This manual is a very important tool! Keep it with the machine at all times.
The purpose of this manual is to provide owners, users, operators, lessors, and
lessees with the precautions and operating procedures essential for the safe and
proper machine operation for its intended purpose.
Due to continuous product improvements, JLG Industries, Inc. reserves the right to
make specification changes without prior notification. Contact JLG Industries, Inc.
for updated information.
Operator Qualifications
The operator of the machine must not operate the machine until this manual has
been read, training is accomplished and operation of the machine has been
completed under the supervision of an experienced and qualified operator.
Operation within the U.S.A. requires training per OSHA 1910.178.
Operators of this equipment must possess a valid, applicable driver’s license, be in
good physical and mental condition, have normal reflexes and reaction time, good
vision and depth perception and normal hearing. Operator must not be using
medication which could impair abilities nor be under the influence of alcohol or any
other intoxicant during the work shift.
In addition, the operator must read, understand and comply with instructions
contained in the following material furnished with the telehandler:
• This Operation and Safety Manual
• Telehandler Safety Manual (ANSI only)
• All instructional decals and plates
• Any optional equipment instructions furnished
The operator must also read, understand and comply with all applicable Employer,
Industry and Governmental rules, standards and regulations.
Modifications
Modifications to this machine may affect compliance with Industry Standards
and/or Governmental Regulations. Any modification must be approved by
JLG.
b31200743
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. must be notified immediately in all instances where JLG
products have been involved in an accident involving bodily injury or death of
personnel or when damage has occurred to personal property or the JLG product.
FOR:
• Accident Reporting and Product Safety Publications
• Current Owner Updates
• Questions Regarding Product Applications and Safety
• Standards and Regulations Compliance Information
• Questions Regarding Product Modifications
CONTACT:
Product Safety and Reliability Department
JLG Industries, Inc.
13224 Fountainhead Plaza
Hagerstown, MD 21742
USA
In USA:
Toll Free:1-877-JLG-SAFE (1-877-554-7233)
Outside USA:
Phone:+1-717-485-6591
E-mail:
ProductSafety@JLG.com
c31200743
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1
ULTRA LOW
SULFUR DIESEL
FUEL ONLY
S < 15 mg/kg
1001125387 A
OAH2300
Other Publications Available
Service Manual..........................................................................................31200926
Illustrated Parts Manual.............................................................................31200725
Note: The following standards may be referenced in this manual:
ANSI is compliant to ANSI/ITSDF B56.6
AUS is compliant to AS 1418.19
CE is compliant to EN1459
Refer to the machine Serial Number Plate to identify the applicable compliance
standard.
Machine Configuration
Two configurations of each machine are included in this manual. Determine if
machine is equipped with Ultra Low Sulfur Fuel Decal (1) as indicated below.
• If equipped with the Ultra Low Sulfur decal, all specific references to this machine
configuration will be referred to as Ultra Low Sulfur (ULS) from this point forward.
•If not equipped with the Ultra Low Sulfur decal, all specific references to this
machine configuration will be referred to as Low Sulfur (LS) from this point
forward.
d31200743
Table of Contents
TABLE OF CONTENTS
Revision Log
Read This First
Operator Qualifications ...................................................... b
Modifications ...................................................................... b
Other Publications Available .............................................. d
Machine Configuration ....................................................... d
Table of Contents
Section 1 - General Safety Practices
1.1 Hazard Classification System ..............................................1-1
Safety Alert System and Safety Signal Words................1-1
1.2 General Precautions ............................................................1-1
DANGER indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
WARNIN G indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION indicates a potentiality hazardous situation which, if not avoided, may
result in minor or moderate injury.
1.2GENERAL PRECAUTIONS
WARNING
Before operation, read and understand this manual. Failure to comply with the
safety precautions listed in this manual could result in machine damage, property
damage, personal injury or death.
1-131200743
Section 1 - General Safety Practices
OW0040
10 FT
(3 M)
1.3OPERATION SAFETY
Note: The manufacturer has no direct control over machine application and
operation. Therefore, safety issues listed in this manual are non-exhaustive. The
user and operator are responsible for conforming with good safety practices.
Electrical Hazards
• 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.
• Follow employer, local and governmental regulations for clearance from
powerlines.
