Operation & Safety Manual Original Instructions Keep this manual with machine at all times. Agrovector 40.8 & 40.
Revision Log Revision Log REVISION LOG September 30, 2008 - A - Original Issue of Manual November 11, 2010 - B - Revised manual.
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............................................................................................31200206 Illustrated Parts Manual...............................................................................31200204 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 Parking Procedure........................................................ 3-11 Transmission Control Lever.......................................... 3-12 Load Stability Indicator (LSI) ........................................ 3-14 Steering Column Adjuster............................................. 3-17 Joystick......................................................................... 3-18 Armrest and Right Hand Console.................................
Table of Contents Section 5 - Attachments and Hitches 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 Approved Attachments ........................................................5-1 Unapproved Attachments ....................................................5-1 JLG Supplied Attachments ..................................................5-2 Telehandler/Attachment/Fork Capacity................................5-4 Use of the Capacity Chart....................................................
Table of Contents Section 7 - Lubrication and Maintenance 7.1 Introduction.......................................................................... 7-1 Clothing and Safety Gear ............................................... 7-1 7.2 General Maintenance Instructions....................................... 7-2 7.3 Service and Maintenance Schedules .................................. 7-3 8 & 1st 50 Hour Maintenance Schedule ......................... 7-3 50, 250 & 500 Hour Maintenance Schedule...................
Section 1 - General Safety Practices SECTION 1 - GENERAL SAFETY PRACTICES 1.1 HAZARD CLASSIFICATION SYSTEM Safety Alert System and Safety Signal Words DANGER OW0010 DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING OW0021 WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Section 1 - General Safety Practices 1.3 OPERATION SAFETY Electrical Hazards 10 FT (3 M) OW0040 • This machine is not insulated and does not provide protection from contact or being near electrical current. • NEVER operate the telehandler in an area where overhead power lines, overhead or underground cables, or other power sources may exist without ensuring the appropriate power or utility company de-energizes the lines. • Always check for power lines before raising the boom.
Section 1 - General Safety Practices Tip Over Hazard General • For additional load requirements, refer to the appropriate capacity chart. OW0050 • Never use an attachment without the appropriate JLG approved capacity chart installed on the telehandler. • Understand how to properly use the capacity charts located in cab. • DO NOT exceed rated lift capacity. • Be sure that the ground conditions are able to support the machine.
Section 1 - General Safety Practices OH2291 • MAINTAIN proper tire pressure at all times. If proper tire pressures are not maintained, this machine could tip over. • Refer to manufacturer’s specifications for proper fill ratio and pressure requirements for tires equipped with ballast. OH20911 • Always wear the seat belt. • Keep head, arms, hands, legs and all other body parts inside operator’s cab at all times.
Section 1 - General Safety Practices Non-Suspended Load OW0060 • DO NOT drive with boom raised. Suspended Load OW0150 • Tether suspended loads to restrict movement. • Weight of all rigging (slings, etc.) must be included as part of load. • Beware of wind. Wind can cause a suspended load to swing and cause dangerous side loads - even with tag lines. • DO NOT attempt to use telehandler frame-leveling to compensate for load swing. • Keep heavy part of load closest to attachment.
Section 1 - General Safety Practices Travel Hazard 2-Wheel Front Steer 4-Wheel Circle Steer 4-Wheel Crab Steer OAL2030 • Steering characteristics differ between steer modes. Identify the steer mode settings of the telehandler being operated. • DO NOT change steer modes while traveling. Steer modes must be changed while telehandler is stationary. • Visually verify proper wheel alignment after each steer mode change.
Section 1 - General Safety Practices Load Falling Hazard OW0130 • Never suspend load from forks or other parts of carriage. • DO NOT burn or drill holes in fork(s). • Forks must be centered under load and spaced apart as far as possible.
Section 1 - General Safety Practices Lifting Personnel OW0170 • When lifting personnel, USE ONLY a JLG approved personnel work platform, with proper capacity chart displayed in the cab. OW0190 • DO NOT drive machine from cab when personnel are in platform.
Section 1 - General Safety Practices Driving Hazards on Slopes OW0200 To maintain sufficient traction and braking capabilities, travel on slopes as follows: • When unloaded, the rear of the machine is the “heavy end.” Drive with forks pointed downhill. • When loaded, the front of the machine is the “heavy end.” Drive with the forks pointed uphill. • For additional travel requirements, refer to the appropriate capacity chart.
Section 1 - General Safety Practices Pinch Points and Crush Hazards Stay clear of pinch points and rotating parts on the telehandler. OW0210 • Stay clear of moving parts while engine is running. OW0220 • Keep clear of steering tires and frame or other objects. OW0230 • Keep clear from under boom.
Section 1 - General Safety Practices OW0240 • Keep clear of boom holes. OW0250 • Keep arms and hands clear of attachment tilt cylinder. OW0260 • Keep hands and fingers clear of carriage and forks. OW0960 • Keep others away while operating.
Section 1 - General Safety Practices Fall Hazard OW0280 • Enter using the proper hand holds and steps provided. Always maintain 3-point contact when mounting or dismounting. Never grab control levers or steering wheel when mounting or dismounting the machine. • DO NOT get off the machine until the shutdown procedure on page 4-3 has been performed. OW0290 • DO NOT carry riders. Riders could fall off machine causing death or serious injury.
Section 1 - General Safety Practices Chemical Hazards Exhaust Fumes • DO NOT operate machine in an enclosed area without proper ventilation. • DO NOT operate the machine in hazardous environments unless approved for that purpose by JLG and site owner. Sparks from the electrical system and the engine exhaust can cause an explosion. • If spark arrestors are required, ensure they are in place and in good working order.
