JLG G6-42A Operator Manual

Download

Operation & Safety

Manual

Keep this manual with machine at all times.

Model

G6-42P

S/N 0160004018 & After

31200148

Original

November 25, 2008

An Oshkosh Corporation Company

CALIFORNIA PROPOSITION 65

BATTERY WARNING

Battery posts,

terminals and related

accessories contain

lead and lead compounds,

chemical known to the

State of California

to cause cancer and

reproductive harm.

WASH HANDS

AFTER HANDLING!

CALIFORNIA PROPOSITION 65

EXHAUST WARNING

Diesel Engine exhaust and

some of its constituents

are known to the State of

California to cause cancer,

birth defects and other

reproductive harm.

Revision Log

November 25, 2008 - A - Original Issue of Manual

REVISION LOG

a31200148

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 material handler:

• This Operation & Safety Manual

• Telehandler Safety Manual (as required)

• 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.

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Read This First

This product must comply with all safety related bulletins. Contact JLG Industries, Inc. or the local authorized JLG representative for information regarding safetyrelated bulletins which may have been issued for this product.

JLG Industries, Inc. sends safety related bulletins to the owner of record of this machine. Contact JLG Industries, Inc. to ensure that the current owner records are updated and accurate.

JLG Industries, Inc. must be notified immediately in all instances where JLG products have been involved in an accident involving bodily injury or death of personnel or when damage has occurred to personal property or the JLG product.

FOR:

• Accident Reporting and Product Safety Publications

• Current Owner Updates

• Questions Regarding Product Applications and Safety

• Standards and Regulations Compliance Information

• Questions Regarding Product Modifications

CONTACT:

Product Safety and Reliability Department JLG Industries, Inc. 13224 Fountainhead Plaza

Hagerstown, MD 21742 USA

or Your Local JLG Office (Addresses on back cover)

In USA:

Toll Free: 1-877-JLG-SAFE (877-554-7233)

Outside USA:

Phone: +1-717-485-5161 E-mail: ProductSafety@JLG.com

Other Publications Available

Service Manual .............................................................91404002

Illustrated Parts Manual.................................................91404001

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d 31200148

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

Section 3 - Controls and Indicators

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

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

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

Ignition Switch .................................................................3-4

Boom Joystick .................................................................3-5

Attachment Tilt and Frame Sway Lever ..........................3-6

Auxiliary Control Joystick (if equipped) ...........................3-7

Dash Controls and Indicators.......................................... 3-8

Park Brake Switch........................................................... 3-9

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Table of Contents

Parking Procedure.......................................................... 3-9

Heater........................................................................... 3-10

3.3 Operator Seat.................................................................... 3-11

Seat Adjustments ......................................................... 3-11

Seat Belt ....................................................................... 3-13

3.4 Boom Angle and Extension Indicators .............................. 3-14

3.5 Mirror................................................................................. 3-14

Section 4 - Operation

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

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

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

Battery Boosted Starting................................................. 4-3

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

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

4.2 Operating with a Load ......................................................... 4-5

Lift Load Safely............................................................... 4-5

Picking Up a Load .......................................................... 4-5

Transporting the Load .................................................... 4-6

Leveling Procedure......................................................... 4-6

Placing the Load............................................................. 4-7

Disengaging the Load..................................................... 4-7

4.3 Operating with a Suspended Load ...................................... 4-8

Lift Load Safely............................................................... 4-8

Picking Up a Suspended Load ....................................... 4-8

Transporting a Suspended Load .................................... 4-9

Leveling Procedure......................................................... 4-9

Placing a Suspended Load........................................... 4-10

Disengaging a Suspended Load .................................. 4-10

4.4 Loading and Securing for Transport.................................. 4-11

Tiedown ........................................................................ 4-11

Lifting ............................................................................ 4-12

Section 5 - Attachments

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

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

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

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

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

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

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

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

5.6 Adjusting/Moving Forks ....................................................... 5-9

5.7 Attachment Operation ....................................................... 5-10

Carriage w/Forks .......................................................... 5-11

ii 31200148

Crane Hook...................................................................5-12

Bucket ...........................................................................5-14

Truss Boom...................................................................5-16

Boom Head-Mounted Winch.........................................5-18

6 ft (1,8 m) Mast with 48 or 72 in (1,2 & 1,8 m)

Carriage ........................................................................5-19

6 ft (1,8 m) - 100° Swing Mast W/Side Shift..................5-21

Swing Carriage .............................................................5-23

Side Tilt Carriage ..........................................................5-25

Personnel Work Platform ..............................................5-27

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 Lower of Boom..................................................6-2

6.3 Emergency Exit from Enclosed Cab ....................................6-2

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 Schedules...................................7-3

10 & 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

50 Hour Lubrication Schedule.........................................7-6

250 Hour Lubrication Schedule....................................... 7-7

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

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

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

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

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

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

Hydraulic Return Filter ..................................................7-17

Engine Cooling System................................................. 7-18

Battery........................................................................... 7-19

Table of Contents

Section 8 - Additional Checks

Section 9 - Specifications

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

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

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

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

iii31200148

Table of Contents

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

Index

Inspection, Maintenance and Repair Log

iv 31200148

Section 1 - General Safety Practices

SECTION 1 - GENERAL SAFETY PRACTICES

1.1 HAZARD CLASSIFICATION SYSTEM

Safety Alert System and Safety Signal Words

DANGER

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

WARNING

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

CAUTION

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

OW0010

OW0021

OW0031

1.2 GENERAL PRECAUTIONS

WARNING

Before operation, read 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.

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Section 1 - General Safety Practices

1.3 OPERATION SAFETY

Electrical Hazards

10 FT

(3 M)

OW0040

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

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

• Always check for power lines before raising the boom.

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

1-2 31200148

Section 1 - General Safety Practices

Tip Over Hazard

General

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

OW0050

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

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

• DO NOT exceed rated lift capacity.

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

OW0080

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

4 FT

(1,2 M)

OW0100

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

1-331200148

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

1-4 31200148

Non-Suspended Load

•DO NOT drive with boom raised.

Suspended Load

Section 1 - General Safety Practices

OW0060

OW0150

• Tether suspended loads to restrict movement.

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

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

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

• When driving with the boom raised, DO NOT exceed walking speed.

• 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.

1-531200148

Section 1 - General Safety Practices

Travel Hazard

4-Wheel Steer Pivot Steer

OW0120

• 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.

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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.

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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 31200148

Section 1 - General Safety Practices

Driving Hazards on Slopes

OW0200

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

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

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

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

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

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

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

• DO NOT park on a slope.

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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 31200148

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.

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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 4-4 has been performed.

OW0290

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

1-12 31200148

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.

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Section 1 - General Safety Practices

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1-14 31200148

Section 2 - Pre-Operation and Inspection

SECTION 2 - PRE-OPERATION AND INSPECTION

2.1 PRE-OPERATION CHECK AND INSPECTION

Note: Complete all required maintenance before operating unit.

