Operation & Safety Manual Original Instructions Keep this manual with machine at all times.
CALIFORNIA PROPOSITION 65 BATTERY WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemical known to the State of California to cause cancer and reproductive harm. WASH HANDS AFTER HANDLING! CALIFORNIA PROPOSITION 65 EXHAUST WARNING Diesel Engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm.
Revision Log Revision Log REVISION LOG March 18, 2009 - A - Original Issue of Manual April 23, 2009 - B - Revised page 9-2. December 21, 2010 - C - Revised pages 7-13, 9-2, 9-3 & 9-5. September 19, 2011 - D - Revised covers and pages b, d, 1-5, 1-6, 1-9, 2-3, 2-6, 27, 2-8, 2-11, 2-13, 3-1, 3-4, 3-5, 3-6, 3-7, 4-3, 4-6, 4-9, 4-10, 5-2, 5-15, 5-16, 5-18, 5-20, 5-21, 5-22, 5-24, 5-26, 5-28, 5-30, 5-32, 6-1, 7-3, 7-4, 7-5, 7-9, 7-10, 7-11, 7-12, 7-13, 7-17, 7-18, 7-19, 7-20, 7-22, 7-23, 9-1 & 9-2.
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 Before S/N 0160041827 excluding 0160041630 ..................................8990461 S/N 0160041827 & After including 0160041630..................................31200355 Illustrated Parts Manual...............................................................................8990462 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.......................................................... 3-9 Transmission Control Lever.......................................... 3-10 Front Joystick ............................................................... 3-12 Middle Joystick ............................................................. 3-13 Single Joystick (if equipped)......................................... 3-14 Frame Level Joystick....................................................
Table of Contents Section 5 - Attachments 5.1 5.2 5.3 5.4 5.5 Approved Attachments ........................................................5-1 Unapproved Attachments ....................................................5-1 JLG Supplied Attachments ..................................................5-2 Telehandler/Attachment/Fork Capacity................................5-4 Use of the Capacity Chart....................................................5-5 Capacity Indicator Locations ............................
Table of Contents 7.5 Operator Maintenance Instructions ..................................... 7-8 Fuel System.................................................................... 7-8 Engine Oil ..................................................................... 7-10 Hydraulic Oil ................................................................. 7-11 Engine Cooling System ................................................ 7-12 Tires..............................................................................
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, drive with forks pointed downhill. • When loaded, drive with the forks pointed uphill. • For additional travel requirements, refer to the appropriate capacity chart. • To avoid overspeeding the engine and drivetrain when driving down slopes, downshift to a lower gear and use the service brake as necessary to maintain a slow speed.
Section 1 - General Safety Practices Pinch Points and Crush Hazards Stay clear of pinch points and rotating parts on the telehandler. OW0210 • Stay clear of moving parts while engine is running. OW0220 • Keep clear of steering tires and frame or other objects. OW0230 • Keep clear from under boom.
Section 1 - General Safety Practices OW0240 • Keep clear of boom holes. OW0250 • Keep arms and hands clear of attachment tilt cylinder. OW0260 • Keep hands and fingers clear of carriage and forks. OW0960 • Keep others away while operating.
Section 1 - General Safety Practices Fall Hazard OW0280 • Enter using the proper hand holds and steps provided. Always maintain 3-point contact when mounting or dismounting. Never grab control levers or steering wheel when mounting or dismounting the machine. • DO NOT get off the machine until the shutdown procedure on page 4-5 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 2-12) 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. Before S/N 0160041827 excluding 0160041630 4110361 SAFETY INSTRUCTIONS 1. Read operator's manual before operating. 2. Fasten seat belt. 3. Allow no riders. 4. Use a compliant work platform to lift or lower personnel.
Section 2 - Pre-Operation and Inspection 4110130 1706300 50 60 70 80 4105262 7301380 40 20 -10 0 10 30 WARNING FALLING OFF ATTACHMENT, can result in death or serious injury. 4 7301380 4109801 7301380 4109801 Lift or lower personnel only in a compliant work platform. 3 5 6 4109801 A B DO NOT TRAVEL with personnel in a work platform.
Section 2 - Pre-Operation and Inspection 1705883 7301380 4110356 6 190cm 5 Ft Ft 200cm 180cm 170cm 160cm 4 140cm 130cm 120cm 3 Ft Ft 150cm 110cm 100cm 90cm 2 Ft 80cm 70cm 60cm 50cm 40cm 1 Ft 30cm 20cm 10cm 0 4110356 6 7301380 4109801 4109801 7301380 4109801 4109801 4110405 1001103931 10 50 LB-FT 100 (Nm) 250 1000 P 2000 4110350 2 2 4110349 4110349 UNDERSIDE VIEW OF ENGINE COVER 1706300 4110184 1707079 MOVING PARTS can cut.
Section 2 - Pre-Operation and Inspection S/N 0160041827 & After including 0160041630 1706299 CONTACTING POWER LINES will result in death or serious injury. 1706299A 1706306 1706850 WARNING CRUSHING HAZARD Lowering boom or falling load could cause death or serious injury. Keep others away while operating. 1706306A 1706850A CAPACITY CHARTS 4110359 15 20 10 1/2 F E °F 176 RPM X 100 104 25 5 80 °C 248 120 D 30 r/min 0000000 4110359 VIEW INSIDE CAB 1706767 Fasten seat belt.
Section 2 - Pre-Operation and Inspection 4110130 1706300 1706768 50 60 70 80 4105262 7301380 40 20 -10 0 10 30 4 7301380 4109801 3 5 7301380 6 4109801 4109801 A B 4109801 10 2 Pressure Tap Function Tested Location 10 2 Main Valve Pressure Refer to Hydraulic Test Laminate or Service 3 Pilot Pressure Manual for proper 4 testing procedures. Park Brake 5 Pump #1 6 Accumulator Pressure *Consult with OQT Technical Service Department for A Load Sense (Steering)* additional testing information.
