JLG 534D-9 Operator Manual

Operation & Safety

Manual

Keep this manual with machine at all times.

Models 534D-9

534D-10

S/N 0160003966 & After

31200169

Revised

January 14, 2009

An Oshkosh Corporation Company

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

January 8, 2007 - A - Original Issue of Manual

May 1, 2008 - B - Revised manual and added Tier III engine information.

November 25, 2008 - C - Revised covers.

January 14, 2009 - C - Revised manual.

REVISION LOG

a31200169

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 31200169

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

c31200169

Read This First

Other Publications Available

Service Manual..........................................................................................31200170

Illustrated Parts Manual.............................................................................91344005

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 31200169

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 Check 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 (if equipped)....................................2-10

Section 3 - Controls and Indicators

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

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

Dash Controls and Indicators.......................................... 3-3

Ignition ............................................................................3-5

Park Brake ......................................................................3-6

Parking Procedure ..........................................................3-6

Transmission Control Lever ............................................3-7

Boom Joystick .................................................................3-8

Right Hand Levers (if equipped) .....................................3-9

i31200169

Table of Contents

Outrigger Levers (534D-10).......................................... 3-10

Left Hand Lever (if equipped) ....................................... 3-11

Heater (if equipped)...................................................... 3-12

3.3 Operator Seat.................................................................... 3-13

Adjustments.................................................................. 3-13

Seat Belt ....................................................................... 3-15

3.4 Boom Angle and Extension Indicators .............................. 3-16

Section 4 - Operation

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

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

Cold Weather Starting Aids ............................................ 4-2

Battery Boosted Starting................................................. 4-3

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

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

4.2 Operating with a Non-Suspended Load .............................. 4-5

Lift Load Safely............................................................... 4-5

Picking Up a Load .......................................................... 4-5

Transporting a Load ....................................................... 4-6

Leveling Procedure......................................................... 4-6

Placing a Load................................................................ 4-7

Disengaging a Load........................................................ 4-7

4.3 Operating with a Suspended Load ...................................... 4-8

Lift Load Safely............................................................... 4-8

Picking Up a Suspended Load ....................................... 4-8

Transporting a Suspended Load .................................... 4-9

Leveling Procedure......................................................... 4-9

Placing a Suspended Load........................................... 4-10

Disengaging a Suspended Load .................................. 4-10

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

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

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

Section 5 - Attachments

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

5.2 Unapproved Attachments.................................................... 5-2

5.3 Telehandler/Attachment/Fork Capacity ............................... 5-3

5.4 Use of the Capacity Chart ................................................... 5-4

Capacity Indicator Locations .......................................... 5-4

Sample Capacity Chart................................................... 5-6

Example........................................................................ 5-10

5.5 Attachment Installation ...................................................... 5-11

Hydraulic Operated Attachment ................................... 5-14

5.6 Adjusting/Moving Forks ..................................................... 5-15

ii 31200169

5.7 Attachment Operation........................................................5-16

Carriage w/Forks........................................................... 5-18

Side Tilt Carriage ..........................................................5-20

Swing Carriage .............................................................5-22

Mast Carriage ...............................................................5-24

Mast Carriage w/Swing and Side Shift

(Before S/N 0160037689) .............................................5-26

Mast Carriage w/Side Tilt (S/N 0160037689 & After) ... 5-28

Fork Mounted Hook (Before S/N 0160037689) ............ 5-30

Fork Mounted Hook (S/N 0160037689 & After) ............ 5-32

Truss Boom...................................................................5-34

Bucket ...........................................................................5-36

Grapple Bucket (S/N 0160037689 & After) ...................5-38

Boom Head-Mounted Winch

(Before S/N 0160037689) .............................................5-40

Personnel Work Platform (Before S/N 0160037689) ....5-41

Personnel Work Platform (S/N 0160037689 & After).... 5-42

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

6.3 Emergency Exit from Enclosed Cab ....................................6-2

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

10 & 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

50 Hour Lubrication Schedule.........................................7-6

250 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

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

Hydraulic Return Filter ..................................................7-17

Engine Cooling System................................................. 7-18

Battery........................................................................... 7-19

iii31200169

Table of Contents

Section 8 - Additional Checks

Section 9 - Specifications

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

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

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

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

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

Index

Inspection, Maintenance and Repair Log

iv 31200169

Section 1 - General Safety Practices

SECTION 1 - GENERAL SAFETY PRACTICES

1.1 HAZARD CLASSIFICATION SYSTEM

Safety Alert System and Safety Signal Words

DANGER

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

CAUTION indicates a potentiality hazardous situation which, if not avoided, may result in minor or moderate injury.