WARNING

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

reach. Use an approved ladder.

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

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

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

OAH1000

PARENT METAL CRACK WELD CRACK

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

4. Operation and Safety Manuals - Operation and Safety Manual and AEM Safety Manual (as required) are located in cab manual holder.

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

6. Fluid Levels - Check fluids, including fuel, hydraulic oil, engine oil 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 and Safety Manual of each attachment or accessory installed for specific inspection, operation and maintenance instructions.

2-131200148

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 31200148

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.

Model

Year of Manufacture

Serial Number

Maximim Capacity (lbs/kg)*

1705881

(After S/N

0160022389)

Maximum Weight Without Attachments (lbs/kg)

Refer to load capacity chart for truck with attachment, and individual load ratings stamped on forks, if equipped. Use lowest capacity of all rattings.

As released from factory this truck meets design specifications in ASME B56.6-2002 Part III

One or more of the following patents may apply to this truck: U.S. Nos. 4,954,041 6,349,969 5,639,119 5,813,697 5,230,399 5,052,532. Other patents pending.

Manufactured by JLG Industries Inc. McConnellsburg, PA 17233-9533 USA

1705882

(Before S/N

0160022389)

NO RIDERS PERMITTED ON HANDLER.

OPERATOR ONLY IN MACHINE

WHILE RUNNING.

RIDERS COULD FALL OFF MACHINE

1705882

CAUSING SERIOUS INJURY OR DEATH.

9114-3283

91143283

DIESEL FUEL IS FLAMMABLE

EXTINGUISH ALL OPEN FLAME AND

SMOKING MATERIALS WHEN REFUELING

INJURY OR DEATH COULD RESULT

FROM FIRE.

91143286

STAY CLEAR OF PINCH POINT AREA

ANYTIME ENGINE IS RUNNING.

BEING IN PINCH POINT AREA COULD

9114-3286

CAUSE SERIOUS INJURY OR DEATH.

9114-3282

91143282

TURBOCHARGER DAMAGE CAN RESULT FROM QUICK START-UP & SHUTDOWN.

FOR LONGER TURBOCHARGER LIFE AND TO MINIMIZE TURBOCHARGER

DAMAGE, IDLE ENGINE AT LEAST

3-5 MINUTES AFTER START-UP

AND BEFORE SHUTDOWN.

91343016

91503102

9134-3016

9150-3102 REV. -

WHEN LIFTING PERSONNEL USE ONLY A GRADALL MANUFACTURED PERSONNEL WORK PLATFORM.

WHEN PERSONNEL ARE IN PLATFORM REMAIN SEATED IN CAB WITH PERSONNEL

READ AND UNDERSTAND PERSONNEL WORK PLATFORM USER'S MANUAL BEFORE LIFTING PERSONNEL.

DO NOT USE PERSONNEL WORK PLATFORM WITHOUT THE PROPER GRADALL MATERIAL

HANDLER/PERSONNEL WORK PLATFORM CAPACITY CHART DISPLAYED IN CAB.

READ AND UNDERSTAND THE FOLLOWING PRIOR TO LIFTING PERSONNEL.

DO NOT DRIVE MACHINE WITH PERSONNEL IN PLATFORM.

IN DIRECT LINE OF SIGHT.

OPERATE CONTROLS LIGHTLY AND CAUTIOUSLY WHEN LIFTING PERSONNEL.

FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY OR DEATH.

90553027

91323030

NEVER OPERATE MACHINE WITHOUT

CONSULTING PROPER CAPACITY CHART FOR THE

CARRIAGE/FORK COMBINATION BEING USED.

9132-3030

90553028

FOR SAFE OPERATION OF MACHINE AND TO MINIMIZE RISK OF

SERIOUS INJURY, READ AND OBSERVE THE FOLLOWING:

15. BEFORE ADJUSTING OR SERVICING, PLACE

7. WHEN TRAVELING WITH LOAD, FULLY RETRACT BOOM AND

1. ONLY TRAINED AND AUTHORIZED PERSONNEL MAY OPERATE THIS MACHINE.

2. BEFORE OPERATING, READ AND UNDERSTAND ALL CAPACITY CHARTS, OPERATOR MANUALS AND SAFETY MANUALS. IF MANUALS ARE NOT AVAILABLE, CONSULT AN AUTHORIZED GRADALL DEALER. UNDERSTAND ALL CONTROLS IN CAB AND CHECK FOR PROPER OPERATION. CLEAR LOOSE OBJECTS OFF MACHINE AND SOUND HORN BEFORE STARTING ENGINE.

3. OPERATOR MUST BE SEATED WITH SEAT BELT FASTENED. ASSURE FORWARD/REVERSE LEVER IS IN NEUTRAL,PARK BRAKE APPLIED AND ALL HYDRAULIC CONTROLS ARE IN NEUTRAL BEFORE IGNITION SWITCH IS TURNED ON.

4. DO NOT OPERATE MACHINE WITHOUT PROPER CAPACITY CHART IN PLACE.

5. BEFORE MOVING, BE SURE OF A CLEAR PATH AND SOUND HORN. WATCH FOR PEDESTRIANS AND OBSTRUCTIONS. CHECK OVERHEAD AND SIDE CLEARANCES. ALWAYS LOOK IN DIRECTION OF TRAVEL.

6. START, TURN, AND BRAKE SMOOTHLY. REDUCE TRAVEL SPEEDS FOR TURNS, SLIPPERY, OR UNEVEN SURFACES. AVOID RUNNING OVER LOOSE OBJECTS OR HOLES IN THE ROADWAY SURFACE.

91413012

GRADALL HANDLER SERVICE INSTRUCTIONS FOR: G6-42P

DIESEL ENGINE AIR CLEANER ELEMENT--------------**--------------------------------------------FUEL FILTERS--------------------------------------

OIL FILTER--------------------------------OIL (14.5 QT.) (13.6 LTR.)----DIESEL FUEL (38 GAL.) (143.8 LTR.) HYDRAULIC SYSTEM OIL (43 GAL.)------------------ -------------FILTERS--------------------------*----------------------------HYD.TANK BREATHER/FILTER CAP FRONT AXLE LUBE

CENTER SECTION (15.75 QT.)(14.9 LTR.) EACH WHEEL HUB (1.4 QT.)(1.3 LTR.)

