Manual

Table of Contents
1
 2004 JLG Industries, Inc.
Introduction
The Manual....................................2
Replacement Parts........................2
Reports..........................................2
Disclaimer......................................3
Safety Practices
Hazard Classification System........3
Accident Prevention Tags..............5
New or Additional Operators .........5
Instructional Symbols ....................6
Instructional Symbols (cont’d) .......7
Hazard Symbols ............................8
Avoidance Symbols.......................9
Avoidance Symbols (cont’d)........10
Avoidance Symbols (cont’d)........11
Personal Considerations .............12
Operational Considerations.........15
Equipment Considerations ..........20
Operation
Pre-Operation Inspection.............23
Operator Controls........................26
Front Dash Panel.........................48
Optional Features........................55
Carriages.....................................66
Indicators.....................................68
Fork Rating..................................70
Using the Capacity Chart.............71
Stabil-TRAK System....................74
Stabil-TRAK™ System Test ........77
Refueling .....................................83
Normal Starting............................85
Cold Starting................................86
Jump Starting ..............................87
How To Pick, Carry & Place A
Load..........................................88
Elevating Personnel.....................89
Using Other Attachments ............93
Shut-Off .......................................95
Emergency Operations
Towing a Disabled Vehicle ..........96
Emergency Boom Lowering ........98
General Maintenance
Introduction................................104
Maintenance Schedule and
Checklist .................................105
1. Lubrication Points.............106
2. Air Cleaner .......................107
3. Optional Closed Cab Air
Filters ................................109
4. Engine Cooling System.....110
5. Engine Oil and Filter..........114
6. Engine Fuel System..........118
7. Engine Fan Belt.................123
8. Air Conditioner Compressor
Belt (Optional) ...................124
9. Hydraulic Oil and Filter......125
10. Transmission Oil and
Filter ..................................128
11. Transfer Case Oil..............131
12. Axle Oil..............................133
13. Brake Disc Inspection .......135
14. Wheel End Oil ...................138
15. Wheels and Tires ..............140
16. Battery...............................142
17. Fuse & Relay
Replacement .....................143
18. Boom Chains and Wear
Pads..................................150
19. Transfer Carriage Rollers and
Wear Pads ........................163
Storage and Transport ..............170
Storage......................................170
Transport...................................171
Test Procedures
Parking Brake/Transmission
De-Clutch Test Procedures....172
Specifications
Fluid & Lubrication Capacities...174
Tires ..........................................175
Weights .....................................175
Vehicle Dimensions...................176
Electrical System.......................177
Engine.......................................177
Index.............................................179
Load Charts
Accident Prevention Tags