Section 2 - Pre-Operation and Inspection 1706296 (BETWEEN FRAME RAILS) 1705883 7301380 4110356 6 190cm 5 Ft Ft 200cm 180cm 170cm 160cm 4 140cm 130cm 120cm 3 Ft Ft 150cm 110cm 100cm 90cm 2 Ft 80cm 70cm 60cm 50cm 40cm 1 Ft 30cm 20cm 10cm 0 4110356 6 7301380 4109801 4109801 7301380 4109801 4109801 4110405 1001136373 10 50 LB-FT 100 (Nm) 250 1000 P 2000 4110350 2 2 4110349 UNDERSIDE VIEW OF ENGINE COVER 4110349 1001125892 1706300 (BOTH SIDES OF ENGINE COMPAR
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Section 2 - Pre-Operation and Inspection 2.3 WALK-AROUND INSPECTION 15 1 2 14 4 13 3 4 5 12 6 11 7 10 8 9 OU1811 Begin your walk-around inspection at item 1, as noted below. Continue to your right (counterclockwise when viewed from top) checking each item in sequence. INSPECTION NOTE: On all components, make sure there are no loose or missing parts, that they are securely fastened and no visible leaks or excessive wear exists in addition to any other criteria mentioned.
Section 2 - Pre-Operation and Inspection 5. Cab and Electrical • General appearance; no visible damage. • Frame level indicator and window glass undamaged and clean. • Gauges, switches, joysticks, foot controls and horn operational. • Check seat belt for damage, replace belt if frayed or cut webbing, damaged buckles or loose mounting hardware. 6. Main Control Valve (under cab floor) - See Inspection Note. 7. Wheel/Tire Assembly - Properly inflated and secured; no loose or missing lug nuts.
Section 2 - Pre-Operation and Inspection 2.4 WARM-UP AND OPERATIONAL CHECKS Warm-Up Check During warm-up period, check: 1. Heater, defroster and windshield wiper (if equipped). 2. Check all lighting systems (if equipped) for proper operation. 3. Adjust mirror(s) for maximum visibility. WARNING CUT/CRUSH/BURN HAZARD. Keep engine cover closed while engine is running except when checking transmission oil level. Operational Check When engine warms, perform an operational check: 1.
Section 2 - Pre-Operation and Inspection 2.5 OPERATOR CAB The telehandler is equipped with an open or enclosed ROPS/FOPS cab. WARNING Never operate telehandler unless the overhead guard, cab structure and right side glass or screen are in good condition. Any modification to this machine must be approved by JLG to assure compliance with ROPS/FOPS certification for this cab/machine configuration. If the overhead guard or cab structure is damaged, the CAB CANNOT BE REPAIRED. It must be REPLACED.
Section 2 - Pre-Operation and Inspection 2.6 WINDOWS Keep all windows and mirrors clean and unobstructed. Cab Door Window (if equipped) 4 2 3 1 OU1821 • 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 with the latch handle (3) and secure in place on outside of cab. • Turn either inside or outside knob (4) to unlatch the window.
Section 3 - Controls and Indicators SECTION 3 - CONTROLS AND INDICATORS 3.1 GENERAL This section provides the necessary information needed to understand control functions. Note: The manufacturer has no direct control over machine application and operation. The user and operator are responsible for conforming with good safety practices. NOTICE EQUIPMENT DAMAGE.
Section 3 - Controls and Indicators 3.2 CONTROLS 8 9 10 14 7 13 6 11 5 12 13 SINGLE JOYSTICK CONFIGURATION 4 3 2 1 OU1911 1. Accelerator Pedal: Pressing down the pedal increases engine and hydraulic speed. 2. Ignition Switch: Key activated. See page 3-8. 3. Service Brake Pedal: The further the pedal is depressed, the slower the travel speed. With service brake pedal depressed and boom angles above 40°, the locked mode of the Stabil-Trak system is activated. See page 3-19. 4.
Section 3 - Controls and Indicators 11. Front Joystick: See page 3-12. 12. Middle Joystick: See page 3-13. 13. Frame Level Joystick: See page 3-16. 14. Single Joystick (if equipped): See page 3-14.
Section 3 - Controls and Indicators Instrument Panel 1 2 3 4 5 6 7 8 15 20 10 1/2 F E RPM X 100 25 5 °F 176 140 104 40 60 212 248 80 100 °C 120 D 30 r/min 0000000 OU1921 17 16 15 14 13 12 11 10 9 1. Fuel Gauge: Indicates amount of fuel in fuel tank. 2. Engine Air-Intake Heater Indicator: Illuminates with ignition key in the “RUN” position. Indicator goes out when start temperature is reached. At temperatures below 40° F (4° C), do not start until indicator turns off.
Section 3 - Controls and Indicators 11. Air Filter Restriction Indicator: Illuminates when air filter(s) require maintenance. 12. Hydraulic Oil Temperature Indicator: Illuminates when hydraulic oil temperature is too high. 13. Hourmeter: Records and indicates engine operating hours. 14. Transmission Oil Temperature Indicator: Illuminates and buzzer sounds when transmission oil temperature is too high. 15. Park Brake Indicator: Illuminates when park brake is applied. See page 3-9. 16.
Section 3 - Controls and Indicators Dash Panel 5 6 7 1 b a 8 9 3 4 13 2 12 11 10 OU1992 1. Steer Mode Selector: Three positions: 4-wheel circle steer, 4-wheel crab steer and 2-wheel steer. See page 3-18. 2. Transmission Disconnect Switch: Depress bottom of switch to activate transmission disconnect function and have transmission disconnect while depressing service brake. Indicator illuminates to indicate transmission has disconnected.
Section 3 - Controls and Indicators 7. Work Lights Switch (if equipped): Three position switch. Move switch to middle position to turn on front work lights. Push bottom of switch to turn on all work lights. Push top of switch to turn all work lights off. 8. Roof Wiper/Washer Switch (if equipped): Three position switch. Move switch to middle position to turn on wiper. Push and hold bottom of switch to activate washer. Push top of switch to turn off wiper. 9.
