JLG G12-55A Operator Manual

Operation & Safety

An Oshkosh Corporation Company

Manual

Original Instructions

Keep this manual with machine at all times.

Models G10-55A G12-55A

Before S/N 0160045636 excluding

0160045082, 0160045094, 0160045209, 0160045295,

0160045296, 0160045449

3126018

Revised

May 3, 2012

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

July 9, 2004 - A - Original Issue of Manual

August 8, 2007 - B - Revised manual and added Tier III information.

November 13, 2008 - C - Revised manual.

January 5, 2010 - D - Revised covers and pages b, 1-5, 1-6, 2-1, 2-6, 3-6, 3-14, 4-1, 4-3, 4-5, 4-7, 5-3, 5-4, 5-5, 5-19, 5-20, 5-22, 5-24, 5-26, 5-28, 5-30 thru 5-33, 5-36, 5-38, 5-39, 5-40, 5-42, 7-2, 7-3, 7-5, 7-16, 7-19, 7-21, 8-1, 9-1, 9-2 & 9-4.

July 19, 2010 - E - Revised pages 1-9, 2-3, 2-4, 2-7, 2-9, 3-1, 3-2, 3-4, 3-5, 4-1 thru 4-4, 4-10, 4-11, 5-40, 6-1, 7-2 thru 7-5, 7-7, 7-8, 7-10 thru 7-15, 7-18 thru 7-22, 9-1, 9-5 & 9-6.

December 21, 2010 - F - Revised pages 7-16, 9-3 & 9-6.

August 5, 2011 - G - Revised pages 2-3 thru 2-11 & 7-2.

May 3, 2012 - H - Revised covers and pages 5-5, 5-24, 5-24 thru 5-27 & 7-1.

REVISION LOG

a3126018

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 3126018

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

c3126018

Read This First

Other Publications Available

Service Manual............................................................................................3126019

Illustrated Parts Manual...............................................................................3126020

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 3126018

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

ANSI................................................................................2-3

ISO (S/N 0160040120 & After, If Equipped) ...................2-9

2.3 Walk-Around Inspection.....................................................2-12

2.4 Warm-Up and Operational Checks ....................................2-14

Warm-Up Check ...........................................................2-14

Operational Check ........................................................2-14

2.5 Operator Cab .....................................................................2-15

2.6 Windows ............................................................................2-16

Cab Door Window (if equipped)....................................2-16

Section 3 - Controls and Indicators

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

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

Dash Controls and Indicators..........................................3-4

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

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

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

i3126018

Table of Contents

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

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

Frame Level Joystick.................................................... 3-11

Auxiliary Hydraulic Joystick (if equipped) ..................... 3-12

Outrigger Joysticks ....................................................... 3-13

Right Hand Panel ......................................................... 3-14

Accessory Control Lever (if equipped) ......................... 3-15

3.3 Steer Modes ...................................................................... 3-16

Steer Mode Change ..................................................... 3-16

3.4 Operator Seat.................................................................... 3-17

Adjustments.................................................................. 3-17

Seat Belt ....................................................................... 3-18

3.5 Boom Angle and Extension Indicators .............................. 3-19

Section 4 - Operation

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

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

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

Extreme Cold Weather Starting (if equipped) ................. 4-3

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

Normal Engine Operation ............................................... 4-5

Shut-Down Procedure .................................................... 4-5

4.2 Operating with a Non-Suspended Load .............................. 4-6

Lift Load Safely............................................................... 4-6

Picking Up a Load .......................................................... 4-6

Transporting a Load ....................................................... 4-7

Leveling Procedure......................................................... 4-7

Placing a Load................................................................ 4-8

Disengaging a Load........................................................ 4-8

4.3 Operating with a Suspended Load ...................................... 4-9

Lift Load Safely............................................................... 4-9

Picking Up a Suspended Load ....................................... 4-9

Transporting a Suspended Load .................................. 4-10

Leveling Procedure....................................................... 4-10

Placing a Suspended Load........................................... 4-11

Disengaging a Suspended Load .................................. 4-11

4.4 Loading and Securing for Transport .................................. 4-12

Tiedown ........................................................................ 4-12

Lifting ............................................................................ 4-13

ii 3126018

Section 5 - Attachments

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

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

5.3 JLG Supplied Attachments .................................................. 5-3

Before S/N 0160037689 .................................................5-3

S/N 0160037689 & After .................................................5-5

5.4 Telehandler/Attachment/Fork Capacity................................ 5-6

5.5 Use of the Capacity Chart....................................................5-7

Capacity Indicator Locations ...........................................5-7

Sample Capacity Chart ...................................................5-8

Example ........................................................................5-12

