G12-55A
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Operation & Safety
Manual
Original Instructions
Keep this manual with machine at all times.
An Oshkosh Corporation Company
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
a3126018
Revision Log
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.
Read This First
b 3126018
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.
Read This First
c3126018
This product must comply with all safety related bulletins. Contact JLG Industries,
Inc. or the local authorized JLG representative for information regarding safety-
related 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
Read This First
d 3126018
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.
Table of Contents
i3126018
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
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
Table of Contents
Table of Contents
ii 3126018
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
Table of Contents
iii3126018
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
Section 6 - Emergency Procedures
6.1 Towing a Disabled Product ..................................................6-1
Moving Short Distances ..................................................6-1
Moving Longer Distances ............................................... 6-1
6.2 Emergency Lowering of Boom.............................................6-2
6.3 Emergency Exit from Enclosed Cab ....................................6-2
Table of Contents
iv 3126018
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
Section 1 - General Safety Practices
1-13126018
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.
DANGER
OW0010
WARNING
OW0021
CAUTION
OW0031
Section 1 - General Safety Practices
1-2 3126018
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.
OW0040
10 FT
(3 M)
Section 1 - General Safety Practices
1-33126018
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.)
OW0050
OW0080
OW0100
4 FT
(1,2 M)
Section 1 - General Safety Practices
1-4 3126018
• 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
OH2291
OH
20911
OH2221
Section 1 - General Safety Practices
1-53126018
Non-Suspended Load
• DO NOT drive with boom raised.
Suspended Load
• 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.
OW0060
OW0150
Section 1 - General Safety Practices
1-6 3126018
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).
OAL2030
2-Wheel Front Steer 4-Wheel Circle Steer 4-Wheel Crab Steer
Section 1 - General Safety Practices
1-73126018
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.
OW0130
Section 1 - General Safety Practices
1-8 3126018
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.
OW0170
OW0190
Section 1 - General Safety Practices
1-93126018
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.
OW0200
Section 1 - General Safety Practices
1-10 3126018
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.
OW0210
OW0220
OW0230
Section 1 - General Safety Practices
1-113126018
• 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.
OW0240
OW0250
OW0260
OW0960
Section 1 - General Safety Practices
1-12 3126018
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.
OW0280
OW0290
Section 1 - General Safety Practices
1-133126018
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.
OW0300
OW0950
Section 1 - General Safety Practices
1-14 3126018
This Page Intentionally Left Blank
Section 2 - Pre-Operation and Inspection
2-13126018
SECTION 2 - PRE-OPERATION AND INSPECTION
2.1 PRE-OPERATION CHECK AND INSPECTION
Note: Complete all required maintenance before operating unit.
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.
WARNING
FALL HAZARD. Use extreme caution when checking items beyond your normal
reach. Use an approved ladder.
OAH1000
PARENT METAL CRACK WELD CRACK
Section 2 - Pre-Operation and Inspection
2-2 3126018
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.
Section 2 - Pre-Operation and Inspection
2-33126018
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
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)
1
2
3
4
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
4
A
A
A
A
1000
A
A
A
A
A
A
B
1001121126
10
D
50
250
50
1001121125A
LB
-
FT
(
N
m)
1001121125
S/N 0160039451 THRU 0160040119
INCLUDING 0160039394 & 0160039397
VIEW OF CAB DASH
CAPACITY
CHARTS
Section 2 - Pre-Operation and Inspection
2-4 3126018
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
Check
Check
Check
Check
Check
Check
Check
Check
Check
Check
Check
Check
Check
Grease
Grease
Grease
Grease
Grease
Grease
Grease
Grease
Grease
Grease
Grease
Grease
Change
Change
Change
Change
Change
Change
Change
Change
Change
Change
Change
Change
SAE 15W-40 CE Oil
Etheylene Glycol
No. 2 Diesel Fuel
Mobil 424
Mobil 424
Mobil 424
Mobil 424
Mobil 424
Mystik Tetrimoly
Mystik Tetrimoly
Mystik Tetrimoly
Mystik Tetrimoly
Mystik Tetrimoly
Mystik Tetrimoly
Mystik Tetrimoly
Mystik Tetrimoly
Mystik Tetrimoly
Mystik Tetrimoly
Mystik Tetrimoly
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
OR
SPECIFICATION
YEARLY
OR
1500 HRS
6 MO.
OR
1000 HRS
3 MO.
OR
500 HRS
EVERY 5
WKS OR
250 HRS
WEEKLY
OR
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
Section 2 - Pre-Operation and Inspection
2-53126018
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
0
10
20
30
40
50
60
7
0
8
0
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 attach-
ments and moving parts while
engine is running.
20
°
1
0
°
0°
-10°
-20°
30°
40°
50°
60°
70°
91003031
(Before S/N 0160012584)
VIEW A-A
AA
Section 2 - Pre-Operation and Inspection
2-6 3126018
S/N 0160040120 & After, If Equipped
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
1701640
VIEW A-A
A
A
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