Section 3 - Controls and Indicators Ignition OFF RUN START OU1891 • In the "RUN" position, voltage is available for all electrical functions. • Full clockwise rotation to "START" engages starter motor. • Counter-clockwise rotation to "OFF" stops engine and removes voltage from all electrical functions.
Section 3 - Controls and Indicators Park Brake 1 2 OU1901 Park brake switch controls the application and release of the park brake. Indicator on switch 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.
Section 3 - Controls and Indicators Transmission Control Lever Direction of Travel Selection F N R 1 OU1871 Transmission control lever (1) engages forward or reverse travel. • Push lever forward for forward travel; pull lever rearward for reverse travel. Move lever to centered position for neutral. • Forward or reverse travel can be selected while in any gear. • When traveling in reverse, the back-up alarm will automatically sound. • Drive in reverse and turn only at slow rates of speed.
Section 3 - Controls and Indicators Gear Selection 1st 2nd 3rd 4th 2 OU1881 Gear selection is located on the twist grip handle (2) of transmission control lever. • Twist hand grip to select gear. • Select the appropriate gear for the task being performed. Use a lower gear when transporting a load. Use a higher gear only when driving unloaded for longer distances. • Slow down prior to downshifting. Do not downshift more than one gear at a time.
Section 3 - Controls and Indicators Front Joystick 2 1 OU1961 The front joystick (1) controls attachment tilt, transfer carriage and auxiliary hydraulic functions. Attachment Tilt Function • Move the joystick forward to tilt down, move the joystick back to tilt up. Transfer Carriage Function • Move the joystick right to extend transfer carriage; move joystick left to retract transfer carriage. • For two simultaneous functions, move the joystick between quadrants.
Section 3 - Controls and Indicators Middle Joystick 3 OU1951 The middle joystick (3) controls boom 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. • For two simultaneous boom functions, move the joystick between quadrants.
Section 3 - Controls and Indicators Single Joystick (if equipped) 3 1 2 OU1971 The single joystick (1) controls boom, attachment tilt, transfer carriage and auxiliary hydraulic 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 functions depends upon the amount of joystick travel in corresponding direction. Increasing engine speed will also increase function speed.
Section 3 - Controls and Indicators • The speed of functions depends upon the amount of joystick travel in corresponding direction. Increasing engine speed will also increase function speed. • For two simultaneous functions, move the joystick between quadrants. For example; moving the joystick forward and to the left will extend transfer carriage and activate auxiliary hydraulics simultaneously. Attachment Tilt • Slide the thumb control (3) forward to tilt down, slide the thumb control back to tilt up.
Section 3 - Controls and Indicators Frame Level Joystick 1 2 OU1941 The frame level joystick (1) controls the left to right frame level. • Lift detent ring (2) and move the joystick left to rotate frame left; lift detent ring and move the joystick right to rotate frame right. • A level indicator is located above the front cab window to permit the operator to determine whether the telehandler frame is level. WARNING TIP OVER HAZARD.
Section 3 - Controls and Indicators Accessory Control Lever (if equipped) The accessory control lever (3) operates the turn signals, parking lights and headlights. 4 6 9 7 8 3 5 OU1931 Turn Signals • Push lever forward (4) to activate the left turn signal. • Pull lever back (5) to activate the 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.
Section 3 - Controls and Indicators 3.3 STEER MODES Three steer modes are available for operator use. 2-Wheel Front Steer 4-Wheel Circle Steer 4-Wheel Crab Steer OAL2030 Note: 2-Wheel Front Steer mode is required for travel on public roads. Steer Mode Change 1 2 3 OU2380 1. Bring machine to a stop using service brake while either circle steer mode (1) or crab steer mode (3) is selected. 4 5 OAM2400 2.
Section 3 - Controls and Indicators 3.4 STABIL-TRAK™ SYSTEM 2 3 4 15 1 20 10 1/2 F E RPM X 100 25 5 °F 176 140 104 40 60 212 248 80 100 °C 120 D 30 r/min 0000000 OU2041 Free Pivot Mode With boom below 40° (1), the Stabil-Trak system is in free pivot mode. • The rear axle pivots freely and frame level functions normally. • The Stabil-Trak slow pivot (3) and lock (4) indicators will not illuminate.
Section 3 - Controls and Indicators 3.5 OPERATOR SEAT Adjustments Prior to starting engine adjust seat for position and comfort. 3 1 2 OAL1270 1. Suspension: Use knob to adjust suspension to the appropriate setting. Turn clockwise to increase stiffness. Turn counterclockwise to reduce stiffness. 2. Fore/Aft: Pull up on handle to move seat fore and aft. 3. Seat Belt: Always fasten seat belt during operation. If required, a 3 in (76 mm) seat belt is available.
Section 3 - Controls and Indicators Seat Belt OH20912 Fasten seat belt as follows: 1. Grasp both free ends of the belt making certain that belt webbing is not twisted or entangled. 2. With back straight in the seat, couple the retractable end (male end) of the belt into the receptacle (buckle) end of the belt. 3. With belt buckle positioned as low on the body as possible, pull the retractable end of the belt away from the buckle until it is tight across the lap. 4.
Section 3 - Controls and Indicators 3.6 INDICATORS Boom Angle and Extension 1 2 ° 60 ° 70° 80° B 50 A ° -10° 0° 10° 20° 30 ° 40 OU1831 • 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 5-5). • Boom extension indicators (2) are located on the left side of the boom.
Section 4 - Operation SECTION 4 - OPERATION 4.1 ENGINE Starting the Engine This machine can be operated under normal conditions in temperatures of 0°F to 104°F (-20°C to 40°C). Consult JLG for operation outside this range or under abnormal conditions. 1. Make sure all controls are in “Neutral” and all electrical components (lights, heater, defroster, etc.) are turned off. Apply parking brake. 2.
