JLG G5-18A Operator Manual

Download

Operation & Safety

Manual

Keep this manual with machine at all times.

Models

G5-19A

G6-23A

31200192

Revised

August 29, 2007

An Oshkosh Truck Corporation Company

CALIFORNIA PROPOSITION 65

BATTERY WARNING

Battery posts,

terminals and related

accessories contain

lead and lead compounds,

chemical known to the

State of California

to cause cancer and

reproductive harm.

WASH HANDS

AFTER HANDLING!

CALIFORNIA PROPOSITION 65

EXHAUST WARNING

Diesel Engine exhaust and

some of its constituents

are known to the State of

California to cause cancer,

birth defects and other

reproductive harm.

Revision Log

March 24, 2006 - A - Original Issue of Manual

August 29, 2007 - B - Revised pages 2-3, 2-4, 2-5, 3-2, 3-3, 3-7, 3-8, 3-9, 3-12, 3-14, 3-19, 4-1, 4-7, 4-8, 5-11, 5-14 thru 5-17, 5-22, 7-14, 7-15, 7-16, 9-2, 9-3 and 9-4.

REVISION LOG

a31200192

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

• 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 31200192

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. 1 JLG Drive McConnellsburg, PA 17233 USA

or Your Local JLG Office (Addresses on back cover)

In USA:

Toll Free: 877-JLG-SAFE (877-554-7233)

Outside USA:

Phone: 717-485-5161 or 717-485-6591 E-mail: ProductSafety@JLG.com

Other Publications Available

Service Manual .............................................................31200193

Illustrated Parts Manual.................................................31200194

c31200192

Read This First

This Page Intentionally Left Blank

d 31200192

TABLE OF CONTENTS

Revision Log

Read This First

Operator Qualifications ...................................................... b

Modifications ...................................................................... b

Other Publications Available .............................................. c

Table of Contents

Section 1 - General Safety Practices

1.1 Hazard Classification System ..............................................1-1

Safety Alert System and Safety Signal Words................1-1

1.2 General Precautions ............................................................1-1

1.3 Operation Safety ..................................................................1-2

Electrical Hazards ...........................................................1-2

Tip Over Hazard..............................................................1-3

Travel Hazard .................................................................1-6

Load Falling Hazard ........................................................1-7

Lifting Personnel .............................................................1-8

Driving Hazards on Slopes .............................................1-9

Pinch Points and Crush Hazards ..................................1-10

Fall Hazard....................................................................1-12

Chemical Hazards.........................................................1-13

Table of Contents

Section 2 - Pre-Operation and Inspection

2.1 Pre-Operation Check and Inspection...................................2-1

2.2 Safety Decals.......................................................................2-3

2.3 Walk-Around Inspection.......................................................2-6

2.4 Warm-Up and Operational Checks ......................................2-8

Warm-Up Check .............................................................2-8

Operational Check ..........................................................2-8

2.5 Operator Cab .......................................................................2-9

2.6 Windows ............................................................................2-10

Cab Door Window (if equipped)....................................2-10

Rear Window ................................................................2-10

Section 3 - Controls and Indicators

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

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

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

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

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

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

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

i31200192

Table of Contents

Gear Selection Switch .................................................... 3-9

Accessory Control Lever (if equipped) ......................... 3-10

Steering Column Adjuster............................................. 3-11

Joystick......................................................................... 3-12

Control and Indicator Console ...................................... 3-16

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

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

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

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

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

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

Section 4 - Operation

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

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

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

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

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

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

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

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

Transporting the Load .................................................... 4-5

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

Placing the Load............................................................. 4-6

Disengaging the Load..................................................... 4-6

4.3 Loading and Securing for Transport.................................... 4-7

Tiedown .......................................................................... 4-7

Lifting .............................................................................. 4-8

Section 5 - Attachments

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

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

5.3 Telehandler/Attachment/Fork Capacity ............................... 5-2

5.4 Use of the Capacity Chart ................................................... 5-3

Capacity Indicator Locations .......................................... 5-3

Sample Capacity Chart................................................... 5-4

Example.......................................................................... 5-6

5.5 Attachment Installation ........................................................ 5-7

Mechanical Quick-Switch Device ................................... 5-8

Hydraulic Quick-Switch Device....................................... 5-9

Hydraulic Operated Attachment ................................... 5-10

5.6 Adjusting/Moving Forks ..................................................... 5-11

ii 31200192

5.7 Attachment Operation ........................................................5-11

Carriage w/Forks........................................................... 5-12

Truss Boom...................................................................5-13

Side Shift Carriage ........................................................5-14

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

Bucket ...........................................................................5-18

Manure Bucket ..............................................................5-20

Fork Hook ..................................................................... 5-22

Personnel Work Platform ..............................................5-23

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

Electronic Control Unit Failure ........................................6-2

Engine Failure .................................................................6-3

6.3 Cab Emergency exit ............................................................6-4

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

8 & 1st 50 Hour Maintenance Schedule .........................7-3

50, 250 & 500 Hour Maintenance Schedule ...................7-4

1000 & 1500 Hour Maintenance Schedule .....................7-5

7.4 Lubrication Schedules .........................................................7-6

8 Hour Lubrication Schedule...........................................7-6

50 Hour Lubrication Schedule.........................................7-7

7.5 Operator Maintenance Instructions......................................7-8

Fuel System ....................................................................7-8

Air Intake System ..........................................................7-10

Engine Oil .....................................................................7-12

Hydraulic Oil.................................................................. 7-13

Tires ..............................................................................7-14

Brake System................................................................ 7-17

Battery........................................................................... 7-18

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

Table of Contents

Section 8 - Additional Checks

iii31200192

Table of Contents

Section 9 - Specifications

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

Fluid and Lubrication Capacities .................................... 9-1

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

Performance ................................................................... 9-2

Dimensions..................................................................... 9-3

Index

Inspection, Maintenance and Repair Log

iv 31200192

Section 1 - General Safety Practices

SECTION 1 - GENERAL SAFETY PRACTICES

1.1 HAZARD CLASSIFICATION SYSTEM

Safety Alert System and Safety Signal Words

DANGER

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

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

CAUTION

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

OW0010

OW0020

OW0030

1.2 GENERAL PRECAUTIONS

WARNING

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

1-131200192

Section 1 - General Safety Practices

1.3 OPERATION SAFETY

Electrical Hazards

10 FT

(3 M)

OW0040

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

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

• Always check for power lines before raising the boom.

1-2 31200192

Section 1 - General Safety Practices

Tip Over Hazard

OW0050

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

• DO NOT exceed rated lift capacity.

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

OW0060

• DO NOT drive with boom raised.

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

OW0080

• DO NOT raise boom unless frame is level (0 degrees).

1-331200192

Section 1 - General Safety Practices

4 FT

(1,2 M)

OW0100

• DO NOT level machine with boom/attachment above 4 ft (1,2 m).

OW0150

• Carry load as low as possible. Tether suspended loads to restrict movement.

• Understand how to properly use the capacity charts located in cab (see page 5-3).

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

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

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

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

• Keep heavy part of load closest to attachment.