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Section 2 - Pre-Operation and Inspection SECTION 2 - PRE-OPERATION AND INSPECTION 2.1 PRE-OPERATION CHECK AND INSPECTION Note: Complete all required maintenance before operating unit. WARNING FALL HAZARD. Use extreme caution when checking items beyond your normal reach. Use an approved ladder. The pre-operation check 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 8005675 8005616 8008657 8008657 8005616 3700016 40 B B A C Optional 2999964 (40) 2603207 (20) 8009885 (12) B ABC A - 1706753 B - 1706754 C - 1706755 3700016 1001094708B 1001094708 8005617 3700016 VIEW OF FRONT TIEDOWN POINTS 8005617 8006038 VIEW B-B OZ3210 2-4 31200537
Section 2 - Pre-Operation and Inspection 1001094900 (LIFT PATTERN) 1001094900B 1001094901 (LOADER PATTERN) LOAD CHARTS XXXX P/N XXXXXX P/N XXXXXX P/N XXXXXX P/N XXXXXX 14 11 G F E 50° 10 D 9 C 1.000kg 1.500kg 500kg 10° 400kg 3 2 B A 750kg 4 2.000kg 30° 20° 2.500kg 7 6 4.000kg 40° 8 3.000kg 3.
Section 2 - Pre-Operation and Inspection 2.3 WALK-AROUND INSPECTION 18 1 2 17 3 4 16 5 6 5 15 6 7 14 13 8 12 9 11 10 5 5 OZ3231 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. Work Lights (if equipped) - Clean and undamaged. 6. Mirrors - Clean and undamaged. 7. Cab and Electrical • General appearance; no visible damage. • Frame level indicator(s) and window glass undamaged and clean. • Gauges, switches, joystick, foot controls and horn operational. • Check seat belt for damage, replace belt if frayed or cut webbing, damaged buckles or loose mounting hardware. 8. Wheel Chock (if equipped) - See inspection note. 9.
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 covers 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 enclosed ROPS/FOPS cab. WARNING CRUSH HAZARD. Never operate telehandler unless the overhead guard and cab structure are in good condition. Any modification to this machine must be approved by JLG to assure compliance with ROPS/FOPS certification for this cab/machine configuration. If damaged, the CAB CANNOT BE REPAIRED. It must be REPLACED.
Section 2 - Pre-Operation and Inspection 2.6 WINDOWS Keep all windows clean and unobstructed. Cab Door Window 2 3 1 OZ0211 • 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. • Press the release button (3) inside the cab to unlatch the window. Rear Window 5 4 OAL1500 • Lift lever (4) and push to open the rear window (5). • Lift lever and pull to close.
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 12 11 8 9 10 13 14 15 7 6 5 4 3 2 1 16 OZ3241 1. Park Brake: See page 3-11. 2. Accelerator Pedal: Pressing down the pedal increases engine and hydraulic speed. 3. Service Brake Pedal: The further the pedal is depressed, the slower the travel speed. 4. Ignition Switch: Key Activated. See page 3-10. 5. Hydraulic Quick Attach Switch (if equipped): Used in conjuction with the joystick to hydraulically lock or unlock an attachment. 6.
Section 3 - Controls and Indicators 9. 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 3-26. 10. Instrument Panel: See page 3-4. 11. Accessory Control Lever: See page 3-24. 12. LSI Indicator: See page 3-14. 13. Keypad: See page 3-8. 14. Joystick: See page 3-18. 15. Armrest and Right Hand Console: See page 3-22. 16.
Section 3 - Controls and Indicators Instrument Panel 2 3 4 5 6 7 1 24 8 9 23 10 22 21 20 19 18 17 16 15 14 13 12 11 OZ2061 1. Low Fuel Indicator: Illuminates and buzzer sounds briefly when fuel level is low. 2. Fuel Gauge: Indicates amount of fuel in fuel tank. 3. Left Turn Signal Indicator: Illuminates when left turn signal is active. 4. Display Screen: See page 3-6. 5. Right Turn Signal Indicator: Illuminates when right turn signal is active. 6.
Section 3 - Controls and Indicators 16. System Distress Indicator: Illuminates and buzzer sounds when critical machine and engine faults exist. 17. Engine Fault Critical Indicator: Illuminates and buzzer sounds when a critical engine fault exists. 18. Engine Fault Warning Indicator: Illuminates and buzzer sounds when engine is operating outside the normal range. 19. Air Filter Restriction Indicator: Illuminates and buzzer sounds briefly when air filter(s) require maintenance. 20.
Section 3 - Controls and Indicators Display Screen DISPLAY SHOWN WITH CONTINUOUS AUXILIARY HYDRAULICS ACTIVE 1 2 3 00 F2 0000 0000 100 00 RPM km/h DISPLAY SHOWN WITH ANTI THEFT ACTIVE AT SYSTEM START 4 5 6 8 00 0000 0000 RPM km/h 0 7 OAH1270 1. Joystick Mode: Displays current joystick mode. Joystick mode can be changed by the machine owner in Operator Tools Menu (level 2 password required). See Service Manual for information. a.
Section 3 - Controls and Indicators 9 MENU: HELP: PRESS ENTER OAH2000 9. Menus: Menus display fault codes and other machine information while allowing modification of some operating parameters. Depress and hold the C and OK buttons on the keypad to access menus. a. Help - Displays active fault code. Depress OK button again and use keypad arrows to cycle through the last 25 fault codes. Active faults are denoted with an asterisk. b.
Section 3 - Controls and Indicators Keypad 1 OZ2361 4 2 5 3 6 7 1. C (Clear or escape): Use in conjuction with display screen. Returns user interface one level during navigation. If at top level menu, depress and hold for one second to exit. 2. Up/Down Arrows: Use in conjuction with display screen. Navigate menu selections and change adjustable values. 3. OK (Enter): Use in conjuction with display screen. Confirms user interface inputs. 4.
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Section 3 - Controls and Indicators Ignition 0 I II III OZ3250 • Position 0 - Engine off. • Position I - Voltage available for all electrical functions. • Position II - Engine preheat at temperatures below 0° C (32° F). Wait to start engine until preheat indicator on instrument panel goes out. • Position III - Engine start. In the event the engine does not start, rotate key to position 0 then back to position III to re-engage the starter. Note: Key is removable in the 0 and P positions.