REAR AXLE WHEEL END LUBE (4 PT.) (1.9 LTR.) WHEEL NUT TORQUE-300/350 FT-LBS RADIATOR (1.9 GAL.) (7.2 LTR.) WATER (1.9 GAL.) (7.2 LTR.) ANTI-FREEZE (.5 QT.)(.47 LTR.) OF SUPPLIMENTAL COOLANT ADDITIVE (SCA)

TIRES: (12 PLY) 65 PSI ------------------------------ -------------------------

----------------

TIRES: RADIAL 70 PSI CYLINDER FITTINGS EACH END- ----****REAR AXLE (12) FITTINGS--------****FRONT AXLE PIVOT (2) FITTINGS

--------

-------------------

ALL BEARINGS PADS FRONT BOTTOM BEARING PADS-- - -- - - -- - BOOM PIVOT (2) FITTINGS---------****HEAD PIN (2) FITTINGS-----------****-

QUICK SWITCH (1) FITTING------------RETRACT & EXTEND CHAIN --------------------SEE OPERATOR & MAINTENANCE MANUAL

RETRACT & EXTEND CHAIN SHEAVES----------------

THIS CHART MUST BE USED IN CONJUNCTION WITH SERVICE MANUAL AND RECOMMENDED PROCEDURE. * CHECK INDICATOR ON HYDRAULIC FILTER. CHANGE FILTER IF NEEDLE IS IN RED

AT FULL THROTTLE AND AT OPERATING TEMPERATURE. ** CHECK AIR CLEANER RESTRICTION INDICATOR. CLEAN OR CHANGE PRIMARY FILTER IF NECESSARY.

SAFETY ELEMENT TO BE CHANGED EVERY 3RD CHANGE OF PRIMARY FILTER ELEMENT.

*** CONSULT DEALER FOR RECOMMENDATIONS AT EXTREME TEMPERATURES.

**** DAILY SERVICE MAY BE REQUIRED FOR OPTIMUM LIFE DEPENDING UPON APPLICATION SEVERITY. *****IF COOLANT IS ADDED TO RADIATOR ADD 3% SCA BY VOLUME.

IT IS RECOMMENDED THAT FILTER ELEMENTS, FRONT AXLE LUBRICANT, AND ENGINE OIL BE CHANGED AFTER FIRST 100 HRS ON NEW OR REBUILT UNITS.

PLACE FORKS IN CARRY POSITION (APPROX.12" ABOVE GROUND). TILT CARRIAGE BACK SLIGHTLY TO CRADLE LOAD. USE EXTREME CAUTION WHEN TURNING.

8. ON INCLINES, TRAVEL WITH LOAD UP-GRADE.

9. DO NOT USE BOOM AS WALKWAY.

10. USE TWO HANDS WHEN CLIMBING ON MACHINE.

11. USE ONLY A GRADALL MANUFACTURED PERSONNEL WORK PLATFORM FOR LIFTING PERSONNEL. NO RIDERS ON MACHINE, FORKS, LOAD, OR OTHER LIFTING ATTACHMENTS AT ANY TIME. DO NOT USE PERSONNEL WORK PLATFORM WITHOUT THE PROPER GRADALL MATERIAL HANDLER/PERSONNEL WORK PLATFORM CAPACITY CHART DISPLAYED IN THE CAB. DO NOT DRIVE MACHINE WITH PERSONNEL IN PLATFORM.

12. KEEP OTHERS AWAY FROM MACHINE WHILE OPERATING. DO NOT STAND UNDER BOOM OR LOAD.

13. USE EXTREME CARE WHEN HANDLING LONG, HIGH, OR WIDE LOADS. DO NOT HANDLE UNSTABLE OR LOOSELY STACKED LOADS.

14. FORKS TO BE CENTERED UNDER LOAD AND SPACED APART AS FAR AS POSSIBLE.

SERVICE INTERVALS

DAILY

WEEKLY

EVERY

3 MO.

5WKS OR

10 HRS

50 HRS

250 HRS

500 HRS

CHANGE

-------------------

CHANGE

-------------------

CHANGE-----

CHECK

--------------------------------

FILL

CHECK

INSPECT

------

------------CHECK

------

------------CHECK

------

-------------

------

CHECK

-------------------

TORQUE

------ --------------------------

*****

CHECK

--------------------------

CHECK GREASE

--------------------------

GREASE

--------------------------

GREASE

-------------------------GREASE

--------------------------

CHECK

GREASE

-------------------

GREASE

--------------------------

GREASE

--------------------------

GREASE

--------------------------

-------------------

CHECK

--------------------------

GREASE

FORWARD/REVERSE LEVER IN NEUTRAL, REST BOOM ON GROUND OR SUPPORT, SET PARKING BRAKE, SHUT OFF ENGINE AND CHOCK WHEELS.

16. BEFORE LEAVING MACHINE UNATTENDED, PLACE FORWARD/REVERSE LEVER IN NEUTRAL, LOWER BOOM, SET PARKING BRAKE,AND SHUT-OFF ENGINE. CHOCK WHEELS IF MACHINE MUST PARK ON AN INCLINE.

17. LEVEL MACHINE BEFORE LIFTING ANY LOAD ABOVE 4 FEET. (IF EQUIPPED WITH FRAME LEVELING).

18. OPERATOR PROTECTION (SUCH AS HARD HATS, SAFETY GLASSES, AND/OR HEARING PROTECTION) SHOULD BE WORN WHEN JOB CONDITIONS WARRANT. ALWAYS USE SEAT BELT.

19. IMPROPER USE OF MACHINE COULD RESULT IN MACHINE TIPPING OVER. IF MACHINE STARTS TO TIP OVER, DO NOT LEAVE OPERATORS SEAT. LEAN AWAY FROM TIP & BRACE YOURSELF.

20. KEEP MIRROR(S) CLEAN AND PROPERLY ADJUSTED. OBJECTS IN MIRROR ARE CLOSER THAN THEY APPEAR.

9055-3028 REV. A

ANNUALLY

6 MO.

TYPE OR

EQUIVALENT

1500 HRS

1000 HRS

-------------

SAE 15W-40-CD *** DIESEL FUEL #2

MOBIL 424

------

CHANGE CHANGE

------

CHANGE

MOBIL 424

------

CHANGE

------

-----MOBIL 424

CHANGE

-------------

ETHYLENE GLYCOL ANTI-FREEZE

MYSTIK TETRIMOLY MYSTIK TETRIMOLY MYSTIK TETRIMOLY MYSTIK TETRIMOLY MYSTIK TETRIMOLY MYSTIK TETRIMOLY MYSTIK TETRIMOLY MYSTIK TETRIMOLY

MYSTIK TETRIMOLY

9141-3012

91323030

NEVER OPERATE MACHINE WITHOUT

CONSULTING PROPER CAPACITY CHART FOR THE

CARRIAGE/FORK COMBINATION BEING USED.

9132-3030

9055-3027 REV. A

80603022

AVOID HIGH VOLTAGE LINES.

IT IS UNLAWFUL TO PLACE

ANY PART OF THIS MACHINE

OR LOAD WITHIN 10 FEET

OF HIGH VOLTAGE LINES

UP TO 50,000 VOLTS.

DEATH OR INJURY MAY

RESULT FROM CONTACTING

ELECTRIC LINES.