• Never drag the load; lift vertically.

1-4 31200192

Section 1 - General Safety Practices

OH2291

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

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

OH20911

• Always wear the seat belt.

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

OH2221

If the telehandler starts to tip over:

• DO NOT JUMP

• BRACE YOURSELF and STAY WITH THE MACHINE

• KEEP YOUR SEAT BELT FASTENED

•HOLD ON FIRMLY

• LEAN AWAY FROM THE POINT OF IMPACT

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

1-531200192

Section 1 - General Safety Practices

Travel Hazard

4-Wheel Steer Pivot Steer

• Steering characteristics differ between 4-Wheel Steer & Pivot Steer telehandlers as shown above. Identify the telehandler you are operating & others on the jobsite.

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

• Unlike a conventional 4-wheel steer telehandler the rear wheels of a pivot steer telehandler turn a wider circle than the front wheels.

• 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.

OW0120

1-6 31200192

Section 1 - General Safety Practices

Load Falling Hazard

OW0130

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

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

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

1-731200192

Section 1 - General Safety Practices

Lifting Personnel

OW0170

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

OW0190

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

1-8 31200192

Section 1 - General Safety Practices

Driving Hazards on Slopes

OW0200

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

• When unloaded, the rear of the machine is the “heavy end.” Drive with forks pointed downhill.

• When loaded, the front of the machine is the “heavy end.” Drive with the forks pointed uphill.

• 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.

1-931200192

Section 1 - General Safety Practices

Pinch Points and Crush Hazards

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

• Stay clear of moving parts while engine is running.

OW0220

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

OW0210

OW0230

• Keep clear from under boom.

1-10 31200192

Section 1 - General Safety Practices

OW0240

• Keep clear of boom holes.

OW0250

• Keep arms and hands clear of attachment tilt cylinder.

OW0260

• Keep hands and fingers clear of carriage and forks.

OW0960

• Keep others away while operating.

1-1131200192

Section 1 - General Safety Practices

Fall Hazard

OW0280

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

• DO NOT get off the machine until the shutdown procedure on page 4-3 has been performed.

OW0290

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

1-12 31200192

Section 1 - General Safety Practices

Chemical Hazards

Exhaust Fumes

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

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

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

Flammable Fuel

OW0300

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

Hydraulic Fluid

OW0950

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

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

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

1-1331200192

Section 1 - General Safety Practices

This Page Intentionally Left Blank

1-14 31200192

Section 2 - Pre-Operation and Inspection

SECTION 2 - PRE-OPERATION AND INSPECTION

2.1 PRE-OPERATION CHECK AND INSPECTION

Note: Complete all required maintenance before operating unit.

WARNING

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

reach. Use an approved ladder. Failure to comply could result in death or serious injury.

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

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

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

OAH1000

PARENT METAL CRACK WELD CRACK

3. Safety Decals - Ensure all safety decals are legible and in place. Clean or replace as required. See page 2-3 for details.

4. Operation and Safety Manuals - Operation & Safety Manual and AEM Safety Manual are located in cab manual holder.

5. Walk-Around Inspection - See page 2-6 for details.

6. Fluid Levels - Check fluids, including fuel, brake fluid, hydraulic oil, engine oil and coolant. When adding fluids, refer to Section 7 - Lubrication and Maintenance and Section 9 - Specifications to determine proper type and intervals. Before removing filler caps or fill plugs, wipe all dirt and grease away from the ports. If dirt enters these ports, it can severely reduce component life.

7. Attachments/Accessories - Ensure correct load 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.

2-131200192

Section 2 - Pre-Operation and Inspection

8. Operational Check - Once the walk-around inspection is complete, perform a warm-up and operational check (see page 2-8) of all systems in an area free of overhead and ground level obstructions. See Section 3 - Controls and Indicators for more specific operating instructions.

WARNING

If telehandler does not operate properly, immediately bring machine to a stop, lower boom and attachment to ground and stop the engine. Determine cause and correct before continued use.

2-2 31200192

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.

1701500

1702300

(S/N 116002234

& AFTER)

1705998

-1

60°

° 0

° 0 4

° 0 3

° 0 2

-1

0°

Model

SerialNumber

MaximumWeightWithout Attachments (lbs/kg)

°Referto load capacity chart for truck with attachment, and individual load ratings stamped

onforks,if equipped. Use lowest capacity of all ratings.

Asreleasedfrom factory this truck meets specifications in ASME B56.6-2002 Part III.

Oneormore of the following patents may apply to this truck; U.S. Nos. 4,954,041 6,349,969

5,639,1195,813,6975,230,399 5,052,532. Other patents pending.

MaximumCapacity(lbs/kg)

Manufacturedby

JLGManufacturing Europe BVBA

IndustrieterreinOudeBunders 1034, Breitwaterstraat 12 3630Maasmechelen- Belgium

YearOfManufacture

1706910

1706835

Riders could falloff machine

No Riders

causing deathor serious injury.

1702300

1706835A

1702300

2447967

OIL

60°

50°

40°

30°

1706910A

Dexron

ATF

2447 967

OAH0921

1706391

1706298A

1706298

1702300

(BEFORE

S/N 116002234)

1702300

(BEFORE

S/N 116002234)

OAH0802

2-331200192

Section 2 - Pre-Operation and Inspection

1702300

(S/N 116002234

& AFTER)

1702300

1701500

1706301

1701504

1706297

A 7 9 2 6 0

1701504 A

7 1

VIEW OF ENGINE COMPARTMENT

WITH ENGINE REMOVED

(BEFORE S/N 116002380)

8009815

1704972

A 7 9 2 6 0 7 1

1701504

1701504 A

WARNING

EXPLOSION/FIREHAZARD

Donot use starting fluid. Thisunit isequipped withan airintake heater or glow plugs.

Failureto follow instructions could

1706301A

resultin death or serious injury.

1706297

1704972C

1706301

1706301A

VIEW OF ENGINE COMPARTMENT

WITH ENGINE REMOVED

(S/N 116002380 & AFTER)

1701500

OAH0811

2-4 31200192

Section 2 - Pre-Operation and Inspection

1706306

1706299

CONTACTING POWERLINES

willresult in death

orserious injury.

1706850

WARNING

CRUSHING HAZARD

Loweringboom or falling load could

causedeath or serious injury.

1706850

WARNING

CRUSHING HAZARD

1706303

Loweringboom or falling load could

causedeath or serious injury.

1706303

Operatormust be trained and

mustread and understand

allcapacity charts, operator

1706209

XXXXXXX

1706306

1706299

CONTACTING POWERLINES

willresult in death

orserious injury.

Keepothers

awaywhile

operating.

Keepothers

awaywhile

operating.

Operatormust be trained and

1706850A

mustread and understand

allcapacity charts, operator

andsafety manuals.

XXXXX

28'

24'

60°

20'

50°

40°

16'

30°

12'

6600 lbs

20°

b l

5 3

10°

5 2

0°

-4'

LOAD

CHARTS

1706304

RUN-OVER

HAZARD

1706767

couldcause

1706306A

1706299A

1706850A

A 3

Fasten

0 3

seat

6 0

belt.

