JLG G10-43A Operator Manual

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Operation & Safety

Manual

Original Instructions

Keep this manual with machine at all times.

Models

G10-55A

G12-55A

AccuPlace

3128447

Revised

January 5, 2010

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

December 5, 2008 - A - Original Issue of Manual

December 19, 2008 - B - Revised page 3-15.

January 5, 2010 - C - Revised covers and pages b, 1-5, 1-6, 2-1, 2-6, 4-5, 4-8, 5-2, 5-14, 5-15, 5-16, 5-18, 5-20, 5-22, 5-24 thru 5-28, 5-30, 5-32, 7-3, 7-5, 7-16, 7-19, 7-21, 9-2 & 9-3.

REVISION LOG

a3128447

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 (ANSI only)

• All instructional decals and plates

• Any optional equipment instructions furnished

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

Modifications

Any modification to this machine must be approved by JLG.

b 3128447

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

c3128447

Read This First

Other Publications Available

Service Manual..........................................................................................31200452

Parts Manual .............................................................................................31200454

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 3128447

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

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

Display ............................................................................3-5

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

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

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

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

i3128447

Table of Contents

Boom Joystick .............................................................. 3-10

Frame Level Joystick.................................................... 3-12

Auxiliary Hydraulic Joystick .......................................... 3-13

Outrigger Joysticks ....................................................... 3-14

Right Panel ................................................................... 3-15

Accessory Control Lever (if equipped) ......................... 3-16

Heater and Air Conditioning Controls (if equipped) ...... 3-17

3.3 Steer Modes...................................................................... 3-18

Steer Mode Change ..................................................... 3-18

3.4 Operator Seat.................................................................... 3-19

Adjustments.................................................................. 3-19

Seat Belt ....................................................................... 3-20

3.5 Boom Angle and Extension Indicators .............................. 3-21

Section 4 - Operation

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

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

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

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

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

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

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

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

Transporting a Load ....................................................... 4-5

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

Placing a Load................................................................ 4-6

Disengaging a Load........................................................ 4-6

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

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

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

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

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

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

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

4.4 Loading and Securing for Transport.................................. 4-10

Tiedown ........................................................................ 4-10

Lifting ............................................................................ 4-11

Section 5 - Attachments

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

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

5.3 JLG Supplied Attachments.................................................. 5-2

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

ii 3128447

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

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

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

Example ..........................................................................5-8

5.6 Attachment Installation ......................................................5-10

5.7 Hydraulic Operated Attachment.........................................5-12

5.8 Adjusting/Moving Forks......................................................5-13

5.9 Attachment Operation........................................................5-14

Carriage w/Forks........................................................... 5-15

Side Tilt Carriage ..........................................................5-16

Swing Carriage .............................................................5-18

Mast Carriage ...............................................................5-20

Mast Carriage w/Side Tilt ..............................................5-22

Fork Mounted Hook ...................................................... 5-24

Truss Boom...................................................................5-26

Bucket ........................................................................... 5-28

Grapple Bucket .............................................................5-30

Personnel Work Platform - Fork Mounted..................... 5-32

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 100 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

iii3128447

Table of Contents

Transmission Oil........................................................... 7-17

Hydraulic Return Filter .................................................. 7-18

Engine Cooling System ................................................ 7-19

Battery .......................................................................... 7-20

Windshield Washer System (if equipped)..................... 7-21

Section 8 - Additional Checks

Section 9 - Specifications

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

Capacities....................................................................... 9-1

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

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

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

Index

Inspection, Maintenance and Repair Log

iv 3128447

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 & 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.

1-13128447

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 3128447

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.)

1-33128447

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

Trying to escape from a tipping machine could result in death or serious injury.

1-4 3128447

Non-Suspended Load

• DO NOT drive with boom raised.

Suspended Load

Section 1 - General Safety Practices

OW0060

OW0150

• Tether suspended loads to restrict movement.

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

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

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

• Keep heavy part of load closest to attachment.

• Never drag the load; lift vertically.

When driving with a suspended load:

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

• DO NOT extend boom.

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

• DO NOT exceed walking speed.

1-53128447

Section 1 - General Safety Practices

Travel Hazard

2-Wheel Front Steer 4-Wheel Circle Steer 4-Wheel Crab Steer

OAL2030

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

• DO NOT change steer modes while traveling. Steer modes must be changed while telehandler is stationary.

• Visually verify proper wheel alignment after each steer mode change.

• Ensure that adequate clearance is provided for both rear tail swing and front fork swing.

• Look out for and avoid other personnel, machinery and vehicles in the area. Use a spotter if you DO NOT have a clear view.

• Before moving be sure of a clear path and sound horn.

• When driving, retract boom and keep boom/attachment as low as possible while maintaining visibility of mirrors and maximum visibility of path of travel.

• Always look in the direction of travel.

• Always check boom clearances carefully before driving underneath overhead obstructions. Position attachment/load to clear obstacles.

• When driving in high speed, use only front wheel steer (if steering modes are selectable).

1-6 3128447

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.

1-73128447

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 3128447

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.

1-93128447

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 3128447

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.

1-113128447

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 4-3 has been performed.

OW0290

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

1-12 3128447

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.

1-133128447

Section 1 - General Safety Practices

This Page Intentionally Left Blank

1-14 3128447

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 & 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 (ANSI only) 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, transmission fluid 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.

2-13128447

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 3128447

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.

