of travel Always check boom clearances carefully before driving underneath overhead obstructions Position attachment load to clear obstacles 1 6 31200148 Section 1 General Safety Practices Load Falling Hazard OWO0130 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 31200148 1 7 Section 1 General Safety Practices Lifting Personnel OWO0170 When lifting personnel USE ONLY a JLG approved personnel work platform with proper capacity chart displayed in the cab OWO0190 DO NOT drive machine from cab when personnel are in platform 1 8 31200148 Section 1 General Safety Practices Driving Hazards on Slopes Ow 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 To avoid overspeeding the engine and drivetrain when driv
60. s 4 11 EHIN guis edes moie nete 4 12 Tiedown 4 11 Transporting a Suspended 4 9 Transporting the Load 4 6 Travel 1 6 Truss 5 16 Walk Around Inspection 2 6 Warm Up 2 8 Weights een ente 9 2 Wheel Lug Nut esseere 9 2 Wheel Replacement 7 15 31200148 Inspection Maintenance and Repair Log Serial Number Date Comments Inspection Maintenance and Repair Log Date Comments AL 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 Please use this form to provide JLG with updated information with regard to the current ownership of
61. se uU i tet acts gees 15W 40 CD Fuel Tank Gapacitya ei A tene oen 38 gallons 143 8 liters Bros 2 Diesel Cooling System System Capacity cited f nile nae 15 5 quarts 14 7 liters Coolant srcane 50 50 ethylene glycol amp water Hydraulic System System Capacity uude I e ERES 43 gallons 163 liters Reservoir Capacity to Full 20 gallons 75 7 liters Type Of Oil eee Mobilfluid 424 Tractor Hydraulic Fluid ISO 46 Axles Housing Capacity Front Axle 5 gallons 18 9 liters Hubs Hear AXI ee ERR Ms 3 pints each 1 6 liters Type of Fluid Mobilfluid 424 Tractor Hydraulic Fluid ISO 46 31200148 9 1 Section 9 Specifications Tires Pressure 13 00 x 24 G 2 L 2 Bias Ply Traction 12 Ply Prie rmatl 3 ie onec eere rege erede ER et 65 psi 4 5 bar 542 10 246 kg 60 psi 4 1 bar 13 00 x 24 G 3 L 3 Bias Ply Rock 12 Ply Pne uralic 2 etie Rai emi nbi nb 65 psi 4 5 bar 542 10 246 kg Foam iiin a 65 psi 4 5 bar 13 00 x 24 G 2 L 2 Radial 1 Star Pneumatic IERI dE ED EE ED EG 70 psi 4 8 bar 542 1b 246 kg FOAM as i eee eden vet nde pereo 70 psi 4 8 bar 15 50 x 25 G 2 L 2 Bias Ply Traction 12 Ply Prie mmaltic soon ed onec e e a rd e Rte 58 psi 4 0
62. see Attachment Installation on page 5 7 31200148 2 7 Section 2 Pre Operation and Inspection 2 4 WARM UP AND OPERATIONAL CHECKS Warm Up Check During warm up period check 1 Heater defroster and windshield wiper if equipped 2 Check all lighting systems if equipped for proper operation 3 Voltmeter should show 13 5 to 14 volts 4 Adjust mirror s for maximum visibility A WARNING CUT CRUSH BURN HAZARD Keep engine cover closed while engine is running except when checking hydraulic filter condition indicator Operational Check When engine warms perform an operational check 1 Service brake and parking brake operation Forward and reverse travel Steering in both directions with engine at low idle A Im Horn and back up alarm Must be audible from inside operators cab with engine running All boom and attachment functions operate smoothly and correctly 6 Perform any additional checks described in Section 8 7 Hydraulic Filter Condition Indicator 2 8 31200148 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 A 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 config
63. spended 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 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 Never drag the load lift vertically 31200148 1 5 Section 1 General Safety Practices Travel Hazard I 4WheelSteer I Va Pivot Steer ow0120 Steering characteristics differ between 4 Wheel Steer amp Pivot Steer telehandlers as shown above Identify the telehandler you are operating amp 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 Look out for and avoid other personnel machinery and vehicles in the area Use a spotter if you DO NOT have a clear view Befo
64. sting 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 OW0540 Leveling Procedure Position machine in best location to lift or place load Apply parking brake and move transmission control lever to NEUTRAL Move boom attachment to 4 ft 1 2 m off ground A m Observe level indicator to determine whether machine must be leveled prior to lifting load Important things to remember Never raise the boom attachment more than 4 ft 1 2 m above ground unless telehandler is level The combination of sway and load could cause the telehandler to tip over The telehandler is designed to permit swaying the main frame 8 to left or right to compensate for uneven ground conditions 4 6 31200148 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 Lower the boom until the load rests in position and the forks are free to retract Disengaging the Load Once the loa