8060-3022

OY1061

VIEW A-A

2-331200148

Section 2 - Pre-Operation and Inspection

91143282

STAY CLEAR OF PINCH POINT AREA

ANYTIME ENGINE IS RUNNING. BEING IN PINCH POINT AREA COULD CAUSE SERIOUS INJURY OR DEATH.

91163028

91413061

91143280

BEFORE

S/N 0160026801

EXHAUST SYSTEMS CAN BE HOT.

KEEP AWAY FROM EXHAUST SYSTEM WHEN HOT.

HOT EXHAUST COMPONENTS CAN CAUSE

SEVERE BURNS.

9114-3280

9114-3282

STAY CLEAR OF PINCH POINT AREA

ANYTIME ENGINE IS RUNNING. BEING IN PINCH POINT AREA COULD CAUSE SERIOUS INJURY OR DEATH.

9114-3282

91143282

91143285

JUMP STARTING INSTRUCTIONS

WHEN JUMP STARTING MATERIAL HANDLER * NEVER ALLOW VEHICLES TO TOUCH * CONNECT THE POSITIVE (+) JUMPER CABLE TO

POSITIVE (+) POST OF DISCHARGED BATTERY

* CONNECT 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

91083492

9114-3285

91143281

STAY CLEAR OF MOVING PARTS

WHILE ENGINE IS RUNNING. MOVING PARTS CAN CAUSE

SERIOUS INJURY.

Genuine Parts

HYDRAULIC SYSTEM

FILL WITH TRACTOR HYDRAULIC FLUID

or equivalent.

For Mobil Product Information, Call 1-800-662-4525.

91143288

91403573

9114-3281

* DO NOT USE SMOKING MATERIALS NEAR BATTERIES * KEEP FLAMES AND SPARKS AWAY FROM BATTERIES * WEAR SAFETY GLASSES * ASSURE BATTERY IS NOT FROZEN AND ELECTROLYTE

IS AT PROPER LEVEL IN EACH CELL

FAILURE TO FOLLOW THESE INSTRUCTIONS COULD

9114-3288

LEAD ACID BATTERIES PRODUCE FLAMABLE AND

EXPLOSIVE GASSES

WHEN CHECKING, TESTING, USING

BOOSTER BATTERY OR CHARGING BATTERIES:

RESULT IN SERIOUS INJURY OR DAMAGE TO THE

ELECTRICAL SYSTEM

5 3

0 4

91403569

FULL

ADD

HYDRAULIC OIL LEVEL

CHECK OIL LEVEL WITH HANDLER LEVEL AND ALL CYLINDERS RETRACTED.

2.5 GALLON BETWEEN ADD AND FULL MARKS

9140-3569

9114-3284

91143284

9151-3207 REV.-

VIEW B-B

91403529

TRACTION LOCK

LOCKS FRONT & REAR AXLES

HYDRAULICALLY FOR INCREASED

TRACTION. DO NOT USE ON

IMPROVED SURFACES.

MACHINE MUST BE IN 4X4

MODE.

9140-3529

80603026

COOLING SYSTEM IS PRESSURIZED.

REMOVE CAP SLOWLY.

HOT FLUID CAN CAUSE BURNS.

8060-3026

VIEW C-C VIEW D-D

91413024

FORWARD DRIVE PRESSURE TEST PORT

REVERSE DRIVE PRESSURE TEST PORT

CHARGE PRESSURE TEST PORT

IMPLEMENT PRESSURE TEST PORT

9141-3024 (-)

OY1071

VIEW OF HYDRAULIC TANK

2-4 31200148

Safety Decals 3

Section 2 - Pre-Operation and Inspection

9114-3282

80603037

PINCH POINT

KEEP OUT

REACHING INTO BOOM

HOLES AND OTHER PINCH

POINTS CAN CAUSE

SERIOUS INJURY

OR DEATH.

8060-3037-A

91143282

STAY CLEAR OF PINCH POINT AREA

ANYTIME ENGINE IS RUNNING. BEING IN PINCH POINT AREA COULD CAUSE SERIOUS INJURY OR DEATH.

4105262

9114-3282

-10

80°

70°

° 0 6

° 0 5

° 0 4

° 0 3

20°

10°

-1 0

0°

ATTACHMENT MUST BE SECURED TO MACHINE.

CHECK TO ASSURE QUICK SWITCH PLUNGER PIN IS FULLY ENGAGED AND LOCKED AFTER

ATTACHMENT CHANGE. IF PLUNGER PIN IS NOT FULLY ENGAGED AND LOCKED ATTACHMENT MAY FALL OFF

CAUSING SERIOUS INJURY OR DEATH.

91143290

91513210

PINCH POINT

KEEP OUT

REACHING INTO BOOM

HOLES AND OTHER PINCH

POINTS CAN CAUSE

SERIOUS INJURY

OR DEATH.

9114-3290

91513210

PINCH POINT

KEEP OUT

REACHING INTO BOOM

HOLES AND OTHER PINCH

POINTS CAN CAUSE SERIOUS INJURY

OR DEATH.

8060-3037-A

91143282

STAY CLEAR OF PINCH POINT AREA

ANYTIME ENGINE IS RUNNING.

BEING IN PINCH POINT AREA COULD

8060-3037-A

CAUSE SERIOUS INJURY OR DEATH.

91513210

READ AND UNDERSTAND THE FOLLOWING PRIOR TO LIFTING PERSONNEL.

WHEN LIFTING PERSONNEL USE ONLY A GRADALL MANUFACTURED

PERSONNEL WORK PLATFORM.

ALL PERSONNEL IN PLATFORM MUST WEAR A FULL BODY HARNESS WITH

LANYARD ATTACHED TO A DESIGNATED ANCHORAGE POINT.

READ AND UNDERSTAND PERSONNEL WORK PLATFORM USER'S MANUAL

BEFORE OCCUPYING PERSONNEL WORK PLATFORM.

FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY OR DEATH.

9055-3026 REV. A

VIEW A-A

91513210

PINCH POINT

KEEP OUT

REACHING INTO BOOM

HOLES AND OTHER PINCH

POINTS CAN CAUSE SERIOUS INJURY

OR DEATH.

VIEW B-B

8060-3037-A

OY1250

2-531200148

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.

OY0181

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.

• Check extend/retract cables and adjustment blocks for adequate tension.

2. Front Axle

3. Wheel/Tire Assembly - Properly inflated and secured; no loose or missing lug

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

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

2-6 31200148

Section 2 - Pre-Operation and Inspection

4. Cab & Electrical -

• Check window glass is in place and clean; gauges, switches, joysticks, foot controls & horn operational.

• General appearance; no visible damage; proper load charts and applicable Operator & Safety manual located in manual holder.

• Make sure emergency escape hammer is in place (enclosed cabs only).

• Check seat belt for damage, replace belt if frayed or cut webbing, damaged buckles or loose mounting hardware.

5. Fuel Tank

- Check fluid level, refill as required; filler cap is securely fastened.