7 1

A 3

Fasten

0 3

VIEW OF DECALS LOCATED INSIDE CAB

seat

6 0

belt.

7 1

deathor

serious

injury.

1706304

1706306A

RUN-OVER

HAZARD

1706767

couldcause

deathor

serious

injury.

1706304A

ON RIGHT HAND WINDOW

(BEFORE S/N 116002380)

1707078

Operatormust be trained and

mustread and understand

allcapacity charts, operator

andsafety manuals.

CONTACTING POWERLINES willresult in death orserious injury.

DONOT place machineor load within10 feet (3m) ofpower lines.

P/N 1234567 P/N 9876543 P/N 9876541

24

0'4'8'12'16'

WARNING

LOWERINGBOOM or FALLINGLOAD

cancrush causing death orserious injury.

RUN-OVER

HAZARD

ouldcause

deathor serious

injury.

4017

50°

40°

EN 1459 B (1998)

30°

g k 0 0 0

20°

5 .

1 0 5

g k

0 5 7

10°

g k

0 0 4

0° 0

8008746 B

8210

Fasten

seat belt.

Keepothers

awaywhile

operating.

P/N 1170001

P/N 2340029

P/N 4802111

P/N 8008014

70°

2 0 00kg

60°

g k

0 .

5 .

0 5 . 2

VIEW OF DECALS LOCATED INSIDE CAB

ON RIGHT HAND WINDOW

(S/N 1160002380 & AFTER)

MACHINE ROLL-AWAY couldcause deathor seriousinjury.

JUMPINGOFF ofa tipping machinecould resultin deathor seriousinjury.

1707078A

A 7 6 7 6 0 7 1

(Standard)

1706944A

A 7 6 7 6 0

1706944A

7 1

1706944A

1706944

(Standard)

1706944

(Standard)

1706951

(Optional)

1706951A

1706851

1706951A

1706851

1706951A

9116-3028

1706951

(Optional)

1706851A

1706951

(Optional)

VIEW OF PARK BRAKE LEVER

1706463

VIEW OF REAR WINDOW

8005870

LOAD

CHARTS

XXXXX

28'

24

24'

60°

20'

50°

40°

16'

30°

12'

6600 lbs

20°

b l

5 3

10°

5 2

0°

8005870

-4'

XXXXXXX

0'4'8'12'16'

8005870

91163028

P/N 1234567 P/N 9876543 P/N 9876541

4017

50°

40°

EN 1459 B (1998)

30°

g k 0 0 0

20°

1 g k 0

0 5

g k

0 5 7

10°

g k

0 0 4

0°

8008746 B

8210

1706801

P/N 1170001

P/N 2340029

P/N 4802111

P/N 8008014

70°

2 0

0 0

60°

k g

g k

0 .

. g

2 k

5 .

0 5

. g k

2 0 0 5 . 1

1706801A

1706209

1706859

1706859A

OAH0821

OAH0822

TOP VIEW OF DASH

2-531200192

Section 2 - Pre-Operation and Inspection

2.3 WALK-AROUND INSPECTION

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

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

OAH0790

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

• Check front, top, side & rear slider pads for adequate grease.

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

2. Front Axle undamaged, not leaking.

- Steer cylinders undamaged, not leaking; hydraulic hoses

2-6 31200192

Section 2 - Pre-Operation and Inspection

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

4. Worklights

(if equipped) - Clean, undamaged and work properly.

5. Cab & Electrical

• General appearance; no visible damage.

• Window glass undamaged and clean.

• Gauges, switches, joystick, foot controls, park brake & horn operational.

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

buckles or loose mounting hardware.

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

7. Rear Axle hydraulic hoses undamaged, not leaking.

8. Main Control Valve

9. Wheel/Tire Assembly

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

10. Engine Compartment

• Drive belts, check condition & replace as required.

• Air cleaner element condition indicator, check for clogged condition. Replace

element as required.

• Check and clean Pre-Cleaner as required.

• Battery cables tight, no visible damage or corrosion.

• Engine cover properly secured and latched.

11. Mirrors

- Clean and undamaged.

- Properly inflated and secured; no loose or missing lug

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

- See Inspection Note.

- Properly inflated and secured; no loose or missing lug

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

13. Attachment

- Properly installed, see “Attachment Installation” on page 5-7.

- Properly inflated and secured; no loose or missing lug

2-731200192

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. Failure to comply could result in death or serious injury.

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 boom and attachment functions - operate smoothly and correctly.

7. Perform any additional checks described in Section 8.

2-8 31200192

Section 2 - Pre-Operation and Inspection

2.5 OPERATOR CAB

The telehandler is equipped with a standard open ROPS/FOPS cab. An optional enclosed ROPS/FOPS cab is available.

WARNING

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

2-931200192

Section 2 - Pre-Operation and Inspection

2.6 WINDOWS

Keep all windows and mirrors clean and unobstructed.

Cab Door Window (if equipped)

OZ0210

• During operation the window must either be latched open or closed.

• Open the cab door window (1) and secure it in the latch.

• Press the release button (2) inside the cab to unlatch the window.

Rear Window

OZ0220

• Lift lever (3) and push to open the rear window (4).

• Lift lever and pull to close.

2-10 31200192

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.

3-131200192

Section 3 - Controls and Indicators

3.2 CONTROLS

OAH0661

1. Parking Brake: See page 3-7 for details.

2. Accelerator Pedal

speed.

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

4. Service Brake Pedal speed.

5. Ignition: Key activated. See page 3-6 for details.

6. Steering Column Adjuster: See page 3-11 for details.

7. Transmission Control Lever

8. Brake Fluid Reservoir

MAX marks. The sight gauge is on the left side of the reservoir.

: Pressing down the pedal increase engine and hydraulic

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

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

: See page 3-8 for details.

: The brake fluid level should be between the MIN and

3-2 31200192

Section 3 - Controls and Indicators

9. Steering Wheel: Turning the steering wheel to the left or right steers the machine in the corresponding direction.

10. Level Indicator of the telehandler.

11. Instrument Panel: See page 3-4 for details.

12. Accessory Control Lever (if equipped): See page 3-10 for details.

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

13. Gear Selection Switch

14. Joystick

15. Continuous Hydraulic Powered Attachment Operation Switch: Press switch for

continuous operation of hydraulic powered attachment. See Section 5 - Attachments for approved attachments and control instructions.

16. Bucket Mode Switch attachment tilt function.

17. Control & Indicator Console: See page 3-16 for details.

18. Heater and Air Conditioner Controls (if equipped): See page 3-17 for details.

: See page 3-12 for details.

: See page 3-9 for details.

(if equipped): Press switch for increased reponse to

3-331200192

Section 3 - Controls and Indicators

Instrument Panel

rpm x 100

8910111213141516

OAH0670

1. Fuel Gauge: Gauge for the diesel fuel tank.

2. Low Fuel Warning Indicator

: Illuminates when diesel fuel level is below 1/8 tank.