OW0010

OW0021

OW0031

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.

1-131200169

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.

• Follow employer, local and governmental regulations for clearance from powerlines.

1-2 31200169

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.

OW0080

• DO NOT raise boom unless frame is level (0 degrees), unless otherwise noted on capacity chart.

4 FT

(1,2 M)

OW0100

• 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.)

1-331200169

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.

OH2221

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 31200169

Non-Suspended Load

• DO NOT drive with boom raised.

Suspended Load

Section 1 - General Safety Practices

OW0060

OW0150

• Tether suspended loads to restrict movement.

• DO NOT raise the load more than 11.8 in (300 mm) 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.

1-531200169

Section 1 - General Safety Practices

Travel Hazard

PIVOT STEER

OX0650

• Steering characteristics differ between steer modes. Identify the steer mode settings of the telehandler being operated.

• Ensure that adequate clearance is provided between 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 31200169

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.

1-731200169

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.

1-8 31200169

Section 1 - General Safety Practices

Driving Hazards on Slopes

OW0200

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.

1-931200169

Section 1 - General Safety Practices

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.

OW0220

• Keep clear of steering tires and frame or other objects.

OW0210

OW0230

• Keep clear from under boom.

1-10 31200169

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.

1-1131200169

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 4-4 has been performed.

OW0290

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

1-12 31200169

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.

Flammable Fuel

OW0300

• 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

OW0950

• 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.

1-1331200169

Section 1 - General Safety Practices

This Page Intentionally Left Blank

1-14 31200169

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. 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.

OAH1000

PARENT METAL CRACK WELD CRACK

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.

2-131200169

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.

2-2 31200169

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.

NT RO

Model

Year of Manufacture

Serial Number

Maximim Capacity (lbs/kg)*

Maximum Weight Without Attachments (lbs/kg)

Refer to load capacity chart for truck with attachment, and individual load ratings stamped on forks, if equipped. Use lowest capacity of all rattings.

As released from factory this truck meets design specifications in ASME B56.6-2002 Part III

One or more of the following patents may apply to this truck: U.S. Nos. 4,954,041 6,349,969 5,639,119 5,813,697 5,230,399 5,052,532. Other patents pending.

1705882 Manufactured by JLG Industries Inc. McConnellsburg, PA

(S/N 0160003966

thru 0160034816)

17233-9533 USA

1705882

1705881

(S/N 0160034838

& After)

NO RIDERS PERMITTED ON HANDLER.

OPERATOR ONLY IN MACHINE

WHILE RUNNING.

RIDERS COULD FALL OFF MACHINE

CAUSING SERIOUS INJURY OR DEATH.

91143283

9114-3283

STAY CLEAR OF PINCH POINT AREA

ANYTIME ENGINE IS RUNNING. BEING IN PINCH POINT AREA COULD CAUSE SERIOUS INJURY OR DEATH.

91143282

91303047

9114-3282

THE PROTECTION OFFERED BY THIS ROPS WILL BE IMPAIRED IF IT HAS BEEN SUBJECTED TO ANY MODIFICATION, STRUCTURAL DAMAGE, OR HAS BEEN INVOLVED IN AN OVERTURN INCIDENT. THIS ROPS MUST BE REPLACED AFTER A ROLL OVER. SEAT BELTS MUST BE WORN WHILE OPERATING VEHICLE.

000850

91164094

90553027

READ AND UNDERSTAND THE FOLLOWING PRIOR TO LIFTING PERSONNEL.

WHEN LIFTING PERSONNEL USE ONLY A GRADALL MANUFACTURED PERSONNEL WORK PLATFORM.

DO NOT DRIVE MACHINE WITH PERSONNEL IN PLATFORM.

WHEN PERSONNEL ARE IN PLATFORM REMAIN SEATED IN CAB WITH PERSONNEL

OPERATE CONTROLS LIGHTLY AND CAUTIOUSLY WHEN LIFTING PERSONNEL.

READ AND UNDERSTAND PERSONNEL WORK PLATFORM USER'S MANUAL BEFORE LIFTING PERSONNEL.

DO NOT USE PERSONNEL WORK PLATFORM WITHOUT THE PROPER GRADALL MATERIAL

HANDLER/PERSONNEL WORK PLATFORM CAPACITY CHART DISPLAYED IN CAB.

FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY OR DEATH.

O R F

IN DIRECT LINE OF SIGHT.

91343073

JLG HANDLER

SERVICE INTERVALS

SERVICE INSTRUCTIONS

DAILY

WEEKLY

EVERY

5WKS OR

FOR: 534D-9, 534D-10

10 HRS

50 HRS

250 HRS

DIESEL ENGINE

---------------**---------------------------------

AIR CLEANER ELEMENTS

--------------------------------------- ------------

FUEL FILTERS

----------------------------------- -------------------

OIL FILTER

CHANGE

---------------------- ------ -------------------

OIL (12 QT.)

CHANGE

CHECK

--------------- --------------------------------

DIESEL FUEL (38 GAL.)

FILL

HYDRAULIC SYSTEM

-----------------------------------------------------

--------------------- ------------ ------

OIL (47 GAL.)

CHECK

-------------------------------------------------------

FILTERS

------------------- ------ ------

HYD.TANK BREATHER/FILTER CAP

CHECK

FRONT AXLE

-------------------------------------- ------------------CHECK

(5 GAL)

REAR AXLE WHEEL END LUBE(4 PT.)

CHECK

WHEEL NUT TORQUE-350/400 FT-LBS

-------------------- -------------------------

BATTERY & TERMINALS

CHECK

RADIATOR 3 GAL. WATER

----------------------- ------------------------CHECK

3 GAL ANTI-FREEZE

----------------

-------------------------

TIRES: 13.00x24(12 PLY) 65 PSI

CHECK

----------------

-------------------------

CHECK

TIRES: 14.00x24(12 PLY) 65 PSI

--------------------

-------------------------

TIRES: RADIAL 70 PSI

CHECK

-------------------------

---------------

CYLINDER FITTINGS EACH END

GREASE

-------------------------

------------------GREASE

REAR AXLE (12) FITTINGS

-------------------------

--------------

FRONT AXLE PIVOT (2) FITTINGS

GREASE

----------------------------

ALL BEARINGS PADS

GREASE

--------------

FRONT BOTTOM BEARING PADS

GREASE

CHECK

-------------------------

-------------------

BOOM PIVOT (2) FITTINGS

GREASE

-------------------------

--------------------GREASE

HEAD PIN (2) FITTINGS

-------------------------

----------------

BOOM SHEAVES (3) FITTINGS

GREASE

-------------------------

-----------------GREASE

QUICK SWITCH (1) FITTING

------------------------

CHECK RETRACT & EXTEND CABLE SEE OPERATOR & MAINTENANCE MANUAL

THIS CHART MUST BE USED IN CONJUNCTION WITH SERVICE MANUAL AND RECOMMENDED PROCEDURE.

CHECK INDICATOR ON HYDRAULIC FILTER. CHANGE FILTER IF NEEDLE IS IN YELLOW

AT FULL THROTTLE & AT OPERATING TEMPERATURE.

CHECK AIR CLEANER RESTRICTION INDICATOR. CLEAN OR CHANGE PRIMARY FILTER IF NECESSARY.

SAFETY ELEMENT TO BE CHANGED EVERY 3RD CHANGE OF PRIMARY FILTER ELEMENT.

CONSULT DEALER FOR RECOMMENDATIONS AT EXTREME TEMPERATURES.

DAILY SERVICE MAY BE REQUIRED FOR OPTIMUM LIFE DEPENDING UPON APPLICATION SEVERITY.

*******

IT IS RECOMMENDED THAT FILTER ELEMENTS AND FRONT AXLE LUBRICANT BE CHANGED AFTER FIRST 50 HRS ON NEW OR REBUILT UNITS.

9130-3047

FOR SAFE OPERATION OF MACHINE AND TO MINIMIZE RISK OF

1. ONLY TRAINED AND AUTHORIZED PERSONNEL MAY OPERATE THIS MACHINE.

2. BEFORE OPERATING, READ AND UNDERSTAND ALL CAPACITY CHARTS, OPERATOR MANUALS AND SAFETY MANUALS. IF MANUALS ARE NOT AVAILABLE, CONSULT AN AUTHORIZED JLG DEALER. UNDERSTAND ALL CONTROLS IN CAB AND CHECK FOR PROPER OPERATION. CLEAR LOOSE OBJECTS OFF MACHINE AND SOUND HORN BEFORE STARTING ENGINE.

