JLG G12-55A Operator Manual

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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

OY2650

4109801

1706296

1706304A

RUN-OVER

HAZARD

couldcause

deathor

serious

injury.

1706304

1706767A

1706767

1706851A

1706851

Fasten

seat belt.

1706303A

Operatormust be trained and

mustread and understand

allcapacity charts, operator

andsafety manuals.

1706303

91163028

1001121126

1001092897A

L BF

T ( N

m )

1001092896A

1001121125

91413061

1001131745A

1001131745

91563220

9156-3220 REV A

4100181

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

1706301A

1706301

1001109053

2.5 GPM

9.5 lpm

MAX

1001109053 REV A

VIEW B-B VIEW C-C VIEW D-D

D D

CAPACITY

CHARTS

Section 2 - Pre-Operation and Inspection

2-73126018

Section 2 - Pre-Operation and Inspection

OY2660

1706302

17063021706302

1706298A

1706298

1706302

1 0 °

0°

1706302

-10

4105262

17063021706302

91553072

VIEW E-E

VIEW F-F

2-8 3126018

Section 2 - Pre-Operation and Inspection

OY2670

1706288

1706284

1001092877

91503112

9150-3112 REV -

1705881

1701640

1001092878

(OPEN CAB)

1001092878

(ENCLOSED CAB)

VIEW A-A

ISO (S/N 0160040120 & After, If Equipped)

2-93126018

Section 2 - Pre-Operation and Inspection

OY2680

4109801

91163028

1001121126

1001092897A

-F T ( N

m )

1001092896

1001121125

1706283

1706287

1706289

1706293

91413061

1001131745A

1001131745

1706281

91563220

9156-3220 REV A

4100181

1001109053

2.5 GPM

9.5 lpm

MAX

1001109053 REV A

1706098

1706098B

1706285

VIEW B-B VIEW C-C VIEW D-D

D D

CAPACITY

CHARTS

2-10 3126018

Section 2 - Pre-Operation and Inspection

OY2690

1706282

1706292 1706292

91553072

1706292

17062921706292

1706292

1 0 °

0°

20°2

0°

-10

4105262

1706292

VIEW E-E

VIEW F-F

2-113126018

Section 2 - Pre-Operation and Inspection

OW0322

2.3 WALK-AROUND INSPECTION

Begin your walk-around inspection at item 1, as noted below. Continue to your right (counterclockwise when viewed from top) checking each item in sequence.

INSPECTION NOTE: On all components, make sure there are no loose or missing parts, that they are securely fastened and no visible leaks or excessive wear exists in addition to any other criteria mentioned. Inspect all structural members including attachment for cracks, excessive corrosion and other damage.

1. Boom Sections and Lift, Tilt, Extend/Retract, Compensating (Slave) Cylinders

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

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

2. Left Outrigger leaking.

3. Front Axle hydraulic hoses undamaged, not leaking.

2-12 3126018

- Pins secure; hydraulic hoses and cylinder undamaged, not

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

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

6. Cab and Electrical

7. Air Cleaner

8. Main Control Valve

9. Wheel/Tire Assembly

10. Stabilizer Cylinder

11. Rear Axle

12. Wheel/Tire Assembly

13. Engine Compartment

14. Wheel/Tire Assembly

15. Frame Level Cylinder

16. Right Outrigger

17. Attachment

- Clean and undamaged.

• 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.

(Before S/N 0160039451 excluding 0160039394 & 0160039397) Air cleaner element condition indicator, check for clogged condition. Replace element as required.

- See Inspection Note.

- Properly inflated and secured; no loose or missing lug

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

- Pins secure; hydraulic hoses undamaged, not leaking.

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

hydraulic hoses undamaged, not leaking.

- Properly inflated and secured; no loose or missing lug

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

• Drive belts, check condition and replace as required.

• Engine mounts - See inspection note.

• Air cleaner element condition indicator (S/N 0160039451 & After including

0160039394 & 0160039397), check for clogged condition. Replace element as required.