Section 3 - Controls and Indicators Park Brake 1 2 OZ3260 8, 9, 12 & 13M The park brake lever (1) controls the application and release of the park brake. • Pull lever back to apply park brake. • Squeeze release (2) and push lever forward to release park brake. WARNING MACHINE ROLL-AWAY HAZARD. Always move park brake switch to "ON" position, lower boom to ground and stop engine before leaving cab. WARNING CRUSH HAZARD.
Section 3 - Controls and Indicators Transmission Control Lever Direction of Travel Selection F N R 1 OZ2310 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 2 2nd 3rd 4th OZ2320 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 Load Stability Indicator (LSI) WARNING TIP OVER HAZARD. The LSI considers only longitudinal stability limitations, observe all operating parameters. Failure to follow operating parameters of the telehandler could damage the equipment and/or cause tip over.
Section 3 - Controls and Indicators S/N 1160005993 & After including 1160005949 & 1160005950 9 15 13 11 12 14 10 OZ3711 The LSI (9) provides visual and audible indication of forward stability limitations when machine is static on firm, level surface. • Green LED (10) will illuminate when LSI power is on. • When approaching forward stability limitations LEDs progressively illuminate, green (11), then orange (12) and finally red (13). • If the red LED illuminates the warning buzzer also sounds.
Section 3 - Controls and Indicators • Travel in accordance with the requirements set forth in Section 1 - General Safety Practices. • Test LSI (14) at the beginning of each work shift. See Section 8 - Additional Checks. • When placing a load, ensure axles are not fully steered in either direction. WARNING TIP OVER HAZARD. If the green, orange and red LEDs flash and warning buzzer sounds, retract and lower boom immediately. Determine cause and correct before continued use.
Section 3 - Controls and Indicators Steering Column Adjuster 1 OZ2330 • Follow “Shut-Down Procedure” on page 4-3. • Turn lever (1) counterclockwise to unlock. • Place steering column in desired position. • Turn lever clockwise to lock. 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.
Section 3 - Controls and Indicators Joystick Lift Joystick Pattern 1 2 OAH1351 Verify the lift joystick pattern icon (2) is active on the display (1) and the joystick decal located inside the cab matches the machine controls. 4 3 2 1 OZ3270 The joystick (1) controls the boom, attachment, auxiliary hydraulics and outrigger 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.
Section 3 - Controls and Indicators 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. Attachment Functions Attachment tilt is controlled by the roller switch (2). • Push the roller switch up to tilt attachment down; push the roller switch down to tilt attachment up.
Section 3 - Controls and Indicators Loader Joystick Pattern 1 3 OAH1381 Verify the loader joystick pattern icon (3) is active on the display (1) and the joystick decal located inside the cab matches the machine controls. 4 3 2 1 OZ3280 The joystick (1) controls the boom, attachment, auxiliary hydraulics and outrigger functions. Boom Functions • Move the joystick back to lift boom; move joystick forward to lower boom. • Extend/retract is controlled by the roller switch (2).
Section 3 - Controls and Indicators 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. Attachment Functions Attachment tilt is controlled by the joystick. • Move joystick right to tilt down; move joystick left to tilt up.
Section 3 - Controls and Indicators Armrest and Right Hand Console 1 14 2 3 4 15 5 13 6 16 17 12 7 8 11 10 9 OZ2420 1. Frame Level Switch (if equipped): Controls the left to right frame level. Depress right side of switch to rotate frame right; depress left side of switch to rotate frame left. Frame level operable with boom below 20 degrees. If equipped with boom retracted switch, frame level operable with boom below 20 degrees or with boom fully retracted and between 20 and 55 degrees. 2.
Section 3 - Controls and Indicators 13. Continuous Auxiliary Hydraulics Switch: a. Depress and release front of switch for continuous operation of hydraulic powered attachments. Set continuous auxiliary hydraulic level (-100% to 100%) within 10 seconds using the keypad up/down arrow buttons (see page 3-8). See Section 5 - Attachments and Hitches for approved attachments and control instructions. b. Relieves auxiliary hydraulic circuit pressure. See page 5-14. Heater and Air Conditioning Controls 14.
Section 3 - Controls and Indicators Accessory Control Lever Turn Signals and Low/High Beam Headlights 4 1 2 3 OZ3450 • Push accessory control lever (1) forward (2) to activate left turn signal. • Pull lever backward (3) to activate right turn signal. • The lever must be manually returned to the center position to deactivate either turn signal. The lever will not cancel automatically after a turn. • Pull lever up (4) to switch between low and high beam headlights.
Section 3 - Controls and Indicators 3.3 ANTI THEFT Machines with the anti theft feature active require entering a numeric code before operation to prevent unauthorized use. Code entry is accomplished using the display and keypad. 00 0000 0000 2 3 RPM km/h 0 1 OAH1430 1. Turn ignition switch to position I. If anti theft is active, the display (1) will prompt the operator for a numeric code. 2. Use the up/down arrow buttons (2) to select the first digit. 3.
Section 3 - Controls and Indicators 3.4 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. Manual Steering Alignment Mode Change If manual steering alignment mode is active under the Operator Tools menu (see page 3-7), use the following procedure for steer mode change. Note: Steer mode will change immediately after selection. 1 2 3 OAM2381 1.
Section 3 - Controls and Indicators All Wheel Assisted Steering Alignment Mode Change If all wheel assisted steering alignment mode is active under the Operator Tools menu (see page 3-7), use the following procedure for steer mode change. 1. Bring machine to a stop using service brake. 1 2 3 OAM2381 2. Select desired steer mode: circle steer (1), front steer (2) or crab steer (3). Note: Selected steer mode LED will flash and display will show steering alignment screens until the change is complete.