Section 4 - Operation Cold Weather Starting Aids If the telehandler is equipped with an engine air-intake heater, the following applies: • Air-intake heater is triggered by a temperature sensor on the engine. • At start-up, temperature sensor will detect if air-intake heater is needed. • A second battery is added for additional cold-cranking capacity. WARNING ENGINE EXPLOSION. If your telehandler is equipped with a cold start aid, do not spray additional ether into air cleaner.
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. • (Before S/N 0160041827 excluding 0160041630) Connect the positive (+) jumper cable to positive (+) post of discharged battery. (S/N 0160041827 & After including 0160041630) Connect the positive (+) jumper cable to positive (+) jumper post of discharged machine.
Section 4 - Operation Normal Engine Operation • Observe gauges and indicators frequently to be sure all engine systems are functioning properly. • Be alert for unusual noises or vibration. When an unusual condition is noticed, park machine in safe position and perform shut-down procedure. Report condition to your supervisor or maintenance personnel. • Avoid prolonged idling. If the engine is not being used, turn it off.
Section 4 - Operation 4.2 OPERATING WITH A NON-SUSPENDED LOAD Lift Load Safely • You must know the weight and load center of every load you lift. If you are not sure of the weight and load center, check with your supervisor or with the supplier of the material. WARNING TIP OVER HAZARD. Exceeding lift capacity of the telehandler could damage the equipment and/or cause tip over.
Section 4 - Operation Transporting a Load OW0540 After engaging the load and resting it against the backrest, tilt the load back to position it for travel and fully retract transfer carriage. Travel in accordance with the requirements set forth in Section 1 - General Safety Practices and Section 5 - Attachments. Leveling Procedure 1. Position machine in best location to lift or place load. 2. Apply parking brake and move transmission control lever to NEUTRAL. 3.
Section 4 - Operation Placing a Load Before placing any load be sure that: • The landing point can safely support the weight of the load. • The landing point is level; front to back and side to side. • Use the capacity chart to determine safe boom and transfer carriage extension range. See “Use of the Capacity Chart” on page 5-5. • Align forks at the level load is to be placed, then position boom slowly until load is just above area where it is to be placed.
Section 4 - Operation 4.3 OPERATING WITH A SUSPENDED LOAD Lift Load Safely • You must know the weight and load center of every load you lift. If you are not sure of the weight and load center, check with your supervisor or with the supplier of the material. WARNING TIP OVER HAZARD. Exceeding lift capacity of the telehandler could damage the equipment and/or cause tip over.
Section 4 - Operation Transporting a Suspended Load OZ3160 OW0130 • Travel in accordance with the requirements set forth in Section 1 - General Safety Practices and Section 5 - Attachments. • For additional requirements, refer to the appropriate capacity chart in the operator cab. Important things to remember: • Ensure the boom and transfer carriage is fully retracted. • Never raise the load more than 11.8 in (300 mm) above ground surface or the boom more than 45°.
Section 4 - Operation Placing a Suspended Load Before placing any load be sure that: • The landing point can safely support the weight of the load. • The landing point is level; front to back and side to side. • Use the capacity chart to determine safe boom and transfer carriage extension range. See “Use of the Capacity Chart” on page 5-5. • 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 LOADING AND SECURING FOR TRANSPORT 4109801 4109801 OU2031 Tiedown 1. Level the telehandler prior to loading. 2. Using a spotter, load the telehandler with boom as low as possible. 3. Once loaded, apply parking brake and lower boom until boom or attachment is resting on deck. Move all controls to “Neutral,” stop engine and remove ignition key. 4. Secure machine to deck by passing chains through the designated tie down points as shown in the figure. 5.
Section 4 - Operation Lifting • When lifting machine, it is very important that the lifting device and equipment is attached only to designated lifting points. If machine is not equipped with lifting lugs contact JLG Product Safety for information. • Make adjustments to the lifting device and equipment to ensure the machine will be level when elevated. The machine must remain level at all times while being lifted.
Section 5 - Attachments SECTION 5 - ATTACHMENTS 5.1 APPROVED ATTACHMENTS To determine if an attachment is approved for use on the specific telehandler you are using, perform the following prior to installation. • The attachment type, weight, dimensions and load center must be equal to or less than the data shown on a capacity chart located in the operator cab. • The model on the capacity chart must match the model telehandler being used.
Section 5 - Attachments 5.
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Section 5 - Attachments 5.4 TELEHANDLER/ATTACHMENT/FORK CAPACITY 1 3 2 OW0550 Prior to installing the attachment verify it is approved and the telehandler is equipped with the proper capacity chart. See “Approved Attachments” on page 5-1. To determine the maximum capacity of the telehandler and attachment, use the smallest of the following capacities: • Capacity stamped on the attachment identification plate (1). • Fork capacities and load centers are stamped on the side of each fork (2) (if equipped).
Section 5 - Attachments 5.5 USE OF THE CAPACITY CHART To properly use the capacity chart (see page 5-6), 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(s). 3. Weight of the load being lifted. 4. Load placement information: a. HEIGHT where the load is to be placed. b. DISTANCE from the front tires of the telehandler where the load is to be placed. 5.
Section 5 - Attachments Sample Capacity Chart Load zones indicate the maximum weight that may be safely lifted. XXXXXXXXXX X XX XX XX XX XX XX XX XX XX XX XX X XX XX XX XXXX XX XXXX XX XX XXXX XX XX XX XX XX X XX XX Boom Angle Boom Extension Indicator (arc) XX XX XX XX XX XX XX XX XX XX XX XX XX XX X XXXXXX XX MAX XXXX XX MAX Load center must be equal to or less than value shown. =XXXX XX MAX OU2390 This Capacity Chart may be used with this model ONLY.
Section 5 - Attachments To identify the proper capacity chart on telehandlers equipped with transfer carriage, refer to the following icons which may be located on the load chart. 80" 1" • Use for any forward movement (1 to 80 in) of the transfer carriage. OW0910 0" • Use for no forward movement (0 in) of the transfer carriage. Fully retracted position only.