• Battery cables tight, no visible damage or corrosion.

• Engine cover properly secured.

- Properly inflated and secured; no loose or missing lug

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

- Pins secure; hydraulic hoses undamaged, not leaking.

- Pins secure; hydraulic hoses and cylinder undamaged, not

leaking.

- Properly installed, see See “Attachment Installation” on

page 5-13.

2-133126018

Section 2 - Pre-Operation and Inspection

2.4 WARM-UP AND OPERATIONAL CHECKS

Warm-Up Check

During warm-up period, check:

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

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

3. Voltmeter should show 13.5 to 14 volts.

4. Adjust mirror(s) for maximum visibility.

WARNING

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

running except when checking 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 operators cab with engine running.

6. All joystick functions - operate smoothly and correctly.

7. Perform any additional checks described in Section 8.

8. Hydraulic filter condition indicator.

2-14 3126018

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, cab structure and right side glass or screen 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 the overhead guard or cab structure is damaged, the CAB CANNOT BE REPAIRED. It must be REPLACED.

2-153126018

Section 2 - Pre-Operation and Inspection

OAL0011

2.6 WINDOWS

Keep all windows and mirrors clean and unobstructed.

Cab Door Window (if equipped)

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

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

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

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

2-16 3126018

Section 3 - Controls and Indicators

SECTION 3 - CONTROLS AND INDICATORS

3.1 GENERAL

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

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

NOTICE

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

3-13126018

Section 3 - Controls and Indicators

OW0363

3.2 CONTROLS

1. Transmission Control Lever: See page 3-8.

2. Instrument Panel

3. Steering Wheel

machine in the corresponding direction. Three steering modes are available. See “Steer Modes” on page 3-16.

4. Frame Level Indicato condition of the telehandler.

5. Accessory Control Lever

6. Right Hand Panel

7. Boom Joystick

8. Frame Level Joystick

9. Auxiliary Hydraulic Joystick

10. Outrigger Joysticks

3-2 3126018

: See page 3-4.

: Turning the steering wheel to the left or right steers the

r: Enables the operator to determine the left to right level

: See page 3-14.

: See page 3-10.

: See page 3-11.

: See page 3-13.

(if equipped): See page 3-15.

(if equipped): See page 3-12.

Section 3 - Controls and Indicators

11. Decompression Valve: Depress button to relieve pressure in auxiliary hydraulic circuit.

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

3-33126018

Section 3 - Controls and Indicators

OW0433

8910

432

12 35

8910

432

PERKINS

(BEFORE S/N 0160037186)

JOHN DEERE

PERKINS

(S/N 0160037186 THRU 0160039451

EXCLUDING 0160039394 & 0160039397)

CUMMINS

(S/N 0160039451 & AFTER INCLUDING

0160039394 & 0160039397)

Dash Controls and Indicators

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

hours.

2. 4-in-1 Gauge

a. Engine Coolant Temperature Gauge

b. Engine Oil Pressure Gauge

c. Fuel Gauge

d. Voltmeter indicates alternator output and battery condition.

3. Shutdown Override Switch

(John Deere Only): Delays engine shutdown for 30 seconds when depressed. The switch resets the shutdown timer to 30 seconds and may be used repeatedly. However, continuously holding the switch will not reset the 30 second timer.

4. Transmission Temperature Light: Illuminates when transmission temperature is too high.

5. Check Engine Light

(John Deere Only): Illuminates for 30 seconds before

engine shuts down when a “Shutdown” fault is detected.

6. Engine Pre-Heat Indicator Light ignition key in the “RUN” position. Light goes out when start temperature is reached. At temperatures below 32°F (0°C), do not start until light goes out.

(Perkins and Cummins Only): Illuminates with

3-4 3126018

Section 3 - Controls and Indicators

7. Warning and Check Engine Lights (Perkins and Cummins Only): Any combination of illumination indicates an engine fault and/or a parameter that is outside of acceptable range. Engine may derate or shutdown.