Section 3 - Controls and Indicators 3.5 OPERATOR SEAT Adjustments Prior to starting the engine adjust seat for position and comfort. Mechanical Suspension Seat 5 1 6 7 7 2 3 4 OAH1471 1. Backrest: Use handle to adjust backrest angle. 2. Fore/Aft: Use handle to move seat fore and aft. 3. Suspension: Use handle to adjust suspension to the appropriate weight setting. 4. Weight: Displays current weight setting. 5. Lumbar Support: Use knob to adjust lumbar support. 6.
Section 3 - Controls and Indicators Pneumatic Suspension Seat 5 1 6 2 7 3 OAH1481 4 1. Backrest Angle: Use handle to adjust backrest angle. 2. Fore/Aft: Use handle to move seat fore and aft. 3. Suspension: Use knob to adjust suspension to the appropriate weight setting. 4. Height: Use knob to adjust height to the appropriate setting. 5. Lumbar Support: Use knob to adjust lumbar support. 6. Seat Belt: Always fasten seat belt during operation. 7. Fore/Aft Isolator: Use handle to lock or unlock.
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 3.6 BOOM INDICATORS 1 OZ2410 Boom Extension • The boom extension indicators (1) 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 5-5).
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Section 4 - Operation SECTION 4 - OPERATION 4.1 ENGINE Starting the Engine This machine can be operated under normal conditions in temperatures of -18°C to 45°C (0°F to 113°F). 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 position I. If active, enter anti theft code. 3. Turn ignition switch to position II.
Section 4 - Operation Battery Boosted Starting OW0530 If battery-boost starting (jump-start) is necessary, proceed as follows: • Never allow vehicles to touch. • Ensure boosting vehicle engine is running. • Connect the positive (+) jumper cable to positive (+) post of discharged battery. • Connect the opposite end of positive (+) jumper cable to positive (+) post of booster battery. • Connect the negative (-) jumper cable to negative (-) post on booster battery.
Section 4 - Operation Normal Engine Operation • Observe instrument panel and display frequently to be sure all systems are functioning properly. • Be alert for unusual noises or vibration. When an unusual condition is noticed, park machine in safe position and perform shut-down procedure. Report condition to your supervisor or maintenance personnel. • Avoid prolonged idling. If the engine is not being used, turn it off.
Section 4 - Operation 4.2 OPERATING WITH A NON-SUSPENDED LOAD Lift Load Safely • You must know the weight and load center of every load you lift. If you are not sure of the weight and load center, check with your supervisor or with the supplier of the material. WARNING TIP OVER HAZARD. Exceeding lift capacity of the telehandler could damage the equipment and/or cause tip over.
Section 4 - Operation Transporting a Load OW0540 • After engaging the load and resting it against the backrest, tilt the load back to position it for travel. Travel in accordance with the requirements set forth in Section 1 - General Safety Practices and Section 5 - Attachments and Hitches. Leveling Procedure 1. Position machine in best location to lift or place load. 2. Apply parking brake and move transmission control lever to NEUTRAL. 3.
Section 4 - Operation Placing a Load Before placing any load be sure that: • The landing point can safely support the weight of the load. • The landing point is level; front to back and side to side. • Use the capacity chart to determine safe boom extension range. See “Use of the Capacity Chart” on page 5-5. • Align forks at the level load is to be placed, then extend boom slowly until load is just above area where it is to be placed.
Section 4 - Operation 4.3 OPERATING WITH A SUSPENDED LOAD Lift Load Safely • You must know the weight and load center of every load you lift. If you are not sure of the weight and load center, check with your supervisor or with the supplier of the material. WARNING TIP OVER HAZARD. Exceeding lift capacity of the telehandler could damage the equipment and/or cause tip.
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 and Hitches. • 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 300 mm (11.8 in) above ground surface or the boom more than 45°.
Section 4 - Operation Placing a Suspended Load Before placing any load be sure that: • The landing point can safely support the weight of the load. • The landing point is level; front to back and side to side. • Use the capacity chart to determine safe boom extension range. See “Use of the Capacity Chart” on page 5-5. • Align load at the level load is to be placed, then position boom slowly until load is just above area where it is to be placed.
Section 4 - Operation 4.4 ROAD OPERATION 1. Preparation a. Remove load from attachment. b. Remove any large amounts of dirt from machine. c. Check lights and mirrors and adjust if necessary. Note: Be sure to follow all local and federal/provincial traffic regulations. 2. Lower boom. Front edge of attachment should be approximately 30-40 cm (12-16 in) above the ground. 3. Fully tilt attachment back. 4.
Section 4 - Operation 4.5 LOADING AND SECURING FOR TRANSPORT OZ3290 Tiedown 1. If equipped, level the telehandler prior to loading. 2. Using a spotter, load the telehandler with boom as low as possible. 3. Once loaded, apply parking brake and lower boom until boom or attachment is resting on deck. Move all controls to “Neutral,” stop engine and remove ignition key. 4. Secure machine to deck by passing chains through the designated tiedown points as shown in the figure. 5. Do not tiedown front of boom.
Section 4 - Operation Lifting • When lifting machine, it is very important that the lifting device and equipment is attached only to designated lifting points. If machine is not equipped with lifting lugs contact JLG Product Safety for information. • Make adjustments to the lifting device and equipment to ensure the machine will be level when elevated. The machine must remain level at all times while being lifted.
Section 5 - Attachments and Hitches SECTION 5 - ATTACHMENTS AND HITCHES 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 model/option number on the attachment identification plate must match the attachment number on a capacity chart located in the operator cab. • The model on the capacity chart must match the model telehandler being used.
Section 5 - Attachments and Hitches 5.3 JLG SUPPLIED ATTACHMENTS Attachment Part Number 40.
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Section 5 - Attachments and Hitches 5.4 TELEHANDLER/ATTACHMENT/FORK CAPACITY 3 1 2 OZ0810 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).