3. Engine RPM Indicator: Indicates engine speed in revolutions per minute (rpm).

4. Engine Coolant Temperature Gauge

5. Engine Coolant Temperature Warning Indicator

: Gauge for engine coolant temperature.

: Illuminates when coolant

temperature is too high.

6. Hourmeter

: Indicates total time of engine operation in hours and tenths of

hours. Hourmeter symbol is visible and flashes only when engine is running.

7. High beam Indicator

(if equipped): Illuminates while high beam lights are

activated.

8. Turn Signal Indicator (if equipped): Illuminates and flashes while turn signals are activated in either direction or the hazard lights have been activated.

9. All Wheel Steering Mode Indicator

: Illuminates while activated: All wheels are

steering. The front wheels steer in the opposite direction from the rear wheels.

10. Crab Steer Mode Indicator

: Illuminates while activated: All wheels are steering

in the same direction.

11. Front Wheel Steer Mode Indicator: Illuminates while activated: The front wheels are steering.

12. Park Brake Indicator

: Illuminates when park brake is activated (see page 3-7).

Park brake must be applied to start engine.

13. Hydraulic Return Filter Indicator

: Illuminates when filter requires maintenance.

3-4 31200192

Section 3 - Controls and Indicators

14. Engine Pre-Heat Indicator: Illuminates with ignition key in position 1. Light goes out when start temperature is reached. At temperatures below 32°F (0°C), do not start until light goes out.

15. Engine Oil Pressure Indicator engine immediately.

16. Battery Charge Indicator briefly during starting. Illuminates during operation when battery is at low charge.

: Illuminates when low oil pressure occurs. Stop

: Illuminates with the ignition key in position 1 and

CAUTION

EQUIPMENT DAMAGE. When a red light illuminates and a warning tone is

heard, immediately bring machine to a stop, lower boom and attachment to ground and stop the engine. Determine cause and correct before continued use.

3-531200192

Section 3 - Controls and Indicators

Ignition

III

OZ1110

•Position 0 - Engine off

•Position I- Voltage is available for all electrical functions. Engine preheat at temperature below 32°F (0°C). Wait to start engine until preheat indicator light on instrument panel goes out.

•Position II- Prohibits rotating key switch to position 3 in the event the engine does not start. Rotate the key to position 0 then back to position 3 to re-engage the starter.

•Position III- Engine start.

3-6 31200192

Section 3 - Controls and Indicators

Park Brake

OAH0680

The Park Brake Lever (4) controls the application and release of the park brake.

• Pull back to apply.

• Lift detent ring (5) and push forward to release.

WARNING

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

position, lower boom to ground and stop engine before leaving cab. Machine roll-away could cause death or serious injury.

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, resulting in death or serious injury. Either may be used in an emergency situation.

Parking Procedure

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

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

3-731200192

Section 3 - Controls and Indicators

Transmission Control Lever

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.

OAH0690

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. Failure to comply could result in death or serious injury.

3-8 31200192

Section 3 - Controls and Indicators

Gear Selection Switch

OAH0701

Gear selection switch controls the displacement of the hydrostatic transmission. Select the appropriate gear for the task being performed.

• Use lower gear (2) when transporting a load.

• Use higher gear (3) only when driving unloaded for longer distances.

• Slow down prior to downshifting.

3-931200192

Section 3 - Controls and Indicators

Accessory Control Lever (if equipped)

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

OAH0710

Turn Signal

• 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 & 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 beam and high beam.

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

3-10 31200192

Steering Column Adjuster

Section 3 - Controls and Indicators

•Follow “Shut-Down Procedure” on page 4-3.

• Turn the lever (8) counterclockwise to unlock.

• Place the steering column in the desired position.

• Turn to lever clockwise to lock steering column.

OAH0720

WARNING

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

engine before adjusting steering column. A sudden change in direction of travel could reduce stability and/or cause load to shift or fall. Failure to comply could result in death or serious injury.

3-1131200192

Section 3 - Controls and Indicators

Joystick

Refer to the joystick decal located inside the cab to verify control pattern. Ensure the joystick decal matches the machine controls before operating.

Construction Pattern

The joystick (1) controls the boom and attachment 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.

OAH0611

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. Failure to comply could result in death or serious injury.

3-12 31200192

Section 3 - Controls and Indicators

Attachment Functions

• Attachment tilt is controlled by the rocker switch (2). Push the rocker switch up to tilt attachment forward (down); push the rocker switch down to tilt attachment back (up).

• Auxiliary Hydraulics (if equipped) buttons (3 & 4) control functions of attachments that require hydraulic supply for operation. Buttons (4) can be used simultaneously with normal boom attachment functions. Button (3) must be used independently of boom lift/lower functions. See Section 5 - Attachments for approved attachments and control instructions.

3-1331200192

Section 3 - Controls and Indicators

Agricultural Pattern

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

Boom Functions

• Move the joystick back to lift boom; move joystick forward to lower boom. Extend/ retract is controlled by the rocker switch (2). Push the rocker switch up to extend boom; push the rocker switch down 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 functions, move the joystick between quadrants. For example; moving the joystick forward and to the left will lower boom and tilt attachment back (up) simultaneously.

OAH0621

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. Failure to comply could result in death or serious injury.

3-14 31200192

Section 3 - Controls and Indicators

Attachment Functions

• Move joystick right to tilt attachment forward (down); move joystick left to tilt attachment back (up).

3-1531200192

Section 3 - Controls and Indicators

Control and Indicator Console

Controls and indicates the electrical accessories of the telehandler.

1. Hazard Switch (if equipped): On/Off switch.

2. Boom Work Light Switch

3. Front Work Light Switch

4. Rear Work Light Switch (if equipped): On/Off switch.

5. Rotating Beacon Switch

beacon on the cab roof. Power is supplied by a 12v receptacle at the left rear part of the cab roof.

6. Windshield Wiper & Washer Switch Press and hold to third position to turn on washer. Return switch to first position to turn off wiper.

7. Horn Switch

8. Front/Rear Hydraulic Select Switch

position to activate rear hydraulics. Return switch to first position to activate front auxiliary hydraulics.

9. Auxiliary Hydraulic Circuit/ Hydraulic Quick-Switch Switch Press button to select the desired auxiliary hydraulic circuit. See Section 5 - Attachments for approved attachments and control instructions.

: Press and hold to sound horn.

(if equipped): On/Off switch.

(if equipped): Place the magnetic base of the rotating

(if equipped): Press switch to activate wiper.

(if equipped): Press switch to second

(if equipped):

OAH0730

3-16 31200192

Section 3 - Controls and Indicators

Heater and Air Conditioner Controls (if equipped)

10. Fan Speed: 3-position rotary switch for heater and air conditioner.

11. Temperature Control: Adjustable rotary switch.

12. A/C Switch

13. Round Vent

14. Air Louver: Four individually adjustable air louvers.

: On/Off switch.

: Three individually adjustable round vents.

OAH0740

Heater

Turn the temperature control to the desired temperature and set the fan speed. Adjust the air flow through the air louvers and round vents.

Air Conditioner

Turn on the air conditioner and set the fan speed. Adjust the air flow through the air louvers and round vents.

