JLG 534D-9 Operator Manual

Download

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.)

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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

Section 2 - Pre-Operation and Inspection

4. Wheel/Tire Assembly - Properly inflated and secured; no loose or missing lug nuts. Inspect for worn tread, cuts, tears or other discrepancies.

5. Cab and Electrical

• General appearance; no visible damage.

• Frame level indicator and window glass undamaged and clean.

• Gauges, switches, joysticks, foot controls and horn operational.

• Emergency escape hammer in place (enclosed cab only).

• Check seat belt for damage, replace belt if frayed or cut webbing, damaged

buckles or loose mounting hardware.

6. Main Control Valve

- See Inspection Note.

7. Air Cleaner condition. Replace element as required.

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

9. Stabilizer Cylinder - Pins secure; hydraulic hoses undamaged, not leaking.

10. Rear Axle - Steer cylinders undamaged, not leaking; pivot pins secure;

hydraulic hoses undamaged, not leaking.

11. Wheel/Tire Assembly - Properly inflated and secured; no loose or missing lug nuts. Inspect for worn tread, cuts, tears or other discrepancies.

12. Engine Compartment

• Drive belts, check condition and replace as required.

• Engine mounts - See inspection note.

• Engine cover properly secured.

13. Battery

14. Mirror

15. Wheel/Tire Assembly

nuts. Inspect for worn tread, cuts, tears or other discrepancies.

16. Frame Level Cylinder

17. Right Outrigger

undamaged, not leaking.

18. Attachment

- Air cleaner element condition indicator, check for clogged

- Properly inflated and secured; no loose or missing lug

- Cables tight, no visible damage or corrosion. Cover properly secured.

- Clean and undamaged.

- Properly inflated and secured; no loose or missing lug

- Pins secure; hydraulic hoses undamaged, not leaking.

(534D-10) - Pins secure; hydraulic hoses and cylinder

- Properly installed, See “Attachment Installation” on page 5-11.

2-731200169

Section 2 - Pre-Operation and Inspection

2.4 WARM-UP AND OPERATIONAL CHECKS

Warm-Up Check

During warm-up period, check:

1. Heater, defroster and windshield wiper (if equipped).

2. Check all lighting systems (if equipped) for proper operation.

3. Voltmeter should show 13.5 to 14 volts.

4. Adjust mirror(s) for maximum visibility.

WARNING

CUT/CRUSH/BURN HAZARD. Keep engine cover closed while engine is running

except when checking hydraulic filter condition indicator.

Operational Check

When engine warms, perform an operational check:

1. Service brake and parking brake operation.

2. Forward and reverse travel.

3. Steering in both directions with engine at low idle.

4. Horn and back-up alarm. Must be audible from inside operators cab with engine running.

5. All joystick functions - operate smoothly and correctly.

6. Perform any additional checks described in Section 8.

7. Hydraulic filter condition indicator.

2-8 31200169

Section 2 - Pre-Operation and Inspection

2.5 OPERATOR CAB

The telehandler is equipped with an open or enclosed ROPS/FOPS cab.

WARNING

Never operate telehandler unless the overhead guard and cab structure are in good condition. Any modification to this machine must be approved by JLG to assure compliance with ROPS/FOPS certification for this cab/machine configuration. If damaged, the CAB CANNOT BE REPAIRED. It must be REPLACED.

2-931200169

Section 2 - Pre-Operation and Inspection

2.6 WINDOWS

Keep all windows and mirrors clean and unobstructed.

Cab Door Window (if equipped)

OAL0011

• Cab door (1) must be closed during operation.

• During operation the cab door window (2) must either be latched open or closed.

• Open the cab door window and secure it in the latch (3).

• Press latch release button inside the cab or pull on lever (4) outside the cab to unlatch the window.

2-10 31200169

Section 3 - Controls and Indicators

SECTION 3 - CONTROLS AND INDICATORS

3.1 GENERAL

This section provides the necessary information needed to understand control functions.

Note: The manufacturer has no direct control over machine application and operation. The user and operator are responsible for conforming with good safety practices.

NOTICE

EQUIPMENT DAMAGE. When a red light illuminates, immediately bring machine to a stop, lower boom and attachment to ground and stop the engine. Determine cause and correct before continued use.

3-131200169

Section 3 - Controls and Indicators

3.2 CONTROLS

9136-30

VIEW A-A

FUEL

OIL

240

TEMP

100

QUARTZ

000000

VOLTS

- +

891011

13 6

OX0362

1. Transmission Control Lever: See page 3-7.

2. Steering Wheel: Turning the steering wheel to the left or right steers the

machine in the corresponding direction.

3. Frame Level Indicator: Enables the operator to determine the left to right level condition of the telehandler.

4. Boom Joystick

5. Right Hand Levers

: See page 3-8.

(if equipped): See page 3-9.

6. Accelerator Pedal: Pressing down the pedal increases engine and hydraulic speed.

7. Service Brake/Inching Travel Pedal: Operates service brakes on front axle. Permits slow travel speed while engine speed is kept high for other telehandler functions. The further the pedal is depressed, the slower the travel speed.

8. Left Hand Lever

9. Instrument Panel

10. Ignition Switch

11. Horn Button

(if equipped): See page 3-11.

: See page 3-3.

: Key activated. See page 3-5.

: Depress to sound horn.

12. Outrigger Levers (534D-10): See page 3-10.

13. Traction-Lock Pedal

: Pedal operates traction-lock. With machine in four-wheel

drive mode, depress and hold down to restore traction when a wheel spins.

3-2 31200169

Dash Controls and Indicators

John Deere Engine

Section 3 - Controls and Indicators

AUXILIARY ELECTRICS

CONTROL

SIDE SHIFT

SWING

ONLY ONE FUNCTION CAN

BE ACTIVE AT A TIME

MAST

523 46

FUEL

OIL

240

TEMP

VOLTS

100

SHUTDWN

HEATER

OVERRIDE

OFF

QUARTZ

PARK

DRIVE

BRAKE

4X4

000000

ALT

4X2

OFF

11 10 917

OX0034

1. Park Brake Indicator: See page 3-6 for details.

2. 4-in-1 Gauge

a. Engine Coolant Temperature Gauge

b. Engine Oil Pressure Gauge

c. Fuel Gauge

d. Voltmeter indicates alternator output and battery condition.