8. Steer Select Switch and 2-wheel steer. See page 3-16 for details.

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

9. Park Brake Switch

10. Horn Button

11. Auxiliary Electrics Switches

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

12. 3-in-1 Gauge & Display excluding 0160039394 & 0160039397):

a. Engine Coolant Temperature Gauge

b. Engine Oil Pressure Gauge

c. Fuel Gauge

d. Display - Displays engine operating hours, battery voltage and engine rpm.

Engine fault codes displayed when detected. See Service Manual for details.

: See page 3-7 for details.

: Depress button to sound horn.

(if equipped): Enables functions of attachments that

(Cummins) (Perkins S/N 0160037186 thru 0160039451

3-53126018

Section 3 - Controls and Indicators

OW0391

ACC

RUN

START

OFF

9141-3061

Ignition

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

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

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

3-6 3126018

Section 3 - Controls and Indicators

OAL0471

Park Brake

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

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

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

WARNING

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

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

WARNING

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

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

Parking Procedure

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

2. Follow “Shut-Down Procedure” on page 4-5.

3-73126018

Section 3 - Controls and Indicators

OAL0481

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.

WARNING

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

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

3-8 3126018

Section 3 - Controls and Indicators

OAL0491

1st

2nd

3rd

4th

Gear Selection

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.

3-93126018

Section 3 - Controls and Indicators

OAL0500

Boom Joystick

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

Boom Functions

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

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

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

Attachment Function

Tilt control is actuated by the switch (2).

• Depress the left side of the switch to tilt up; depress the right side of switch to tilt down.

• Use rotary switch (3) to regulate the speed of the tilt. Rotate knob counterclockwise to increase speed; rotate knob clockwise to decrease speed.

WARNING

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

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

3-10 3126018

Section 3 - Controls and Indicators

OAL0510

Frame Level Joystick

The frame level joystick (4) 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 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.

3-113126018

Section 3 - Controls and Indicators

OW0521

Auxiliary Hydraulic Joystick (if equipped)

The auxiliary hydraulic joystick (1) controls function of attachments that require hydraulic supply for operation. See Section 5 - Attachments for approved attachments and control instructions.

3-12 3126018

Section 3 - Controls and Indicators

OAL0530

Outrigger Joysticks

The rear joysticks (2) 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.

3-133126018

Section 3 - Controls and Indicators

OAL0541

Right Hand Panel

Heater and Air Conditioning Controls (if equipped)

1. Air Vent

2. Air Louver

3. Defroster Fan

switch up for fast speed. Return switch to middle position to turn off.

4. Temperature Control Switch

5. Fan Speed

6. Air Conditioning Switch

7. Air Louver

8. Recirculation Vent

heat. Close louvers when operating air conditioning.

Other Controls (if equipped)

9. Work Light Switch

10. Beacon Light Switch

11. Hazard Light Switch

12. Windshield Wiper and Washer Switch

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

13. Attachment Tilt Speed Switch

: Two individually adjustable round vents.

: Three individually adjustable air louvers.

: Two speed fan. Press fan switch down for slow speed; press

: Adjustable rotary switch

: Four-position rotary switch.

: On/Off switch.

(S/N 0160038377 & After): Two individually adjustable air louvers.

(S/N 0160038377 & After): Open louvers when operating

: On/Off switch.

: Two speed rotary switch. Depress to

: See “Boom Joystick” on page 3-10.

3-14 3126018

Section 3 - Controls and Indicators

OY1350

Accessory Control Lever (if equipped)

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

Tur n S ignals

• 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.

3-153126018

Section 3 - Controls and Indicators

OAL2030

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

OY1490

123

OAM2400

4 5

3.3 STEER MODES

Three steer modes are available for operator use.

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

Steer Mode Change

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

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.

3-16 3126018

Section 3 - Controls and Indicators

OW0480

3.4 OPERATOR SEAT

Adjustments

Prior to starting engine adjust seat for position and comfort.