1705881

CONTACTING ELECTRIC POWER LINES will result in death or serious injury.

91503108

MOVING PARTS could crush causing death or serious injury.

91503110

10 FT. (3 M)

Do not place machine or load within 10 feet (3m) of electric power lines.

91563246

Down-shift to a lower gear when descending. Overspeeding of drivetrain could result in equipment damage or personal injury.

Keep clear of wheels and moving parts while engine is running.

9150-3110 REV - A

GEAR

3 2 1

9156-3246 REV A

91503109

NO RIDERS. Riders could FALL OFF

9150-3108 REV -

machine causing death or serious injury.

9150-3109 REV -

1706300

ENGINE EXPLOSION could result in death or serious injury.

1706300C

DO NOT use Ether or other high energy starting aids.

Engine equipped with Pre-heating system.

91503108

MOVING PARTS could crush causing death or serious injury.

Keep clear of wheels and moving parts while engine is running.

9150-3108 REV -

1707038

91503098

For safe operation of machine, and to minimize risk of

serious injury, READ AND OBSERVE the following:

1. Only trained and authorized personnel may operate this machine.

2. Before operating, read and understand all capacity charts, operator manual and safety manuals.

1707038D

3. Operator must be seated with seat belt fastened. Assure all controls are in neutral before ignition switch is turned on.

4. Do not travel with boom raised. When traveling, fully retract boom and place forks in carry position, which is approximately 4 feet (1.2 m) above ground. Tilt carriage back slightly to cradle load. Use extreme caution when turning.

5. On inclines, travel with load up-grade.

6. Keep others away from machine when operating. Do not allow others to stand under boom or load. Always look in direction of travel.

7. Use extreme care when handling long, high or wide loads. Do not handle unstable or loosely stacked loads.

8. Forks must be centered under load, and spaced apart as far as possible.

9. Level machine before lifting any load above 4 feet (1.2m).

10. Improper use of machine could result in machine tipping over. If machine starts to tip over, do not leave operator's seat. Lean away from tip, and brace yourself.

11. Keep mirror(s) clean and properly adjusted. Objects in mirror(s) are closer than they appear.

9150-3098 REV. A

91513208

When lifting personnel, USE ONLY a Gradall manufactured personnel work platform, with proper personnel work platform CAPACITY CHART DISPLAYED in cab.

READ AND UNDERSTAND personnel work platform Owner/Operator manual before lifting personnel.

DO NOT DRIVE machine from cab when personnel are on platform.

All personnel on platform must WEAR A FULL BODY HARNESS, with lanyard attached to a designated anchorage point.

When personnel are on platform, the OPERATOR MUST REMAIN SEATED in cab with personnel in direct line of sight.

OPERATE CONTROLS CAUTIOUSLY and lightly when lifting or positioning personnel.

Failure to comply could result in death or serious injury.

9151-3208 REV -

1001100996A

1001100996

1001100999A

1001100999

1001100998A

1001100998

OY1260

2-33128447

Section 2 - Pre-Operation and Inspection

91163028

CAPACITY CHARTS

MOVING PARTS could crush causing death or serious injury.

91503108

Keep clear of wheels and moving parts while engine is running.

91503097

MOVING PARTS can cut or entangle. Keep clear while engine is running.

9150-3097 REV. -

9150-3108 REV -

VIEW OF CAB DASH

91563227

LUBRICATION AND MAINTENANCE

SERVICE INTERVALS

6 MO.

YEARLY

3 MO.

EVERY 5

DAILY

LUBRICANT TYPE

WEEKLY

WKS OR

MATERIAL HANDLER

Diesel Engine

Air Cleaner Element

Fuel Filter

Engine Oil Filter

Engine Oil

Coolant

Diesel Fuel

Transmission

Lubricant

Filter

Transfer Case

Lubricant

Axle Lubricant

Center Section

Planetary Hubs

Hydraulic System

Lubricant

Filter

Breather/Filter

Grease Fittings

Axles (6 Pts. Ea.)

Boom Head Pivot (2 Pts.)

Boom Pivot (2 Pts.)

Cylinder Pins(13 Pts.)

Drive Shafts (1 Pt. Ea.)

Extend Chain Sheave (1 Pt.)

Quick Switch Pin (1 Pt.)

Retract Chain Sheave (1 Pt.)

Boom

Front Bottom Bearing Pads

All Other Bearing Pads

Extend/Retract Chains

Options And Attachments

Stabilizer Cylinder (3 Pts.)

Attachment Pivots And Pins

Tires

14.00R24 12 Radial

17.5-25 12 Ply

17.5R25 Radial

Lug Nut Torque

Use this chart in conjunction with the "Lubrication & Maintenance" and "Recommended Lubricants & Capacities" sections of the Owner/Operator Manual.

Service intervals may need to be more frequent than those shown depending upon application severity. Consult your Gradall dealer for recommendations.

It is recommended that engine oil and filter, transmission lubricant and filter, transfer case lubricant and axle lubricant be changed after first 100 hours on new, or rebuilt units.