3. Heater Switch

(if equipped): See page 3-12 for details.

4. Shutdown Override Switch: Depress and release to delay engine shutdown for 30 seconds. The switch resets the shutdown timer to 30 seconds and may be used repeatedly. Switch also used to retrieve engine fault codes. See Service Manual for details.

5. Hourmeter: Indicates total time of engine operation in hours and tenths of hours.

6. 4x2/4x4 Switch

: Engages and disengages rear wheel drive motors. Rear drive

motors are engaged for four wheel drive.

7. Park Brake Switch

: See page 3-6 for details.

8. Auxiliary Electrics Switches (if equipped): Enables functions of attachments that require auxiliary electrics. See Section 5 - Attachments for approved attachments and control instructions.

9. 4x4 Indicator

: Illuminates when four-wheel drive is engaged. The indicator will

not illuminate when park brake is applied.

10. Check Engine Indicator: Illuminates for 30 seconds before engine shuts down when a “Shutdown” fault is detected. Indicator also flashes engine fault codes. See Service Manual for details.

11. Alternator Indicator

: Illuminates when alternator is not charging.

3-331200169

Section 3 - Controls and Indicators

Cummins Engine

19 16 13 14 15 23

100

FUEL

OIL

240

TEMP

VOLTS

100

DIAG.LIGHT

WAIT-TO-START

HEATER

LIGHT

OFF

PARK

ENG.

DRIVE

SHUTDOWN

BRAKE

LIGHT

4X4

1/10

4X2

OFF

ALT

21221218

OX0621

12. Park Brake Indicator: See page 3-6 for details.

13. 4-in-1 Gauge

e. Engine Coolant Temperature Gauge

f. Engine Oil Pressure Gauge

g. Fuel Gauge

h. Voltmeter indicates alternator output and battery condition.

14. Heater Switch

(if equipped): See page 3-12 for details.

15. Diagnostic Indicator: Illuminates when diagnostic system detects an engine fault.

16. Hourmeter: Indicates total time of engine operation in hours and tenths of hours.

17. 4x2/4x4 Switch

: Engages and disengages rear wheel drive motors. Rear drive

motors are engaged for four wheel drive.

18. Park Brake Switch: See page 3-6 for details.

19. Auxiliary Electrics Switches (if equipped): Enables functions of attachments that

require auxiliary electrics. See Section 5 - Attachments for approved attachments and control instructions.

20. 4x4 Indicator

: Illuminates when four-wheel drive is engaged. The indicator will

not illuminate when park brake is applied.

21. Engine Shutdown Indicator: Illuminates to indicate an engine fault and/or a parameter is outside the acceptable range. Engine may derate and shutdown.

22. Alternator Indicator

23. Preheat Indicator

: Illuminates when alternator is not charging.

: Illuminates with ignition in “RUN” position. Light goes out when start temperature is reached. At temperatures below 32°F (0°C), do not start until engine is preheated.

3-4 31200169

Section 3 - Controls and Indicators

Ignition

FUEL

OIL

240

TEMP

VOLTS

100

QUARTZ

OFF

ACC

RUN

START

• In "ACC" or "RUN" position, voltage is available for all electrical functions.

• Full clockwise rotation to "START" engages starter motor.

• Counter-clockwise rotation to "OFF" stops engine and removes voltage from all electrical functions.

000000

OX0072

3-531200169

Section 3 - Controls and Indicators

Park Brake

FUEL

OIL

240

TEMP

VOLTS

100

QUARTZ

PARK

DRIVE

BRAKE

4X4

000000

4X2

OFF

PARK

BRAKE

OFF

PARK

BRAKE

OFF

OX0043

Park brake switch controls the application and release of the park brake. Indicator light (3) illuminates to indicate brake is applied.

• With the engine running and the park brake switch in "OFF" position (1), park brakes are disengaged.

• With switch in "ON" position (2), park brake is engaged and transmission will not engage forward or reverse.

WARNING

MACHINE ROLL-AWAY HAZARD. Always move park brake switch to "ON"

position, lower boom to ground and stop engine before leaving cab.

WARNING

CRUSH HAZARD. Turning engine off applies the park brake. Applying park brake

or turning engine off while traveling will cause unit to stop abruptly and could cause load loss. Either may be used in an emergency situation.

Parking Procedure

1. Using service brake, stop telehandler in an appropriate parking area.

2. Follow “Shut-Down Procedure” on page 4-4.

3-6 31200169

Transmission Control Lever

Section 3 - Controls and Indicators

OX0083

T N O R

Transmission control lever (4) engages forward or reverse travel.

• Lift and push lever forward for forward travel; lift and pull lever rearward for reverse travel. Move lever to centered position for neutral.

• When traveling in reverse, the back-up alarm will automatically sound.

• Drive in reverse and turn only at slow rates of speed.

• Do not increase engine speed with the transmission in forward or reverse and the service brake depressed in an attempt to get quicker hydraulic performances. This could cause unexpected machine movement.

WARNING

TIP OVER/CRUSH HAZARD. Bring telehandler to a complete stop before

shifting transmission control lever. A sudden change in direction of travel could reduce stability and/or cause load to shift or fall.

3-731200169

Section 3 - Controls and Indicators

Boom Joystick

IF EQUIPPED

The boom joystick (1) controls the boom and attachment tilt (if equipped) functions.

Boom Functions

• Move the joystick back to lift boom; move joystick forward to lower boom; move joystick right to extend boom; move joystick left to retract boom.

• The speed of boom functions depends upon the amount of joystick travel in corresponding direction. Increasing engine speed will also increase function speed.

• For two simultaneous boom functions, move the joystick between quadrants. For example; moving the joystick forward and to the left will lower and retract boom simultaneously.

Attachment Tilt (if equipped)

Tilt control is actuated by the switch (2).