6. Air Cleaner condition. Replace element as required.

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

8. Main Control Valve

9. Back-up Alarm

10. Rear Axle

hydraulic hoses undamaged, not leaking.

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

12. Engine Compartment

• Engine Crankcase and Radiator, check level & refill as required.

• Drive belts, check condition & replace as required.

• Hydraulic pump & reservoir, recommended fluid level on sight gauge

(lubricant must be cool), breather cap secure and working.

• Engine cover properly secured.

13. Mirrors

14. Wheel/Tire Assembly

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

15. Sway Cylinder

- Air cleaner element condition indicator, check for clogged

- Properly inflated and secured; no loose or missing lug

- See Inspection Note.

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

- Properly inflated and secured; no loose or missing lug

- Clean and undamaged.

- Properly inflated and secured; no loose or missing lug

- Pins secure; hydraulic hoses undamaged, not leaking.

16. Attachment

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

2-731200148

Section 2 - Pre-Operation and Inspection

2.4 WARM-UP AND OPERATIONAL CHECKS

Warm-Up Check

During warm-up period, check:

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

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

3. Voltmeter should show 13.5 to 14 volts.

4. Adjust mirror(s) for maximum visibility.

WARNING

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

except when checking hydraulic filter condition indicator.

Operational Check

When engine warms, perform an operational check:

1. Service brake and parking brake operation.

2. Forward and reverse travel.

3. Steering in both directions with engine at low idle.

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

5. All boom and attachment functions - operate smoothly and correctly.

6. Perform any additional checks described in Section 8.

7. Hydraulic Filter Condition Indicator.

2-8 31200148

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.

2-931200148

Section 2 - Pre-Operation and Inspection

2.6 WINDOWS

Keep all windows and mirrors clean and unobstructed.

Cab Door Window (if equipped)

OAL0010

• 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 or pull on the lever (3) outside the cab to unlatch the window.

• During operation the lower door (4) must be closed.

2-10 31200148

Section 3 - Controls and Indicators

SECTION 3 - CONTROLS AND INDICATORS

3.1 GENERAL

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

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

NOTICE

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

3-131200148

Section 3 - Controls and Indicators

3.2 CONTROLS

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

OY0023

2. Instrument Panel

3. Steering Wheel

: See “Dash Controls and Indicators” on page 3-8.

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

machine in the corresponding direction.

4. Frame Level Indicator

: Enables the operator to determine the left to right level

condition of the telehandler.

5. Boom Joystick

6. Heater Control (if equipped)

7. Accelerator Pedal

: See page 3-5.

: See page 3-10.

: Pressing down the pedal increases engine and hydraulic

speed.

Traction Lock Pedal: Operates traction-lock valve which functions to restore traction when a wheel spins.

9. Service Brake Pedal/Inching Travel Pedal: Operates the service brakes on the front axle. Permits slow travel speed while engine speed is kept high for other handler functions. The further the pedal is depressed, the slower the travel speed.

10. Ignition Switch: Key activated. See page 3-4.

11. Attachment Tilt and Frame Sway Lever

Auxiliary Control Joystick (if equipped):

: See page 3-6 See page 3-7

3-2 31200148

Section 3 - Controls and Indicators

Transmission Control Lever

OX0081

Transmission control lever (15) 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’.

• When traveling in REVERSE, the back-up alarm will automatically sound.

• Drive in reverse and turn only at slow rates of speed.

• Do not increase engine speed with the transmission in forward or reverse and the service brake depressed in an attempt to get quicker hydraulic performances. This could cause unexpected machine movement.

WARNING

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

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

3-331200148

Section 3 - Controls and Indicators

Ignition Switch

OFF

ACC

RUN

START

OY0051

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

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

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

3-4 31200148

Boom Joystick

Section 3 - Controls and Indicators

IF EQUIPPED

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

Boom Functions

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

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

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

Attachment Functions (if equipped)

Tilt control is actuated by the switch (2).

• Depress the rear of the switch to tilt up; depress the front of switch to tilt down.

OX0060

WARNING

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

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

3-531200148

Section 3 - Controls and Indicators

- +

Attachment Tilt and Frame Sway Lever

FUEL

QUARTZ

000000

This lever (4) controls the attachment tilt and the left to right frame sway.

Attachment Tilt Function

• Move lever forward to tilt attachment down; move lever back to tilt attachment up.

Sway Function

• Move the lever left to sway frame left, move the lever right to sway frame right.

• A level indicator is located in the upper front window frame to permit operator to determine whether the telehandler frame is level.

OIL

240

TEMP

VOLTS

100

WORK

OFF

RUN

ACC

START

IGNITION

TRAVEL

MACHINE MUST BE IN NEUTRAL AND PARK BRAKE ON

TO START

OY0143

WARNING

TIP OVER HAZARD. Always move boom as low as possible while allowing for

best visibility of right hand mirror before leveling frame. Attempting to level machine with boom raised could cause it to tip over.

3-6 31200148

Section 3 - Controls and Indicators

- +

Auxiliary Control Joystick (if equipped)

Auxiliary

Hydraulics

QUARTZ

000000

FUEL

OIL

240

TEMP

VOLTS

100

WORK

OFF

RUN

ACC

START

IGNITION

TRAVEL

MACHINE MUST BE IN NEUTRAL AND PARK BRAKE ON

TO START

Sway

(optional)

Attachment

Tilt

(optional)

OX0224

The auxiliary control joystick (1) controls the auxiliary hydraulic functions, left to right frame sway (if equipped), and attachment tilt (if equipped).

Auxiliary Hydraulics Function

• Controls function of attachments that require hydraulic supply for operation. See Section 5 - Attachments for approved attachments and control instructions.

Frame Sway (if equipped)

• Move the joystick left to sway frame left, move the joystick right to sway frame right.

• A level indicator is located in the upper front window frame to permit operator to determine whether the telehandler frame is level.

Attachment Tilt (if equipped)

• Move joystick up to tilt down; move joystick down to tilt up.

3-731200148

Section 3 - Controls and Indicators

- +

Dash Controls and Indicators

123

FUEL

QUARTZ

000000

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

OIL

240

TEMP

VOLTS

100

WORK

OFF

RUN

ACC

START

IGNITION

TRAVEL

MACHINE MUST BE IN NEUTRAL AND PARK BRAKE ON

TO START

WORK

OFF

RUN

ACC

IGNITION

TRAVEL

START

OY0084

2. Park Brake Switch

3. 4-in-1 Gauge

: See page 3-9.

a. Engine Coolant Temperature Gauge

b. Engine Oil Pressure Gauge

c. Fuel Gauge

d. Voltmeter indicates alternator output and battery condition.

4. Horn Button

5. Ignition Switch

: Depress button to sound horn.

: See page 3-?.