Note: When the windows are misted over, run the air conditioner and heater at the same time.

Defrosting

Direct the flow of air through the louvers and the left front round vent toward the windshield. Close the other two round vents.

3-1731200192

Section 3 - Controls and Indicators

3.3 STEER MODES

Stop the telehandler before changing steering modes. An indicator light on the instrument panel will indicate the steering mode selected.

All-Wheel Steer

OAH0751

Front-Wheel Steer

OAH0761

Crab Steer

OAH0771

3-18 31200192

Section 3 - Controls and Indicators

3.4 OPERATOR SEAT

Adjustments

Prior to starting the engine adjust seat for position and comfort as follows:

1. Turn the knob to adjust suspension to the appropriate weight setting.

2. Use knob to adjust backrest angle.

3. Always fasten seat belt during operation.

4. Lift handle to move seat fore and aft.

5. Lift latch to adjust cushion angle.

3-1931200192

Section 3 - Controls and Indicators

Seat Belt

OH20912

Fasten seat belt as follows:

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

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

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

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

3-20 31200192

Section 3 - Controls and Indicators

3.5 BOOM ANGLE AND EXTENSION INDICATORS

0 7 °

0 6 °

0 5

0 4 °

0 3

° 2

2 ° 0

1 0

° 0

OAH0650

• 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 5-3).

• 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 5-3).

3-2131200192

Section 3 - Controls and Indicators

This Page Intentionally Left Blank

3-22 31200192

Section 4 - Operation

SECTION 4 - OPERATION

4.1 ENGINE

Starting the Engine

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

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

2. Turn ignition switch to position 1. If temperature is below 32°F (0°C), wait for preheat light to go out.

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

4. After engine starts, if oil pressure does not rise for more than ten seconds, the engine oil pressure indicator will illuminate on instrument panel and buzzer will sound. 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 is applied.

WARNING

ENGINE EXPLOSION. Do not spray ether into air intake for cold weather

starting. Failure to comply could result in death or serious injury.

WARNING

UNEXPECTED MOVEMENT HAZARD. Always ensure that transmission control

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

4-131200192

Section 4 - Operation

Battery Boosted Starting

OW0530

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

• Never allow vehicles to touch.

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

• Connect the opposite end of positive (+) jumper cable to positive (+) post of booster battery.

• Connect the negative (-) jumper cable to negative (-) post on booster battery.

• Connect opposite end of negative (-) jumper cable to ground point on machine away from discharged battery.

• Follow standard starting procedures.

• Remove cables in reverse order after machine has started.

WARNING

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

as it could explode. Keep sparks, flames and lighted smoking materials away from the battery. Lead acid batteries generate explosive gases when charging. Wear safety glasses. Failure to comply could result in death or serious injury.

4-2 31200192

Section 4 - Operation

Normal Engine Operation

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

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

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

Shut-Down Procedure

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

1. Apply the park brake.

2. Shift the transmission to “Neutral.”

3. Lower forks or attachment to the ground.

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

5. Shut off engine and remove ignition key.

6. Exit telehandler properly

7. Block wheels (if necessary).

4-331200192

Section 4 - Operation

4.2 OPERATING WITH A 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 resulting in death or serious injury.

• 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.

Before 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 5-11.

• 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’s cab for the telehandler/attachment combination you are using.

4-4 31200192

Section 4 - Operation

Transporting the Load

OW0540

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

Leveling Procedure

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

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

3. Move boom/attachment to 4 ft (1,2 m) off ground.

4. Observe level indicator to determine whether machine must be leveled prior to lifting load.

Important things to remember:

• Never raise the boom/attachment more than 4 ft (1,2 m) above ground unless telehandler is level.

• The combination of side tilt and load could cause the telehandler to tip over.

4-531200192

Section 4 - Operation

Placing the 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 5-3.

• 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 the 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.

4-6 31200192

Section 4 - Operation

4.3 LOADING AND SECURING FOR TRANSPORT

° 0 6

° 0 5

40°

° 0 3

° 0

0°

1702300

1701500

1702300

OAH0831

1701500

Tiedown

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

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

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

4. Do not tie down front of boom.

Note: The user assumes all responsibility for choosing the proper method of transportation and tie-down devices, making sure the equipment used is capable of supporting the weight of the vehicle being transported and that all manufacturer’s instructions and warnings, regulations and safety rules of their employer, the Department of Transportation and/or any other state or federal 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, resulting in an accident causing death or serious injury.

4-731200192

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.

4-8 31200192

Section 5 - Attachments

SECTION 5 - ATTACHMENTS

5.1 APPROVED ATTACHMENTS

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

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

• The fork model/option number stamped on the side of the forks must match the fork 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.

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 your local distributor for further information.

5.2 UNAPPROVED ATTACHMENTS

Do not use unapproved attachments for the following reasons:

• JLG cannot establish range and capacity limitations for “will fit,” homemade, altered, or other non-approved attachments.

• 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.

• JLG cannot assure the ability of a non-approved attachment to perform its intended function safely.

WARNING

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

5-131200192

Section 5 - Attachments

5.3 TELEHANDLER/ATTACHMENT/FORK CAPACITY

OZ0810

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

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

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

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

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

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

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

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

WARNING

Never use an attachment without the appropriate JLG supplied capacity chart installed on the telehandler. Failure to install the proper JLG supplied capacity chart could cause an accident resulting in death or serious injury.

5-2 31200192

Section 5 - Attachments

5.4 USE OF THE CAPACITY CHART

To properly use the capacity chart (see page 5-4), the operator must first determine and/or have the following:

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

2. The proper Capacity Chart.

3. Weight of the load being lifted.

4. Load placement information:

a. HEIGHT where the load is to be placed.

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

placed.

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

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

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

Capacity Indicator Locations

Attachment

Identification

Plate

Fork Part

Number and

Capacity Stamp

Boom Extension

Indicator

Boom Angle

Indicator

0 7 °

0 6

0 5 °

0 4 °

0 3 °

° 2

° 0

1 0

° 0

OAH0291

5-331200192

Section 5 - Attachments

Sample Capacity Chart

This Capacity Chart may be used with this model ONLY.

The model of your

telehandler is indicated on

the boom or chassis.

Model XXXX is used for

demonstration purposes only.

28'

24'

20'

16'

XXXXX

60°

50°

40°

These numbers must match the

model/option number stamped on the attachment ID Plate and

on the forks being used.

P/N 1234567 P/N 9876543 P/N 9876541

24

Boom Extension

Indicator (arc)

4000 lbs

3500 lbs

5600 lbs

4600 lbs

6600 lbs

0'4'8'12'16'

OAH0950

Load zones indicate

the maximum weight

that may be safely lifted.

Boom Angle

XXXXXXX

12'

30°

20°

3000 lbs

10°

-4'

2500 lbs

0°

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

WARNING

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

machine being on firm ground with frame level (see page 4-5); the forks being positioned evenly on carriage; the load being centered on forks; proper size tires being properly inflated; and the telehandler being in good operating condition. Failure to comply could result in death or serious injury.

5-4 31200192

Section 5 - Attachments

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

• Use when lifting a load with outriggers up.