Section 5 - Attachments Example A contractor owns a model xxxxx telehandler with a fork carriage. He knows this attachment may be used with his model since: • The attachment style, weight, dimensions and load center match the attachment data on the capacity chart. • The capacity chart is clearly marked for model xxxxx and corresponds with machine configuration being used. Below are examples with various conditions the contractor may encounter and whether or not the load may be lifted.
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Section 5 - Attachments 5.6 ATTACHMENT INSTALLATION 1 2 3 6 4 5 OH4430 1. Attachment 2. Attachment Pin Recess 3. Attachment Pin 4. Lock Pin 5. Lock Lever 6. Quick Attach (attachment tilt control in cab, see page 3-12) WARNING CRUSH HAZARD. Always be certain that carriage or attachment is properly positioned on boom and is secured by lock pin and lock lever. Failure to ensure proper installation could permit carriage/attachment/load to disengage.
Section 5 - Attachments This installation procedure is designed for one-person operation. Prior to exiting cab, perform “Shut-Down Procedure” on page 4-4. 1. Tilt quick attach back to provide clearance. Check to be sure lock pin is removed. OH4440 2. Align attachment pin with recess in attachment. Raise boom slightly to engage attachment pin in recess. OH4450 3. Tilt quick attach forward to engage attachment. OH4460 4. Lift lock lever and insert lock pin completely through quick attach.
Section 5 - Attachments Hydraulic Operated Attachment 1. Install attachment (see page 5-10). 2. Lower attachment to ground and perform “Shut-Down Procedure” on page 4-4. 1 OH4480 3. Connect attachment hoses to both auxiliary fittings (1).
Section 5 - Attachments 5.7 ADJUSTING/MOVING FORKS Carriages may have different locations where forks can be positioned. Two different methods can be used for repositioning, depending upon the carriage structure. Note: Apply a light coating of appropriate lubricant to ease sliding of forks or fork bar. To slide forks: 1. Ensure attachment is properly installed. See “Attachment Installation” on page 5-10. 2.
Section 5 - Attachments 5.8 ATTACHMENT OPERATION • Capacities and range limits for the telehandler change depending on the attachment in use. • Separate attachment instructions must be kept in manual holder in cab with this Operation & Safety Manual. An additional copy must be kept with the attachment if it is equipped with a manual holder. • Operations described within this section reference a dual joystick configuration. Refer to page 3-14 if equipped with a single joystick configuration.
Section 5 - Attachments Carriage w/Forks Use Carriage Attachment Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-4. to “Telehandler/ OY0690 2 1 OU2181 The middle joystick (1) controls lift/lower and extend/retract movement of the boom. The front joystick (2) controls fork tilt. • Move joystick back to tilt up. • Move joystick forward to tilt down. Installation Procedure: Refer to “Attachment Installation” on page 5-10.
Section 5 - Attachments Side Tilt Carriage Use Side Tilt Carriage Attachment Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-4. to “Telehandler/ OAL1550 2 1 3 OU2181 The middle joystick (1) controls lift/lower and extend/retract movement of the boom. The front joystick (2) controls fork tilt. • Move joystick back to tilt up. • Move joystick forward to tilt down. To Side Tilt: The button (3) on the front joystick enables carriage side tilt.
Section 5 - Attachments WARNING CRUSH HAZARD. Do not use side tilt to push or pull objects or load. Failure to comply could cause object or load to fall. Operation: • Approach load with forks centered on load and stop telehandler. • Level telehandler before side tilting carriage to engage load. • Side tilt carriage to left or right to align forks with load and engage load. • Raise load slightly and level carriage side to side.
Section 5 - Attachments Swing Carriage Use Swing Carriage Attachment Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-4. to “Telehandler/ OU2150 2 1 3 OU2161 The middle joystick (1) controls lift/lower and extend/retract movement of the boom. The front joystick (2) controls fork tilt. • Move joystick back to tilt up. • Move joystick forward to tilt down. To Swing: The button (3) on the front joystick enables the swing function.
Section 5 - Attachments WARNING CRUSH HAZARD. Always level forks (horizontally) and telehandler frame before swinging load to side. Swinging unlevel forks could cause load to slide off forks. WARNING CRUSH HAZARD. Do not use swing carriage to push or pull objects or load. Failure to comply could cause object or load to fall. WARNING CRUSH HAZARD. Use retaining pin (if equipped) for locking swing frame to fixed frame when carrying loads greater than 5000 lb.
Section 5 - Attachments Dual Fork Positioning Carriage Use Carriage Attachment Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-4. to “Telehandler/ OZ3670 2 1 3 OU2460 The middle joystick (1) controls lift/lower and extend/retract movement of the boom. The front joystick (2) controls fork tilt. • Move joystick back to tilt up. • Move joystick forward to tilt down. To Fork Position: The button (3) on the front joystick enables fork positioning.
Section 5 - Attachments WARNING CRUSH HAZARD. Do not use fork positioning to push or pull objects or load. Failure to comply could cause object or load to fall. Operation: • Travel in accordance with the requirements set forth in Section 1 - General Safety Practices. Equipment Damage Precautions: • Do not use forks as a lever to pry material. Excessive prying forces could damage forks or machine structure. • Do not attempt to lift loads that are attached or connected to another object.
Section 5 - Attachments Mast Carriage Use Mast Carriage Attachment Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-4. to “Telehandler/ OY0580 2 1 3 OU2400 The middle joystick (1) controls lift/lower and extend/retract movement of the boom. The front joystick (2) controls fork tilt. • Move joystick back to tilt up. • Move joystick forward to tilt down. To Raise/Lower Mast: The button (3) on the front joystick enables the raise/lower movement of the mast.
Section 5 - Attachments WARNING CRUSH HAZARD. Do not use mast to push or pull objects or load. Failure to comply could cause object or load to fall. Operation: • Always lower forks fully in mast before engaging load. • To drive with a load, lower forks fully in mast and travel in accordance with the requirements set forth in Section 1 - General Safety Practices. • Use a signal person to assist in positioning of load if necessary. Equipment Damage Precautions: • Do not use forks as a lever to pry material.