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

2. Fore/Aft

3. Arm Rest

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

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

4. Seat Belt seat belt is available.

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

3-173126018

Section 3 - Controls and Indicators

OH20912

Seat Belt

Fasten seat belt as follows:

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

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

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

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

3-18 3126018

Section 3 - Controls and Indicators

OW1220

-10

3.5 BOOM ANGLE AND EXTENSION INDICATORS

• 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 5-7).

• 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 5-7).

3-193126018

Section 3 - Controls and Indicators

This Page Intentionally Left Blank

3-20 3126018

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.

If equipped for extreme cold weather, -40°F to 0°F (-40°C to -20°C), see page 4-3 for starting procedure.

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

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

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

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

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

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

WARNING

UNEXPECTED MOVEMENT HAZARD. Always ensure that transmission control

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

4-13126018

Section 4 - Operation

Cold Weather Starting Aids

John Deere Engine

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

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

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

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

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

WARNING

ENGINE EXPLOSION. If your telehandler is equipped with a cold start aid, do not

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

Perkins or Cummins Engine

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

WARNING

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

4-2 3126018

Section 4 - Operation

OY1971

Extreme Cold Weather Starting (if equipped)

If equipped with extreme cold weather components, machine can be operated in temperatures of -40°F to 0°F (-40° C to -20° C).

1. Machine must be equipped with heating components and extreme cold weather fluids. See Section 9 - Specifications for fluid details.

2. Locate two yellow heating component extension cords stored behind batteries in engine compartment. Connect each to separate A/C power supplies with a minimum rating of 15 Amps each.

3. Allow heating components to operate a minimum of 12 hours prior to machine operation.

4. Locate recirculation hoses stored behind seat in cab.

5. Connect recirculation hose (1) to tilt circuit quick disconnects (2). Connect the other recirculation hose (1) to auxiliary hydraulic quick disconnects (3).

6. Follow start-up procedure on page 4-1 and allow engine to idle 20 minutes.

7. Operate tilt and auxiliary hydraulic functions continuously for five minutes to circulate the warm hydraulic fluid.

8. Operate all boom functions continuously for another five minutes.

9. Perform “Shut-Down Procedure” on page 4-5.

10. Disconnect recirculation hoses and A/C power supplies and place back in storage locations.

11. Machine is ready for operation.

4-33126018

Section 4 - Operation

OW0530

Battery Boosted Starting

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

• Never allow vehicles to touch.

• Ensure boosting vehicle engine is running.

• 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.

4-4 3126018

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).

4-53126018

Section 4 - Operation

4.2 OPERATING WITH A NON-SUSPENDED LOAD

Lift Load Safely

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

WARNING

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

equipment and/or cause tip over.

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

Picking Up a Load

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

• Avoid lifting double-tiered loads.

• Make sure load is clear of any adjacent obstacles.

• Adjust spacing of forks so they engage the pallet or load at maximum width. See “Adjusting/Moving Forks” on page 5-17.

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

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

4-6 3126018

Section 4 - Operation

OW0540

Transporting a Load

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

Leveling Procedure

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

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

3. Observe level indicator to determine whether machine must be leveled prior to lifting load. Level machine with frame level joystick (see page 3-11) or outrigger joysticks (see page 3-13).

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.

4-73126018

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 5-7.

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

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

Disengaging a Load

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

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

2. Lower the carriage.

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

4-8 3126018

Section 4 - Operation

4.3 OPERATING WITH A SUSPENDED LOAD

Lift Load Safely

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

WARNING

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

equipment and/or cause tip over.

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

Picking Up a Suspended Load

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

• Avoid lifting double-tiered loads.

• Make sure load is clear of any adjacent obstacles.

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

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

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

• Ensure to always properly tether loads to restrict movement.

• Refer to See “Use of the Capacity Chart” on page 5-7. for proper lifting guidelines in addition to the appropriate capacity chart in the operator cab.

4-93126018

Section 4 - Operation

OW0130

OZ3160

Transporting a Suspended Load

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

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

Important things to remember:

• Ensure the boom is fully retracted.

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

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

• The guide persons 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 persons between the suspended load and the telehandler.