1-231200743
Section 1 - General Safety Practices
OW0050
OW0080
OW0100
4 FT
(1,2 M)
Tip Over Hazard
General
• For additional load requirements, refer to the appropriate capacity chart.
• 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.
• DO NOT raise boom unless frame is level (0 degrees), unless otherwise noted
on capacity chart.
• DO NOT level machine with boom/attachment above 4 ft (1,2 m).
(AUS - DO NOT level machine with load more than 11.8 in (300 mm) above
ground surface.)
1-331200743
Section 1 - General Safety Practices
OH2291
OH20911
OH2221
• 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.
• Always wear the seat belt.
• Keep head, arms, hands, legs and all other body parts inside operator’s cab at all
times.
If the telehandler starts to tip over:
• DO NOT JUMP
• BRACE YOURSELF and STAY WITH THE MACHINE
• KEEP YOUR SEAT BELT FASTENED
• HOLD ON FIRMLY
• LEAN AWAY FROM THE POINT OF IMPACT
1-431200743
Non-Suspended Load
OW0060
O
W0150
• DO NOT drive with boom raised.
Suspended Load
Section 1 - General Safety Practices
• 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.
• Never drag the load; lift vertically.
When driving with a suspended load:
• Start, travel, turn and stop slowly to prevent load from swinging.
• DO NOT extend boom.
• DO NOT raise the load more than 11.8 in (300 mm) above ground surface or
the boom more than 45°.
• DO NOT exceed walking speed.
1-531200743
Section 1 - General Safety Practices
OAL2030
2-Wheel Front Steer4-Wheel Circle Steer4-Wheel Crab Steer
Travel Hazard
• 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.
• Ensure that adequate clearance is provided for both rear tail swing and front fork
swing.
• Look out for and avoid other personnel, machinery and vehicles in the area. Use
a spotter if you DO NOT have a clear view.
• Before moving be sure of a clear path and sound horn.
• When driving, retract boom and keep boom/attachment as low as possible while
maintaining visibility of mirrors and maximum visibility of path of travel.
• Always look in the direction of travel.
• Always check boom clearances carefully before driving underneath overhead
obstructions. Position attachment/load to clear obstacles.
• When driving in high speed, use only front wheel steer (if steering modes are
selectable).
1-631200743
Section 1 - General Safety Practices
OW0130
Load Falling Hazard
• 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.
1-731200743
Section 1 - General Safety Practices
OW0170
O
W0190
Lifting Personnel
• When lifting personnel, USE ONLY an approved personnel work platform, with
proper capacity chart displayed in the cab.
• DO NOT drive machine from cab when personnel are in platform.
1-831200743
Section 1 - General Safety Practices
OW0200
Driving Hazards on Slopes
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. DO NOT shift into neutral and coast downhill.
• Avoid excessively steep slopes or unstable surfaces. To avoid tip over DO NOT
drive across excessively steep slopes under any circumstances.
• Avoid turning on a slope. Never engage “inching” or shift to “Neutral” when going
downhill.
• DO NOT park on a slope.
1-931200743
Section 1 - General Safety Practices
OW0210
OW0220
O
W0230
Pinch Points and Crush Hazards
Stay clear of pinch points and rotating parts on the telehandler.
• Stay clear of moving parts while engine is running.
• Keep clear of steering tires and frame or other objects.
• Keep clear from under boom.
1-1031200743
Section 1 - General Safety Practices
OW0240
OW0250
OW0260
OW0960
• Keep clear of boom holes.
• Keep arms and hands clear of attachment tilt cylinder.
• Keep hands and fingers clear of carriage and forks.
• Keep others away while operating.
1-1131200743
Section 1 - General Safety Practices
OW0280
OW0290
Fall Hazard
• Enter using the proper hand holds and steps provided. Always maintain 3-point
contact when mounting or dismounting. Never grab control levers or steering
wheel when mounting or dismounting the machine.
• DO NOT get off the machine until the shutdown procedure on page 4-4 has been
performed.
• DO NOT carry riders. Riders could fall off machine causing death or serious
injury.
1-1231200743
Section 1 - General Safety Practices
OW0300
OW0950
Chemical Hazards
Exhaust Fumes
• DO NOT operate machine in an enclosed area without proper ventilation.
• DO NOT operate the machine in hazardous environments unless approved for
that purpose by JLG and site owner. Sparks from the electrical system and the
engine exhaust can cause an explosion.