• Depress the rear of the switch to tilt up; depress the front of switch to tilt down.

OX0060

WARNING

TIP OVER/CRUSH HAZARD. Rapid, jerky operation of controls will cause rapid,

jerky movement of the load. Such movements could cause the load to shift or fall or could cause the machine to tip over.

3-8 31200169

Section 3 - Controls and Indicators

Right Hand Levers (if equipped)

ATTACHMENT

OX0660

The right hand levers control attachment tilt, frame level or auxiliary hydraulics.

Attachment Tilt (if equipped)

The attachment tilt lever (3) controls attachment tilt.

TILT

FRAME

LEVEL

AUXILIARY

HYDRAULICS

• Move lever forward to tilt down; move lever back to tilt up.

Frame Level (if equipped)

The frame level lever (4) controls the left to right frame level.

• Move lever forward to rotate frame left, move lever back to rotate frame right.

• A level indicator is located above the front cab window to permit operator to determine whether the telehandler frame is level.

WARNING

TIP OVER HAZARD. Always move boom as low as possible while allowing for

best visibility of right hand mirror before leveling frame. Attempting to level machine with boom raised could cause it to tip over.

Auxiliary Hydraulics (if equipped)

• The auxiliary hydraulics lever (4) controls function of attachments that require hydraulic supply for operation. See Section 5 - Attachments for approved attachments and control instructions.

3-931200169

Section 3 - Controls and Indicators

Outrigger Levers (534D-10)

OX0492

The rear levers (1 & 2) control the outriggers.

• The left lever controls the left outrigger and the right lever controls the right outrigger.

• Push levers forward to lower outriggers; push levers back to raise outriggers.

• Use outriggers to increase stability and/or load capacity and in leveling the telehandler. Study capacity charts to determine maximum load capacities, with and without outriggers.

WARNING

TIP OVER HAZARD. Outriggers increase stability and load capacity only if they

are used properly. Using outriggers on soft surfaces could cause telehandler to tip over. Always ensure surface can support telehandler and load.

3-10 31200169

Left Hand Lever (if equipped)

Section 3 - Controls and Indicators

AUXILIARY

HYDRAULICS

FRAME

9136-30

FUEL

OIL

240

TEMP

VOLTS

- +

100

QUARTZ

PARK

DRIVE

BRAKE

4X4

000000

4X2

OFF

ALT

LEVEL

ATTACHMENT

TILT

OX0222

The left hand lever (3) controls auxiliary hydraulics, frame level, or attachment tilt.

Auxiliary Hydraulics (if equipped)

• Controls function of attachments that require hydraulic supply for operation. See Section 5 - Attachments for approved attachments and control instructions.

Frame Level (if equipped)

• Move lever left to rotate frame left, move lever right to rotate frame right.

• A level indicator is located in the upper front window frame to permit operator to determine whether the telehandler frame is level.

WARNING

TIP OVER HAZARD. Always move boom as low as possible while allowing for

best visibility of right hand mirror before leveling frame. Attempting to level machine with boom raised could cause it to tip over.

Attachment Tilt (if equipped)

• Move joystick up to tilt down; move joystick down to tilt up.

3-1131200169

Section 3 - Controls and Indicators

Heater (if equipped)

FUEL

OIL

240

TEMP

VOLTS

100

HEATER

OFF

QUARTZ

PARK

DRIVE

BRAKE

4X4

000000

ALT

4X2

OFF

OX0234

1. Defroster Fan: Two speed fan. Press fan switch down for slow speed; press switch up for fast speed. Return switch to middle position to turn off.

2. Heater Fan Switch

: On/Off switch.

3-12 31200169

Section 3 - Controls and Indicators

3.3 OPERATOR SEAT

Adjustments

Prior to starting engine adjust seat for position and comfort.

Before S/N 0160016100

OX0013

1. Fore/Aft

2. Seat Belt

seat belt is available.

3. Arm Rest

: Pull up on handle to move seat fore and aft.

: Always fasten seat belt during operation. If required, a 3 in (76 mm)

: Arm rest can be moved up or down for comfort.

3-1331200169

Section 3 - Controls and Indicators

S/N 0160016100 & After

OW0480

1. Suspension: Use knob to adjust suspension to the appropriate setting. Turn clockwise to increase stiffness. Turn counterclockwise to reduce stiffness.

2. Fore/Aft

: Pull up on handle to move seat fore and aft.

3. Arm Rest

4. Seat Belt

: Arm rest can be moved up or down for comfort.

: Always fasten seat belt during operation. If required, a 3 in (76 mm)

seat belt is available.

3-14 31200169

Section 3 - Controls and Indicators

Seat Belt

OH20912

Fasten seat belt as follows:

1. Grasp both free ends of the belt making certain that belt webbing is not twisted or entangled.

2. With back straight in the seat, couple the retractable end (male end) of the belt into the receptacle (buckle) end of the belt.

3. With belt buckle positioned as low on the body as possible, pull the retractable end of the belt away from the buckle until it is tight across the lap.

4. To release belt latch, depress red button on the buckle and pull free end from buckle.

3-1531200169

Section 3 - Controls and Indicators

3.4 BOOM ANGLE AND EXTENSION INDICATORS

-10

OW1220

• The boom angle indicator (1) is located on the left side of the boom. Use this indicator to determine the boom angle when using the capacity chart (see “Use of the Capacity Chart” on page 5-4).

• Boom extension indicators (2) are located on the left side of the boom. Use these indicators to determine boom extension when using the capacity chart (see “Use of the Capacity Chart” on page 5-4).

3-16 31200169

Section 4 - Operation

SECTION 4 - OPERATION

4.1 ENGINE

Starting the Engine

This machine can be operated under normal conditions in temperatures of 0°F to 104°F (-20°C to 40°C). Consult JLG for operation outside this range or under abnormal conditions.

1. Make sure all controls are in “Neutral” and all electrical components (lights, heater, defroster, etc.) are turned off. Set parking brake.