Section 5 - Attachments Fork Mounted Hook Use Appropriate Carriage Attachment 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 OU2091 The middle joystick (1) controls lift/lower and extend/retract movement of the boom. The front joystick (2) controls fork tilt. • Move joystick back to tilt up. • Move joystick forward to tilt down.
Section 5 - Attachments 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 Truss Boom Use Appropriate Truss Boom Attachment Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-4. OY0570 to “Telehandler/ Suspend loads in accordance with requirements set forth in Section 1 - General Safety Practices. 2 1 3 OU2141 The middle joystick (1) controls lift/lower and extend/retract movement of the boom. The front joystick (2) controls truss boom tilt. • Move joystick back to tilt up. • Move joystick forward to tilt down.
Section 5 - Attachments 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. Operation: • Weight of rigging must be included as part of total load being lifted.
Section 5 - Attachments Bucket Use Appropriate Bucket Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-4. to “Telehandler/ OZ0730 2 1 OU2111 The middle joystick (1) controls lift/lower and extend/retract movement of the boom. The front joystick (2) controls bucket tilt. • Move joystick back to tilt up. • Move joystick forward to tilt down. Installation Procedure: • Refer to “Attachment Installation” on page 5-10.
Section 5 - Attachments Equipment Damage Precautions • Except for lifting or dumping a load, the boom must be fully retracted for all bucket operations. • Do not corner-load bucket. Distribute material evenly within the bucket. Bucket capacity charts are for evenly distributed loads only. • Do not use bucket as a lever to pry material. Excessive prying forces could damage bucket or machine structure. • Do not attempt to load material which is hard or frozen.
Section 5 - Attachments Grapple Bucket Use Grapple Bucket Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-4. to “Telehandler/ OZ1450 2 1 3 OU2410 The middle joystick (1) controls lift/lower and extend/retract movement of the boom. The front joystick (2) controls grapple bucket tilt. • Move joystick back to tilt up. • Move joystick forward to tilt down. To open/close grapple: The button (3) on the front joystick enables the open/close movement of the grapple.
Section 5 - Attachments Operation: • Raise or lower boom to appropriate height and open grapple for loading material from stockpile. • Align telehandler with face of stockpile and drive slowly and smoothly into pile to load bucket. • Tilt bucket up far enough to retain load, close grapple and back away from pile. • Travel in accordance with requirements set forth in Section 1 - General Safety Practices. • Open grapple and tilt bucket down to dump load.
Section 5 - Attachments Personnel Work Platform Use Appropriate Carriage Attachment Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-4. to “Telehandler/ OY1610 The operator and personnel in platform must read and understand the separate personnel work platform manual prior to installing and using a platform. 2 1 OU2420 The middle joystick (1) controls lift/lower and extend/retract movement of the boom. The front joystick (2) controls platform tilt.
Section 5 - Attachments Preparation and Setup: 1. Ensure the telehandler is on a firm surface and is level. 2. Engage the park brake. Blocking the wheels is also recommended. 3. Level the platform, both side to side (frame level) and front to back (attachment tilt). 4. Keep area under platform free from personnel. 5. When personnel are on platform, the operator must remain seated in cab with personnel in direct line of sight. 6. DO NOT lift or carry persons in a bucket or on forks. WARNING FALL HAZARD.
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Section 6 - Emergency Procedures SECTION 6 - EMERGENCY PROCEDURES 6.1 TOWING A DISABLED PRODUCT The following information assumes the telehandler cannot be moved under its own power. • Before moving the telehandler, read all of the following information to understand options available. Then select the appropriate method. • Machine mounted retrieval devices provide suitable means to attach a tow rope, chain or tow bar only in the event the telehandler becomes stuck or disabled.
Section 6 - Emergency Procedures 6.2 EMERGENCY LOWERING OF BOOM In the event of total loss of engine power or hydraulic pump failure with an elevated load, the situation must be properly evaluated and dealt with on an individual basis. Contact a local Authorized Distributor for specific instructions. Secure the telehandler using the following procedures: 1. Clear the area around telehandler of all personnel. 2. Engage the parking brake. Place the transmission control lever in “NEUTRAL”. 3.
Section 7 - Lubrication and Maintenance SECTION 7 - LUBRICATION AND MAINTENANCE 7.1 INTRODUCTION Service the product in accordance with the maintenance schedule on the following pages. OU2221 1 2 The Maintenance (1) and Lubrication (2) decals contain instructions that must be followed to keep this product in good operating condition. The Operation & Safety Manual and Service Manual contain more detailed service information with specific instructions.
Section 7 - Lubrication and Maintenance 7.2 GENERAL MAINTENANCE INSTRUCTIONS Prior to performing any service or maintenance on the telehandler, follow the shut-down procedure on page 4-4 unless otherwise instructed. Ensure telehandler is level, for proper fluid readings. • Clean lubrication fittings before lubricating. • After greasing telehandler, cycle all functions several times to distribute lubricants. Perform this maintenance procedure without attachment installed.
Section 7 - Lubrication and Maintenance 7.
Section 7 - Lubrication and Maintenance 1st 100, 250 & 1st 500 Hour Maintenance Schedule 1st 100 LB/F T (N m) Change Transmission Oil and Filter Change Transfer Case Oil Change Hydraulic Filters Check Wheel Lug Nut Torque EVERY 250 LB/F T (N m) Change Engine Oil and Filter* (Before S/N 0160041827) Change Air Filter Elements Change Fuel Filter and Strainer (Before S/N 0160041827) Check Wheel Lug Nut Torque Lubricate Boom Extend Chains Check Axle Oil Level Check Wheel End Oil Levels Check Boo
Section 7 - Lubrication and Maintenance 500, 1000 & 2000 Hour Maintenance Schedule EVERY 500 Change Fuel Change Engine Filters Oil and Filter (S/N 0160041827 & After) EVERY 1000 Change Transmission Oil and Filter Change Transfer Case Oil Change Hydraulic Fluid and Filters Change Axle Oil Change Wheel End Oil P Lubricate Boom Retract Chains Check Boom Retract Chains and Tension Check Axle Brake Discs Check Fan Belt EVERY 2000 Change Engine Coolant OU2253 31200354 7-5
Section 7 - Lubrication and Maintenance 7.