1000 HRS

1500 HRS

500 HRS

250 HRS

10 HRS

SPECIFICATION

50 HRS

Check

Change Change

Change

SAE 15W-40 CE Oil

Check

Change

Etheylene Glycol

No. 2 Diesel Fuel

Fill

Change

Mobil 424

Check

Change

Check

Change

Mobil 424

Check

Change

Mobil 424

Check

Change

Mobil 424

Change

Mobil 424

Check

Change

Check

Change

Grease

Mystik Tetrimoly

Grease

Mystik Tetrimoly

Grease

Mystik Tetrimoly

Grease

Mystik Tetrimoly

Grease

Mystik Tetrimoly

Grease

Mystik Tetrimoly

Grease

Mystik Tetrimoly

Grease

Mystik Tetrimoly

Grease

Check

Mystik Tetrimoly

Grease

Mystik Tetrimoly

Check

See Manual

Grease

Mystik Tetrimoly

Grease

Mystik Tetrimoly

Check

70 PSI (483 kPa)

Check

51 PSI (352 kPa)

Check

73 PSI (503 kPa)

Torque

350-400 Lb-Ft (475-540 Nm)

9156-3227 REV(A)

9156-3220 REV A

91563220

91513209

9151-3209 REV -

MOVING PARTS could crush causing death or serious injury.

91503108

91413061

91503099

Batteries produce EXPLOSIVE GASES. EXPLOSION could result in serious injury.

Keep clear of wheels and moving parts while engine is running.

9150-3108 REV -

Keep sparks, flames and lighted materials away from batteries.

9150-3099 REV -

OY1270

2-4 3128447

91513210

MOVING PARTS could cut or crush causing death or serious injury. Keep clear of moving parts while engine is running.

9151-3210 REV -

MOVING PARTS could crush causing death or serious injury.

91563157

4105262

-10

Keep clear of swing attachments and moving parts while engine is running.

Section 2 - Pre-Operation and Inspection

91513210

9156-3157 REV C

MOVING PARTS could cut or crush causing death or serious injury. Keep clear of moving parts while engine is running.

VIEW A-A

MOVING PARTS could cut or crush causing death or serious injury. Keep clear of moving parts while engine is running.

91513210

9151-3210 REV -

91513210

MOVING PARTS could cut or crush causing death or serious injury. Keep clear of moving parts while engine is running.

9151-3210 REV -

91513210

MOVING PARTS could cut or crush causing death or serious injury. Keep clear of moving parts while engine is running.

91553072

9151-3210 REV -

OW0352

2-53128447

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.

OY1940

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 Cylinders

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

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

2. Left Outrigger leaking.

3. Front Axle hydraulic hoses undamaged, not leaking.

- Pins secure; hydraulic hoses and cylinder undamaged, not

- Steer cylinders undamaged, not leaking; pivot pins secure;

2-6 3128447

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. Mirrors

- Clean and undamaged.

6. 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.

7. Air Cleaner condition. Replace element as required.

8. Lift Valve

9. Wheel/Tire Assembly

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

10. Stabilizer Cylinder

11. Rear Axle

hydraulic hoses undamaged, not leaking.

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

13. Ride Control Accumulator (if equipped)- See Inspection Note.

14. Engine Compartment -

• Drive belts, check condition and replace as required.

• Engine mounts - See inspection note.

• Outrigger Valve - See inspection note.

• Battery cables tight, no visible damage or corrosion.

• Engine cover properly secured.

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

- See Inspection Note.

- Steer cylinders undamaged, not leaking; pivot pins secure;

- Air cleaner element condition indicator, check for clogged

- Properly inflated and secured; no loose or missing lug

- Pins secure; hydraulic hoses undamaged, not leaking.

- Properly inflated and secured; no loose or missing lug

16. Frame Level Cylinder

17. Right Outrigger

leaking.

18. Attachment

- Pins secure; hydraulic hoses and cylinder undamaged, not

- Properly installed, see “Attachment Installation” on page 5-10.

- Pins secure; hydraulic hoses undamaged, not leaking.

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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. Adjust mirror(s) for maximum visibility.

WARNING

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

except when checking transmission oil level and 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. Each gear.

4. Steering in both directions with engine at low idle (steering lock to lock will not be reached). Check in each steering mode.

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

6. All joystick functions - operate smoothly and correctly.

7. Hydraulic filter condition indicator.

8. Perform any additional checks described in Section 8.

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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.

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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.

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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.

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Section 3 - Controls and Indicators

3.2 CONTROLS

OY1282

1. Heater and Air Conditioning Controls (if equipped): See page 3-17.

2. Transmission Control Lever

3. Instrument Panel

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

machine in the corresponding direction. Three steering modes are available. See “Steer Modes” on page 3-18.

5. Frame Level Indicator condition of the telehandler.

6. Accessory Control Lever (if equipped): See page 3-16.

7. Right Panel: See page 3-15.

8. Boom Joystick

9. Frame Level Joystick

10. Auxiliary Hydraulic Joystick

: See page 3-4.

: See page 3-10.

: See page 3-8.

: Enables operator to determine the left to right level

: See page 3-12.

: See page 3-13.

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Section 3 - Controls and Indicators

11. Outrigger Joysticks: See page 3-14.

12. Accelerator Pedal

speed.

13. Service Brake Pedal speed.

14. Ignition Switch

: Pressing down the pedal increases engine and hydraulic

: Key activated. See page 3-6.

: The further the pedal is depressed, the slower the travel

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Section 3 - Controls and Indicators

Instrument Panel

7 6 5

OY1291

1. 3-in-1 Gauge and Display: a. Engine Coolant Temperature Gauge

b. Engine Oil Pressure Gauge

c. Fuel Gauge

d. Display - See page 3-5.

2. Warning and Check Engine Indicators: Any combination of illumination indicates

an engine fault and/or parameter that is outside of acceptable range. Engine may derate or shutdown.