3. OPERATOR MUST BE SEATED WITH SEAT BELT FASTENED. ASSURE FORWARD/REVERSE LEVER IS IN NEUTRAL,PARK BRAKE APPLIED AND ALL HYDRAULIC CONTROLS ARE IN NEUTRAL BEFORE IGNITION SWITCH IS TURNED ON.

4. DO NOT OPERATE MACHINE WITHOUT PROPER CAPACITY CHART IN PLACE.

5. BEFORE MOVING, BE SURE OF A CLEAR PATH AND SOUND HORN. WATCH FOR PEDESTRIANS AND OBSTRUCTIONS. CHECK OVERHEAD AND SIDE CLEARANCES. ALWAYS LOOK IN DIRECTION OF TRAVEL.

6. START, TURN, AND BRAKE SMOOTHLY. REDUCE TRAVEL SPEEDS FOR TURNS, SLIPPERY, OR UNEVEN SURFACES. AVOID RUNNING OVER LOOSE OBJECTS OR HOLES IN THE ROADWAY SURFACE.

SERIOUS INJURY, READ AND OBSERVE THE FOLLOWING:

7. WHEN TRAVELING WITH LOAD, FULLY RETRACT BOOM AND PLACE FORKS IN CARRY POSITION (APPROX.12" ABOVE GROUND). TILT CARRIAGE BACK SLIGHTLY TO CRADLE LOAD. USE EXTREME CAUTION WHEN TURNING.

8. ON INCLINES, TRAVEL WITH LOAD UP-GRADE.

9. DO NOT USE BOOM AS WALKWAY.

10. USE TWO HANDS WHEN CLIMBING ON MACHINE.

11. USE ONLY A GRADALL MANUFACTURED PERSONNEL WORK PLATFORM FOR LIFTING PERSONNEL. NO RIDERS ON MACHINE, FORKS, LOAD, OR OTHER LIFTING ATTACHMENTS AT ANY TIME. DO NOT USE PERSONNEL WORK PLATFORM WITHOUT THE PROPER GRADALL MATERIAL HANDLER/PERSONNEL WORK PLATFORM CAPACITY CHART DISPLAYED IN THE CAB. DO NOT DRIVE MACHINE WITH PERSONNEL IN PLATFORM.

12. KEEP OTHERS AWAY FROM MACHINE WHILE OPERATING. DO NOT STAND UNDER BOOM OR LOAD.

13. USE EXTREME CARE WHEN HANDLING LONG, HIGH, OR WIDE LOADS. DO NOT HANDLE UNSTABLE OR LOOSELY STACKED LOADS.

14. FORKS TO BE CENTERED UNDER LOAD AND SPACED APART AS FAR AS POSSIBLE.

15. BEFORE ADJUSTING OR SERVICING, PLACE FORWARD/REVERSE LEVER IN NEUTRAL, REST BOOM ON GROUND OR SUPPORT, SET PARKING BRAKE, SHUT OFF ENGINE AND CHOCK WHEELS.

16. BEFORE LEAVING MACHINE UNATTENDED, PLACE FORWARD/REVERSE LEVER IN NEUTRAL, LOWER BOOM, SET PARKING BRAKE,AND SHUT-OFF ENGINE. CHOCK WHEELS IF MACHINE MUST PARK ON AN INCLINE.

17. LEVEL MACHINE BEFORE LIFTING ANY LOAD ABOVE 4 FEET. (IF EQUIPPED WITH FRAME LEVELING).

18. OPERATOR PROTECTION (SUCH AS HARD HATS, SAFETY GLASSES, AND/OR HEARING PROTECTION) SHOULD BE WORN WHEN JOB CONDITIONS WARRANT. ALWAYS USE SEAT BELT.

19. IMPROPER USE OF MACHINE COULD RESULT IN MACHINE TIPPING OVER. IF MACHINE STARTS TO TIP OVER, DO NOT LEAVE OPERATORS SEAT. LEAN AWAY FROM TIP & BRACE YOURSELF.