• Only transport the load at walking speed, 0.9 mph (0,4 m/s), or less.

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 3-11) or outrigger joysticks (see page 3-13).

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°.

4-10 3126018

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 5-7.

• 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 persons and operator remain in constant communication (verbal or hand) when placing the load.

Disengaging a Suspended Load

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

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

4-113126018

Section 4 - Operation

OAL0591

4.4 LOADING AND SECURING FOR TRANSPORT

Tiedown

1. Level the telehandler prior to loading.

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

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

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

5. Do not tie down front of boom.

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

WARNING

TELEHANDLER SLIDE HAZARD. Before loading telehandler for transport,

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

4-12 3126018

Section 4 - Operation

Lifting

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

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

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

• Remove all loose items from machine prior to lifting.

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

4-133126018

Section 4 - Operation

This Page Intentionally Left Blank

4-14 3126018

Section 5 - Attachments

SECTION 5 - ATTACHMENTS

5.1 APPROVED ATTACHMENTS

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

Before S/N 0160037689

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

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

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

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

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

S/N 0160037689 & After

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

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

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

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

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

5-13126018

Section 5 - Attachments

5.2 UNAPPROVED ATTACHMENTS

Do not use unapproved attachments for the following reasons:

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

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

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

WARNING

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

5-2 3126018

5.3 JLG SUPPLIED ATTACHMENTS

Before S/N 0160037689

Section 5 - Attachments

Attachment Part Number

Carriage, 48 in (1220 mm) 91405073 X X

Carriage, 50 in (1270 mm) 1170019 X X

Carriage, 60 in (1524 mm) 1170022 X X

Carriage, 72 in (1829 mm) 91405074 X X

Carriage, 72 in (1829 mm) 1170025 X X

Carriage, Drywall 72 in (1829 mm) 91405077 X X

Side Tilt Carriage, 48 in (1220 mm) 91405101 X X

Side Tilt Carriage, 72 in (1829 mm) 91405079 X X

100° Swing Carriage, 72 in (1829 mm) 91405075 X X

100° Drywall Swing Carriage, 72 in (1829 mm) 91405078 X X

180° Swing Carriage, 72 in (1829 mm) 91563146 X X

6 ft Mast Carriage, 48 in (1220 mm) 91405060 X X

6 ft Mast Carriage, 72 in (1829 mm) 91405061 X X

6 ft Mast Carriage, 100°, 72 in (1829 mm) 91405070 X X

Fork, Pallet 1.75x4x48 in (44x101x1220 mm) 91403364 X X

6 ft Mast Carriage, 100°, 60 in (1524 mm) 91415026 X X

Fork, Pallet 2x6x60 in (50x152x1524 mm) 91403580 X X

8 ft Mast Carriage with Side Tilt, 72 in (1830 mm) 1001108669 X X

Fork, Pallet 2.25x4x48 in (57x101x1220 mm) 91513206 X X

Fork, Pallet 2.36x4x48 in (60x101x1220 mm) 2340045 X X

Fork, Pallet 2.25x5x48 in (57x127x1220 mm) 91563141 X X

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

Fork, Pallet 2x6x48 in (50x152x1220 mm) 91403363 X X

Fork, Pallet 2x6x60 in (50x152x1524 mm) 91403360 X X

Fork, Pallet 2x6x60 in (50x152x1524 mm) 91403365 X X

Fork, Lumber 2.25x6x60 in (57x152x1524 mm) 91563142 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 (50x152x1830 mm) 1001092391 X X