3. Continuous Auxiliary Hydraulics

desired level and depress switch for continuous operation. Depress switch again to deactivate continuous hydraulics.

4. Auxiliary Electrics Switch

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

5. Horn Button

6. Park Brake Switch

7. Steer Select Switch

and 2-wheel steer. See page 3-18 for details.

8. Engine Preheat Indicator: Illuminates with ignition key in position II. At

temperatures below 32°F (0°C), do not start until engine is preheated.

9. Transmission Temperature Indicator: Illuminates when transmission

temperature is too high.

: Depress button to sound horn.

: See page 3-7 for details.

: Three positions: 4-wheel circle steer, 4-wheel crab steer

(if equipped): Activate auxiliary hydraulics to

(if equipped): Enables function of attachments that

NOTICE

EQUIPMENT DAMAGE. If check engine or transmission temperature indicators illuminate, immediately bring machine to a stop, lower boom and attachment to ground and stop the engine. Determine cause and correct before continued use.

3-4 3128447

Display

Section 3 - Controls and Indicators

DISPLAY SHOWN WITH ENGINE FAULT ACTIVE

10. Operating Hours: Displays total hours of telehandler operation.

11. Voltmet e r

12. Engine Speed

13. Engine Fault Indicator: Displays engine fault indicator and fault code if an active

engine fault exists. Code indicates Suspect Parameter Number/Failure Mode Indicator (SPN/FMI). Contact a local Perkins Engine Distributor for fault code information.

14. Machine Fault Indicator: Displays machine fault indicator and fault code if an

active machine fault exists (other then engine fault). Code indicates Diagnostic Trouble Code (DTC). See machine Service Manual for fault code information.

: Displays alternator output and battery condition.

XXXXXX.X

XX.X V

XXXXRPM

DISPLAY SHOWN WITH MACHINE FAULT ACTIVE

XXXXXX.X

XXX.XX

XXXX

XX.X V

XXXXRPM

: Displays engine speed in revolutions per minute (rpm).

OY1930

NOTICE

EQUIPMENT DAMAGE. If engine or machine faults become active, immediately bring machine to a stop, lower boom and attachment to ground and stop the engine. Determine cause and correct before continued use.

3-53128447

Section 3 - Controls and Indicators

Ignition

III

•Position 0 - Engine off.

•Position I - Voltage available for all electrical functions.

•Position II - Engine preheat at temperatures below 0° C (32° F). Hold in position for approximately 10 seconds.

•Position III - Engine start. In the event engine does not start, rotate key to position 0 then back to position III to re-engage the starter.

OY1470

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Park Brake

Section 3 - Controls and Indicators

OY1480

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

• Depress top of switch (1) to engage park brake. With park brake applied, transmission will not engage forward or reverse.

• Depress bottom of switch (2) to disengage park brake.

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 4-3.

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Section 3 - Controls and Indicators

Transmission Control Lever

Direction of Travel Selection

Transmission control lever (1) 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.

• Forward or reverse travel can be selected while in any gear.

• 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.

OAL0481

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.

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Gear Selection

Section 3 - Controls and Indicators

1st

2nd

3rd

4th

OAL0491

Gear selection is located on the twist grip handle (2) of transmission control lever.

• Twist hand grip to select gear.

• Select the appropriate gear for the task being performed. Use a lower gear when transporting a load. Use a higher gear only when driving unloaded for longer distances.

• Slow down prior to downshifting. Do not downshift more than one gear at a

time.

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Section 3 - Controls and Indicators

Boom Joystick

OY1310

The boom joystick (1) controls boom mode and boom and attachment functions.

Boom Mode

Boom mode is controlled by the left button (2).

• Depress button to switch between standard and AccuPlace modes.

Boom Functions - Standard Mode

OY1960

With machine in standard mode, the joystick functions as a conventional telehandler.

• 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 the 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.

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Section 3 - Controls and Indicators

Boom Functions - AccuPlace Mode

OY1950

With machine in AccuPlace mode, a single motion of the joystick will move the attachment along a vertical or horizontal path.

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

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

• Moving the joystick between quadrants will change the manner in which the boom moves. Boom movement will not be strictly vertical or horizontal.

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.

Attachment Functions

Attachment tilt is controlled by the roller switch (3).

• Push roller switch up to tilt attachment down; push roller switch down to tilt attachment up.

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Section 3 - Controls and Indicators

Frame Level Joystick

OY1320

The frame level joystick (1) controls the left to right frame level.

• Move the joystick left to rotate frame left; move the joystick right to rotate frame right.

• A level indicator is located above the front cab window to permit the 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.

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Section 3 - Controls and Indicators

Auxiliary Hydraulic Joystick

OY1330

The auxiliary hydraulic joystick (2) controls function of attachments that require hydraulic supply for operation. See Section 5 - Attachments for approved attachments and control instructions.

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Section 3 - Controls and Indicators

Outrigger Joysticks

OY1340

The outrigger joysticks (1) control the outriggers.

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

• Push joysticks forward to lower outriggers; push joysticks 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.

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Section 3 - Controls and Indicators

Right Panel

OY1301

2. Boom Ride Control Switch: Depress switch to activate boom ride control. Blue indicator light on switch flashes and slight boom movement may occur as system engages. Indicator then illuminates to indicate boom ride control is active. While activated and traveling, the system acts to cushion boom movement. Depress switch again to deactivate boom ride control.

