JLG 266 Operator Manual

Operation & Safety

An Oshkosh Corporation Company

Manual

Original Instructions

Keep this manual with machine at all times.

Models

266, 307

266 LoPro

3126023

Revised

August 28, 2012

Revision Log

January 14, 2005 - A - Original Issue of Manual

June 10, 2005 - B - Revised pages 2-6, 2-8, 2-9, 2-18, 4-12 thru 4-14, 4-16, 4-18, 4-20, 4-22, 6-2, 6-3, 6-6 thru 6-8, 6-10, 6-12 thru 6-15, 7-1 & 8-1.

December 7, 2005 - C - Revised Manual to add 266 LoPro.

August 30, 2006 - D - Revised pages 2-2, 2-29, 2-30, 4-11, 4-12, 6-14, 8-2 & 8-3.

January 29, 2008 - E - Revised pages 2-4, 2-5, 2-26, 4-10 & 4-22, added pages 4-27, 4-28. Revised Hazard Classification signal box colors to standard black.

April 17, 2008 - F - Added pages 5-6 & 5-7. Reformat manual sections. Added “CE” and “AUS” marking to pages 5-14 thru 5-32. Revised pages 1-4, 1-10, 2-3, 3-2, 3-12 thru 3-16, 3-19, 3-20, 4-4 thru 4-6, 5-12, 5-29 & 9-2.

May 23, 2008 - G - Revised pages c, d, 1-4, 2-3, 4-5, 4-8, 5-4, 5-5, 5-12, 5-14, 5-18, 5-20, 5-22, 5-23, 5-24, 5-26, 9-2, & 9-3.

April 27, 2011 - H - Revised covers and pages b, c, d, 1-1 thru 1-13, 2-1, 2-6 thru 2-9, 3-3, 3-7, 3-8, 3-11, 3-13, 3-14, 3-16, 3-18, 3-19, 3-20, 4-1, 4-2, 4-4, 4-7, 4-11, 5-1, 5-2, 5-4, 5-5, 5-7, 5-12, 5-15, 5-20, 5-28, 7-1, 7-2, 7-15 & 7-17.

August 28, 2012 - I - Revised page 5-16.

REVISION LOG

a3126023

Read This First

This manual is a very important tool! Keep it with the machine at all times.

The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and operating procedures essential for the safe and proper machine operation for its intended purpose.

Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without prior notification. Contact JLG Industries, Inc. for updated information.

Operator Qualifications

The operator of the machine must not operate the machine until this manual has been read, training 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 & Safety Manual

• Telehandler Safety Manual (as required)

• All instructional decals and plates

• Any optional equipment instructions furnished

The operator must also read, understand and comply with all applicable Employer, Industry and Governmental rules, standards and regulations.

Modifications

Any modification to this machine must be approved by JLG.

b 3126023

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

or Your Local JLG Office (Addresses on back cover)

In USA

Toll Free: 1-877-JLG-SAFE (1-877-554-7233)

Outside USA

Phone: +1-717-485-6591

E-mail

ProductSafety@JLG.com

c3126023

Read This First

Other Publications Available

Service Manual............................................................................................3126024

Illustrated Parts Manual...............................................................................3126025

Load Management Indicator System Operation & Safety

Manual (if equipped)..............................................................................Contact JLG

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.

d 3126023

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 ..............................................1-1

Safety Alert System and Safety Signal Words................ 1-1

1.2 General Precautions ............................................................1-1

1.3 Operation Safety ..................................................................1-2

Electrical Hazards ...........................................................1-2

Tip Over Hazard..............................................................1-3

Travel Hazard ................................................................. 1-6

Load Falling Hazard ........................................................1-7

Lifting Personnel .............................................................1-8

Driving Hazards on Slopes .............................................1-9

Pinch Points and Crush Hazards ..................................1-10

Fall Hazard....................................................................1-12