OW0930

• Use when lifting a load with outriggers down.

OW0940

80"

• Use for any forward movement (1 to 80 in) of the transfer carriage.

OW0910

• Use for no forward movement (0 in) of the transfer carriage. Fully retracted position only.

OW0920

5-531200192

Section 5 - Attachments

Example

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

• The attachment and fork model/option numbers match the attachment and fork numbers on the capacity chart.

• The capacity chart is clearly marked for model xxxx 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 4,250 lb (1928 kg) 6.5 ft (2,0 m) 18.5 ft (5,6 m) Yes

2 3,400 lb (1542 kg) 10 ft (3,0 m) 9.5 ft (2,9 m) NO

3 6,450 lb (2926 kg) 2 ft (0,6 m) 15 ft (4,6 m) Yes

4 6,100 lb (2767 kg) 6 ft (1,8 m) 6 ft (1,8 m) NO

P/N 1234567

XXXXX

P/N 9876543 P/N 9876541

Example 1

Example 2

XXXXXXX

28'

24'

20'

16'

12'

-4'

40°

30°

20°

10°

2500 lbs

0°

60°

50°

5600 lbs

4600 lbs

4000 lbs

3500 lbs

3000 lbs

6600 lbs

24

Example 3

Example 4

0'4'8'12'16'

OAH0960

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

5-6 31200192

5.5 ATTACHMENT INSTALLATION

1. Attachment

2. Attachment Pin Recess

Section 5 - Attachments

3. Attachment Pin

4. Lock Pin

5. Retainer Pin (mechanical quick-switch only)

6. Quick-Switch device

(attachment tilt control in cab, see page 3-12 for details)

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 causing death or serious injury.

5-731200192

Section 5 - Attachments

Mechanical Quick-Switch Device

This installation procedure is designed for one-person operation.

1. Retract quick-switch device to provide clearance. Check to be sure lock pin and retainer pin is out.

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

3. Engage quick-switch device.

4. Shut off engine. Exit cab and insert lock pin and secure with retainer pin.

5. If attachment is equipped, connect auxiliary hydraulic hoses. See “Hydraulic Operated Attachment” on page 5-10.

5-8 31200192

Section 5 - Attachments

Hydraulic Quick-Switch Device

This installation procedure is designed for one-person operation.

1. Retract quick-switch device to provide clearance. Check to be sure lock pin is disengaged.

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

3. Engage quick-switch device.

4. Press the button (1) and at the same time

move the joystick (2) to engage or (3) to disengage the quick-switch device.

OZ0610

5. Raise boom to eye level and visually check that the quick-switch pin protrudes through the hole. If the pin does not protrude through the hole, place the attachment on the ground and return to step 2.

ENGAGED DISENGAGED

OZ0900

6. If attachment is equipped, connect auxiliary hydraulic hoses. See “Hydraulic Operated Attachment” on page 5-10.

5-931200192

Section 5 - Attachments

Hydraulic Operated Attachment

OAH0640

OAH0940

1. Install attachment (see page 5-8 or 5-9).

2. Lower attachment to ground and set parking brake.

3. Quickly depress and release button (3) to relieve pressure at the male auxiliary fitting.

4. Connect to the male auxiliary fitting (1).

5. Quickly depress and release button (4) to relieve pressure at the female auxiliary fitting.

6. Connect to the female auxiliary fitting (1).

5-10 31200192

Section 5 - Attachments

5.6 ADJUSTING/MOVING FORKS

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

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

To slide forks:

1. Ensure attachment is properly installed. See “Attachment Installation” on page 5-7.

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).

5.7 ATTACHMENT OPERATION

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

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

• Operations described within this section reference construction joystick pattern, see page 3-12. Refer to page 3-14 if equipped with agricultural joystick pattern.

CAUTION

EQUIPMENT DAMAGE. Some attachments may contact the front tires or

machine structure when the boom is retracted and the attachment is rotated. Machine or attachment damage may occur from contact.

5-1131200192

Section 5 - Attachments

Carriage w/Forks

Description P/N

Carriage..........................................................................1170028

Forks, 2x4.7 in ................................................................2340040

OZ0770

Use Carriage Attachment Capacity Chart

To determine maximum capacity, refer to “Telehandler/Attachment/Fork Capacity” on page 5-2.

Forks, 2x3.9 in ................................................................2340041

OAH0870

The joystick (1) controls movement of the boom.

The rocker switch (2) located on the boom joystick controls carriage tilt.

• Push rocker switch down to tilt up.

• Push rocker switch up to tilt down.

Installation Procedure:

• Refer to “Attachment Installation” on page 5-7.

5-12 31200192

Section 5 - Attachments

Truss Boom

Description P/N

Truss Boom, 11.8 ft - 1433 lb..........................................0240110

OZ0780

Use Truss Boom Attachment Capacity Chart

To determine maximum capacity, refer to “Telehandler/Attachment/Fork Capacity” on page 5-2.

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

The joystick (1) controls movement of the boom.

The rocker switch (2) located on the boom joystick controls truss boom tilt.

• Push rocker switch down to tilt up.

• Push rocker switch up to tilt down.

Installation Procedure:

• Refer to “Attachment Installation” on page 5-7.

OAH0880

5-1331200192

Section 5 - Attachments

Side Shift Carriage

Description P/N

Side Shift Carriage ......................................................... 1170002

Forks, 1.7x4.9 in ............................................................. 2340029

OZ0800

Use Side Shift Carriage Attachment Capacity Chart

To determine maximum capacity, refer to “Telehandler/Attachment/Fork Capacity” on page 5-2.

Forks, 2.0x3.9 in ............................................................. 2340030

Forks Cubing, 2.0x2.0............................................... 1001097922

OAH0870

The joystick (1) controls movement of the boom.

The rocker switch (2) located on the boom joystick controls carriage tilt.

• Push rocker switch down to tilt up.

• Push rocker switch up to tilt down.

5-14 31200192

Section 5 - Attachments

To Side Shift:

• Use the button (3) to select the auxiliary hydraulic circuit.

• Press joystick button (4) to shift forks right or press joystick button (5) to shift forks left.

• While pressing and holding the joystick button (6), move the joystick forward (7) to shift forks right or move the joystick back (8) to shift forks left.

Installation Procedure:

• Refer to “Attachment Installation” on page 5-7.

OAH0970

WARNING

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

comply could cause object or load to fall resulting in death or serious injury.

5-1531200192

Section 5 - Attachments

Side Tilt Carriage

Description P/N

Side Tilt Carriage............................................................ 1170046

Forks, 2x4.7 in ................................................................2340040

OZ0800

Use Side Tilt Carriage Attachment Capacity Chart

To determine maximum capacity, refer to “Telehandler/Attachment/Fork Capacity” on page 5-2.

Forks, 2x3.9 in ................................................................2340041

OAH0870

The joystick (1) controls movement of the boom.

The rocker switch (2) located on the boom joystick controls carriage tilt.

• Push rocker switch down to tilt up.

• Push rocker switch up to tilt down.