2. If equipped with Cummins engine and the temperature is below 32° F (0° C), turn the ignition switch to “RUN”. Wait until the preheat indicator light goes out.

3. Turn ignition switch to “START” to engage starting motor. Release key immediately when engine starts. If engine fails to start within 20 seconds, release key and allow starting motor to cool for a few minutes before trying again.

4. After engine starts, observe oil pressure gauge. If gauge remains on zero for more than ten seconds, stop engine and determine cause before restarting engine. Reference engine manual for minimum pressure at operating temperature.

5. Warm up engine at approximately 1/2 throttle.

Note: Engine will not start unless transmission control lever is in “Neutral” and park brake switch is applied.

WARNING

UNEXPECTED MOVEMENT HAZARD. Always ensure that transmission control

lever is in neutral and the service brake is applied before releasing park brake. Releasing park brake in either forward or reverse could cause the machine to move abruptly, causing an accident.

4-131200169

Section 4 - Operation

Cold Weather Starting Aids

John Deere Engine

JLG approved starting aids employ ether. If your telehandler is equipped with an ether starting aid, the following applies:

• Injection of ether is triggered by temperature sensor located on engine.

• At start-up, temperature sensor on engine will detect if ether is needed. Follow normal start-up procedure.

• Ether will be automatically injected if needed, to keep engine running.

• A second battery is added for additional cold-cranking capacity.

WARNING

ENGINE EXPLOSION. If your telehandler is equipped with a cold start aid, do

not spray additional ether into air cleaner. If machine is not equipped with cold start aid, follow instructions listed in the engine manual supplied with the telehandler.

Cummins Engine

Cummins engines are equipped with preheat for cold weather starting. Refer to “Starting the Engine” on page 4-1 for cold weather starting procedure.

WARNING

ENGINE EXPLOSION. Do not use ether for cold weather starting.

4-2 31200169

Section 4 - Operation

Battery Boosted Starting

OW0530

If battery-boost starting (jump-start) is necessary, proceed as follows:

• Never allow vehicles to touch.

• Connect the positive (+) jumper cable to positive (+) post of discharged battery.

• Connect the 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.

WARNING

BATTERY EXPLOSION HAZARD. Never jump start or charge a frozen battery

as it could explode. Keep sparks, flames and lighted smoking materials away from the battery. Lead acid batteries generate explosive gases when charging. Wear safety glasses.

4-331200169

Section 4 - Operation

Normal Engine Operation

• Observe instrument panel frequently to be sure all engine systems are functioning properly.

• Be alert for unusual noises or vibration. When an unusual condition is noticed, park machine in safe position and perform shut-down procedure. See Shut-Down Procedure. Report condition to your supervisor or maintenance personnel.

• Avoid prolonged idling. If the engine is not being used, turn it off.

Shut-Down Procedure

When parking the telehandler, park in a safe location on flat level ground and away from other equipment and/or traffic lanes.

1. Apply the park brake.

2. Shift the transmission to “Neutral.”

3. Lower forks or attachment to the ground.

4. Operate engine at low idle for 3 to 5 minutes. DO NOT over rev engine.

5. Shut off engine and remove ignition key.

6. Exit telehandler properly.

7. Block wheels (if necessary).

4-4 31200169

Section 4 - Operation

4.2 OPERATING WITH A NON-SUSPENDED LOAD

Lift Load Safely

• You must know the weight and load center of every load you lift. If you are not sure of the weight and load center, check with your supervisor or with the supplier of the material.

WARNING

TIP OVER HAZARD. Exceeding lift capacity of the telehandler could damage the

equipment and/or cause tip over.

• Know the rated load capacities (see Section 5) of the telehandler to determine the operating range in which you can safely lift, transport and place a load.

Picking Up a Load

• Note the conditions of the terrain. Adjust travel speed and reduce amount of load if conditions warrant.

• Avoid lifting double-tiered loads.

• Make sure load is clear of any adjacent obstacles.

• Adjust spacing of forks so they engage the pallet or load at maximum width. See “Adjusting/Moving Forks” on page 5-15.

• Approach load slowly and squarely with fork tips straight and level. NEVER attempt to lift a load with just one fork.

• NEVER operate telehandler without a proper and legible capacity chart in the operator cab for the telehandler/attachment combination you are using.

4-531200169

Section 4 - Operation

Transporting a Load

OW0540

After engaging the load and resting it against the backrest, tilt the load back to position it for travel. Travel in accordance with the requirements set forth in Section 1 - General Safety Practices and Section 5 - Attachments.

Leveling Procedure

1. Position machine in best location to lift or place load.

2. Apply parking brake and move transmission control lever to NEUTRAL.

3. Move boom/attachment to 4 ft (1,2 m) off ground. (AUS - Move boom so forks are no more than 11.8 in (300 mm) above ground surface.)

4. Observe level indicator to determine whether machine must be leveled prior to lifting load. Level machine with frame level joystick (see page 3-9 or page 3-11) or if equipped, outrigger joysticks (see page 3-10).

Important things to remember:

• Never raise the boom/attachment more than 4 ft (1,2 m) above ground unless telehandler is level. (AUS - Never raise the forks more than 11.8 in (300 mm) above ground surface unless telehandler is level.)

• The combination of frame leveling and load could cause the telehandler to tip over.

The telehandler is designed to permit leveling the main frame 8° to left or right to compensate for uneven ground conditions.

4-6 31200169

Section 4 - Operation

Placing a Load

Before placing any load be sure that:

• The landing point can safely support the weight of the load.

• The landing point is level; front to back and side to side.

• Use the capacity chart to determine safe boom extension range. See “Use of the Capacity Chart” on page 5-4.

• Align forks at the level load is to be placed, then extend boom slowly until load is just above area where it is to be placed.

• Lower the boom until the load rests in position and the forks are free to retract.

Disengaging a Load

Once the load has been placed safely at the landing point, proceed as follows:

1. With the forks free from the weight of the load, the boom can be retracted and/or the telehandler can be backed away from under the load if surface will not change level condition of telehandler.