Fork, Lumber 2.25x6x72 in (57x152x1830 mm) 91563143 X X

Fork, Cubing 2x2x48 in (50x50x1220 mm) 91403359 X X

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

Fork, Drywall 1.75x4x48 in (50x101x1220 mm) 91403366 X X

Bucket, 60 in - 0.75 yd

Bucket, 74 in - 1.25 yd

Bucket, 102 in -1.25 yd

91405054 X X

91405055 X X

91405071 X X

Applicable Model

G10-55A G12-55A

5-33126018

Section 5 - Attachments

Attachment Part Number

Grapple Bucket, 96 in -1.75 yd

Hook, Fork Mounted 90553036 X X

Hook, Fork Mounted 91565094 X X

Truss Boom, 10 ft (3048 mm) 91405083 X X

Truss Boom w/ Winch, 10 ft (3048 mm) 91405081 X X

Truss Boom, 15 ft (4572 mm) 91405082 X X

Truss Boom w/ Winch, 15 ft (4572 mm) 91405080 X X

Winch, Boom Head-Mounted

Platform, Quick Switch Mounted 91415025 X X

Platform, Fork Mounted (ASME)

Platform, Fork Mounted (ASME - French)

Platform, Fork Mounted (ISO)

0930021 X X

91565037 X X

1001097944 X X

1001092280 X X

1001103637 X X

1001097072 X X

1001103736 X X

1001096306 X X

1001103730 X X

Applicable Model

G10-55A G12-55A

5-4 3126018

S/N 0160037689 & After

Section 5 - Attachments

Attachment Part Number

Carriage, 50 in (1270 mm) 1170021 X X

Carriage, 60 in (1524 mm) 1170024 X X

Carriage, 72 in (1829 mm)

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) 1001095418 X X

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

Dual Fork Positioning Carriage, 50 in (1270 mm) 7301295 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 (50x152x1830 mm) 1001092391 X X

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

Fork Extension, 90 in (2286 mm) 1001137512 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

Truss Boom, 12 ft (3658 mm) 1001099902 X X

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

Truss Boom, 15 ft (4572 mm) 1001099901 X X

Platform, Fork Mounted (ASME)

Platform, Fork Mounted (ASME - French)

Platform, Fork Mounted (ISO)

1170027 X X

1001132514 X X

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

Applicable Model

G10-55A G12-55A

5-53126018

Section 5 - Attachments

OW0550

5.4 TELEHANDLER/ATTACHMENT/FORK CAPACITY

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.

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

5-6 3126018

WARNING

Section 5 - Attachments

OY1510

-10

DO NOT GO NEAR LEAKS

10814B

* 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.

BOOM

EXTENSION

INDICATOR

BOOM ANGLE

INDICATOR

ATTACHMENT

IDENTIFICATION

PLATE

FORK

WEIGHT

STAMP

5.5 USE OF THE CAPACITY CHART

To properly use the capacity chart (see page 5-8), the operator must first determine and/or have the following:

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

2. The proper Capacity Chart(s).

3. Weight of the load being lifted.

4. Load placement information:

a. HEIGHT where the load is to be placed.

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

placed.

5. On the capacity chart, find the line for the height and follow it over to the distance.

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

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

Capacity Indicator Locations

5-73126018

Section 5 - Attachments

XXXX-XXXX

48" & 72"

CARRIAGES

MODEL XXXXX

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

RATED CAPACITY @ 2 FT. LOAD CENTER

48'

44'

40'

36'

32'

28'

24'

20'

16'

12'

-4'

-8'

69°

60°

50°

40°

30°

20°

10°

0°

-6°

9000 LBS

7000 LBS

6000 LBS

5000 LBS

4000 LBS

3000 LBS

2000 LBS

1100 LBS

DEDUCT 350 LBS

FROM ALL CAPACITIES

WHEN MACHINE IS

EQUIPPED WITH WINCH

36'

0'4'8'

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

OWO650

This Capacity Chart may be

used with this model ONLY.

The model of your

telehandler is indicated on

the boom or chassis.

Model XXXXX is used for

demonstration purposes only.

Boom Extension

Indicator (arc)

Load zones indicate

the maximum weight

that may be safely lifted.

These numbers must match the

model/option number stamped

on the attachment ID Plate.

Boom Angle

Sample Capacity Chart

Before S/N 0160037689

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

TIP OVER HAZARD. All loads shown on rated capacity chart are based on machine being on firm ground with frame level (see page 4-7); 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.