65. t fore and aft 2 A two inch seat belt is standard equipment If required an optional three inch belt is available 31200148 3 11 Section 3 Controls and Indicators S N 0160016100 amp After N 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 3 12 31200148 Section 3 Controls and Indicators Seat Belt Y y OH20912 1 Grasp both free ends of the belt making certain that belt webbing is not twisted or entangled Fasten seat belt as follows 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 To release belt latch depress red button on the buckle and pull free end from buckle 31200148 3 13 Section 3 Controls and Indicators 3 4 BOOM ANGLE AND EXTENSION INDICATORS 4 5 OX0540
66. t tires of the telehandler where the load is to be placed On the Capacity Chart find the line for the height and follow it over to the distance The number in the load zone where the two cross is the maximum capacity for this lift If the two cross at a division between zones the smaller number must be used The number in the load zone must be equal to or greater than the weight of the load to be lifted Determine the limits of the load zone on the Capacity Chart and keep within these limits Capacity Indicator Locations Boom Attachment Boom Extension Angle Identification Indicator Indicator Plate OX0190 31200148 Sample Capacity Chart Section 5 Attachments This Capacity Chart may DEDUCT 350 LBS FROM ALL CAPACITIES WHEN MACHINE IS EQUIPPED WITH WINCH MODEL XXXXX used with this model ONLY The model of your telehandler is indicated on the boom or chassis 48 RATED CAPACITY CENTER 69 2 FT LOAD 60 LO 40 36 48 amp 72 CARRIAGES 32 28 7000 LBS 24 30 6000 LBS P Boom 2 Extension 5000 LBS Boom Angle 4000 LBS 3000 LBS 1100 LBS m 2000 LBS 36 32 28 USE WITH 1234 5678 8765 4321 48 CARRIAGE 72 CAR
67. te all required maintenance before operating unit A WARNING FALL HAZARD Use extreme caution when checking items beyond your normal reach Use an approved ladder The pre operation check amp inspection performed at beginning of each work shift or at each change of operator should include the following 1 Cleanliness Check all surfaces for leakage oil fuel or battery fluid or foreign objects Report any leakage to the proper maintenance personnel 2 Structure Inspect the machine structure for dents damage weld or parent metal cracks or other discrepancies RON OAH1000 PARENT METAL CRACK WELD CRACK w Safety Decals Ensure all safety decals are legible and in place Clean or replace as required See page 2 3 for details 4 Operation and Safety Manuals Operation and Safety Manual and AEM Safety Manual as required are located in cab manual holder 5 Walk Around Inspection See page 2 6 for details Fluid Levels Check fluids including fuel hydraulic oil engine oil and coolant When adding fluids refer to Section 7 Lubrication and Maintenance and Section 9 Specifications to determine proper type and intervals Before removing filler caps or fill plugs wipe all dirt and grease away from the ports If dirt enters these ports it can severely reduce component life 7 Attachments Accessories Ensure correct load charts are installed on the telehandler If provided reference the Op
68. ternating pattern as indicated in figure Torque to 350 400 Ib ft 475 543 Nm A WARNING TIP OVER HAZARD Lug nuts must be installed and maintained at the proper torque to prevent loose wheels broken studs and possible separation of wheel from the axle 7 16 31200148 Section 7 Lubrication and Maintenance Hydraulic Return Filter A Hydraulic Return Filter Indicator Check 1 0 x B m OX0170 2 v 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 With the engine at full throttle and the assistant observing the indicator 2 located on the hydraulic return filter 1 extend and retract the boom 10 12 ft 3 0 3 7 m The gauge should be within the green area 5 Replace filter before the gauge reaches the red area on the indicator If it reaches the red area the filter is too dirty and hydraulic oil is bypassing the filter 6 Close and secure the tank cover 31200148 7 17 Section 7 Lubrication and Maintenance Engine Cooling System A Engine Coolant Level Check 50 A be So g A n C
69. tion 12 1 58 psi 4 0 bar 15 50 x 25 G 3 L 3 Bias Ply Rock 12 65 psi 4 5 bar 15 50 x 25 G 2 L 2 Radial 1 70 psi 4 8 bar 5 Replace valve stem cap B Tire Damage For pneumatic tires JLG recommends that when any cut rip or tear is discovered that exposes sidewall or tread area cords in the tire measures be taken to remove the JLG product from service immediately Arrangements must be made for replacement of the tire or tire assembly For polyurethane foam filled tires JLG recommends that when any of the following are discovered measures must be taken to remove the product from service immediately Arrangements must be made for replacement of the tire or tire assembly A smooth even cut through the cord piles which exceeds 3 in 7 5 cm in total length Any tears or rips ragged edges in the cord plies which exceeds 1 in 2 5 cm in any direction Any punctures which exceed 1 in 2 5 cm in diameter If a tire is damaged but within the above noted criteria the tire must be inspected daily to ensure the damage has not propagated beyond the allowable criteria 7 14 31200148 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 i
