October 1, 2014 - C - Revised pages 5-2, 5-16, 5-26, 9-4 & 9-7.
a31200938
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. 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 material handler:
• This Operation & Maintenance 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.
b31200938
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 safety-related 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, MD21742
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
c31200938
Read This First
OZ4390
D
1001139654 A
S
15 mg/kg
1
Other Publications Available
Service Manual.............................................................................................................................31200940
Parts Manual .................................................................................................................................31200939
Engine Parts Manual ..................................................................................................................31211006
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.
d31200938
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
1.1Hazard Classification System ....................................................................1-1
Safety Alert System and Safety Signal Words...............................1-1
DANGER indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury.
WAR NIN 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 & 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.
1-131200938
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.
1-231200938
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.)
1-331200938
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
1-431200938
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 300 mm (11.8 in) above ground surface or the
boom more than 45°.
• DO NOT exceed walking speed.
1-531200938
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).
• Telehandlers equipped with solid tires should not be used in applications requiring
excessive roading or driving extended distances. In the event an application requires
excessive roading or driving expanded distances, it is recommended to use
telehandlers not equipped with solid tires.
1-631200938
Section 1 - General Safety Practices
OW0130
Load Falling Hazard
• Never suspend load from forks or other parts of carriage weldment. Use only JLG
approved lift points.
• DO NOT burn or drill holes in fork(s).
• Forks must be centered under load and spaced apart as far as possible.
1-731200938
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.
1-831200938
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.
1-931200938
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.
1-1031200938
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.
1-1131200938
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.
1-1231200938
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.
1-1331200938
Section 1 - General Safety Practices
This Page Intentionally Left Blank
1-1431200938
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
FAL L HA ZARD. 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 & Maintenance Manual and AEM Safety
Manual (ANSI only) 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 & Maintenance Manual of each
attachment or accessory installed for specific inspection, operation and maintenance
instructions.
2-131200938
Section 2 - Pre-Operation and Inspection
8. Operational Check - Once the walk-around inspection is complete, perform a warmup 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.
2-231200938
Section 2 - Pre-Operation and Inspection
OZ4360
1001100957
1001100957
8006038
8006038
1706285
1706098
1706098B
8005670
1001139164A
1001139164
AU2105
AU2105
1001138051
(IF EQUIPPED -
GERMANY)
JLG MANUFACTURING EUROPE BVBA
1001138051
HOMOLOGATION NUMBER:
NUMERO DI OMOLOGAZIONE:
GENEHMIGUNGS NUMMER:
NUMERO IDENTIFICAZIONE:
VEHICLE IDENTIFICATION NUMBER:
FAHRZEUG-IDENTIFIZIERUNGS-NUMMER:
ALLOWED TOTAL WEIGHT:
MASSA TOTALEAMMISSIBILE:
ZUL. GESAMTGEWICHT:
HYDRAULSCH ODER PNEUMATISCH GEBREMSTE
ANHAENGELAST:
MASA REMOLCABLE CON FRENADOASISTID:
(HIDRÁULICO-NEUMÁTICO)
YEAR OF MANUFACTURE:
ANNO DI FABRICAZIONE:
BAUJAHR:
AÑO DE FABRICACIÓN:
8008657
8008657B
8005617
20 - 2603207
(GERMANY)
25 - 1001153442
(FRANCE)
20
3700016
8008657
8008657B
8005671
8005671
8005675
8005616
3700016
3700016
8006612
1001121555
(RUSSIA)
MP13
1001121555 A
1001168718A
1001168718
1001139647
ModelYear:
100100YYYA
Model:
Year of Manufacture:
Product Identification Number
Serial Number
Nominal engine power, kW:
Unladen mass:
Maximum capacity:
Maximum capacity at max. Height:
kg
kg
kg
JLG Manufacturing Europe BVBA
Industrieterrein Oude Bunders 1034
Breitwaterstraat 12
3630 Maasmechelen - Belgium
1001139647A
1001173703
(RUSSIA)
VIEW OF ENGINE
COMPART MENT
2.2SAFETY DECALS
Ensure all DANGER, WAR NI NG, CAUTION and instructional decals and proper capacity
charts are legible and in place. Clean and replace as required.
2-331200938
Section 2 - Pre-Operation and Inspection
OZ4370
20 - 2603207
(GERMANY)
25 - 1001153442
(FRANCE)
20
8006612
8006612
8005870
8005870
1001104319
1001158844
1001158844A
8005675
3700016
8008657
8008657B
8005617
8005616
37000163700016
8005671
8005671
8006612
8008657
8008657B
A
1001168718A
1001168718
20 - 2603207
(GERMANY)
25 - 1001153442
(FRANCE)
20
D
1001139654 A
S
15 mg/kg
1001139654
(IF EQUIPPED FOR ULS)
1001102782
L
WA
06
dB
1
1705980
A - 1706753
B - 1706754
C - 1706755
D - 1706756
ABCD
2-431200938
OZ4381
1706209
ONOFF
PP
A
A
B
B
B
A
B
B
B
A
A
A
A
A
C
C
A
A
A
EVERY
C
5
00
5
0
A
5
0
B
3614RS - 1001161264
4017RS - 1001165433
XXX kg MAX
-
XXX mm
XXX mm
XXXX
EN 1459:1998-ANNEX B
8m
9m
10m
11m
12m
13m
14m
o
10
o
20
o
30
o
40
o
50
o
60
o
75
o
0
0m
-1m
1m
2m
3m
4m
5m
6m
7m
0m
1m
2m
3m4m5m
9m 8m
7m
6m
XXX mm
350kg
500kg
750kg
100
0kg
1500kg
2000kg
2500kg
3700kg
A
B
C
D
10
D
50
150
LB
F
T
(m
N
)
50
1001161263
XXXX
XXX
XX
XXXXXX
1001094708B
1001094708
1001158300
3m
1001101895
1001101895
8005670
8005670
Korrekter Bodenabstand von 290-300mm
(ab Unterkante Schaufel)
wird durch rote Linie angezeigt
1001119218
(GERMANY)
1001172172
(LIFT PATTERN)
1001158303
(LOADER PATTERN)
1001158309
1001092878
1001120989A
1001120989
(IF EQUIPPED
WITH CLEARSKY)
VIEW A-A
AA
CAPACITY
CHARTS
B
EN 15830
CHARTS
B
VIEW B-B
Section 2 - Pre-Operation and Inspection
2-531200938
Section 2 - Pre-Operation and Inspection
OZ3892
16
2
3
1
4
5
6
8
9
11
10
12
13
14
15
17
18
7
19
19
20
20
2.3WALK-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 and Lift, Tilt, Extend/Retract, Compensating (Slave) Cylinders
• Check front, top, side and rear wear pads for presence of grease.
• Pivot pins secure; hydraulic hoses undamaged, not leaking.
2-631200938
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