Section 5 - Attachments and Hitches 5.5 USE OF THE CAPACITY CHART To properly use the capacity chart (see page 5-6), the operator must first determine and/or have the following: 1. An approved attachment. See “Approved Attachments” on page 5-1. 2. The proper Capacity Chart. 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 and Hitches Sample Capacity Chart This Capacity Chart may be used with this model ONLY. The telehandler model is indicated on the boom or chassis. Model XXXX is used for demonstration purposes only. These numbers must match the model/option number stamped on the attachment ID Plate. XXXX P/N 1234567 P/N 9876543 P/N 1122334 P/N 9988776 14 70° 13 kg F 10 D C 40° 2 10° 500kg 400kg 3 2.000kg B A 750kg 20° 4 1.000kg 6 1.500kg 30° 2.500kg 7 4.
Section 5 - Attachments and Hitches Example A contractor owns a model xxxx telehandler with a fork 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 xxxx 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 and Hitches 5.6 ATTACHMENT INSTALLATION Quick Attach MECHANICAL 1 2 HYDRAULIC 3 6 3 6 4 5 4 OZ3470 1. Attachment 2. Attachment Pin Recess 3. Attachment Pin 4. Lock Pin 5. Retainer Pin (mechanical quick attach) 6. Quick Attach (attachment tilt control in cab, see page 3-18 for details) WARNING CRUSH HAZARD. Always be certain that carriage or attachment is properly positioned on boom and is secured by lock pin and retainer pin.
Section 5 - Attachments and Hitches Mechanical Quick Attach This installation procedure is designed for one-person operation. Prior to exiting cab, perform “Shut-Down Procedure” on page 4-3. 1. Tilt quick attach forward to provide clearance. Check to be sure lock pin is out. OZ3480 2. Align attachment pin with recess in attachment. Raise boom slightly to engage attachment pin in recess. OZ3490 3. Tilt quick attach back to engage attachment. OZ3500 4. Insert lock pin and secure with retainer pin.
Section 5 - Attachments and Hitches Manual Hydraulic Quick Attach This installation procedure is designed for one-person operation. Prior to exiting cab, perform “Shut-Down Procedure” on page 4-3. 1 1. Turn auxiliary hydraulic valve handle (1) back, toward the operator cab, to enable hydraulic quick attach function. OZ3520 2. Tilt quick attach forward to provide clearance. Check to be sure lock pin is disengaged. OZ3530 3. Align attachment pin with recess in attachment.
Section 5 - Attachments and Hitches OAL1930 6. Raise boom to eye level and visually check that the lock pin protrudes through the hole. If the pin does not protrude through the hole, place the attachment on the ground and return to step 2. DISENGAGED ENGAGED 1 7. Turn auxiliary hydraulic valve handle (1) forward, away from the operator cab, to enable attachment auxiliary hydraulics function. OZ3560 8. If attachment is equipped, connect auxiliary hydraulic hoses.
Section 5 - Attachments and Hitches Hydraulic Quick Attach This installation procedure is designed for one-person operation. 1. Tilt quick attach forward to provide clearance. Check to be sure lock pin is disengaged. OZ3580 2. Align attachment pin with recess in attachment. Raise boom slightly to engage attachment pin in recess. OZ3590 3. Tilt quick attach back to engage attachment. OZ3600 4.
Section 5 - Attachments and Hitches Hydraulic Operated Attachment 1 2 OZ2220 OZ0632 1. Install attachment (see page 5-9). 2. Lower attachment to ground. 3. Quickly depress and release continuous auxiliary hydraulics switch (1) twice. Depress again and hold to relieve pressure at both auxiliary fittings (2). Note: Depressing of auxiliary hydraulics switch three times must be accomplished within two seconds. If buzzer sounds or continuous auxiliary hydraulics indicator illuminates, repeat step 3. 4.
Section 5 - Attachments and Hitches 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. Refer to “Attachment Installation” page 5-9. 2.
Section 5 - Attachments and Hitches 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. Note: Operations described within this section reference the Lift joystick pattern. Refer to page 3-20 if utilizing the Loader joystick pattern.
Section 5 - Attachments and Hitches Carriage w/Forks Use Carriage Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-4. to “Telehandler/ OZ0770 2 1 OZ2200 The joystick (1) controls movement of the boom. The attachment tilt roller switch (2) controls carriage tilt. • Push roller switch down to tilt up. • Push roller switch up to tilt down. Installation Procedure: • Refer to “Attachment Installation” on page 5-9.
Section 5 - Attachments and Hitches Side Shift Carriage Use Side Shift Carriage Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-4. to “Telehandler/ OAL1540 2 1 OZ2200 The joystick (1) controls movement of the boom. The attachment tilt roller switch (2) controls carriage tilt. • Push roller switch down to tilt up. • Push roller switch up to tilt down.
Section 5 - Attachments and Hitches To Side Shift: • Press and hold button (3) to shift forks right or press and hold button (4) to shift forks left. OR • While pressing and holding button (5), move joystick forward to shift forks right or move joystick back to shift forks left. 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.
Section 5 - Attachments and Hitches Fork Extension Use Appropriate Carriage Capacity Chart OZ0750 To determine maximum capacity of the carriage, refer to “Telehandler/Attachment/Fork Capacity” on page 5-4. Note: 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 and Hitches Equipment Damage Precautions • The heavy part of the load must be against the carriage backrest. • Do not allow load center of gravity to be in front of tip of the supporting fork. • Do not pick up a load or pry materials with the tip of a fork extensions.
Section 5 - Attachments and Hitches Fork Mounted Hook Use Fork Mounted Hook Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-4. to “Telehandler/ OY0640 Suspend loads in accordance with requirements set forth in Section 1 - General Safety Practices. 2 1 OZ2590 The joystick (1) controls movement of the boom. The attachment tilt roller switch (2) controls fork mounted hook tilt. • Push roller switch down to tilt up. • Push roller switch up to tilt down.
Section 5 - Attachments and Hitches 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. • Do not use with mast carriage attachment. • Do not use fork mounted hook with attachments capable of rotating (i.e. side tilt and swing carriages) without disabling the rotation feature(s).