Note: If boom is raised above 8 degrees or extended more than 3 ft (0,9 m), Boom Ride Control is disabled.

3. AccuPlace Fault Reset Indicator AccuPlace mode. Depress switch to acknowledge fault and continue operation.

4. AccuPlace Mode Indicator mode. Flashes to indicate a cylinder has reached mechanical limitations and AccuPlace movement is no longer coordinated. When coordinated movement is possible again, AccuPlace indicator stops flashing.

: Flashes orange when fault occurs while in

: Illuminates green when machine is in AccuPlace

5. Beacon Light Switch (if equipped): On/Off switch.

6. Windshield Wiper and Washer Switch

Depress to activate washer. Return to first position to turn off wiper.

7. Work Light Switch

(if equipped): On/Off switch.

(if equipped): Two speed rotary switch.

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Section 3 - Controls and Indicators

Accessory Control Lever (if equipped)

The accessory control lever (1) operates the turn signals, parking lights and headlights.

OY1350

Turn Signals

• Push the lever forward (2) to activate the left turn signal.

• Pull the lever back (3) to activate the right turn signal.

• The lever must be manually returned to the center position to deactivate either turn signal. The lever will not cancel automatically after a turn.

Parking Lights and Headlights

• Turn the twist grip (4) of the lever counterclockwise to the first position (5) to turn on the parking lights.

• Turn the twist grip to the second position (6) to turn on the headlights.

• Raise/lower the lever to switch between low and high beam.

• Turn the twist grip clockwise to the OFF position (7) to turn all lights off.

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Section 3 - Controls and Indicators

Heater and Air Conditioning Controls (if equipped)

1. Fan Speed Switch: Four position rotary switch.

2. Air Conditioning Switch: On/Off switch.

3. Temperature Control Switch

4. Air Vent

5. Air Louver: Three individually adjustable air louvers. Third air louver located

under operator seat.

6. 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.

: Two individually adjustable air vents.

: Adjustable rotary switch.

OY1361

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Section 3 - Controls and Indicators

3.3 STEER MODES

Three steer modes are available for operator use.

2-Wheel Front Steer 4-Wheel Circle Steer 4-Wheel Crab Steer

OAL2030

Note: 2-Wheel Front Steer mode is required for travel on public roads.

Steer Mode Change

123

OY1490

1. Bring machine to a stop using service brake while either circle steer mode (1) or crab steer mode (3) is selected.

4 5

OAM2400

2. Turn the steering wheel until the left rear wheel (4) is aligned with the side of the machine.

3. Select front steer mode (2).

4. Turn the steering wheel until the left front wheel (5) is aligned with the side of the machine.

5. Wheels are now aligned. Select desired steer mode.

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Section 3 - Controls and Indicators

3.4 OPERATOR SEAT

Adjustments

Prior to starting engine adjust seat for position and comfort.

OW0480

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

4. Seat Belt

seat belt is available.

: Use knob to adjust suspension to the appropriate setting. Turn

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

3-193128447

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.

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Section 3 - Controls and Indicators

3.5 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).

• The 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).

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Section 3 - Controls and Indicators

This Page Intentionally Left Blank

3-22 3128447

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. Apply park brake.

2. If the temperature is below 32° F (0° C), turn the ignition switch to “position II” and hold for approximately 10 seconds.

3. Turn ignition switch to “position III” 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 indicators. If indicators remain on for more than five seconds, stop engine and determine cause before restarting engine.

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

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

WARNING

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

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

4-13128447

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.

4-2 3128447

Section 4 - Operation

Normal Engine Operation

• Observe instrument panel frequently to be sure all 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. 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).

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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 (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 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 5-13.

• 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.

AccuPlace mode (see page 3-11) is recommended for picking and placing a load. The machine control system moves forks/attachment along straight lines allowing, for example, retracting forks from a pallet without operator having to constantly judge position of the forks in relation to the pallet.

4-4 3128447

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.

• Boom ride control mode (see page 3-15) is recommended for transport of a load over longer distances. When activated, the boom ride control system acts to cushion boom movement.

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. Observe level indicator to determine whether machine must be leveled prior to lifting load. Level machine with frame level joystick (see page 3-12) or outrigger joysticks (see page 3-14).

4. 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.)

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.

4-53128447

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.

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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 Char t” on page 5-4. for proper lifting guidelines in addition to the appropriate load chart in the operator cab.

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Section 4 - Operation

Transporting a Suspended Load

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 load 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. Observe level indicator to determine whether machine must be leveled prior to lifting load. Level machine with frame level joystick (see page 3-12) or outrigger joysticks (see page 3-14).

4. 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°.

4-8 3128447

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.

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Section 4 - Operation

4.4 LOADING AND SECURING FOR TRANSPORT

Tiedown

OAL0591

1. Level the telehandler prior to loading.

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

2. 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.

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

4. 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.

4-10 3128447

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 or weigh machine.

• 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.

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Section 4 - Operation

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4-12 3128447

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.

• 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 the local distributor for further information.

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.