WARNING

5-8 3126018

Section 5 - Attachments

OAL1090

OAL1100

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

• Use when lifting a load with outriggers up.

• Use when lifting a load with outriggers down.

5-93126018

Section 5 - Attachments

OY1520

XXXXXX

30°

50°

XXXXXXXXXX X

ANSI/ITSDF B56.6-2005

XXXX

LBS

XXXX

LBS

XXXX

BLS

XXXX

SLB

-4

0°

10°

20°

40°

60°

71°

=XXXX XX MAX

< = XX

XXXX XX MAX

XXXXXXXXXXXXXXXXXXXXXXXX

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.

Boom Extension

Indicator (arc)

Boom Angle

Load zones indicate the

maximum weight that

may be safely lifted.

Load center must be equal to or less than value shown.

Attachment type,

weight and

dimensions must

be equal to or less

than the data

shown.

S/N 0160037689 & After

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

WARNING

5-10 3126018

Section 5 - Attachments

OAL1090

OAL1100

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.

• Use when lifting a load with outriggers down.

5-113126018

Section 5 - Attachments

OY1710

12'

16'

20'

24'

28'

32'

36'

40'

44'

-4'

12'

16'

20'

24'

28'

32'

36'

40'

44'

48'

52'

56'

60'

48

30°

50°

4000 LBS

10000 LBS

L8000 BS

L6000 BS

5000 BLS

3000 SLB

-4

0°

10°

20°

40°

60°

71°

Example 1

Example 2

Example 3

Example 4

Example

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

Before S/N 0160037689

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

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

S/N 0160037689 & After

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

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

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

Load Weight Distance Height OK to Lift

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

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

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

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

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

5-12 3126018

5.6 ATTACHMENT INSTALLATION

OY1830

BEFORE S/N 0160037689 S/N 0160037689 & AFTER

1. Attachment

Section 5 - Attachments

2. Attachment Pin Recess

3. Attachment Pin

4. Lock Pin

5. Retaining Pin

6. Quick Switch

(attachment tilt control in cab, see page 3-10)

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.

5-133126018

Section 5 - Attachments

OY1840

OY1850

OY1860

OY0601

Before S/N 0160037689

This installation procedure is designed for one-person operation. Prior to exiting cab, perform “Shut-Down Procedure” on page 4-5.

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

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

3. Tilt quick switch forward to engage attachment.

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

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

6. If equipped, connect auxiliary hydraulic hoses. See “Hydraulic Operated Attachment” on page 5-16.

7. If equipped, connect auxiliary electric harness.

5-14 3126018

Section 5 - Attachments

OY1550

Y1560

OY1570

OY1580

S/N 0160037689 & After

This installation procedure is designed for one-person operation. Prior to exiting cab, perform “Shut-Down Procedure” on page 4-5.

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

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

3. Tilt quick switch forward to engage attachment.

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

5. If equipped, connect auxiliary hydraulic hoses. See “Hydraulic Operated Attachment” on page 5-16.

6. If equipped, connect auxiliary electric harness.

5-153126018

Section 5 - Attachments

OW1240

OW1230

OY1720

S/N 0160037689 & AFTERBEFORE S/N 0160037689

Hydraulic Operated Attachment

1. Install attachment (see page 5-13).

2. Lower attachment to ground and perform “Shut-Down Procedure” on page 4-5.

3. Press the decompression valve button (1) to relieve auxiliary hydraulic pressure.

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

5-16 3126018

Section 5 - Attachments

5.7 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 5-13.

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

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

If removing fork bar is necessary:

1. Rest forks on ground.

2. Remove fork bar.

3. Reposition forks.

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

5-173126018

Section 5 - Attachments

5.8 ATTACHMENT OPERATION

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

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

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.

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Carriage w/Forks

OY0690

OAL0662

Use Carriage Attachment Capacity Chart

To determine maximum capacity, refer to “Telehandler/ Attachment/Fork Capacity” on page 5-6.

Section 5 - Attachments

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

The tilt switch (2) controls fork tilt.