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Section 7 - Lubrication and Maintenance 7.5 OPERATOR MAINTENANCE INSTRUCTIONS Fuel System 10 A. Fuel Level Check OW0970 OW0990 1 15 20 10 1/2 F E RPM X 100 25 5 °F 176 140 104 40 60 212 248 80 100 °C 120 D 30 r/min 0000000 3 2 OU2271 1. Check fuel gauge (1) located on instrument panel in cab. 2. If fuel is low, proceed to fuel source and perform “Shut-Down Procedure” on page 4-4. 3. Locate fuel tank (3), turn fuel tank cap (2) and remove from filler neck. 4.
Section 7 - Lubrication and Maintenance 10 B. Drain Fuel/Water Separator OW0970 OW1000 BEFORE S/N 0160041827 EXCLUDING 0160041630 5 4 OU2281 S/N 0160041827 & AFTER INCLUDING 0160041630 OU2480 4 5 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. 4. Tighten drain cock. 5. Close and secure the engine cover.
Section 7 - Lubrication and Maintenance Engine Oil 10 A. Engine Oil Level Check OW0970 BEFORE S/N 0160041827 EXCLUDING 0160041630 OW1020 S/N 0160041827 & AFTER INCLUDING 0160041630 4 4 2 1 3 1 OU2312 1. Perform “Shut-Down Procedure” on page 4-4. 2. Open the 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.
Section 7 - Lubrication and Maintenance Hydraulic Oil 10 A. Hydraulic Oil Level Check OW0970 OW1030 BEFORE S/N 0160041827 EXCLUDING 0160041630 7 5 4108302 6 OU2322 S/N 0160041827 & AFTER INCLUDING 0160041630 7 6 5 OU2470 1. Be sure all cylinders and transfer carriage are fully retracted and machine is level. 2. Perform “Shut-Down Procedure” on page 4-4. 3. Open the engine cover. 4. Check level of hydraulic oil at the sight gauge (6) on the hydraulic tank (5).
Section 7 - Lubrication and Maintenance Engine Cooling System 10 A. Engine Coolant Level Check OW0970 OW1070 Before S/N 0160041827 excluding 0160041630 2 1 OU2301 1. Perform “Shut-Down Procedure” on page 4-4. 2. Open the 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.
Section 7 - Lubrication and Maintenance S/N 0160041827 & After including 0160041630 3 4 OU2490 1. Perform “Shut-Down Procedure” on page 4-4. 2. Open the engine cover. 3. Coolant should be visible in the sight gauge (3). 4. If coolant is low, allow system to cool. Remove radiator cap (4) and add coolant as required. 5. Replace radiator cap. 6. Close and secure the engine cover. Note: When filling coolant, the maximum fill rate is 3.0 gallon per minute (11,4 liter per minute).
Section 7 - Lubrication and Maintenance Tires A. Tire Air Pressure Check 10 OW0970 OW1040 1. Perform “Shut-Down Procedure” on page 4-4. 2. Remove valve stem cap. 3. Check tire pressure. 644E-42 13.00 x 24, G-2/L-2 Bias-Ply Traction - 12 Ply .........................65 psi (4,5 bar) 13.00 x 24, G-3/L-3 Bias Ply Rock - 12 Ply..............................65 psi (4,5 bar) 13.00 x 24, G-2/L-2 Radial - 1 Star ..........................................65 psi (4,5 bar) 370/75-28, 14 Ply.......................
Section 7 - Lubrication and Maintenance C. Tire and Wheel Replacement It is recommended that a replacement tire to be the same size, ply and brand as originally installed. Refer to the appropriate parts manual for ordering information. If not using an approved replacement tire, the replacement tires must have the following characteristics: • Equal or greater ply/load rating and size of original. • Tire tread contact width equal or greater than original.
Section 7 - Lubrication and Maintenance E. Wheel Installation Torque lug nuts before first use and after each wheel removal. Note: If machine is equipped with directional tire assemblies, the wheel and tire assemblies must be installed with the directional tread pattern “arrows” facing in the direction of forward travel. 1. Install wheel lug washers. 2. Start all nuts by hand to prevent cross threading. DO NOT use a lubricant on threads or nuts. 3.
Section 7 - Lubrication and Maintenance Transmission Oil 10 A. Transmission Oil Level Check OW0970 BEFORE S/N 0160041827 EXCLUDING 0160041630 1 OW1050 S/N 0160041827 & AFTER INCLUDING 0160041630 2 T HO LD CO MIN 1 OU2510 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 the engine cover. 4. Remove the transmission dipstick (3) and check oil level.
Section 7 - Lubrication and Maintenance Battery 50 A. Battery Check OW0980 OW1080 Before S/N 0160041827 excluding 0160041630 1 OU2340 1. Perform “Shut-Down Procedure” on page 4-4. 2. Open the engine cover. 3. Rotate upper battery to inspect both batteries (1). 4. Wearing eye protection, visually inspect the batteries. Check terminals for corrosion. Replace battery if it has a cracked, melted or damaged case. 5. Rotate upper battery back. 6. Close and secure the engine cover.
Section 7 - Lubrication and Maintenance S/N 0160041827 & After including 0160041630 2 3 1 OU2520 1. Perform “Shut-Down Procedure” on page 4-4. 2. Remove the battery compartment cover (2). 3. Wearing eye protection, visually inspect the batteries (1). Check terminals for corrosion. Replace battery if it has a cracked, melted or damaged case. 4. Replace and secure the battery compartment cover. 5. Open the engine cover. 6. Check battery jumper post (3) for corrosion. 7. Close and secure the engine cover.