20. KEEP MIRROR(S) CLEAN AND PROPERLY ADJUSTED. OBJECTS IN MIRROR ARE CLOSER THAN THEY APPEAR.

9055-3028 REV. A

90553028

T N

80603022

9055-3027 REV. A

ANNUALLY

6 MO.

3 MO.

TYPE OR

EQUIVALENT

1500 HRS

1000 HRS

500 HRS

CHANGE

SAE 15W-40-CD *** DIESEL FUEL #2

MOBIL 424

CHANGE

INSPECT

CHANGE

MOBIL 424

--------------------------------------MOBIL 424

------------------------------------

TORQUE

ETHYLENE GLYCOL

ANTI-FREEZE

MYSTIK TETRIMOLY

-------------------

MYSTIK TETRIMOLY

-------------------

MYSTIK TETRIMOLY

-------------------

9134-3073 REV -

AVOID HIGH VOLTAGE LINES. IT IS UNLAWFUL TO PLACE ANY PART OF THIS MACHINE

OR LOAD WITHIN 10 FEET OF HIGH VOLTAGE LINES

UP TO 50,000 VOLTS.

DEATH OR INJURY MAY

RESULT FROM CONTACTING

ELECTRIC LINES.

8060-3022

OX0113

VIEW A-A

2-331200169

Section 2 - Pre-Operation and Inspection

91143282

STAY CLEAR OF PINCH POINT AREA

ANYTIME ENGINE IS RUNNING. BEING IN PINCH POINT AREA COULD CAUSE SERIOUS INJURY OR DEATH.

91143280 (BEFORE

S/N 0160027138)

EXHAUST SYSTEMS CAN BE HOT.

KEEP AWAY FROM EXHAUST SYSTEM WHEN HOT.

HOT EXHAUST COMPONENTS CAN CAUSE

SEVERE BURNS.

9114-3280

COOLING SYSTEM IS PRESSURIZED.

REMOVE CAP SLOWLY.

HOT FLUID CAN CAUSE BURNS.

8060-3026

80603026

91163130

9114-3282

91143286

DIESEL FUEL IS FLAMMABLE

EXTINGUISH ALL OPEN FLAME AND

SMOKING MATERIALS WHEN REFUELING

INJURY OR DEATH COULD RESULT

FROM FIRE.

HYDRAULIC

OIL LEVEL

FULL

ADD

CHECK OIL LEVEL WITH HANDLER LEVEL AND ALL CYLINDERS RETRACTED.

1 GALLON BETWEEN

ADD AND FULL MARKS

9116-3130

S/N 0160035983)

9114-3286

91143281

STAY CLEAR OF MOVING PARTS

WHILE ENGINE IS RUNNING. MOVING PARTS CAN CAUSE

SERIOUS INJURY.

91083492

(BEFORE

91143280

(S/N 0160027138

thru

S/N 0160035941)

EXHAUST SYSTEMS CAN BE HOT.

KEEP AWAY FROM EXHAUST SYSTEM WHEN HOT.

HOT EXHAUST COMPONENTS CAN CAUSE

9114-3281

SEVERE BURNS.

S/N 0160035983)

9114-3280

91143288

(BEFORE

Genuine Parts

HYDRAULIC SYSTEM

FILL WITH TRACTOR HYDRAULIC FLUID

or equivalent.

For Mobil Product Information, Call 1-800-662-4525.

91143284

NO RIDERS PERMITTED ON HANDLER.

RIDERS COULD FALL OFF MACHINE

CAUSING SERIOUS INJURY OR DEATH.

9114-3288

OPERATOR ONLY IN MACHINE

WHILE RUNNING.

91143282

STAY CLEAR OF PINCH POINT AREA

ANYTIME ENGINE IS RUNNING. BEING IN PINCH POINT AREA COULD CAUSE SERIOUS INJURY OR DEATH.

91143285 (BEFORE

S/N 0160035983)

WHEN JUMP STARTING MATERIAL HANDLER * NEVER ALLOW VEHICLES TO TOUCH * CONNECT THE POSITIVE (+) JUMPER CABLE TO POSITIVE (+) POST OF DISCHARGED BATTERY * CONNECT OPPOSITE END OF POSITIVE (+) JUMPER CABLE TO POSITIVE (+) POST OF BOOSTER BATTERY * CONNECT THE NEGATIVE (-) JUMPER CABLE TO NEGATIVE (-) POST ON BOOSTER BATTERY * CONNECT OPPOSITE END OF NEGATIVE (-) JUMPER CABLE TO GROUND POINT ON MACHINE AWAY FROM DISCHARGED BATTERY * FOLLOW STANDARD STARTING PROCEDURES * REMOVE CABLES IN REVERSE ORDER AFTER MACHINE HAS STARTED

9114-3283

9114-3282

91143162

JUMP STARTING INSTRUCTIONS

TEST PORTS

IMPLEMENT PRESSURE

9114-3285

9114-3162

1706300

(S/N 0160035983

& AFTER)

VIEW OF CAB DASH

NEVER OPERATE MACHINE WITHOUT

CONSULTING PROPER CAPACITY CHART FOR THE

CARRIAGE/FORK COMBINATION BEING USED.