• Press left side of switch to tilt up.

• Press right side of switch to tilt down.

Installation Procedure:

• Refer to “Attachment Installation” on page 5-13.

Equipment Damage Precautions:

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

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

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Section 5 - Attachments

OAL1550

OAL0731

Side Tilt Carriage

Use Side Tilt Carriage Capacity Chart

To determine maximum capacity, refer to “Telehandler/ Attachment/Fork Capacity” on page 5-6.

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

The tilt switch (2) controls fork tilt.

• Press left side of switch to tilt up.

• Press right side of switch to tilt down.

To Side Tilt:

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

• Move joystick left to (side) tilt left.

• Move joystick right to (side) tilt right.

Installation Procedure:

• Refer to “Attachment Installation” on page 5-13.

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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.

Operation:

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

• Level telehandler before side tilting carriage to engage load.

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

• Raise load slightly and level carriage side to side.

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

Equipment Damage Precautions:

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

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

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Section 5 - Attachments

OU2150

OAL1591

Swing Carriage

Use Swing Carriage Capacity Chart

To determine maximum capacity, refer to “Telehandler/ Attachment/Fork Capacity” on page 5-6.

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

The tilt switch (2) controls fork tilt.

• Press left side of switch to tilt up.

• Press right side of switch to tilt down.

To Swing:

The auxiliary hydraulic joystick (3) controls the swing function.

• Move joystick left to swing left.

• Move joystick right to swing right.

Installation Procedure:

• Refer to “Attachment Installation” on page 5-13.

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Section 5 - Attachments

WARNING

CRUSH HAZARD. Always level forks (horizontally) and telehandler frame 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 the requirements set forth in Section 1 - General Safety Practices.

Equipment Damage Precautions:

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

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

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Section 5 - Attachments

OZ3670

OY3120

Dual Fork Positioning Carriage

Use Carriage Load Chart

To determine maximum capacity, refer to “Telehandler/ Attachment/Fork Capacity” on page 5-6.

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

The tilt switch (2) controls fork tilt.

• Press left side of switch to tilt up.

• Press right side of switch to tilt down.

To Fork Position:

The auxiliary hydraulic joystick (3) controls fork position.

• Move joystick left to shift forks in.

• Move joystick right to shift forks out.

Installation Procedure:

• Refer to “Attachment Installation” on page 5-13.

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Section 5 - Attachments

WARNING

CRUSH HAZARD. Do not use fork positioning to push or pull objects or load.

Failure to comply could cause object or load to fall.

Operation:

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

Equipment Damage Precautions:

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

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

5-253126018

Section 5 - Attachments

OZ0750

OAL0662

Fork Extension

Use Appropriate Carriage Attachment Capacity Chart

To determine maximum capacity, refer to “Telehandler/Attachment/Fork Capacity” on page 5-6. The maximum capacity of the carriage when equipped with fork extensions may be reduced to the capacity indicated on the fork extensions. If the load exceeds the capacity of the fork extension contact JLG to obtain forks and/or fork extensions of the proper load rating and length.

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

The tilt switch (2) controls fork tilt.

• Press left side of switch to tilt up.

• Press right side of switch to tilt down.

Installation Procedure:

• Ensure carriage is properly installed. Refer to “Attachment Installation” on page 5-13.

• Ensure length and cross section of the parent fork arm is equal to or exceeds the parent fork arm blade length stamped into the fork extension.

• Secure the fork extensions to the forks by sliding the fork extensions onto the parent forks and install the retaining pin behind the vertical shank of the fork.

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JLG G12-55A 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

ANSI

ISO (S/N 0160040120 & After, If Equipped)

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

Dash Controls and Indicators

Ignition

Park Brake

Parking Procedure

Transmission Control Lever

Boom Joystick

Frame Level Joystick

Auxiliary Hydraulic Joystick (if equipped)

Outrigger Joysticks

Right Hand Panel

Accessory Control Lever (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

Cold Weather Starting Aids

Extreme Cold Weather Starting (if equipped)

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