Section 5 - Attachments and Hitches Truss Boom Use Appropriate Truss Boom Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-4. to “Telehandler/ OZ0780 Suspend loads in accordance with requirements set forth in Section 1 - General Safety Practices. 2 1 OZ2510 The joystick (1) controls movement of the boom. The attachment tilt roller switch (2) controls truss boom tilt. • Push roller switch down to tilt up. • Push roller switch up to tilt down.
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Section 5 - Attachments and Hitches Bucket Use Appropriate Bucket Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-4. to “Telehandler/ OZ0730 2 1 OZ2210 The joystick (1) controls movement of the boom. The attachment tilt roller switch (2) controls bucket tilt. • Push roller switch down to tilt up. • Push roller switch up to tilt down. Installation Procedure: • Refer to “Attachment Installation” on page 5-9.
Section 5 - Attachments and Hitches 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 and Hitches Multi-Purpose Bucket Use Appropriate Bucket Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-4. to “Telehandler/ OZ2540 2 1 OZ2210 The joystick (1) controls movement of the boom. The attachment tilt roller switch (2) controls bucket tilt. • Push roller switch down to tilt up. • Push roller switch up to tilt down.
Section 5 - Attachments and Hitches To open/close bucket: Press and hold button (3) to close bucket or press and hold button (4) to open bucket. OR While pressing and holding button (5), move joystick forward to close bucket or move joystick back to open bucket. Installation Procedure: • Refer to “Attachment Installation” on page 5-9. Operation: • Raise or lower boom to appropriate height and close bucket for loading material from stockpile.
Section 5 - Attachments and Hitches Grapple Bucket Use Appropriate Bucket Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-4. to “Telehandler/ OZ1450 2 1 OZ2210 The joystick (1) controls movement of the boom. The attachment tilt roller switch (2) controls bucket tilt. • Push roller switch down to tilt up. • Push roller switch up to tilt down.
Section 5 - Attachments and Hitches To Open/Close Grapple: Press and hold button (3) to close grapple or press and hold button (4) to open grapple. OR While pressing and holding button (5), move joystick forward to close grapple or move joystick back to open grapple. 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.
Section 5 - Attachments and Hitches Concrete Bucket - Fork Mounted Use Appropriate Carriage Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-4. to “Telehandler/ OZ2560 2 1 OZ2570 The joystick (1) controls movement of the boom. The attachment tilt roller switch (2) controls bucket tilt. • Push roller switch down to tilt up. • Push roller switch up to tilt down.
Section 5 - Attachments and Hitches To open/close bucket gate: Press and hold button (3) to close bucket gate or press and hold button (4) to open bucket gate. OR While pressing and holding button (5), move joystick forward to close bucket gate or move joystick back to open bucket gate. Installation Procedure: • Ensure carriage is properly installed. Refer to “Attachment Installation” on page 5-9.
Section 5 - Attachments and Hitches 5.9 HITCHES Machines may be equipped with various types of hitches. Maximum towing capacity shall be the smallest of the telehandler and hitch capacities. Refer to local governmental regulations for additional towing requirements and/or restrictions. Note: Ensure hitch is in lowest position when towing trailer. Speed and/or load may need reduced if traveling on ground which is not level.
Section 5 - Attachments and Hitches Pin Hitch - CUNA D2 (Italy) Maximum combined weight of trailer and load ......................... 12 000 kg (26 450 lb) Maximum vertical weight at hitch interface..................................... 2000 kg (4400 lb) 5 2 4 OAM2450 3 1 Connecting trailer for towing: 1. Remove safety pin (1) and pull pin (2) from hitch (3). 2. Align machine and tow eye of trailer. 3. Place pin through hitch and tow eye. Secure pin with safety pin. 4.
Section 5 - Attachments and Hitches Pin Hitch Maximum combined weight of trailer and load ......................... 12 000 kg (26 450 lb) Maximum vertical weight at hitch interface..................................... 2500 kg (5500 lb) 5 2 OAM2460 4 3 1 Connecting trailer for towing: 1. Remove safety pin (1) and pull pin (2) from hitch (3). 2. Align machine and tow eye of trailer. 3. Place pin through hitch and tow eye. Secure pin with safety pin. 4.
Section 5 - Attachments and Hitches Auto Hitch Maximum combined weight of trailer and load ......................... 12 000 kg (26 450 lb) Maximum vertical weight at hitch interface..................................... 2500 kg (5500 lb) 7 1 3 OAM2470 6 5 4 2 Connecting trailer for towing: 1. Rotate lever (1) until pin (2) fully retracts. 2. Align hitch mouth (3) and tow eye of trailer. 3. Reverse machine toward trailer. 4. After the tow eye contacts trigger (4), the pin and lever will be released. 5.
Section 5 - Attachments and Hitches Piton Frame and Auto Hitch Maximum combined weight of trailer and load ......................... 12 000 kg (26 450 lb) Maximum vertical weight at hitch interface..................................... 2500 kg (5500 lb) Note: See page 5-37 for Auto Hitch information. 1 2 3 OAM2480 Connecting trailer for towing: 1. Raise Auto Hitch (1) to highest position. 2. Remove safety pin (2) and lift locking latch (3). 3. Insert safety pin to hold locking latch in the up position. 4.
Section 5 - Attachments and Hitches Hydraulic Hitch Maximum combined weight of trailer and load ......................... 12 000 kg (26 450 lb) Maximum vertical weight at hitch interface..................................... 2000 kg (4400 lb) 2 5 8 7 1 OZ3690 4 3 6 Connecting trailer for towing: 1. Depress back of auxiliary hydraulic switch (1) to enable rear auxiliary hydraulics. Move joystick (2) forward to raise hitch safety posts (3) off safety hooks (4). 2. Pull safety hook release (5). 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 JLG Industries or the local Authorized Distributor for specific instructions. Secure the telehandler using the following procedures: 1. Clear the area around telehandler of all personnel. 2. Apply the parking brake. Place the transmission control lever in “NEUTRAL”.