5-13128447

Section 5 - Attachments

5.3 JLG SUPPLIED ATTACHMENTS

Applicable Model

Attachment Part Number

Carriage, 50 in (1270 mm) 1170021 X X

Carriage, 60 in (1524 mm) 1170024 X X

Carriage, 72 in (1829 mm) 1170027 X X

Side Tilt Carriage, 50 in (1270 mm) 1170054 X X

Side Tilt Carriage, 60 in (1524 mm) 1001101956 X X

Side Tilt Carriage, 72 in (1829 mm) 1170057 X X

90° Swing Carriage, 72 in (1829 mm) 100 1095418 X X

180° Swing Carriage, 72 in (1829 mm) 1001104992 X X

8 ft Mast Carriage, 50 in (1270 mm) 1001108668 X X

8 ft Mast Carriage w/ Side Tilt, 50 in (1270 mm) 1001108669 X X

Fork, Pallet 2.36x4x48 in (60x100x1220 mm) 2340045 X X

Fork, Pallet 2.36x5x48 in (60x127x1220 mm) 2340038 X X

Fork, Dual Taper 1 .75x7x60 in (44x178x1524 mm) 2340046 X X

Fork, Dual Taper 2 .36x6x60 in (60x152x1524 mm) 2340039 X X

Fork, Dual Taper 2x6x72 in (50 x152x1830mm) 1001092391 X X

Fork, Block 2x2x48 in (50x50x1220 mm) 2340037 X X

Bucket, 72 in - 1.0 yd

Bucket, 96 in - 1.5 yd

Bucket, 102 in - 2.0 yd

Grapple Bucket, 96 in - 1.75 yd

Hook, Fork Mounted 91565094 X X

Tr uss Boom, 12 ft (3658 mm) 1001099902 X X

Tr uss Boom w/ Winch, 12 ft (3658 mm) 1001099351 X X

Tr uss Boom, 15 ft (4572 mm) 1001099901 X X

Platform, Fork Mounted (ASME)

Platform, Fork Mounted (ASME - French)

Platform, Fork Mounted (ISO)

1001100822 X X

1001100823 X X

1001100824 X X

0930020 X X

1001092280 X X

1001103637 X X

1001097072 X X

1001103736 X X

1001096306 X X

1001103730 X X

G10-55A

AccuPlace

G12-55A

AccuPlace

5-2 3128447

Section 5 - Attachments

5.4 TELEHANDLER/ATTACHMENT/FORK CAPACITY

XXXX X XXX

XXXXXXX XXXX X XXX

XXXX X XXX

XXXXXXX XXXX X XXX

OY1500

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.

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Section 5 - Attachments

5.5 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 to 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

BOOM

ATTACHMENT

IDENTIFICATION

EXTENSION

INDICATOR

PLATE

FORK

WEIGHT

STAMP

5-4 3128447

BOOM ANGLE

INDICATOR

0 7

0 5

0 1

-10

DO NOT GO NEAR LEAKS

* High pressure oil easily punctures skin causing serious injury, gangrene or death. * If injured, seek emergency medical help. Immediate surgery is required to remove oil. * Do not use finger or skin to check for leaks. * Lower load or relieve hydraulic pressure before loosening fittings.

10814B

OY1510

Section 5 - Attachments

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5-53128447

Section 5 - Attachments

Sample Capacity Chart

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

LBS

XXXX

XXXXXXXXXXXXXXXXXXXXXXXX

=XXXX XX MAX

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

machine being on firm ground with frame level (see page 4-5); 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 3128447

Section 5 - Attachments

Note: Use of AccuPlace mode does not guarantee movement is within a specific

capacity chart zone. Always maintain boom angle and reach within allowable load zone.

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

5-73128447

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:

• 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°

BLS

500

4000 LBS

3000 SLB

36'

24'

32'

28'

71°

60°

16'

20'

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.

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Section 5 - Attachments

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5-93128447

Section 5 - Attachments

5.6 ATTACHMENT INSTALLATION

OY1540

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 3-12)

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.

5-10 3128447

Section 5 - Attachments

This installation procedure is designed for one-person operation. Prior to exiting cab, perform “Shut-Down Procedure” on page 4-3.

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.

OY1570

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

5. If equipped, connect auxiliary hydraulic hoses. See “Hydraulic Operated Attachment” on page 5-12.

6. If equipped, connect auxiliary electric harness.

OY1580

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Section 5 - Attachments

5.7 HYDRAULIC OPERATED ATTACHMENT

OY1590

1. Install attachment (see page 5-10).

2. Perform “Shut-Down Procedure” on page 4-3.

3. Connect attachment hoses to both auxiliary fittings (1).

5-12 3128447

Section 5 - Attachments

5.8 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 5-10.

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).

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Section 5 - Attachments

5.9 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 and Safety Manual. An additional copy must be kept with the attachment if it is equipped with a manual holder.

Note: Operations described within this section reference the standard joystick mode. Refer to page 3-11 if using AccuPlace mode.

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.

5-14 3128447

Carriage w/Forks

Use Carriage Attachment Capacity Chart

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

OY0690

Section 5 - Attachments

OY1390

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

The attachment tilt roller switch (2) controls carriage tilt.

• Push roller switch down to tilt up.

• Push roller switch up to tilt down.

Installation Procedure:

• Refer to “Attachment Installation” on page 5-10.

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.

5-153128447

Section 5 - Attachments

Side Tilt Carriage

Use Side Tilt Carriage Capacity Chart

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

OAL1550

OY1420

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

The attachment tilt roller switch (2) controls carriage tilt.

• Push roller switch down to tilt up.

• Push roller switch up to tilt down.

To Side Tilt:

The auxiliary hydraulic joystick (3) controls carriage side tilt.

• Move joystick right to side tilt right.

• Move joystick left to side tilt left.