5.6 Attachment Installation ......................................................5-13

Hydraulic Operated Attachment ....................................5-16

5.7 Adjusting/Moving Forks......................................................5-17

5.8 Attachment Operation ........................................................5-18

Carriage w/Forks...........................................................5-19

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

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

Dual Fork Positioning Carriage .....................................5-24

Fork Extension ..............................................................5-26

Mast Carriage ...............................................................5-28

Mast Carriage w/Swing and Side Shift

(Before S/N 0160037689) .............................................5-30

Mast Carriage w/Side Tilt

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

Fork Mounted Hook ......................................................5-34

Truss Boom...................................................................5-36

Bucket ...........................................................................5-38

Grapple Bucket .............................................................5-40

Personnel Work Platform - Quick Switch Mounted

(Before S/N 0160037689) .............................................5-42

Personnel Work Platform - Fork Mounted.....................5-44

Boom Head-Mounted Winch

(Before S/N 0160037689) .............................................5-46

Table of Contents

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

iii3126018

Table of Contents

Section 7 - Lubrication and Maintenance

7.1 Introduction.......................................................................... 7-1

Clothing and Safety Gear ............................................... 7-1

7.2 General Maintenance Instructions....................................... 7-2

7.3 Service and Maintenance Schedule .................................... 7-3

10 & 1st 50 and 50 Hour Maintenance Schedule........... 7-3

1st 250, 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

1000 Hour Lubrication Schedule .................................... 7-8

7.5 Operator Maintenance Instructions ................................... 7-10

Fuel System.................................................................. 7-10

Air Intake System ......................................................... 7-12

Engine Oil ..................................................................... 7-14

Hydraulic Oil ................................................................. 7-15

Tires.............................................................................. 7-16

Transmission Oil........................................................... 7-19

Hydraulic Return Filter (Before S/N 0160039451

excluding 0160039394 & 0160039397)........................ 7-20

Engine Cooling System ................................................ 7-21

Battery .......................................................................... 7-22

Windshield Washer System (if equipped)..................... 7-23

Section 8 - Additional Checks

8.1 Auto-Frame Level System (Before S/N 0160038592)......... 8-1

Section 9 - Specifications

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

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

Tires................................................................................ 9-3

Performance ................................................................... 9-4

Dimensions..................................................................... 9-5

Index

Inspection, Maintenance and Repair Log

iv 3126018

Section 1 - General Safety Practices

DANGER

OW0010

WARNING

OW0021

CAUTION

OW0031

SECTION 1 - GENERAL SAFETY PRACTICES

1.1 HAZARD CLASSIFICATION SYSTEM

Safety Alert System and Safety Signal Words

DANGER indicates an imminently hazardous situation which, if not avoided, will

result in death or serious injury.

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

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

1.2 GENERAL PRECAUTIONS

WARNING

Before operation, read and understand this manual. Failure to comply with the safety precautions listed in this manual could result in machine damage, property damage, personal injury or death.

1-13126018

Section 1 - General Safety Practices

OW0040

10 FT

(3 M)

1.3 OPERATION SAFETY

Electrical Hazards

• This machine is not insulated and does not provide protection from contact or being near electrical current.

• NEVER operate the telehandler in an area where overhead power lines, overhead or underground cables, or other power sources may exist without ensuring the appropriate power or utility company de-energizes the lines.

• Always check for power lines before raising the boom.

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

1-2 3126018

Section 1 - General Safety Practices

OW0050

OW0080

OW0100

4 FT

(1,2 M)

Tip Over Hazard

General

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

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

• Understand how to properly use the capacity charts located in cab.

• DO NOT exceed rated lift capacity.

• Be sure that the ground conditions are able to support the machine.

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

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

1-33126018

Section 1 - General Safety Practices

OH2291

20911

OH2221

• MAINTAIN proper tire pressure at all times. If proper tire pressures are not maintained, this machine could tip over.

• Refer to manufacturer’s specifications for proper fill ratio and pressure requirements for tires equipped with ballast.

• Always wear the seat belt.

• Keep head, arms, hands, legs and all other body parts inside operator’s cab at all times.

If the telehandler starts to tip over:

• DO NOT JUMP

• BRACE YOURSELF and STAY WITH THE MACHINE

• KEEP YOUR SEAT BELT FASTENED

• HOLD ON FIRMLY

• LEAN AWAY FROM THE POINT OF IMPACT

1-4 3126018

Non-Suspended Load

OW0060

OW0150

• DO NOT drive with boom raised.

Suspended Load

Section 1 - General Safety Practices

• Tether suspended loads to restrict movement.