91323030

TURBOCHARGER DAMAGE CAN RESULT

FROM QUICK START-UP & SHUTDOWN.

FOR LONGER TURBOCHARGER LIFE AND TO MINIMIZE TURBOCHARGER

DAMAGE, IDLE ENGINE AT LEAST 3-5 MINUTES AFTER START-UP

AND BEFORE SHUTDOWN.

9134-3016

91343016

9132-3030

91163028

TRACTION LOCK SWITCH

SWITCH LOCATED

LIFT TO

ON FLOOR. SWITCH

SHIFT

HYDRAULICALLY

LOCKS FRONT AND

REAR WHEELS

TOGETHER FOR

INCREASED TRACTION.

91083314 (BEFORE

S/N 0160035983)

DO NOT ENGAGE

WHEN WHEELS ARE

IN MOTION OR ON IMPROVED

SURFACES. MACHINE

MUST BE IN 4 WHEEL DRIVE.

FUEL

TEMP

9108-3314

OIL

240

VOLTS

100

OFF

QUARTZ

000000

OFF

ALT

OFF

ACC

MACHINE MUST BE

IN NEUTRAL AND

PARK BRAKE ON TO START

91143120

DRIVE 4X4

4X2

9116-3184

9103-3089

RUN

START

9103-3089

91033089

91143182

9114-3182

CAPACITY

CHARTS

OX0582

2-4 31200169

Section 2 - Pre-Operation and Inspection

91143282

STAY CLEAR OF PINCH POINT AREA

ANYTIME ENGINE IS RUNNING. BEING IN PINCH POINT AREA COULD CAUSE SERIOUS INJURY OR DEATH.

80603037

9114-3282

HOLES AND OTHER PINCH

PINCH POINT

KEEP OUT

REACHING INTO BOOM

POINTS CAN CAUSE

SERIOUS INJURY

OR DEATH.

8060-3037-A

4105262

-10

° 0 8

° 0

° 0 6

° 0 5

° 0 4

° 0

° 0 2

0°

91143290

0 8

80603037

PINCH POINT

KEEP OUT

REACHING INTO BOOM

HOLES AND OTHER PINCH

POINTS CAN CAUSE SERIOUS INJURY

OR DEATH.

80603037

PINCH POINT

KEEP OUT

REACHING INTO BOOM HOLES AND OTHER PINCH

POINTS CAN CAUSE SERIOUS INJURY

OR DEATH.

80603037

PINCH POINT

KEEP OUT

REACHING INTO BOOM

HOLES AND OTHER PINCH

POINTS CAN CAUSE SERIOUS INJURY

8060-3037-A

OR DEATH.

8060-3037-A

91553072

8060-3037-A

80603037

PINCH POINT

KEEP OUT

REACHING INTO BOOM

HOLES AND OTHER PINCH

POINTS CAN CAUSE SERIOUS INJURY

OR DEATH.

8060-3037-A

90553026

READ AND UNDERSTAND THE FOLLOWING PRIOR TO LIFTING PERSONNEL.

WHEN LIFTING PERSONNEL USE ONLY A GRADALL MANUFACTURED

PERSONNEL WORK PLATFORM.

ALL PERSONNEL IN PLATFORM MUST WEAR A FULL BODY HARNESS WITH

LANYARD ATTACHED TO A DESIGNATED ANCHORAGE POINT.

READ AND UNDERSTAND PERSONNEL WORK PLATFORM USER'S MANUAL

BEFORE OCCUPYING PERSONNEL WORK PLATFORM.

FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY OR DEATH.

VIEW A-A

9055-3026 REV. A

80603037

PINCH POINT

KEEP OUT

REACHING INTO BOOM

HOLES AND OTHER PINCH

POINTS CAN CAUSE SERIOUS INJURY

OR DEATH.

8060-3037-A

VIEW B-B

OX0590

2-531200169

Section 2 - Pre-Operation and Inspection

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 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. Left Outrigger (534D-10) - Pins secure; hydraulic hoses and cylinder undamaged, not leaking.

3. Front Axle

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

OX0123

2-6 31200169

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