Chemical Hazards.........................................................1-13

Table of Contents

Section 2 - Pre-Operation And Inspection

2.1 Pre-Operation Checks and Inspection .................................2-1

2.2 Safety Decals.......................................................................2-3

2.3 Walk-Around Inspection.......................................................2-6

2.4 Warm-Up and Operational Checks ......................................2-8

Warm-Up Check ............................................................. 2-8

Operational Check .......................................................... 2-8

2.5 Operator Cab .......................................................................2-9

2.6 Windows ............................................................................2-10

Cab Door Window .........................................................2-10

Rear Window ................................................................2-10

Section 3 - Controls And Indicators

3.1 General ................................................................................3-1

3.2 Controls ...............................................................................3-2

Instrument Panel .............................................................3-4

Ignition ............................................................................ 3-6

Park Brake ......................................................................3-7

Parking Procedure ..........................................................3-7

Transmission Control ......................................................3-8

Wiper, Lights and Turn Signal Control Lever ................3-10

i3126023

Table of Contents

Steering Column Adjuster............................................. 3-11

Joystick......................................................................... 3-12

Load Stability Indicator (LSI) ........................................ 3-18

Control and Indicator Console ...................................... 3-19

Heater and Air Conditioner (If Equipped) Controls ....... 3-21

3.3 Steer Modes ...................................................................... 3-22

3.4 Operator Seat.................................................................... 3-23

Adjustments.................................................................. 3-23

Seat Belt ....................................................................... 3-25

3.5 Boom Angle and Extension Indicators .............................. 3-26

Section 4 - Operation

4.1 Engine ................................................................................. 4-1

Starting the Engine ......................................................... 4-1

Battery Boosted Starting................................................. 4-2

Normal Engine Operation ............................................... 4-3

Shut-Down Procedure .................................................... 4-3

4.2 Operating with a Non-Suspended Load .............................. 4-4

Lift Load Safely............................................................... 4-4

Picking Up a Load .......................................................... 4-4

Transporting the Load .................................................... 4-5

Leveling Procedure......................................................... 4-5

Placing the Load............................................................. 4-6

Disengaging the Load..................................................... 4-6

4.3 Operating with a Suspended Load ...................................... 4-7

Lift Load Safely............................................................... 4-7

Picking Up a Suspended Load ....................................... 4-7

Transporting a Suspended Load .................................... 4-8

Leveling Procedure......................................................... 4-8

Placing a Suspended Load............................................. 4-9

Disengaging a Suspended Load .................................... 4-9

4.4 Road Operation ................................................................. 4-10

4.5 Loading and Securing for Transport .................................. 4-11

Tiedown ........................................................................ 4-11

Lifting ............................................................................ 4-12

Section 5 - Attachments and Hitches

5.1 Approved Attachments ........................................................ 5-1

5.2 Unapproved Attachments.................................................... 5-1

5.3 Telehandler/Attachment/Fork Capacity ............................... 5-2

5.4 Use of the Capacity Chart ................................................... 5-3

Capacity Indicator Locations .......................................... 5-3

Sample Capacity Chart (CE) .......................................... 5-4

Sample Capacity Chart (AUS) ........................................ 5-5

Example.......................................................................... 5-6

ii 3126023

5.5 Attachment Installation ........................................................ 5-7

Mechanical Quick-Switch Device ....................................5-8

Hydraulic Quick-Switch Device .......................................5-9

Hydraulic Operated Attachment ....................................5-10

5.6 Adjusting/Moving Forks......................................................5-11

5.7 Attachment Operation ........................................................5-11

Carriage w/Forks...........................................................5-12

Truss Boom...................................................................5-13

Side Shift Carriage ........................................................5-14

Bucket ...........................................................................5-16

Manure Bucket ..............................................................5-18

Fork Extension ..............................................................5-20

Fork Mounted Hook ......................................................5-22

Round Tine Bale ........................................................... 5-23

Bale Handler .................................................................5-24

Concrete Ladle..............................................................5-26

5.8 Hitches...............................................................................5-28

Mechanical Hitch (CE) ..................................................5-28

Hydraulic Hitch (CE) .....................................................5-28

Section 6 - Emergency Procedures

6.1 Towing a Disabled Product ..................................................6-1

Moving Short Distances ..................................................6-1

Moving Longer Distances ............................................... 6-1

6.2 Emergency Lowering of Boom.............................................6-2

Electronic Control Unit Failure ........................................ 6-2

Engine Failure .................................................................6-3