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

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

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

• Keep heavy part of load closest to attachment.

• Never drag the load; lift vertically.

When driving with a suspended load:

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

• DO NOT extend boom.

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

• DO NOT exceed walking speed.

1-53126018

Section 1 - General Safety Practices

OAL2030

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

Travel Hazard

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

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

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

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

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

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

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

• Always look in the direction of travel.

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

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

1-6 3126018

Section 1 - General Safety Practices

OW0130

Load Falling Hazard

• Never suspend load from forks or other parts of carriage.

• DO NOT burn or drill holes in fork(s).

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

1-73126018

Section 1 - General Safety Practices

OW0170

OW0190

Lifting Personnel

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

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

1-8 3126018

Section 1 - General Safety Practices

OW0200

Driving Hazards on Slopes

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

• When unloaded, drive with forks pointed downhill.

• When loaded, drive with the forks pointed uphill.

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

• To avoid overspeeding the engine and drivetrain when driving down slopes, downshift to a lower gear and use the service brake as necessary to maintain a slow speed. DO NOT shift into neutral and coast downhill.

• Avoid excessively steep slopes or unstable surfaces. To avoid tip over DO NOT drive across excessively steep slopes under any circumstances.

• Avoid turning on a slope. Never engage “inching” or shift to “Neutral” when going downhill.

• DO NOT park on a slope.

1-93126018

Section 1 - General Safety Practices

OW0210

OW0220

OW0230

Pinch Points and Crush Hazards

Stay clear of pinch points and rotating parts on the telehandler.

• Stay clear of moving parts while engine is running.

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

• Keep clear from under boom.

1-10 3126018

Section 1 - General Safety Practices

OW0240

OW0250

OW0260

OW0960

• Keep clear of boom holes.

• Keep arms and hands clear of attachment tilt cylinder.

• Keep hands and fingers clear of carriage and forks.

• Keep others away while operating.

1-113126018

Section 1 - General Safety Practices

OW0280

OW0290

Fall Hazard

• Enter using the proper hand holds and steps provided. Always maintain 3-point contact when mounting or dismounting. Never grab control levers or steering wheel when mounting or dismounting the machine.

• DO NOT get off the machine until the shutdown procedure on page 4-5 has been performed.

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

1-12 3126018

Section 1 - General Safety Practices

OW0300

OW0950

Chemical Hazards

Exhaust Fumes

• DO NOT operate machine in an enclosed area without proper ventilation.

• DO NOT operate the machine in hazardous environments unless approved for that purpose by JLG and site owner. Sparks from the electrical system and the engine exhaust can cause an explosion.

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

Flammable Fuel

• DO NOT fill the fuel tank or service the fuel system near an open flame, sparks or smoking materials. Engine fuel is flammable and can cause a fire and/or explosion.

Hydraulic Fluid

• DO NOT attempt to repair or tighten any hydraulic hoses or fittings while the engine is running or when the hydraulic system is under pressure.

• Stop engine and relieve trapped pressure. Fluid in the hydraulic system is under enough pressure that it can penetrate the skin.

• DO NOT use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks. Wear gloves to protect hands from spraying fluid.

1-133126018

Section 1 - General Safety Practices

This Page Intentionally Left Blank

1-14 3126018

Section 2 - Pre-Operation and Inspection

OAH1000

PARENT METAL CRACK WELD CRACK

SECTION 2 - PRE-OPERATION AND INSPECTION

2.1 PRE-OPERATION CHECK AND INSPECTION

Note: Complete all required maintenance before operating unit.

WARNING

FALL HAZARD. Use extreme caution when checking items beyond your normal

reach. Use an approved ladder.

The pre-operation check and inspection, performed at beginning of each work shift or at each change of operator, should include the following:

1. Cleanliness - Check all surfaces for leakage (oil, fuel or battery fluid) or foreign objects. Report any leakage to the proper maintenance personnel.

2. Structure - Inspect the machine structure for dents, damage, weld or parent metal cracks or other discrepancies.

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 2-12 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.

2-13126018

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 2-14) 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 3126018

OW0334

91503108

9150-3108 REV -

MOVING PARTS could crush causing death or serious injury.

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

1705881

91503112

9150-3112 REV -

91503109

9150-3109 REV -

NO RIDERS. Riders could FALL OFF

machine causing death or serious injury.

91513208

9151-3208 REV -

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.

1701505

(BEFORE

S/N 0160016100)

GEAR

9156-3246 REV A

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

91563246

9150-3108 REV -

MOVING PARTS could crush causing death or serious injury.

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

91503108

DO NOT use Ether or other high energy starting aids.

Engine equipped with Pre-heating system.