2. Lower the carriage.

3. The telehandler can now be driven from the landing location to continue work.

4-731200169

Section 4 - Operation

4.3 OPERATING WITH A SUSPENDED LOAD

Lift Load Safely

• You must know the weight and load center of every load you lift. If you are not sure of the weight and load center, check with your supervisor or with the supplier of the material.

WARNING

TIP OVER HAZARD. Exceeding lift capacity of the telehandler could damage the

equipment and/or cause tip over.

• Know the rated load capacities (refer to Section 5) of the telehandler to determine the operating range in which you can safely lift, transport and place a load.

Picking Up a Suspended Load

• Note the conditions of the terrain. Adjust travel speed and reduce amount of load if conditions warrant.

• Avoid lifting double-tiered loads.

• Make sure load is clear of any adjacent obstacles.

• NEVER operate telehandler without a proper and legible capacity chart in the operator cab for the telehandler/attachment combination you are using.

• Only use approved lifting devices rated for the lifting of the load.

• Identify the proper lifting points of the load, taking into consideration the center of gravity and load stability.

• Ensure to always properly tether loads to restrict movement.

• Refer to See “Use of the Capacity Chart” on page 5-4. for proper lifting guidelines in addition to the appropriate capacity chart in the operator cab.

4-8 31200169

Transporting a Suspended Load

Section 4 - Operation

OZ3160

• Travel in accordance with the requirements set forth in Section 1 - General Safety Practices and Section 5 - Attachments.

• For additional requirements, refer to the appropriate capacity chart in the operator cab.

Important things to remember:

• Ensure the boom is fully retracted.

• Never raise the load more than 11.8 in (300 mm) above ground surface or the boom more than 45°.

• The combination of frame leveling and load could cause the telehandler to tip over.

• The guide men and operator must remain in constant communication (verbal or hand) and be in visual contact with the operator at all times.

• Never place the guide men between the suspended load and the telehandler.

• Only transport the load at walking speed, 0.9 mph (0.4 m/s), or less.

OW0130

Leveling Procedure

1. Position machine in best location to lift or place load.

2. Apply parking brake and move transmission control lever to NEUTRAL.

3. Move boom so load is no more than 11.8 in (300 mm) above ground surface and boom/or boom is raised no more than 45°.

The telehandler is designed to permit leveling the main frame 8° to left or right to compensate for uneven ground conditions.

4-931200169

Section 4 - Operation

Placing a Suspended Load

Before placing any load be sure that:

• The landing point can safely support the weight of the load.

• The landing point is level; front to back and side to side.

• Use the capacity chart to determine safe boom extension range. See “Use of the Capacity Chart” on page 5-4.

• Align load at the level load is to be placed, then position boom slowly until load is just above area where it is to be placed.

• Ensure that the guide men and operator remain in constant communication (verbal or hand) when placing the load.

Disengaging a Suspended Load

• Never place the guide men between the suspended load and the telehandler.

• Once at the destination of the load, ensure to bring the telehandler to a complete stop and apply the park brake prior to disengagement of the lifting devices and tethers.

4-10 31200169

Section 4 - Operation

4.4 LOADING AND SECURING FOR TRANSPORT

OX0670

Tiedown

1. Level the telehandler prior to loading.

2. Using a spotter, load the telehandler with boom as low as possible.

3. Once loaded, apply parking brake and lower boom until boom or attachment is resting on deck. Move all controls to “Neutral,” stop engine and remove ignition key.

4. Secure machine to deck by passing chains through the designated tie down points as shown in the figure.

5. Do not tie down front of boom.

Note: The user assumes all responsibility for choosing the proper method of transportation and tie-down devices, making sure the equipment used is capable of supporting the weight of the vehicle being transported and that all manufacturer’s instructions and warnings, regulations and safety rules of their employer, the Department of Transportation and/or any other local, state or federal/provincial laws are followed.

WARNING

TELEHANDLER SLIDE HAZARD. Before loading telehandler for transport,

make sure deck, ramps and telehandler wheels are free of mud, snow and ice. Failure to do so could cause telehandler to slide.

4-1131200169

Section 4 - Operation

Lifting

• When lifting machine, it is very important that the lifting device and equipment is attached only to designated lifting points. If machine is not equipped with lifting lugs contact JLG Product Safety for information.

• Make adjustments to the lifting device and equipment to ensure the machine will be level when elevated. The machine must remain level at all times while being lifted.

• Ensure that the lifting device and equipment is adequately rated and suitable for the intended purpose. See Section 9 - Specifications for machine weight.

• Remove all loose items from machine prior to lifting.

• Lift machine with smooth, even motion. Set machine down gently. Avoid quick or sudden motions that could cause shock loads to machine and/or lifting devices.

4-12 31200169

Section 5 - Attachments

SECTION 5 - ATTACHMENTS

5.1 APPROVED ATTACHMENTS

To determine if an attachment is approved for use on the specific telehandler you are using, perform the following prior to installation.

Before S/N 0160037689

• The attachment model/option number on the attachment identification plate must match the attachment number on a capacity chart located in the operator cab.

• The model on the capacity chart must match the model telehandler being used.

• The load center of the fork (if equipped) must match the load center as indicated on the capacity chart.

• Hydraulically powered attachments must only be used on machines equipped with auxiliary hydraulics.

• Hydraulically powered attachments that require auxiliary electrics must only be used on machines equipped with auxiliary hydraulics and electrics.

S/N 0160037689 & After

• The attachment type, weight, dimensions and load center must be equal to or less than the data shown on a capacity chart located in the operator cab.

• The model on the capacity chart must match the model telehandler being used.

• Hydraulically powered attachments must only be used on machines equipped with auxiliary hydraulics.

• Hydraulically powered attachments that require auxiliary electrics must only be used on machines equipped with auxiliary hydraulics and electrics.

If any of the above conditions are not met, do not use the attachment. The telehandler may not be equipped with the proper capacity chart or the attachment may not be approved for the model telehandler being used. Contact JLG or a local distributor for further information.