5-16 31200192

Section 5 - Attachments

To Side Tilt:

• Use the button (3) to select the auxiliary hydraulic circuit.

• Press joystick button (4) to side tilt carriage right or press joystick button (5) to side tilt carriage left.

• While pressing and holding the joystick button (6), move the joystick forward (7) to side tilt carriage right or move the joystick back (8) to side tilt carriage left.

Installation Procedure:

• Refer to “Attachment Installation” on page 5-7.

OAH1010

WARNING

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

comply could cause object or load to fall resulting in death or serious injury.

Operation:

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

• Level telehandler before side tilting carriage to engage load.

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

• Raise load slightly and then level carriage side to side.

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

5-1731200192

Section 5 - Attachments

Bucket

Description P/N

Bucket, 4 in 1 - 0.78 yd3................................................. 0930006

Bucket, 4 in 1 - 1.3 yd

Bucket, 2.35 yd

OZ0730

Bucket, 1.96 yd3............................................................. 0930009

Bucket, 1.18 yd

Bucket, 1.05 yd

Use Appropriate Bucket Capacity Chart

To determine maximum capacity, refer to “Telehandler/Attachment/Fork Capacity” on page 5-2.

................................................... 0930003

............................................................. 0930016

............................................................. 0930015

............................................................. 0930008

OAH0890

The joystick (1) controls movement of the boom.

The rocker switch (2) located on the boom joystick controls bucket tilt.

• Push rocker switch down to tilt up.

• Push rocker switch up to tilt down.

Installation Procedure:

• Refer to “Attachment Installation” on page 5-7.

5-18 31200192

Section 5 - Attachments

Equipment Damage Precautions

• Drive into stockpile smoothly with boom fully retracted to load bucket. Loading bucket with boom extended could damage boom. Do not corner-load bucket.

• Distribute material evenly within the bucket. Bucket capacity charts are for evenly distributed loads only.

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

• Do not use bucket for "back dragging". This could cause severe damage to quick switch.

Operation:

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

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

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

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

• Tilt bucket down to dump load.

5-1931200192

Section 5 - Attachments

Manure Bucket

Description P/N

Bucket, 1.31 yd3............................................................. 0930004

Bucket, 1.05 yd

OZ1450

Use Appropriate Bucket Capacity Chart

To determine maximum capacity, refer to “Telehandler/Attachment/Fork Capacity” on page 5-2.

............................................................. 0930005

OAH0900

The joystick (1) controls movement of the boom.

The rocker switch (2) located on the boom joystick controls bucket tilt.

• Push rocker switch down to tilt up.

• Push rocker switch up to tilt down.

OAH0980

5-20 31200192

Section 5 - Attachments

To open/close grapple:

Use the button (3) to select the auxiliary hydraulic circuit.

Press joystick button (4) to close grapple or press joystick button (5) to open grapple.

While pressing and holding the joystick button (6), move the joystick forward to close grapple or move the joystick back to open grapple.

Installation Procedure:

• Refer to “Attachment Installation” on page 5-7.

Equipment Damage Precautions

• Drive into stockpile smoothly with boom fully retracted to load bucket. Loading bucket with boom extended could damage boom. Do not corner-load bucket.

• Distribute material evenly within the bucket. Bucket capacity charts are for evenly distributed loads only.

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

• Do not use bucket for "back dragging". This could cause severe damage to quick switch.

Operation:

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

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

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

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

• Open grapple and tilt bucket down to dump load.

5-2131200192

Section 5 - Attachments

Fork Hook

Description P/N

Fork Hook, 4 ton .............................................................2700097

Fork Hook, 4 ton .............................................................2700118

OZ0740

Use Fork Hook Attachment Capacity Chart

To determine maximum capacity, refer to “Telehandler/Attachment/Fork Capacity” on page 5-2.

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

OAH0930

The joystick (1) controls movement of the boom.

The rocker switch (2) located on the joystick controls fork hook tilt.

• Push rocker switch down to tilt up.

• Push rocker switch up to tilt down.

Installation Procedure:

• Refer to “Attachment Installation” on page 5-7.

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

5-22 31200192

Section 5 - Attachments

Personnel Work Platform

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

Preparation and Setup

1. Check to ensure the personnel platform is securely attached at the Quick Switch™ or is securely attached to the forks and/or carriage if using fork mounted personnel work platform. Follow installation procedure on page 5-7 for JLG Quick Switch™ mounted personnel work platforms.

2. Ensure the telehandler is on a firm surface and is level.

3. Engage the park brake. Blocking the wheels is also recommended.

4. Level the platform, both side to side (frame sway) and front to back (attachment tilt).

5. Keep area under the platform free from personnel.

6. DO NOT lift or carry persons in the bucket or on forks.

Never tilt the platform forward, rearward, or sway the machine when the platform is occupied. Serious injury or death could result.

5-2331200192

Section 5 - Attachments

This Page Intentionally Left Blank

5-24 31200192

Section 6 - Emergency Procedures

SECTION 6 - EMERGENCY PROCEDURES

6.1 TOWING A DISABLED PRODUCT

The following information assumes the telehandler cannot be moved under its own power.

• Before moving the telehandler, read all of the following information to understand options available. Then select the appropriate method.

• The steering system permits manual steering if engine or power assist feature fails; however, steering will be slow and will require much greater force.

• DO NOT attempt to tow a telehandler that is loaded or the boom/attachment is raised above 4 ft (1,2 m).

Moving Short Distances

• If it is only necessary to move telehandler a short distance, less than 100 ft (30 m), it is permissible to use a vehicle of sufficient capacity to tow the unit with no previous preparation. Drive wheels will not roll.

Moving Longer Distances

• If the telehandler must be moved longer distances, it must be loaded onto a trailer of sufficient capacity.

Contact your local Authorized Distributor for specific instructions if neither of these methods are applicable.

6-131200192

Section 6 - Emergency Procedures

6.2 EMERGENCY LOWERING OF BOOM

Valve Layout

EXT/RET

AUX

TILT

LIFT

FRONT OF

MACHINE

OZ1560

Cylinder/Function

Lift Cylinder: Lower Raise Extend/Retract Cylinder: Retract Extend Tilt Cylinder: Down Up Auxiliary Hydraulics

A B

Electronic Control Unit Failure

If the telehandler’s electronic control unit fails, the boom can be retracted then lowered manually. With the engine running perform the following:

1. Shift transmission control lever to neutral, apply parking brake and block wheels.

2. Remove the rear cover.

3. Using a small tool carefully depress the button (1) on the solenoid.

WARNING

TIP OVER HAZARD. To be used for retracting then lowering load only.

Extending/lifting load could damage the equipment and/or cause tip over resulting in death or serious injury.

6-2 31200192

Section 6 - Emergency Procedures

Engine Failure

In the event of total loss of engine power or hydraulic pump failure with an elevated load, the situation must be properly evaluated and dealt with on an individual basis.

Contact JLG Industries or your local Authorized Distributor for specific instructions.

Secure the telehandler using the following procedures:

1. Clear the area around telehandler of all personnel.

2. Engage the parking brake. Place the transmission control lever in “NEUTRAL”.

3. Block all four wheels.

Section off a large area under the boom with string or tape to restrict any personnel from entering this area.