ENGINE EXPLOSION could result in death or serious injury.

1706300C

1706300

(PERKINS ENGINE ONLY -

BEFORE S/N 0160039451

EXCLUDING 0160039394

& 0160039397)

91503098

9150-3098 REV. A

For safe operation of machine, and to minimize risk of

serious injury, READ AND OBSERVE the following:

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.

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

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

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

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.

91503110

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

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

9150-3110 REV - A

power lines.

10 FT. (3 M)

91513201

9151-3201 REV. (-)

91413061

91163028

1000

1001121126

250

1001121125A

( N m)

1001121125

S/N 0160039451 THRU 0160040119

INCLUDING 0160039394 & 0160039397

VIEW OF CAB DASH

CAPACITY

CHARTS

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.

ANSI

Before S/N 0160040120

2-33126018

Section 2 - Pre-Operation and Inspection

OY2011

9150-3097 REV. -

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

91503097

Diesel Engine

SERVICE INTERVALS

LUBRICATION AND MAINTENANCE

MATERIAL HANDLER

9156-3227 REV(A)

Air Cleaner Element

Fuel Filter

Engine Oil Filter

Engine Oil

Coolant

Diesel Fuel

Transmission

Lubricant

Filter

Transfer Case

Lubricant

Center Section

Axle Lubricant

Planetary Hubs

Filter

Lubricant

Hydraulic System

Breather/Filter

Grease Fittings

Axles (6 Pts. Ea.)

Boom Head Pivot (2 Pts.)

Boom Pivot (2 Pts.)

Extend Chain Sheave (1 Pt.)

Drive Shafts (1 Pt. Ea.)

Cylinder Pins(13 Pts.)

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

Torque

Check

Grease

Change

SAE 15W-40 CE Oil

Etheylene Glycol

No. 2 Diesel Fuel

Mobil 424

Mystik Tetrimoly

See Manual

70 PSI (483 kPa)

51 PSI (352 kPa)

73 PSI (503 kPa)

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

Fill

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.

LUBRICANT TYPE

SPECIFICATION

YEARLY OR 1500 HRS

6 MO. OR 1000 HRS

3 MO. OR 500 HRS

EVERY 5 WKS OR 250 HRS

WEEKLY

50 HRS

DAILY OR 10 HRS

91563227

9150-3108 REV -

MOVING PARTS could crush causing death or serious injury.

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

91503108

9150-3108 REV -

MOVING PARTS could crush causing death or serious injury.

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

91503108

91513209

9151-3209 REV -

9156-3220 REV A

91563220

(S/N 0160031867 THRU

0160039450 EXCLUDING

0160039394 & 0160039397)

9156-3220 REV A

91563220

(Before S/N

0160031867)

91503099

9150-3099 REV -

Keep sparks, flames and lighted materials away from batteries.

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

9156-3220 REV A

91563220

91503099

9150-3099 REV -

Keep sparks, flames and lighted materials away from batteries.

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

9150-3108 REV -

MOVING PARTS could crush causing death or serious injury.

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

91503108

9150-3108 REV -

MOVING PARTS could crush causing death or serious injury.

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

91503108

91513209

9151-3209 REV -

9150-3097 REV. -

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

91503097

DO NOT use Ether or other high energy starting aids.

Engine equipped with Pre-heating system.

ENGINE EXPLOSION could result in death or serious injury.

1706300C

1706300

S/N 0160039451 THRU 0160040119 INCLUDING 0160039394 & 0160039397

BEFORE S/N 0160039451 EXCLUDING 0160039394 & 0160039397

2-4 3126018

OW0353

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.

9151-3210 REV -

91553072

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.

9151-3210 REV -

4105262

(S/N 0160012584 thru 0160040119)

-10

91513210

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

9151-3210 REV -

91563157

9156-3157 REV C

MOVING PARTS could crush causing death or serious injury.

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

0°

-10°

-20°

30°

40°

50°

60°

70°

91003031

(Before S/N 0160012584)

VIEW A-A

Section 2 - Pre-Operation and Inspection

2-53126018

Section 2 - Pre-Operation and Inspection

OY2640

1706850A

CRUSHING HAZARD

Keepothers

awaywhile

operating.

Loweringboom or falling load could

causedeath or serious injury.

WARNING

1706850

1706306A

1706306

1706299A

CONTACTING

POWERLINES

willresult in death

orserious injury.

1706299

91503112

9150-3112 REV -

1706768

(ENCLOSED CAB)

1706768

(OPEN CAB)

1705881

1701640

VIEW A-A

S/N 0160040120 & After, If Equipped

2-6 3126018

+ 134 hidden pages