Flammable Fuel
• DO NOT fill the fuel tank or service the fuel system near an open flame, sparks
or smoking materials. Engine fuel is flammable and can cause a fire and/or
explosion.
Hydraulic Fluid
• DO NOT attempt to repair or tighten any hydraulic hoses or fittings while the
engine is running or when the hydraulic system is under pressure.
• Stop engine and relieve trapped pressure. Fluid in the hydraulic system is under
enough pressure that it can penetrate the skin.
• DO NOT use your hand to check for leaks. Use a piece of cardboard or paper to
search for leaks. Wear gloves to protect hands from spraying fluid.
1-1331200743
Section 1 - General Safety Practices
This Page Intentionally Left Blank
1-1431200743
Section 2 - Pre-Operation and Inspection
OAH1000
PARENT METAL CRACKWELD CRACK
SECTION 2 - PRE-OPERATION AND INSPECTION
2.1PRE-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 & inspection, performed at beginning of each work shift or
at each change of operator, should include the following:
1. Cleanliness - Check all surfaces for leakage (oil, fuel or battery fluid) or foreign
objects. Report any leakage to the proper maintenance personnel.
2. Structure - Inspect the machine structure for dents, damage, weld or parent
metal cracks or other discrepancies.
3. Safety Decals - Ensure all safety decals are legible and in place. Clean or
replace as required. See page 2-4 for details.
4. Operation and Safety Manuals - Operation & Safety Manual and AEM Safety
Manual (ANSI only) are located in cab manual holder.
5. Walk-Around Inspection - See page 2-10 for details.
6. Fluid Levels - Check fluids, including fuel, brake fluid, hydraulic oil, engine oil
and coolant. When adding fluids, refer to Section 7 - Lubrication and
Maintenance and Section 9 - Specifications to determine proper type and
intervals. Before removing filler caps or fill plugs, wipe all dirt and grease away
from the ports. If dirt enters these ports, it can severely reduce component life.
7. Attachments/Accessories - Ensure correct capacity charts are installed on the
telehandler. If provided, reference the Operation & Safety Manual of each
attachment or accessory installed for specific inspection, operation and
maintenance instructions.
2-131200743
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. Determine cause and
correct before continued use.
2-231200743
Section 2 - Pre-Operation and Inspection
This Page Intentionally Left Blank
2-331200743
Section 2 - Pre-Operation and Inspection
OAH2231
8005870C
8005870
1701500
1701500
1706302
1702300
1702300
4100181
4100181
1706301A
1706301
1001139578
1706301A
1706301
(in engine
compartment)
1001081395
2.2SAFETY DECALS
Ensure all DANGER, WARNING, CAUTION and instructional decals and proper
capacity charts are legible and in place. Clean and replace as required.
ANSI (G5-18A, if equipped)
2-431200743
Section 2 - Pre-Operation and Inspection
OAH2241
B
A
B C D E
A
1001099783
-10
0
10
20
30
40
50
60
7
0
8
0
4105262
1702300
1702300
1701500
1701500
1706302
1706768
91563220
91563220 REV A
1001125387
ULTRA LOW
SULFUR DIESEL
FUEL ONLY
S < 15 mg/kg
1001125387 A
1706300
1706300C
1706302
1706298A
1706298
1701500
1701500
1702300
1702300
A
A
2-531200743
Section 2 - Pre-Operation and Inspection
OAL3830
1706299A
CONTACTING
POWERLINES
willresult in death
orserious injury.
1706299
1706850A
CRUSHING HAZARD
Keepothers
awaywhile
operating.
Loweringboom or falling load could
causedeath or serious injury.
WARNING
1706850
1001101071B
1001101071
1706296
1001156576
Fasten
seat
belt.
1706303A
Operatormust be trained and
mustread and understand
allcapacity charts, operator
andsafety manuals.
1706303
1706306A
1706306
1706851A
1706851
1706304A
RUN-OVER
HAZARD
couldcause
deathor
serious
injury.
1706304
Axle Trunnions
Axle Kingpins (Both Axles)
Boom Pivot
Tilt Cylinder &
Carriage Pivot
1001100107
1001146038
D
50
10
50
D
250
1
2
3
4
5
XXXXX
XXX
1706767A
1706767
1001156577
(behind chart plate)
VIEW A-A
VIEW OF BATTERY COVER
CAPACITY
CHARTS
2-631200743
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