6-331200192

Section 6 - Emergency Procedures

6.3 CAB EMERGENCY EXIT

OZ0240

• In an emergency the rear window can be used to exit the telehandler.

• Remove the latch pin (1). The window is then free to swing open.

6-4 31200192

Section 7 - Lubrication and Maintenance

SECTION 7 - LUBRICATION AND MAINTENANCE

7.1 INTRODUCTION

Service the product in accordance with the maintenance schedule on the following pages.

Service intervals are based on machine usage of 1500 hours annually. Use of your product may vary significantly and you must adjust service frequency for your usage to obtain maximum service life.

The Lubrication Decal (1) is located as indicated in figure. The lubrication instructions must be followed to keep this product in good operating condition. The Operation & Safety Manual and Service Manual contain more detailed service information with specific instructions.

OAH0910

Clothing and Safety Gear

• Wear all the protective clothing and personal safety devices issued to you or called for by job conditions.

• DO NOT wear loose clothing or jewelry that can get caught on controls or moving parts.

7-131200192

Section 7 - Lubrication and Maintenance

7.2 GENERAL MAINTENANCE INSTRUCTIONS

Prior to performing any service or maintenance on the telehandler, follow the shut-down procedure on page 4-3 unless otherwise instructed. Ensure telehandler is level, for proper fluid readings.

• Clean lubrication fittings before lubricating.

• After greasing telehandler, cycle all functions several times to distribute lubricants. Perform this maintenance procedure without attachment installed.

• Apply a light coating of engine oil to all linkage pivot points.

• Intervals shown are for normal usage and conditions. Adjust intervals for abnormal usage and conditions.

• Drain engine and gear cases after operating when oil is hot.

• Check all lubricant levels when lubricant is cool. For ease of filling hydraulic reservoir, use a funnel with a hose or flexible tube for best results.

WARNING

CUT/CRUSH/BURN HAZARD. Do not perform service or maintenance on the

machine with the engine running. Failure to comply could cause death or serious injury.

7-2 31200192

Section 7 - Lubrication and Maintenance

7.3 SERVICE AND MAINTENANCE SCHEDULE

8 & 1st 50 Hour Maintenance Schedule

EVERY

Check Fuel

Level

Check Brake

Fluid Level

Change Axle Oil

Check Tire

Condition &

Pressure

Lubrication

Schedule

Change Wheel

End Oil

Air Filter

Restriction

Indicator

Change Engine

Oil & Filter

Check Engine

Oil Level

(

)

Check Wheel

Lug Nut

Torque

Check Hydraulic

Oil Level

OAH08401

7-331200192

Section 7 - Lubrication and Maintenance

50, 250 & 500 Hour Maintenance Schedule

EVERY

Drain Fuel/

Water

Separator

Change Engine

Oil and

Filter

Check Boom

Bearing

Pads

Check Engine Coolant Level

EVERY

250

Check Axle

Oil Level

(

)

Check

Battery

Check Wheel

End Oil Levels

EVERY

500

Lubrication

Schedule

Air Filter

Vacuator

Valve

Check

Fan Belt

Change Fuel

Filter

Check Wheel

Lug Nut

Torque

OAH0040

7-4 31200192

Section 7 - Lubrication and Maintenance

1000 & 1500 Hour Maintenance Schedule

EVERY

1000

Change Axle Oil

Change

Engine Coolant

Change Wheel

End Oil

Change

Hydraulic

Fluid & Filters

Change

Hydraulic Tank

Breather

EVERY

1500

Change

Brake Fluid

OAH0050

7-531200192

Section 7 - Lubrication and Maintenance

7.4 LUBRICATION SCHEDULES

8 Hour Lubrication Schedule

Mystik Tetrimoly Grease

(NLGI 2 GC-LB)

EVERY

MAH08201

7-6 31200192

Section 7 - Lubrication and Maintenance

50 Hour Lubrication Schedule

Mystik Tetrimoly Grease

(NLGI 2 GC-LB)

EVERY

MAH08301

7-731200192

Section 7 - Lubrication and Maintenance

7.5 OPERATOR MAINTENANCE INSTRUCTIONS

Fuel System

A. Fuel Level Check

OW1150

OW0990

rpm x 100

OAH0850

1. Check fuel gauge (1) located on instrument panel in cab.

2. If fuel is low, proceed to fuel source and perform “Shut-Down Procedure” on page 4-3.

3. Turn fuel tank cap (2) and remove from filler neck (3). Add diesel fuel as needed. Replace fuel tank cap.

Note: Replenish diesel fuel at end of each work shift to minimize condensation.

7-8 31200192

JLG G5-18A Operator Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Revision Log

Read This First

Table of Contents

Section 1 - General Safety Practices

1.1 HAZARD CLASSIFICATION SYSTEM

Safety Alert System and Safety Signal Words

1.2 GENERAL PRECAUTIONS

1.3 OPERATION SAFETY

Electrical Hazards

Tip Over Hazard

Travel Hazard

Load Falling Hazard

Lifting Personnel

Driving Hazards on Slopes

Pinch Points and Crush Hazards

Fall Hazard

Chemical Hazards

Section 2 - Pre-Operation and Inspection

2.1 PRE-OPERATION CHECK AND INSPECTION

2.2 SAFETY DECALS

2.3 WALK-AROUND INSPECTION

2.4 WARM-UP AND OPERATIONAL CHECKS

Warm-Up Check

Operational Check

2.5 OPERATOR CAB

2.6 WINDOWS

Cab Door Window (if equipped)

Rear Window

Section 3 - Controls and Indicators

3.1 GENERAL

3.2 CONTROLS

Instrument Panel

Ignition

Park Brake

Parking Procedure

Transmission Control Lever

Gear Selection Switch

Accessory Control Lever (if equipped)

Steering Column Adjuster

Joystick

Control and Indicator Console

Heater and Air Conditioner Controls (if equipped)

3.3 STEER MODES

3.4 OPERATOR SEAT

Adjustments

Seat Belt

3.5 BOOM ANGLE AND EXTENSION INDICATORS

Section 4 - Operation

4.1 ENGINE

Starting the Engine

Battery Boosted Starting

Normal Engine Operation

Shut-Down Procedure

4.2 OPERATING WITH A LOAD

Lift Load Safely

Before Picking Up a Load

Transporting the Load

Leveling Procedure

Placing the Load

Disengaging the Load

4.3 LOADING AND SECURING FOR TRANSPORT

Tiedown

Lifting

Section 5 - Attachments

5.1 APPROVED ATTACHMENTS

5.2 UNAPPROVED ATTACHMENTS

5.3 TELEHANDLER/ATTACHMENT/FORK CAPACITY

5.4 USE OF THE CAPACITY CHART

Capacity Indicator Locations

Sample Capacity Chart

Example

5.5 ATTACHMENT INSTALLATION

Mechanical Quick-Switch Device

Hydraulic Quick-Switch Device

Hydraulic Operated Attachment

5.6 ADJUSTING/MOVING FORKS