6. 4X2/4X4 Switch: Engages and disengages rear-wheel drive motors. Rear drive motors are engaged for four-wheel drive. Indicator light on switch glows (amber) to indicate four-wheel drive is engaged. When park brake is applied, light will not glow.

3-8 31200148

Park Brake Switch

Section 3 - Controls and Indicators

OY0122

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

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

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

WARNING

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

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

WARNING

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

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

Parking Procedure

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

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

3-931200148

Section 3 - Controls and Indicators

Heater

OY0060

1. Heater

2. Access Cover/Heat Vent

3. Air Vents

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

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

5. Temperature Control Switch

6. Heater Fan Switch: On/Off switch.

3-10 31200148

Section 3 - Controls and Indicators

3.3 OPERATOR SEAT

Seat Adjustments

Before S/N 0160016100

OX0012

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

1. Use handle to move seat fore and aft

2. A two inch seat belt is standard equipment. If required, an optional three inch

belt is available.

3-1131200148

Section 3 - Controls and Indicators

S/N 0160016100 & After

OX0520

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

1. Turn the knob on the front of seat to adjust the suspension. Turn the knob clockwise to increase stiffness. Turn the knob counterclockwise to reduce stiffness.

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

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

4. A two inch seat belt is standard equipment. If required, an optional three inch

belt is available.

3-12 31200148

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.

3-1331200148

Section 3 - Controls and Indicators

3.4 BOOM ANGLE AND EXTENSION INDICATORS

° 0 8

70°

60°

50°

40°

30°

20°

° 0 1

-1

0°

OX0540

• The boom angle indicator (1) is located on the left side of the boom. Use this indicator to determine the boom angle when using the capacity chart (see “Use of the Capacity Chart” on page 5-4).

• The boom extension indicators (2) are located on the left side of the boom. Use these indicators to determine boom extension when using the capacity chart (see “Use of the Capacity Chart” on page 5-4).

3.5 MIRROR

OW0500

• Keep all windows and mirror(s) clean and unobstructed.

• Adjust mirror(s) as required for maximum visibility, before and during operation.

3-14 31200148

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

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

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

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

WARNING

UNEXPECTED MOVEMENT HAZARD. Always ensure that transmission control

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

4-131200148

Section 4 - Operation

Cold Weather Starting Aids

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

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

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

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

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

WARNING

ENGINE EXPLOSION. If your telehandler is equipped with a cold start aid, do

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

4-2 31200148

Section 4 - Operation

Battery Boosted Starting

OW0530

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

• Never allow vehicles to touch.

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

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

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

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

• Follow standard starting procedures.

• Remove cables in reverse order after machine has started.

WARNING

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

as it could explode. Keep sparks, flames and lighted smoking materials away from the battery. Lead acid batteries generate explosive gases when charging. Wear safety glasses.

4-331200148

Section 4 - Operation

Normal Engine Operation

• Observe gauges 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. 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).

4-4 31200148

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.

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

Picking Up a Load

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

• Avoid lifting double-tiered loads.

• Make sure load is clear of any adjacent obstacles.

• Adjust spacing of forks so they engage the pallet or load at maximum width. See “Adjusting/Moving Forks” on page 5-9.

• 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.

4-531200148

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 sway and load could cause the telehandler to tip over.

The telehandler is designed to permit swaying the main frame 8° to left or right to compensate for uneven ground conditions.

4-6 31200148

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 5-4.

• Align forks at the level load is to be placed, then position 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.

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Section 4 - Operation

4.3 OPERATING WITH A SUSPENDED LOAD

Lift Load Safely

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

WARNING

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

equipment and/or cause tip over.

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

Picking Up a Suspended Load

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

• Avoid lifting double-tiered loads.

• Make sure load is clear of any adjacent obstacles.

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

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

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

• Ensure to always properly tether loads to restrict movement.

• Refer to See “Use of the Capacity Chart” on page 5-4. for proper lifting guidelines in addition to the appropriate capacity chart in the operator cab.

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Transporting a Suspended Load

Section 4 - Operation

OZ3160

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

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

Important things to remember:

• Ensure the boom is fully retracted.

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

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

• The guide men and operator must remain in constant communication (verbal or hand) and be in visual contact with the operator at all times.

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

• Only transport the load at walking speed, 0.9 mph (0.4 m/s), or less.

OW0130

Leveling Procedure

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

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

3. Move boom so load is no more than 11.8 in (300 mm) above ground surface and boom/or boom is raised no more than 45°.

4. Observe level indicator to determine whether machine must be leveled prior to lifting load. Level machine with frame level joystick.

The telehandler is designed to permit leveling the main frame 8° to left or right to compensate for uneven ground conditions.

4-931200148

Section 4 - Operation

Placing a Suspended Load

Before placing any load be sure that:

• The landing point can safely support the weight of the load.

• The landing point is level; front to back and side to side.

• Use the capacity chart to determine safe boom extension range. See “Use of the Capacity Chart” on page 5-4.

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

• Ensure that the guide men and operator remain in constant communication (verbal or hand) when placing the load.

Disengaging a Suspended Load

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

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

4-10 31200148

Section 4 - Operation

4.4 LOADING AND SECURING FOR TRANSPORT

Tiedown

Front Rear

OX0381

1. Level the telehandler prior to loading.

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

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

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

5. Do not tiedown 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.

4-1131200148

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.

4-12 31200148

Section 5 - Attachments

SECTION 5 - ATTACHMENTS

5.1 APPROVED ATTACHMENTS

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

Before S/N 0160037689

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

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

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

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

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

S/N 0160037689 & After

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

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

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

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

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

5-131200148

Section 5 - Attachments

5.2 UNAPPROVED ATTACHMENTS

Do not use unapproved attachments for the following reasons:

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

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

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

WARNING

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

5-2 31200148

Section 5 - Attachments

5.3 TELEHANDLER/ATTACHMENT/FORK CAPACITY

OW0550

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

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

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

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

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

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

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

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

WARNING

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

5-331200148

Section 5 - Attachments

5.4 USE OF THE CAPACITY CHART

To properly use the capacity chart (see page 5-5), 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(s).

3. Weight of the load being lifted.

4. Load placement information:

a. HEIGHT where the load is to be placed.

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

placed.

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

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

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

Capacity Indicator Locations

Attachment

Identification

Boom Extension

Indicator

Plate

Fork

Weight

Stamp

5-4 31200148

Boom Angle

Indicator

° 0 8

° 0 7

° 0 6

° 0

° 0 4

° 0 3

° 0 2

0°

OX0190

Sample Capacity Chart

DEDUCT 350 LBS

FROM ALL CAPACITIES

WHEN MACHINE IS

EQUIPPED WITH WINCH

48'

RATED CAPACITY @ 2 FT. LOAD CENTER

44'

40'

36'

48" & 72"

32'

CARRIAGES

28'

24'

Boom Angle

20'

16'

12'

-4'

-8'

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

These numbers must

match the model/option

30°

20°

10°

1100 LBS

0°

-6°

36'

MODEL

XXXXX

50°

40°

3000 LBS

2000 LBS

4000 LBS

60°

6000 LBS

5000 LBS

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

69°

7000 LBS

Section 5 - Attachments

This Capacity Chart may

be used with this model

ONLY. The model of your

telehandler is indicated

on the boom or chassis.