Installation Procedure:

• Refer to “Attachment Installation” on page 5-10.

5-16 3128447

Section 5 - Attachments

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 resulting in death or serious injury.

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 then level carriage side to side.

• Travel in accordance with 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.

5-173128447

Section 5 - Attachments

Swing Carriage

Use Swing Carriage Capacity Chart

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

OU2150

OY1430

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

The attachment tilt roller switch (2) controls carriage tilt.

• Push roller switch down to tilt up.

• Push roller switch up to tilt down.

To Swing:

The auxiliary hydraulic joystick (3) controls carriage swing.

• Move joystick right to swing right.

• Move joystick left to swing left.

Installation Procedure:

• Refer to “Attachment Installation” on page 5-10.

5-18 3128447

Section 5 - Attachments

WARNING

CRUSH HAZARD. Always level telehandler frame and forks (horizontally) before

swinging load to side. Swinging unlevel forks could cause load to slide off forks.

WARNING

CRUSH HAZARD. Do not use swing carriage to push or pull objects or load.

Failure to comply could cause object or load to fall.

WARNING

CRUSH HAZARD. Use retaining pin (if equipped) for locking swing frame to fixed

frame when carrying loads greater than 5000 lb. Failure to comply could cause object or load to fall.

Operation:

• To drive with a load, keep forks pointed forward and travel in accordance with 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.

5-193128447

Section 5 - Attachments

Mast Carriage

Use Mast Carriage Capacity Chart

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

OY0580

OY1910

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

The attachment tilt roller switch (2) controls mast carriage tilt.

• Push roller switch down to tilt up.

• Push roller switch up to tilt down.

To Raise/Lower Mast:

The auxiliary hydraulic joystick (3) controls the mast raise/lower function.

• Move joystick right to raise.

• Move joystick left to lower.

Installation Procedure:

• Refer to “Attachment Installation” on page 5-10.

5-20 3128447

Section 5 - Attachments

WARNING

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

comply could cause object or load to fall.

Operation:

• Always lower forks fully in mast before engaging load.

• To drive with a load, lower forks fully in mast and travel in accordance with requirements set forth in Section 1 - General Safety Practices.

• Use signal person to assist in positioning load if necessary.

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.

5-213128447

Section 5 - Attachments

Mast Carriage w/Side Tilt

Use Mast Carriage Capacity Chart

WARNING

OY0590

OY1910

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

WARNING

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

The attachment tilt roller switch (2) controls mast carriage tilt.

• Push roller switch down to tilt up.

• Push roller switch up to tilt down.

To Side Tilt:

Press Side Tilt Switch (5) located on dash panel (4) to activate Side Tilt function.

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

• Move joystick left to (side) tilt left.

• Move joystick right to (side) tilt right.

5-22 3128447

Section 5 - Attachments

To Raise/Lower Mast:

Press Forks Raise/Lower Switch (6) located on dash panel to activate Forks Raise/ Lower function.

The auxiliary hydraulic joystick controls the mast raise/lower function.

• Move joystick left to lower.

• Move joystick right to raise.

Installation Procedure:

• Refer to “Attachment Installation” on page 5-10.

WARNING

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

comply could cause object or load to fall.

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:

• Always lower forks fully in mast before engaging load.

• To drive with a load, lower forks fully in mast and travel in accordance with the requirements set forth in Section 1 - General Safety Practices.

• Use a signal person to assist in positioning load if necessary.

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.

5-233128447

Section 5 - Attachments

Fork Mounted Hook

Use Appropriate Carriage Attachment Capacity Chart

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

OY0640

Suspend loads in accordance with requirements set forth in Section 1 - General Safety Practices.

OY1400

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

The attachment tilt roller switch (2) controls fork mounted hook tilt.

• Push roller switch down to tilt up.

• Push roller switch up to tilt down.

Installation Procedure:

• Ensure carriage is properly installed. Refer to “Attachment Installation” on page 5-10.

• Secure to the forks by sliding hook onto the parent forks and install retaining pins behind the heel of each fork.

5-24 3128447

Section 5 - Attachments

Operation:

• Pallet or lumber forks of an appropriate load rating must be used. Do not use with cubing or block forks.

• Weight of fork mounted hook and rigging must be included as part of total load being lifted.

• Do not use with mast carriage attachment.

• Do not use fork mounted hook with attachments capable of rotating (i.e. side tilt and swing carriages) without disabling the rotation feature(s).

5-253128447

Section 5 - Attachments

Truss Boom

Use Appropriate Truss Boom Load Chart

To determine maximum capacity, refer to “Telehandler/

OAM1960

Suspend loads in accordance with requirements set forth in Section 1 - General Safety Practices.

Attachment/Fork Capacity” on page 5-3.

OY1381

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

The attachment tilt roller switch (2) controls truss boom tilt.

• Push roller switch down to tilt up.

• Push roller switch up to tilt down.

Winch Control (if equipped):

The auxiliary hydraulic joystick (3) controls the truss boom mounted winch.

• Move joystick right to raise cable.

• Move joystick left to lower cable.

Installation Procedure:

• Refer to “Attachment Installation” on page 5-10.

5-26 3128447

Section 5 - Attachments

WARNING

CRUSH HAZARD. Maintain a minimum of three wraps of wire rope on the cable

drum at all times. Failure to comply could cause object or load to fall.

Operation:

• Weight of rigging must be included as part of total load being lifted.