5-131200169

Section 5 - Attachments

5.2 UNAPPROVED ATTACHMENTS

Do not use unapproved attachments for the following reasons:

• Range and capacity limitations for “will fit,” homemade, altered, or other non-approved attachments cannot be established.

• An overextended or overloaded telehandler can tip over with little or no warning and cause serious injury or death to the operator and/or those working nearby.

• The ability of a non-approved attachment to perform its intended function safely cannot be assured.

WARNING

Use only approved attachments. Attachments which have not been approved for use with your telehandler could cause machine damage or an accident.

5-2 31200169

Section 5 - Attachments

5.3 TELEHANDLER/ATTACHMENT/FORK CAPACITY

OW0550

Prior to installing the attachment verify it is approved and the telehandler is equipped with the proper capacity chart. See “Approved Attachments” on page 5-1.

To determine the maximum capacity of the telehandler and attachment, use the smallest of the following capacities:

• Capacity stamped on the attachment identification plate (1).

• Fork capacities and load centers are stamped on the side of each fork (2) (if equipped). This rating specifies the maximum load capacity that the individual fork can safely carry at the maximum load center (3). Total attachment capacity is multiplied by the number of forks on the attachment (if equipped), up to the maximum capacity of the attachment.

• Maximum capacity as indicated on the proper capacity chart. See “Approved Attachments” on page 5-1.

• When the load rating of the telehandler differs from the capacity of the forks or attachment, the lower value becomes the overall load capacity.

Use the proper capacity chart to determine maximum capacity at various machine configurations. Lifting and placing a load may require use of more than one capacity chart based on machine configuration.

Other than block forks, all forks should be used in matched pairs, block forks used in matched sets.

WARNING

Never use an attachment without the appropriate JLG approved capacity chart installed on the telehandler.

5-331200169

Section 5 - Attachments

5.4 USE OF THE CAPACITY CHART

To properly use the capacity chart (see page 5-6), the operator must first determine and/or have the following:

1. An approved attachment. See “Approved Attachments” on page 5-1.

2. The proper Capacity Chart(s).

3. Weight of the load being lifted.

4. Load placement information:

a. HEIGHT where the load is to be placed.

b. DISTANCE from the front tires of the telehandler where the load is to be

placed.

5. On the Capacity Chart, find the line for the height and follow it over to the distance.

6. The number in the load zone where the two cross is the maximum capacity for this lift. If the two cross at a division between zones, the smaller number must be used.

The number in the load zone must be equal to or greater than the weight of the load to be lifted. Determine the limits of the load zone on the capacity chart and keep within these limits.

Capacity Indicator Locations

ATTACHMENT

IDENTIFICATION

PLATE

BOOM

EXTENSION

INDICATOR

FORK

WEIGHT

STAMP

5-4 31200169

BOOM ANGLE

INDICATOR

° 0 8

° 0 7

° 0

° 0 5

° 0

° 0 2

0°

OX0190

Section 5 - Attachments

This Page Intentionally Left Blank

5-531200169

Section 5 - Attachments

Sample Capacity Chart

Before S/N 0160037689

DEDUCT 350 LBS

FROM ALL CAPACITIES

WHEN MACHINE IS

EQUIPPED WITH WINCH

48'

RATED CAPACITY @ 2 FT. LOAD CENTER

44'

40'

36'

48" & 72"

32'

CARRIAGES

28'

24'

Boom Angle

20'

16'

12'

-4'

-8'

USE WITH: 1234-5678 48" CARRIAGE 8765-4321 72" CARRIAGE

These numbers must match the

model/option number stamped

on the attachment ID Plate.

30°

20°

10°

1100 LBS

0°

-6°

36'

MODEL

XXXXX

50°

40°

3000 LBS

2000 LBS

00 0

60°

6000 LBS

5000 LBS

12'16'20'24'28'32'

69°

7000 LBS

9000 LBS

This Capacity Chart may be used with this model ONLY.

The model of your

telehandler is indicated on

the boom or chassis.

Model XXXXX is used for

demonstration purposes only.

0'4'8'

Boom Extension

Indicator (arc)

Load zones indicate

the maximum weight

that may be safely lifted.

XXXX-XXXX

OWO650

Note: This is a sample capacity chart only! DO NOT use this chart, use the one located in your operator cab.

WARNING

TIP OVER HAZARD. All loads shown on rated capacity chart are based on

machine being on firm ground with frame level (see page 4-6); the forks being positioned evenly on carriage; the load being centered on forks; proper size tires being properly inflated; and the telehandler being in good operating condition.

5-6 31200169

Section 5 - Attachments

To identify the proper capacity chart on telehandlers equipped with outriggers, refer to the following icons which may be located on the capacity chart.

• Use when lifting a load with outriggers up.

OAL1090

• Use when lifting a load with outriggers down.

OAL1100

5-731200169

Section 5 - Attachments

S/N 0160037689 & After

This Capacity Chart may be used with this model ONLY.

The telehandler model is indicated on the boom or chassis.

Model XXXX is used for demonstration purposes only.

XXXXXX

LBS

50°

BLS

XXXX

XXXX XX MAX

60°

XXXX

71°

Boom Angle

10°

0°

40°

30°

20°

XXXX

SLB

XXXX

-4

XXXX

=XXXX XX MAX

LBS

XXXXXXXXXXXXXXXXXXXXXXXX

Attachment type,

< = XX

weight and

dimensions must

be equal to or less

than the data

shown.

Boom Extension

Indicator (arc)

OY1520

ANSI/ITSDF B56.6-2005

Load zones indicate the

maximum weight that

may be safely lifted.

Load center must

be equal to or less

than value shown.

XXXXXXXXXX X

Note: This is a sample capacity chart only! DO NOT use this chart, use the one located in your operator cab.

WARNING

TIP OVER HAZARD. All loads shown on rated capacity chart are based on

5-8 31200169

Section 5 - Attachments

To identify the proper load chart on telehandlers equipped with outriggers, refer to the following icons which may be located on the load chart.

• Use when lifting a load with outriggers up.

OAL1090

• Use when lifting a load with outriggers down.