6.3 Cab Emergency exit ............................................................ 6-4

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 Schedule .................................... 7-3

8 & 1st 50 Hour Maintenance Schedule .........................7-3

50, 250 & 500 Hour Maintenance Schedule ...................7-4

1000 & 1500 Hour Maintenance Schedule .....................7-5

7.4 Lubrication Schedules ......................................................... 7-6

8 Hour Lubrication Schedule...........................................7-6

50 Hour Lubrication Schedule.........................................7-7

7.5 Operator Maintenance Instructions......................................7-8

Fuel System ....................................................................7-8

Air Intake System ..........................................................7-10

Engine Oil ..................................................................... 7-12

Hydraulic Oil..................................................................7-13

iii3126023

Table of Contents

Tires.............................................................................. 7-14

Brake System ............................................................... 7-16

Engine Cooling System ................................................ 7-17

Battery .......................................................................... 7-18

Section 8 - Additional Checks

8.1 General................................................................................ 8-1

8.2 Load Stability Indicator Test................................................ 8-1

Section 9 - Specifications

9.1 Product Specifications......................................................... 9-1

Fluid and Lubrication Capacities .................................... 9-1

Tires................................................................................ 9-2

Performance ................................................................... 9-3

Dimensions..................................................................... 9-4

Noise Emission Level ..................................................... 9-5

Telehandler Vibration ..................................................... 9-5

Index

Inspection, Maintenance and Repair Log

iv 3126023

Section 1 - General Safety Practices

DANGER

OW0010

WARNING

OW0021

CAUTION

OW0031

SECTION 1 - GENERAL SAFETY PRACTICES

1.1 HAZARD CLASSIFICATION SYSTEM

Safety Alert System and Safety Signal Words

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.

1.2 GENERAL 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.

1-13126023

Section 1 - General Safety Practices

OW0040

10 FT

(3 M)

1.3 OPERATION SAFETY

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.

1-2 3126023

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 1,2 m (4 ft). (AUS - DO NOT level machine with load more than 300 mm (11.8 in) above ground surface.)

1-33126023

Section 1 - General Safety Practices

OH2291

20911

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

1-4 3126023

Non-Suspended Load

OW0060

OW0150

• DO NOT drive with boom raised.

Suspended Load

Section 1 - General Safety Practices

• Tether suspended loads to restrict movement.

• DO NOT raise the load more than 300 mm (11.8 in) above ground surface or the boom more than 45°.

• Weight of all rigging (slings, etc.) must be included as part of load.

• Start, travel, turn and stop slowly to prevent load from swinging.

• When driving with the boom raised, DO NOT exceed walking speed.

• Beware of wind. Wind can cause a suspended load to swing and cause dangerous side loads - even with tag lines.

• DO NOT attempt to use telehandler frame-leveling to compensate for load swing.

• Keep heavy part of load closest to attachment.

• Never drag the load; lift vertically.

1-53126023

Section 1 - General Safety Practices

OAL2030

2-Wheel Front Steer 4-Wheel Circle Steer 4-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).

1-6 3126023

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.

1-73126023

Section 1 - General Safety Practices

OW0170

OW0190

Lifting Personnel

• When lifting personnel, USE ONLY a JLG approved personnel work platform, with proper capacity chart displayed in the cab.

• DO NOT drive machine from cab when personnel are in platform.

1-8 3126023

Section 1 - General Safety Practices

OW0200

Driving Hazards on Slopes

To maintain sufficient traction and braking capabilities, travel on slopes as follows:

• When unloaded, the rear of the machine is the “heavy end.” Drive with forks pointed downhill.

• When loaded, the front of the machine is the “heavy end.” Drive with the forks pointed uphill.

• For additional travel requirements, refer to the appropriate capacity chart.

• To avoid overspeeding the engine and drivetrain when 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.

1-93126023

Section 1 - General Safety Practices

OW0210

OW0220

OW0230

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.

1-10 3126023

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.