Section 7 - Lubrication and Maintenance Air Intake System 50 A. Air Filter Check OW0980 OW1010 Before S/N 0160041827 excluding 0160041630 4 1 6 5 3 OU2291 2 1. Perform “Shut-Down Procedure” on page 4-4. 2. Open the engine cover. 3. Locate air cleaner (1). 4. Remove dust from vacuator valve (2) by squeezing bottom of valve to allow loose particles to fall out. 5. Close and secure the engine cover. Note: Only remove canister cover to service the elements as restriction indicator indicates.
Section 7 - Lubrication and Maintenance B. Element Change (as restriction indicator indicates) If air filter restriction indicator remains on after start up or illuminates during operation, perform the following: 1. Unlock air cleaner cover (3), turn counterclockwise and remove from air cleaner canister (4). 2. Remove outer primary element (5) 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 S/N 0160041827 & After including 0160041630 1 4 6 5 3 OU2500 2 1. Perform “Shut-Down Procedure” on page 4-4. 2. Open the engine cover. 3. Locate air cleaner (1). 4. Remove dust from vacuator valve (2) by squeezing bottom of valve to allow loose particles to fall out. 5. Close and secure the engine cover. Note: Only remove canister cover to service the elements as restriction indicator indicates.
Section 7 - Lubrication and Maintenance B. Element Change (as restriction indicator indicates) If air filter restriction indicator remains on after start up or illuminates during operation, perform the following: 1. Unlock air cleaner cover (3) and remove from air cleaner canister (4). 2. Remove outer primary element (5) and inspect for damage. Damaged elements should not be reused. 3. Thoroughly clean the interior of the air cleaner canister and vacuator valve. 4.
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Section 8 - Additional Checks SECTION 8 - ADDITIONAL CHECKS 8.1 STABIL-TRAK™ 10 A. Stabil-Trak Indicator Test OW0970 OH4340 Stabil-Trak system operates in three modes. In slow pivot mode the Stabil-Trak slow pivot indicator illuminates. In locked mode the Stabil-Trak lock indicator illuminates. If indicator does not illuminate the test was not performed properly or Stabil-Trak system is not functioning correctly and the test should be stopped immediately.
Section 8 - Additional Checks 5. Depress service brake pedal and lower boom below 40°. 6. Depress service brake pedal (5) and shift transmission into forward. 7. Raise the boom above 40°. 8. Stabil-Trak system locked mode will be activated and indicator (7) will illuminate. 9. Lower boom below 40°. 10. Engage park brake switch (3). 11. Release service brake pedal. 12. Raise the boom above 40°. 13. Stabil-Trak system locked mode will be activated and indicator (7) will illuminate. 14. Lower boom below 40°.
Section 9 - Specifications SECTION 9 - SPECIFICATIONS 9.1 PRODUCT SPECIFICATIONS Capacities Engine Crankcase Oil Capacity with Filter Change Before S/N 0160041827 excluding 0160041630 .................... 10.6 quart (10 liter) S/N 0160041827 & After including 0160041630 ................. 13.5 quart (12.8 liter) Type of Oil ................................................................................................ 15W-40 CH Fuel Tank Capacity ..........................................................
Section 9 - Specifications Axles Differential Housing Capacity 644E-42 Before S/N 0160039830 excluding S/N 0160036724, 0160036811, 0160036907 & 0160037012............................................... 9.5 quart (9,0 liter) S/N 0160039830 & After including S/N 0160036724, 0160036811, 0160036907 & 0160037012 Front Axle ................................................................. 12.5 quart (11,8 liter) Rear Axle ................................................................. 12.
Section 9 - Specifications Tires 644E-42 13.00 x 24, G-2/L-2 Bias Ply Traction - 12 ply Pneumatic......................................................................................65 psi (4,5 bar) Foam .................................................................................Approx 542 lb (246 kg) 13.00 x 24, G-3/L-3 Bias Ply Rock - 12 Ply Pneumatic......................................................................................65 psi (4,5 bar) Foam ...........................................
Section 9 - Specifications Performance Maximum Lift Capacity 644E-42 Transfer Carriage Fully Retracted .......................................6,000 lb (2722 kg) Transfer Carriage Extended ................................................4,000 lb (1814 kg) 944E-42 Transfer Carriage Fully Retracted .......................................9,000 lb (4082 kg) Transfer Carriage Extended ................................................4,500 lb (2041 kg) Maximum Lift Height............................................
Section 9 - Specifications Dimensions Overall Height.................................................................................95.5 in (2426 mm) Overall Width.....................................................................................99 in (2489 mm) Track Width........................................................................................84 in (2134 mm) Wheelbase ......................................................................................
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Index Index A Disengaging a Suspended Load.....4-10 Accessory Control Lever ................ 3-17 Driving Hazards on Slopes ...............1-9 Additional Checks............................. 8-1 Dual Fork Positioning Carriage .......5-20 Adjusting/Moving Forks .................. 5-13 Air Filter .......................................... 7-20 Attachment Tilt Function................. 3-12 Attachments Approved..................................... 5-1 Installation.................................
Index L Leveling Procedure.................... 4-6, 4-9 Lifting Personnel............................... 1-8 Load Falling Hazard ......................... 1-7 Lubrication and Maintenance ........... 7-1 Lubrication Schedule 50 Hour ....................................... 7-6 Service and Maintenance Schedule 10 Hour ........................................7-3 1000 Hour ....................................7-5 1st 100 Hour ................................7-4 1st 500 Hour ................................
Index W Walk-Around Inspection ................. 2-10 Warm-Up Check............................. 2-12 Wheel Installation ........................... 7-16 Wheel Lug Nut.................................. 9-3 Wheel Replacement ....................... 7-15 Windows.........................................
Index 4 31200354
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.
31200354 An Oshkosh Corporation Company JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA Phone: +1-717-485-5161 Customer Support Toll Free: 1-877-554-5438 Fax: +1-717-485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia Phone: +61 265 811 111 Fax: +61 265 810 122 JLG Latino Americana Ltda.