5-273128447

Section 5 - Attachments

Bucket

Use Appropriate Bucket Capacity Chart

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

OZ0730

OY1410

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

The attachment tilt roller switch (2) controls bucket tilt.

• Push roller switch down to tilt up.

• Push roller switch up to tilt down.

Installation Procedure:

• Refer to “Attachment Installation” on page 5-10.

5-28 3128447

Section 5 - Attachments

Operation:

• Raise or lower boom to appropriate height for loading material from stockpile.

• Align telehandler with face of stockpile and drive slowly and smoothly into pile to load bucket.

• Tilt bucket up far enough to retain load and back away from pile.

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

• Tilt bucket down to dump load.

Equipment Damage Precautions:

• Except for lifting or dumping a load, the boom must be fully retracted for all bucket operations.

• Do not corner-load bucket. Distribute material evenly within the bucket. Bucket capacity charts are for evenly distributed loads only.

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

• Do not attempt to load material which is hard or frozen. This could cause severe damage to quick switch or machine structure.

• Do not use bucket for "back dragging." This could cause severe damage to quick switch and retraction cables/chains.

5-293128447

Section 5 - Attachments

Grapple Bucket

Use Grapple Bucket Capacity Chart

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

OZ1450

OY1600

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

The attachment tilt roller switch (2) controls bucket tilt.

• Push roller switch down to tilt up.

• Push roller switch up to tilt down.

To open/close grapple:

The auxiliary hydraulic joystick (3) controls the open/close movement of the grapple.

• Move joystick right to open grapple.

• Move joystick left to close grapple.

Installation Procedure:

• Refer to “Attachment Installation” on page 5-10.

5-30 3128447

Section 5 - Attachments

Operation:

• Raise or lower boom to appropriate height and open grapple for loading material from stockpile.

• Align telehandler with face of stockpile and drive slowly and smoothly into pile to load bucket.

• Tilt bucket up far enough to retain load, close grapple, and back away from pile.

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

• Open grapple and tilt bucket down to dump load.

Equipment Damage Precautions:

• Except for lifting or dumping a load, the boom must be fully retracted for all bucket operations.

• Do not corner-load bucket. Distribute material evenly within the bucket. Bucket capacity charts are for evenly distributed loads only.

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

• Do not attempt to load material which is hard or frozen. This could cause severe damage to quick switch or machine structure.

• Do not use bucket for "back dragging." This could cause severe damage to quick switch and retraction cables/chains.

5-313128447

Section 5 - Attachments

Personnel Work Platform - Fork Mounted

Use Appropriate Carriage Attachment Capacity Chart

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

OY1610

The operator and personnel in platform must read and understand the separate personnel work platform manual prior to installing and using a platform.

OY1620

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

The attachment tilt roller switch (2) controls platform tilt.

• Push roller switch down to tilt up.

• Push roller switch up to tilt down.

Installation Procedure:

• Ensure carriage is properly installed. Refer to “Attachment Installation” on page 5-10.

• Check to ensure the personnel platform is securely attached to the forks and/or carriage.

5-32 3128447

JLG G10-43A Operator Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Revision Log

Read This First

Table of Contents

Section 1 - General Safety Practices

1.1 HAZARD CLASSIFICATION SYSTEM

Safety Alert System and Safety Signal Words

1.2 GENERAL PRECAUTIONS

1.3 OPERATION SAFETY

Electrical Hazards

Tip Over Hazard

Travel Hazard

Load Falling Hazard

Lifting Personnel

Driving Hazards On Slopes

Pinch Points and Crush Hazards

Fall Hazard

Chemical Hazards

Section 2 - Pre-Operation and Inspection

2.1 PRE-OPERATION CHECK AND INSPECTION

2.2 SAFETY DECALS

2.3 WALK-AROUND INSPECTION

2.4 WARM-UP AND OPERATIONAL CHECKS

Warm-Up Check

Operational Check

2.5 OPERATOR CAB

2.6 WINDOWS

Cab Door Window (if equipped)

Section 3 - Controls and Indicators

3.1 GENERAL

3.2 CONTROLS

Instrument Panel

Display

Ignition

Park Brake

Parking Procedure

Transmission Control Lever

Boom Joystick

Frame Level Joystick

Auxiliary Hydraulic Joystick

Outrigger Joysticks

Right Panel

Accessory Control Lever (if equipped)

Heater and Air Conditioning Controls (if equipped)

3.3 STEER MODES

Steer Mode Change

3.4 OPERATOR SEAT

Adjustments

Seat Belt

3.5 BOOM ANGLE AND EXTENSION INDICATORS

Section 4 - Operation

4.1 ENGINE

Starting the Engine

Battery Boosted Starting

Normal Engine Operation

Shut-Down Procedure

4.2 OPERATING WITH A NON-SUSPENDED LOAD

Lift Load Safely

Picking Up a Load

Transporting a Load

Leveling Procedure

Placing a Load

Disengaging a Load

4.3 OPERATING WITH A SUSPENDED LOAD

Lift Load Safely

Picking Up a Suspended Load

Transporting a Suspended Load

Leveling Procedure

Placing a Suspended Load

Disengaging a Suspended Load

4.4 LOADING AND SECURING FOR TRANSPORT

Tiedown

Lifting

Section 5 - Attachments

5.1 APPROVED ATTACHMENTS

5.2 UNAPPROVED ATTACHMENTS

5.3 JLG SUPPLIED ATTACHMENTS