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 OZ2230 The lubrication decal (1) contains general 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 4-3 unless otherwise instructed. Ensure telehandler is level, for proper fluid readings. • Clean lubrication fittings before lubricating. • After greasing telehandler, cycle all functions several times to distribute lubricants. Perform this maintenance procedure without attachment installed.
Section 7 - Lubrication and Maintenance 7.
Section 7 - Lubrication and Maintenance 50, 250 & 500 Hour Maintenance Schedule EVERY 50 Drain Fuel/ Water Separator Check Engine Coolant Level Lubrication Schedule Check Battery Check Washer Fluid Level Air Filter Vacuator Valve Check Fan Belt EVERY 250 Change Engine Oil and Filter Check Axle Oil Level Check Boom Wear Pads Check Transfer Case Oil Level Check Wheel End Oil Levels EVERY 500 LB/F T (N m) Change Fuel Filter Check Wheel Lug Nut Torque Check LSI Calibration OZ3351 Note: En
Section 7 - Lubrication and Maintenance 1000 & 1500 Hour Maintenance Schedule EVERY 1000 Change Transmission Oil & Filter Change Transfer Case Oil Change Axle Oil Change Wheel End Oil EVERY 1500 Change Engine Coolant Change Hydraulic Fluid & Filters Change Hydraulic Tank Breather Change Brake Fluid OZ1960 31200537 7-5
Section 7 - Lubrication and Maintenance 7.
Section 7 - Lubrication and Maintenance 50 Hour Lubrication Schedule EVERY 50 2x OZ2270 31200537 7-7
Section 7 - Lubrication and Maintenance 7.5 OPERATOR MAINTENANCE INSTRUCTIONS Fuel System 8 A. Fuel Level Check OW1150 OW0990 1 2 OZ2081 4 OZ0660 3 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 4-3. 3. Open rear access door (2). 4. Turn fuel tank cap (3) to remove from filler neck (4). 5. Add diesel fuel as needed. 6. Replace fuel tank cap. 7. Close and secure rear access door.
Section 7 - Lubrication and Maintenance 50 B. Drain Fuel/Water Separator OW0980 6 5 OW1000 OZ0360 1. Perform “Shut-Down Procedure” on page 4-3. 2. Open engine cover. 3. Loosen drain cock (5) on underside of fuel filter (6) and allow all water to drain into a glass until clear fuel is visible. Tighten drain cock. 4. Close and secure engine cover.
Section 7 - Lubrication and Maintenance Air Intake System 8 A. Air Filter Check OW1150 2 OW1010 3 1 6 4 8 9 7 5 OZ2660 1. Perform “Shut-Down Procedure” on page 4-3. 2. Locate precleaner (1) on top of engine cover, loosen wing nut (2) and remove cover (3) from precleaner canister. 3. Remove dust from bowl. 4. Replace bowl and secure cover. 5. Open engine cover. 6. Locate air cleaner (4) and remove dust from vacuator valve (5) by squeezing bottom of valve to allow loose particles to fall out. 7.
Section 7 - Lubrication and Maintenance B. Element Change (as restriction indicator indicates) If air filter restriction indicator remains on after start up or illuminates while operating machine perform the following: 1. Unlock air cleaner cover (6), turn counterclockwise and remove from air cleaner canister (7). 2. Remove outer primary element (8) and inspect for damage. Damaged elements should not be reused. 3. Thoroughly clean the interior of the air cleaner canister and vacuator valve. 4.
Section 7 - Lubrication and Maintenance Engine Oil 8 A. Engine Oil Level Check OW1150 OW1020 4 AD D 2 3 1 OZ0480 1. Perform “Shut-Down Procedure” on page 4-3. 2. Open engine cover. 3. Remove dipstick (1) and check oil mark. The oil should be between the full (2) and add (3) marks within the crosshatched area of the dipstick. 4. Replace dipstick. 5. 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. 6. Replace oil fill cap. 7.
Section 7 - Lubrication and Maintenance Hydraulic Oil A. Hydraulic Oil Level Check 8 OW1150 OW1030 7 5 6 OZ2620 1. Be sure all cylinders are fully retracted and machine is level. 2. Perform “Shut-Down Procedure” on page 4-3. 3. Check level of hydraulic oil at the sight gauge (5) on the hydraulic tank (6). The oil level should be visible in the gauge window. 4. If hydraulic oil is low, remove oil fill cap (7) from filler neck. Add fluid to bring oil up to the upper mark on the sight gauge. 5.
Section 7 - Lubrication and Maintenance Tires A. Tire Air Pressure Check 8 OW1150 OW1040 1. Perform “Shut-Down Procedure” on page 4-3. 2. Remove valve stem cap. 3. Check tire pressure. 4. Add air if required 405/70-24 MPT-01 ...................................................................4,0 bar (58 psi) 405/70-24 MPT-04 ...................................................................4,0 bar (58 psi) 5. Replace valve stem cap. B.
Section 7 - Lubrication and Maintenance E. Wheel Installation Torque lug nuts after first 50 hours and after each wheel installation. Note: If machine is equipped with directional tire assemblies, the wheel and tire assemblies must be installed with the directional tread pattern “arrows” facing in the direction of forward travel. 1. Start all nuts by hand to prevent cross threading. DO NOT use a lubricant on threads or nuts. 2. Tighten lug nuts in an alternating pattern as indicated in figure.
Section 7 - Lubrication and Maintenance Brake System A. Brake Fluid Level Check 8 OW1150 OZ0540 2 1 OZ3070 1. Perform “Shut-Down Procedure” on page 4-3. 2. The brake fluid level (1) should be between the MIN and MAX marks on the reservoir. 3. If brake fluid level is low, add fluid as needed (2). Note: All other work on the brake system must be performed by qualified personnel.