9000 LBS

0'4'8'

Load zones indicate

the maximum weight

Boom

Extension

XXXX-XXXX

OWO650

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 4-6); the forks being positioned evenly on carriage; the load being centered on forks; proper size tires being properly inflated; and the telehandler being in good operating condition.

5-531200148

Section 5 - Attachments

Example

A contractor owns a model xxxxx telehandler with a 48" Carriage. He knows this attachment may be used with his model since:

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

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

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 2000 lbs (907 kg) 20 ft (6,1 m) 12 ft (3,6 m) Yes

2 3000 lbs (1361 kg) 25 ft (7,6 m) 19 ft (5,8 m) NO

3 6000 lbs (2722 kg) 12 ft (3,6 m) 14 ft (4,3 m) Yes

4 8000 lbs (3629 kg) 8 ft (2,4 m) 30 ft (9,1 m) NO

30°

1100 LBS

MODEL

XXXXX

50°

40°

30 00 LB S

2000 LBS

60°

5000 LBS

4000 LBS

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

70 00 LB S

6000 LBS

69°

90 00 LB S

Example 4

Example 3

0'4'8'

XXXX-XXXX

Example 2

Example 1

DEDUCT 350 LBS

FROM ALL CAPACITIES

WHEN MACHINE IS

EQUIPPED WITH WINCH

48'

RATED CAPACITY @ 2 FT. LOAD CENTER

44'

40'

36'

48" & 72"

32'

CARRIAGES

28'

24'

20'

20°

16'

12'

10°

0°

-6°

-4'

-8' 36'

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

OWO660

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

5-6 31200148

5.5 ATTACHMENT INSTALLATION

Section 5 - Attachments

OX0440

1. Attachment

Attachment Pivot Pin Recess

3. Quick Switch

4. Lock Pin

5. Retaining Pin

This installation procedure is designed for one-person operation.

1. Retract Quick Switch™ to provide clearance. Check to be sure lock pin is secured in out position with retainer pin.

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

OX0450

OX0460

5-731200148

Section 5 - Attachments

3. Engage Quick Switch™.

4. Shut off engine. Exit cab and remove retainer pin and slide lock pin in fully. Secure lock pin in locked position using retainer pin.

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

OX0470

OX0480

6. If equipped, connect auxiliary hydraulic hoses.

7. If equipped, connect auxiliary electric harness.

WARNING

CRUSH HAZARD. Always be certain that carriage or attachment is properly

positioned on boom and is secured by lock pin and retainer pin. Failure to ensure proper installation could permit carriage/attachment/load to disengage.

5-8 31200148

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. Refer to “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).

5-931200148

Section 5 - Attachments

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.

NOTICE

EQUIPMENT DAMAGE. Some attachments may contact the front tires or machine structure when the boom is retracted and the attachment is rotated. Improper use of attachment may result in attachment or machine structural damage.

NOTICE

EQUIPMENT DAMAGE. Avoid contact with any structure or object when lifting a load. Maintain clearance around boom structure and load. Failure to maintain clearance may result in attachment or machine structural damage.

5-10 31200148

Section 5 - Attachments

Carriage w/Forks

Description P/N

Carriage, 48 in.............................................................. 91405073

Carriage, 72 in.............................................................. 91405074

Carriage, Drywall..........................................................91405077

OY0690

Use Carriage Attachment Capacity Chart

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

Fork, Cubing 2x2x48 in................................................. 91403359

Fork 1-3/4x4x48 in........................................................ 91403364

Fork, Drywall 1-3/4x4x48 in ..........................................91403366

Fork 2x6x60 in.............................................................. 91403580

Fork 2-1/4x5x48 in........................................................ 91563141

Fork 2-1/4x6x60 in........................................................ 91563142

TILT SPEED

CONTROL

OY0332

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

The tilt lever (2) controls the fork tilt.

• Move joystick forward to tilt down.

• Move joystick back to tilt up.

Installation Procedure:

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

•

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Section 5 - Attachments

Crane Hook

Description P/N

Crane Hook...................................................................91565094

OY0640

Use Appropriate Carriage Attachment Capacity Char t

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

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

TILT SPEED CONTROL

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

The tilt lever (2) controls the crane hook tilt.

• Move lever forward to tilt down.

• Move lever back to tilt up.

Installation Procedure:

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

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

5-12 31200148

Section 5 - Attachments

Operation:

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

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

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

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Section 5 - Attachments

Bucket

Description P/N

Bucket 60 in - 3/4 yd3................................................... 91405054

Bucket 74 in - 1-1/4 yd

Bucket 102 in - 1-1/4 yd

OZ0730

Use Appropriate Bucket Capacity Chart

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

................................................ 91405055

.............................................. 91405071

TILT SPEED CONTROL

OY0342

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

The tilt lever (2) controls bucket tilt.

• Move joystick forward to tilt down.

• Move joystick back to tilt up.

Installation Procedure:

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

5-14 31200148

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 or extension chains/cables. Do not corner-load bucket.

• 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 and retraction cables/chains.

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.

5-1531200148

Section 5 - Attachments

Truss Boom

Description P/N

Truss Boom 10 ft w/winch .............................................91405081

Truss Boom 10 ft...........................................................91405083

OY0570

Use Truss Boom Attachment Capacity Chart

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

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

Truss Boom 15 ft w/winch .............................................91405080

Truss Boom 15 ft...........................................................91405082

TILT SPEED CONTROL

OY0351

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

Truss Boom Control:

The rear joystick (2) controls truss boom tilt.

• Move joystick forward to tilt down.

• Move joystick back to tilt up.

5-16 31200148

Section 5 - Attachments

Truss Boom W/Winch Control:

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

• Move joystick up to lower cable.

• Move joystick down to raise cable.

Installation Procedure:

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

WARNING

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

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

5-1731200148

Section 5 - Attachments

Boom Head-Mounted Winch

Description P/N

Winch............................................................................91515036

OY0650

Use Carriage Attachment Capacity Chart

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

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

OY0660

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

Winch Control:

The auxiliary control joystick (2) controls the winch.

• Move joystick up to lower cable.

• Move joystick down to raise cable.

WARNING

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

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

5-18 31200148

Section 5 - Attachments

6 ft (1,8 m) Mast with 48 or 72 in (1,2 & 1,8 m) Carriage

Description P/N

Mast 48 in......................................................................91405060

Mast 72 in......................................................................91405061

OY0580

Use 6 ft Mast Attachment Capacity Chart

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

TILT SPEED CONTROL

OY0360

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

The rear joystick (2) controls the mast tilt.