70. tries Inc to ensure that the current owner records are updated and accurate JLG Industries Inc must be notified immediately in all instances where JLG products have been involved in an accident involving bodily injury or death of personnel or when damage has occurred to personal property or the JLG product FOR Accident Reporting and Product Safety Publications Current Owner Updates Questions Regarding Product Applications and Safety e Standards and Regulations Compliance Information Questions Regarding Product Modifications CONTACT Product Safety and Reliability Department JLG Industries Inc 13224 Fountainhead Plaza Hagerstown MD 21742 USA or Your Local JLG Office Addresses on back cover In USA Toll Free 1 877 JLG SAFE 877 554 7233 Outside USA Phone 1 717 485 5161 E mail ProductSafety 9 JL G com Other Publications Available SeivVice Manwulal 3 er n 91404002 Illustrated Parts 91404001 31200148 C Read This First This Page Intentionally Left Blank d 31200148 Table of Contents TABLE OF CONTENTS Revision Log Read This First Operator Qualifications b Modifications ereire eirean aa b Other Publications Available C Table of Contents Section 1 1 1 1 2 1 8
71. ubrication Schedule P d Mystik Tetrimoly Grease NLGI 2 GC LB 7 6 31200148 Section 7 Lubrication and Maintenance 250 Hour Lubrication Schedule P di Mystik Tetrimoly Grease NLGI 2 GC LB Ovo29n 31200148 7 7 Section 7 Lubrication and Maintenance 7 5 OPERATOR MAINTENANCE INSTRUCTIONS Fuel System A Fuel Level Check 10 b E OW0970 OW0990 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 Note Replenish diesel fuel at end of each work shift to minimize condensation 7 8 31200148 Section 7 Lubrication and Maintenance B Drain Fuel Water Separator 50 x V Une 5 4 T c3 3 d cm lt 7 oF IU e 14 1 3 Do P4 LA 0
72. uration If damaged the CAB CANNOT BE REPAIRED It must be REPLACED 31200148 2 9 Section 2 Pre Operation and Inspection 2 6 WINDOWS Keep all windows and mirrors clean and unobstructed Cab Door Window if equipped OALO0010 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 2 10 31200148 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 EQUIPMENT DAMAGE When a red light illuminates immediately bring machine to a stop lower boom and attachment to ground and stop the engine Determine cause and correct before continued use 31200148 3 1 Section 3 Controls and Indicators 3 2 CONTROLS Transmission Control Lever See page 3 3 Instrument Panel See Dash Controls and Indicators on page 3 8 Steering Wheel Turning the steering wheel to the left or right steers the machine in the corresponding direction Fram
73. xtended service interval is desired see the engine manual for specific guidlines for optimizing oil change intervals 7 12 31200148 Section 7 Lubrication and Maintenance Hydraulic Oil A Hydraulic Oil Level Check 1 Be sure all cylinders are fully retracted and machine is level 2 Perform Shut Down Procedure on page 4 4 1027 6 OX0180 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 Add hydraulic fluid to bring oil up to the upper mark on the sight gauge 5 Replace hydraulic oil fill cap 6 Close and secure the tank cover 31200148 7 13 Section 7 Lubrication and Maintenance Tires A Tire Air Pressure Check 1 0 6 3 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 1 65 psi 4 5 bar 13 00 x 24 G 3 L 3 Bias Ply Rock 12 65 psi 4 5 bar 13 00 x 24 G 2 L 2 Radial 1 70 psi 4 8 bar 15 50 x 25 G 2 L 2 Bias Ply Trac
74. y 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 31200148 5 15 Section 5 Attachments Truss Boom Description P N Truss Boom 10 ft w winch ccce 91405081 Truss Boom 10 ft 91405083 Truss Boom 15 ft w winch ccce 91405080 Truss Boom 15 ft 91405082 Use Truss Boom 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 7 1 t puma gt em 7 OY0351 The joystick 1 controls lift lower and the extend retract movement of the boom Truss Boom Control The rear joystick 2 controls truss boom tilt Move joystick forward to tilt down Move joystick back to tilt up 5 16 31200148 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 Referto Attachment Installation on page 5 7 A WARNING CRUSH
75. y electric harness A 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 5 8 31200148 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 Elevate attachment to approximately 5 ft 1 5 m and tilt carriage forward until fork heel is free from attachment 3 Stand at the side of the carriage To slide fork toward the center of the carriage push the fork near the fork eye To slide fork toward the edge of the carriage pull the fork near the fork eye To avoid pinching do not place fingers or thumb between the fork and carriage structure If removing fork bar is necessary Rest forks on ground Remove fork bar Reposition forks A OO Im Reinstall the fork bar and fork bar retaining mechanism s 31200148 5 9 Section 5 Attachments 5 7 ATTACHMENT OPERATION Capacities and range limits for the telehandler change depending on the attachment in use

Operation 31200148

Contents

Download Pdf Manuals

Related Search

Related Contents