OAL1100

5-931200169

Section 5 - Attachments

Example

A contractor owns a model xxxxx telehandler with a fork carriage. He knows this attachment may be used with his model since:

Before S/N 0160037689

• The attachment model/option number matches the attachment number on the capacity chart.

• The capacity chart is clearly marked for model xxxxx and corresponds with machine configuration being used.

S/N 0160037689 & After

• The attachment style, weight, dimensions and load center match the attachment data on the capacity chart.

• The capacity chart is clearly marked for model xxxxx and corresponds with machine configuration being used.

Below are examples with various conditions the contractor may encounter and whether or not the load may be lifted.

Load Weight Distance Height OK to Lift

1 6000 lb (2722 kg) 18 ft (5,5 m) 12 ft (3,7 m) Yes

2 4000 lb (1814 kg) 30 ft (9,1 m) 26 ft (7,9 m) NO

3 7500 lb (3402 kg) 8 ft (2,4 m) 24 ft (7,3 m) Yes

4 5750 lb (2608 kg) 12 ft (3,7 m) 44 ft (13,4 m) NO

Example 2

Example 1

60'

56'

52'

48'

44'

40'

36'

32'

28'

24'

20'

16'

12'

-4'

30°

20°

10°

0°

-4

48

40'

44'

50°

40°

5000 BLS

4000 LBS

3000 SLB

36'

24'

32'

20'

28'

71°

60°

16'

L6000

L8000 BS

10000 LBS

12'

Example 4

Example 3

OY1710

Note: This is a sample capacity chart only! DO NOT use this chart, use the one located in your operator cab.

5-10 31200169

5.5 ATTACHMENT INSTALLATION

BEFORE S/N 0160037689 S/N 0160037689 & AFTER

Section 5 - Attachments

OX0680

1. Attachment

2. Attachment Pin Recess

3. Attachment Pin

4. Lock Pin

5. Retaining Pin

6. Quick Switch

(attachment tilt control in cab, see page 3-8)

WARNING

CRUSH HAZARD. Always be certain that carriage or attachment is properly

positioned on boom and is secured by lock pin and retainer pin. Failure to ensure proper installation could permit carriage/attachment/load to disengage.

5-1131200169

Section 5 - Attachments

Before S/N 0160037689

This installation procedure is designed for one-person operation. Prior to exiting cab, perform “Shut-Down Procedure” on page 4-4.

1. Tilt quick switch back to provide clearance. Check to be sure lock pin is secured in out position with retainer pin.

OX0690

2. Align attachment pin with recess in attachment. Raise boom slightly to engage attachment pin in recess.

OX0700

3. Tilt quick switch forward to engage attachment.

OX0710

4. Remove retainer pin and slide lock pin in fully. Secure lock pin in locked position using retainer pin.

OX0720

5. If equipped, swing attachment saddles down and pin in place.

OY0601

6. If equipped, connect auxiliary hydraulic hoses. See “Hydraulic Operated Attachment” on page 5-14.

7. If equipped, connect auxiliary electric harness.

5-12 31200169

Section 5 - Attachments

S/N 0160037689 & After

This installation procedure is designed for one-person operation. Prior to exiting cab, perform “Shut-Down Procedure” on page 4-4.

1. Tilt quick switch back to provide clearance. Check to be sure lock pin is removed.

OY1550

2. Align attachment pin with recess in attachment. Raise boom slightly to engage attachment pin in recess.

OY1560

3. Tilt quick switch forward to engage attachment.

4. Lift retainer pin and insert lock pin completely through quick switch. Release retainer pin and ensure lock pin is secured.

5. If equipped, connect auxiliary hydraulic hoses. See “Hydraulic Operated Attachment” on page 5-14.

6. If equipped, connect auxiliary electric harness.

OY1570

OY1580

5-1331200169

Section 5 - Attachments

Hydraulic Operated Attachment

1. Install attachment (see page 5-11).

2. Lower attachment to ground and perform “Shut-Down Procedure” on page 4-4.

S/N 0160037689 & AFTERBEFORE S/N 0160037689

OX0740

3. Connect attachment hoses to both auxiliary fittings (2).

OY1720

5-14 31200169

Section 5 - Attachments

5.6 ADJUSTING/MOVING FORKS

Carriages may have different locations where forks can be positioned. Two different methods can be used for repositioning, depending upon the carriage structure.

Note: Apply a light coating of appropriate lubricant to ease sliding of forks or fork bar.

To slide forks:

1. Ensure attachment is properly installed. See “Attachment Installation” on page 5-11.

2. Elevate attachment to approximately 5 ft (1,5 m) and tilt carriage forward until fork heel is free from attachment.

3. Stand at the side of the carriage. To slide fork toward the center of the carriage, push the fork near the fork eye. To slide fork toward the edge of the carriage, pull the fork near the fork eye. To avoid pinching, do not place fingers or thumb between the fork and carriage structure.

If removing fork bar is necessary:

1. Rest forks on ground.

2. Remove fork bar.

3. Reposition forks.

4. Reinstall the fork bar and fork bar retaining mechanism(s).

5-1531200169

Section 5 - Attachments

5.7 ATTACHMENT OPERATION

• Capacities and range limits for the telehandler change depending on the attachment in use.

• Separate attachment instructions must be kept in manual holder in cab with this Operation & Safety Manual. An additional copy must be kept with the attachment if it is equipped with a manual holder.

• Operations described within this section reference right hand attachment tilt and left hand auxiliary hydraulics controls. Refer to pages 3-9 or 3-11 if equipped with a different configuration.

NOTICE

EQUIPMENT DAMAGE. Some attachments may contact the front tires or machine structure when the boom is retracted and the attachment is rotated. Improper use of attachment may result in attachment or machine structural damage.

NOTICE

EQUIPMENT DAMAGE. Avoid contact with any structure or object when lifting a load. Maintain clearance around boom structure and load. Failure to maintain clearance may result in attachment or machine structural damage.