Section 7 - Lubrication and Maintenance Transmission 8 A. Transmission Oil Level Check OW1150 OW1050 4 FUL L ADD 3 OZ2641 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. Open engine cover. 4. Remove the transmission dipstick (3) and check oil level. The oil level should be within the "FULL and ADD" marks (4). 5.
Section 7 - Lubrication and Maintenance Engine Cooling System A. Engine Coolant Level Check 50 OW0980 OW1070 2 1 OZ2630 1. Perform “Shut-Down Procedure” on page 4-3. 2. Open engine cover. 3. Check coolant level in overflow bottle (1). When coolant is hot, bottle should be 1/2 to 3/4 full. When coolant is cool, bottle should be 1/4 to 1/2 full. 4. If coolant is low, remove overflow bottle cap (2) and add coolant as required. 5. Replace overflow bottle cap. 6. Close and secure engine cover.
Section 7 - Lubrication and Maintenance Battery 50 A. Battery Check OW0980 3 OW1080 OZ2650 1. Perform “Shut-Down Procedure” on page 4-3. 2. Open engine cover. 3. Wearing eye protection, visually inspect the battery (3). Check terminals for corrosion. Replace battery if it has a cracked, melted or damaged case. 4. Close and secure engine cover.
Section 7 - Lubrication and Maintenance Windshield Washer System A. Windshield Washer Fluid Level Check 50 OW0980 OAL2040 2 1 OZ3680 1. Perform “Shut-Down Procedure” on page 4-3. 2. Open engine cover. 3. The windshield washer fluid should be visible in the reservoir (1). 4. If washer fluid level is low, remove reservoir cap (2) and add fluid as needed. 5. Replace reservoir cap. 6. Close and secure engine cover.
Section 8 - Additional Checks SECTION 8 - ADDITIONAL CHECKS 8.1 GENERAL If any test gives a different result, the system is not functioning properly and the machine must be removed from service and repaired before continued operation. 8.2 LOAD STABILITY INDICATOR TEST A. Load Stability Indicator Test 8 OW1150 OZ0840 The Load Stability Indicator (LSI) is intended to continuously monitor the forward stability of the telehandler.
Section 8 - Additional Checks 8.3 BOOM INTERLOCK A. Boom Interlock System Test 8 OW1150 Boom interlock system operates in two modes. With boom angle below 20 degrees, frame level functions are operable. With boom raised above 20 degrees, frame level is not operable. To check the system, perform the following: 1. Test system with machine on a level surface and no load. 2. Shift transmission to neutral and engage park brake. 3. Ensure frame level functions are properly functioning.
Section 8 - Additional Checks B. Boom Interlock System Test (if equipped with boom retracted switch) 8 OW1150 Boom interlock system (if equipped with boom retracted switch) operates in three modes. With boom at any extension and angle below 20 degrees, frame level functions are operable. With boom fully retracted and raised between 20 and 55 degrees, frame level is operable. With boom at any extension and raised above 55 degrees, frame level is not operable. To check the system, perform the following: 1.
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Section 9 - Specifications SECTION 9 - SPECIFICATIONS 9.1 PRODUCT SPECIFICATIONS Fluid and Lubrication Capacities Engine Crankcase Oil Capacity with Filter Change ....................................................................8,5 L (9.0 qt) Type of Oil ................................................................ DF Super ENGINE OIL 15W-40 Specifications ....................ACEA F5,F3; API CH-4/CG-4/CF-4/CF; Deutz DOC 2-05 Fuel Tank Capacity .. ....................................................
Section 9 - Specifications Brake System System Capacity..................................................................................... 1,0 L (1.1 qt) Type of Oil .................................................................................................DONAX TA Specifications ............................ (MB 236.6; ZF TE-ML 03D-04D-09A-11A-14A-17C; GM Allison (10750189)) Axles Differential Housing Capacity (Front Axle) ............................................. 8,0 L (8.
Section 9 - Specifications Performance Maximum Lift Capacity .................................................................... 4000 kg (8818 lb) Maximum Lift Height 40.8..................................................................................................8,0 m (26.2 ft) 40.9..................................................................................................9,0 m (29.5 ft) Capacity at Maximum Height 40.8 Frame Level Equipped........................................................
Section 9 - Specifications Dimensions Overall Height.................................................................................2410 mm (94.9 in) Overall Width ..................................................................................2380 mm (93.7 in) Cab Width ...........................................................................................890 mm (35 in) Track Width ....................................................................................1920 mm (75.6 in) Wheelbase........
Section 9 - Specifications Declaration of Vibration Average weighted whole body acceleration. Mechanical Suspension Seat 40.8........................................................................................... 0,6 m/s² (2.0 ft/s²) 40.9........................................................................................... 0,7 m/s² (2.3 ft/s²) Pneumatic Suspension Seat 40.8........................................................................................... 0,6 m/s² (2.0 ft/s²) 40.9..........
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Index Index A Coolant Level ..................................7-18 Accessory Control Lever ................ 3-24 Cooling System.................................9-1 Additional Checks............................. 8-1 Adjusting/Moving Forks .................. 5-15 Air Conditioning System ................... 9-2 Air Filter Check............................... 7-10 Anti Theft ........................................ 3-25 Attachment Installation Hydraulic Operated................... 5-14 Quick Attach........
Index I Picking Up a Suspended Load..........4-7 Ignition ............................................ 3-10 Pin Hitch..........................................5-36 Instrument Panel .............................. 3-4 Pin Hitch - CUNA C.........................5-34 J Joystick Lift Pattern................................. 3-18 Loader Pattern .......................... 3-20 K Keypad ............................................. 3-8 Pin Hitch - CUNA D2.......................
Index Transmission .................................... 9-1 Transmission Control Lever Direction of Travel..................... 3-12 Gear Selection .......................... 3-13 Transmission Oil Level ................... 7-17 Transport Lifting ........................................ 4-12 Tiedown .................................... 4-11 Transporting a Load ......................... 4-5 Transporting a Suspended Load ...... 4-8 Travel Hazard................................... 1-6 Truss Boom ...............
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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.
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