1-113126023

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 4-3 has been performed.

• DO NOT carry riders. Riders could fall off machine causing death or serious injury.

1-12 3126023

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.

• If spark arrestors are required, ensure they are in place and in good working order.

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.

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Section 1 - General Safety Practices

This Page Intentionally Left Blank

1-14 3126023

Section 2 - Pre-Operation And Inspection

OAH1000

PARENT METAL CRACK WELD CRACK

SECTION 2 - PRE-OPERATION AND INSPECTION

2.1 PRE-OPERATION CHECKS 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. 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 2-3 for details.

4. Operation and Safety Manuals - Operation & Safety Manual and AEM Safety Manual (as required) are located in cab manual holder.

5. Walk-Around Inspection - See page 2-6 for details.

6. Fluid Levels - Check fluids, including fuel, hydraulic oil, engine oil and coolant. When adding fluids, refer to Section 7 - Lubrication and Maintenance and Section 9 - Specifications to determine proper type and intervals. Before removing filler caps or fill plugs, wipe all dirt and grease away from the ports. If dirt enters these ports, it can severely reduce component life.

7. Attachments/Accessories - Ensure correct 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.

2-13126023

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. Determine cause and correct before continued use.

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Section 2 - Pre-Operation And Inspection

OAH0134

8005869

8009816

8006038

8005616

8005617

8005616

8005617

8005670

8003198

8005675

8003198

8005617

8008657

1706227 (CE)

1001102513 (AUS)

VIEW OF FRONT OF ENGINE POD

VIEW OF ENGINE

COMPARTMENT

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.

2-33126023

Section 2 - Pre-Operation And Inspection

3931579

OAH0143

8005616

8009377

(optional)

8009377

(optional)

8003198

8005616

8005675

8008657

8005671

266 LoPro

Location

8006612

8009815

8003198

8005617

8005671

8003198

8005617

2-4 3126023

Safety Decals 3

OAH0444

8005671

8005670

8005671

8008613

2447967

8005674

8005672

8008651

OIL

ATF

Dexron

2447 967

8005673

EN 1459 B (1998)

4017

P/N 4802111

P/N 8008014

P/N 1170001

P/N 2340029

g 2

0°

10°

20°

30°

40°

50°

60°

70°

876543210

8008746 B

EN 1459 B (1998)

4017

P/N 4802111

P/N 8008014

P/N 1170001

P/N 2340029

4.000kg

3.500kg

3.000kg

2.500kg

2.000kg

1.500kg

1.000kg

500kg

750kg

400kg

0°

10°

20°

30°

40°

50°

60°

70°

876543210

2 0

0 0

k g

1706463

8005870

Indicator

Load Moment

100

TEST

8008805

1706209

1705980

1706711

1706710

LOAD

CHARTS

Before S/N

1160001327

S/N

1160001327 & After

8008613

Loader Pattern

Lift

Pattern

VIEW OF

REAR WINDOW

VIEW OF LOAD

STABILITY INDICATOR

VIEW OF PARK BRAKE LEVER

Section 2 - Pre-Operation And Inspection

2-53126023

Section 2 - Pre-Operation And Inspection

OAH0123

2.3 WALK-AROUND INSPECTION

Begin your walk-around inspection at item 1, as noted below. Continue to your right (counterclockwise when viewed from top) checking each item in sequence.

INSPECTION NOTE: On all components, make sure there are no loose or missing parts, that they are securely fastened and no visible leaks or excessive wear exists in addition to any other criteria mentioned. Inspect all structural members including attachment for cracks, excessive corrosion and other damage.

1. Boom Sections & Lift, Tilt, Extend/Retract, Compensating (Slave) Cylinders

• Check front, top, side and rear slider pads for presence of grease.

• Pivot pins secure; hydraulic hoses undamaged, not leaking.

2. Front Axle undamaged, not leaking.

3. Wheel/Tire Assembly nuts. Inspect for worn tread, cuts, tears or other discrepancies.

- Steer cylinders undamaged, not leaking; hydraulic hoses

- Properly inflated and secured; no loose or missing lug

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