5-16 31200169

Section 5 - Attachments

This Page Intentionally Left Blank

5-1731200169

Section 5 - Attachments

Carriage w/Forks

Description P/N

Carriage, 48 in (Before S/N 0160037689) .................... 90455051

Carriage, 66 in (Before S/N 0160037689) .................... 90455052

Carriage, 72 in (Before S/N 0160037689) .................... 90555008

OY0690

Fork, Block 2x2x48 in (Before S/N 0160037689)..........90600390

Fork, Pallet 1.75x6x48 in (Before S/N 0160037689) ....90601819

Fork, Pallet 2x4x48 in (Before S/N 0160037689) .........90453002

Fork, Pallet 2.25x4x48 in (Before S/N 0160037689) ....90453048

Fork, Pallet 2x6x48 in (Before S/N 0160037689) .........90553005

Fork, Pallet 2x6x60 in (Before S/N 0160037689) .........90601015

Fork, Pallet 2x6x60 in (Before S/N 0160037689) .........91163269

Fork, Pallet 2x6x72 in (Before S/N 0160037689) .........90553018

Fork, Pallet 2x6x72 in (Before S/N 0160037689) .........91123132

Carriage, 50 in (Before S/N 0160037689) ......................1170020

Carriage, 50 in (S/N 0160037689 & After)......................1170021

Carriage, 60 in (Before S/N 0160037689) ......................1170023

Carriage, 60 in (S/N 0160037689 & After)......................1170024

Carriage, 72 in (Before S/N 0160037689) ......................1170026

Carriage, 72 in (S/N 0160037689 & After)......................1170027

Fork, Block 2x2x48 in .....................................................2340037

Fork, Pallet 2.36x4x48 in ................................................2340045

Fork, Pallet 2.36x5x48 in ................................................2340038

Fork, Dual Taper 1.75x7x60 in........................................2340046

Fork, Dual Taper 2.36x6x60 in........................................2340039

Fork, Dual Taper 2x6x72 in.......................................1001092391

Use Carriage Attachment Capacity Chart

To determine maximum capacity, refer to “Telehandler/Attachment/Fork Capacity” on page 5-3.

T N O R F

OX0241

5-18 31200169

Section 5 - Attachments

The joystick (1) controls lift/lower and extend/retract movement of the boom.

The tilt lever (2) controls the carriage tilt.

• Move lever back to tilt up.

• Move lever forward to tilt down.

Installation Procedure:

Refer to “Attachment Installation” on page 5-11.

Equipment Damage Precautions:

• Do not use forks as a lever to pry material. Excessive prying forces could damage forks or machine structure.

• Do not attempt to lift loads that are attached or connected to another object.

5-1931200169

Section 5 - Attachments

Side Tilt Carriage

Description P/N

Side Tilt Carriage, 48 in (Before S/N 0160037689) ......91085058

Side Tilt Carriage, 50 in (S/N 0160037689 & After)........1170054

Side Tilt Carriage, 60 in (S/N 0160037689 & After)..1001101956

Side Tilt Carriage, 66 in (Before S/N 0160037689) ......91305016

OAL1550

Side Tilt Carriage, 72 in (S/N 0160037689 & After)........1170057

Fork, Block 2x2x48 in (Before S/N 0160037689)..........90600390

Fork, Block 2x2x48 in (S/N 0160037689 & After) ........... 2340037

Fork, Pallet 1.75x6x48 in (Before S/N 0160037689) ....90601819

Fork, Pallet 2.36x4x48 in (S/N 0160037689 & After)...... 2340045

Fork, Pallet 2x4x48 in (Before S/N 0160037689) .........90453002

Fork, Pallet 2.25x4x48 in (Before S/N 0160037689) ....90453048

Fork, Pallet 2.36x5x48 in (S/N 0160037689 & After)...... 2340038

Fork, Pallet 2x6x48 in (Before S/N 0160037689) .........90553005

Fork, Dual Taper 1.75x7x60 in

(S/N 0160037689 & After) ..............................................2340046

Fork, Pallet 2x6x60 in (Before S/N 0160037689) .........90601015

Fork, Pallet 2x6x60 in (Before S/N 0160037689) .........91163269

Fork, Dual Taper 2.36x6x60 in

(S/N 0160037689 & After) ..............................................2340039

Fork, Pallet 2x6x72 in (Before S/N 0160037689) .........90553018

Fork, Pallet 2x6x72 in (Before S/N 0160037689) .........91123132

Fork, Dual Taper 2x6x72 in

(S/N 0160037689 & After) ........................................1001092391

Use Side Tilt Carriage Attachment Capacity Chart

To determine maximum capacity, refer to “Telehandler/Attachment/Fork Capacity” on page 5-3.

OX0311

N O R F

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Section 5 - Attachments

The joystick (1) controls lift/lower and extend/retract movement of the boom.

The tilt lever (2) controls the carriage tilt.

• Move lever back to tilt up.

• Move lever forward to tilt down.

To Side Tilt:

The auxiliary hydraulic lever (3) controls the carriage side tilt.

• Move lever up to (side) tilt left.

• Move lever down to (side) tilt right.

Installation Procedure:

• Refer to “Attachment Installation” on page 5-11.

WARNING

CRUSH HAZARD. Do not use side tilt to push or pull objects or load. Failure to

comply could cause object or load to fall.

Operation:

• Approach load with forks centered on load and stop telehandler.

• Level telehandler before side tilting carriage to engage load.

• Side tilt carriage to left or right to align forks with load and engage load.

• Raise load slightly and level carriage side to side.

• Travel in accordance with the requirements set forth in Section 1 - General Safety Practices.

Equipment Damage Precautions:

• Do not use forks as a lever to pry material. Excessive prying forces could damage forks or machine structure.

• Do not attempt to lift loads that are attached or connected to another object.

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Section 5 - Attachments

Swing Carriage

Description P/N

90° Swing Carriage (S/N 0160037689 & After)........1001095418

100° Swing Carriage (Before S/N 0160037689) ..........90455044

180

° Swing Carriage (534D-10)

OU2150

(Before S/N 0160037689).............................................91553076

180

° Swing Carriage (S/N 0160037689 & After)...... 1001104992