• Move joystick forward to tilt down.

• Move joystick back to tilt up.

To Raise/Lower Mast:

The auxiliary control joystick (3) controls the lift/lower movement of the mast.

• Move joystick up to lower forks.

• Move joystick down to raise forks.

5-1931200148

Section 5 - Attachments

Installation Procedure:

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

WARNING

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

comply could cause object or load to fall.

Operation:

• Lower forks fully in mast before engaging load.

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

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

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Section 5 - Attachments

6 ft (1,8 m) - 100° Swing Mast W/Side Shift

Description P/N

Mast w/ 48 in Fork .........................................................91405070

WARNING

OY0590

Use 6 ft Swing Mast Attachment Capacity Chart

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

Mast w/ 60 in Fork .........................................................91415026

SIDE SHIFT

MAST

SWING

TILT SPEED CONTROL

SIDE SHIFT

MAST

SWING

SIDE SHIFT

MAST

SWING

OY0371

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

The rear joystick (2) controls the mast tilt.

• Move joystick forward to tilt down.

• Move joystick back to tilt up.

5-2131200148

Section 5 - Attachments

To Swing:

• Pull Swing Switch (4) back, located on dash panel to activate Swing function. With Swing Switch activated, move the auxiliary control joystick (3) down to swing forks right or up to swing forks left.

To Raise/Lower Mast:

• Pull Forks Raise/Lower Switch (5) back, located on dash panel to activate Forks Raise/Lower function. With Forks Raise/Lower Switch activated, move the auxiliary control joystick (3) down to raise forks or up to lower forks.

To Side Shift:

• Press Side Shift Switch (6) forward, located on dash panel to activate Side Shift function. With Side Shift Switch activated, move the auxiliary control joystick (3) down to shift forks right or up to shift forks left.

Installation Procedure:

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

WARNING

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

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

WARNING

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

comply could cause object or load to fall.

Operation:

• Always lower forks fully in mast and position forks straight ahead before engaging load.

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

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

5-22 31200148

Section 5 - Attachments

Swing Carriage

Description P/N

100° Swing Carriage....................................................91405075

100

° Swing Drywall Carriage .......................................91405078

180° Swing Carriage....................................................91563146

OY0670

Use Swing Carriage Attachment Capacity Chart

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

TILT SPEED

CONTROL

OY0680

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

The rear joystick (2) controls the carriage tilt.

• Move joystick forward to tilt down.

• Move joystick back to tilt up.

To Swing:

The auxiliary control joystick (3) controls the Swing function.

• Move joystick up to swing left.

• Move joystick down to swing right.

5-2331200148

Section 5 - Attachments

WARNING

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

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

WARNING

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

Failure to comply could cause object or load to fall.

WARNING

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

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

Operation:

• To drive with a load, keep forks pointed forward and travel in accordance with the requirements set forth in Section 1 - General Safety Practices.

5-24 31200148

Section 5 - Attachments

Side Tilt Carriage

Description P/N

Side Tilt 48 in.................................................................91405101

Side Tilt 72 in.................................................................91405079

OY0690

Use Side Tilt Attachment Capacity Chart

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

TILT SPEED CONTROL

OY0380

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

The rear joystick (2) controls the mast tilt.

• Move joystick forward to tilt down.

• Move joystick back to tilt up.

To Side Tilt:

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

• Move joystick up to (side) tilt carriage left.

• Move joystick down to (side) tilt carriage right.

5-2531200148

Section 5 - Attachments

Installation Procedure:

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

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.

5-26 31200148

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 is using a 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. When personnel are on platform, the operator must remain seated in cab with personnel in direct line of sight.

7. 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.

5-2731200148

Section 5 - Attachments

This Page Intentionally Left Blank

5-28 31200148

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.

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.

6-131200148

Section 6 - Emergency Procedures

6.2 EMERGENCY LOWER OF BOOM

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 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.

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

6.3 EMERGENCY EXIT FROM ENCLOSED CAB

IIn an emergency, an escape hammer, located directly below the rear window in an enclosed cab, can be used to exit the telehandler.

ANGUS-PALM 005413

OWO740

6-2 31200148

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.

VIEW A-A

OX0370

The Service Instruction Plate (1) is located as indicated in figure. It contains general service instructions that 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.

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.

7-131200148

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 4-4 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.

Note: Be certain to check boom cable adjustment every 5 weeks or 250 hours and adjust as required. Cable damage can occur if cable is not adjusted properly.

WARNING

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

machine with the engine running, with the exception of the transmission level and hydraulic return filter indicator checks.

7-2 31200148

Section 7 - Lubrication and Maintenance

7.3 SERVICE AND MAINTENANCE SCHEDULES

10 & 1st 50 Hour Maintenance Schedule

EVERY

Check Fuel

Level

Check Hydraulic

Return Filter

Indicator

Change

Axle Oil

Check Tire

Pressure

Change Wheel

End Oil

Air Filter

Restriction

Indicator

Change Engine

Oil & Filter

Check Engine

Oil Level

LB/FT (Nm)

Check Wheel

Lug Nut

Torque

Check Hydraulic

Oil Level

Check Boom

Cable Tension

OX0201

7-331200148

Section 7 - Lubrication and Maintenance

50, 250 & 500 Hour Maintenance Schedule

EVERY

Drain Fuel/

Water

Separator

Change Engine

Oil and

Filter*

Check Boom

Cable

Tension

Check Engine Coolant Level

EVERY

250

Check Front

Axle

Oil Level

Check Boom

Bearing

Pads

LB/FT (Nm)

Check

Battery

Check Front &

Rear Wheel

End Oil Levels

Check

Rear Axle

Stabilization

EVERY

500

Lubrication

Schedule

Air Filter

Vacuator

Valve

Check

Fan Belt

Change Fuel

Filter

Check Wheel

Lug Nut

Torque

OX0530

Note: Engine oil & filter service interval can be extended, see page 7-12 for details.

7-4 31200148

Section 7 - Lubrication and Maintenance

1000 & 1500 Hour Maintenance Schedule

EVERY

1000

Change Front

Axle Oil

Change

Engine Coolant

Change Front &

Rear Wheel

End Oil

Change

Hydraulic

Fluid & Filters

Change

Hydraulic Tank

Breather

EVERY

1500

OY1041

7-531200148

Section 7 - Lubrication and Maintenance

** unknown ** ** unknown ** 2 NO

7733-3027

7.4 LUBRICATION SCHEDULES

50 Hour Lubrication Schedule

Mystik Tetrimoly Grease

EVERY

(NLGI 2 GC-LB)

STAY CLEAR OF PINCH POINT AREA ANYTIME ENGINE IS RUNNING. BEING IN PINCH POINT AREA COULD CAUSE SERIOUS INJURY OR DEATH.

DIESEL FUEL IS FLAMMABLE

EXTINGUISH ALL OPEN FLAME AND

SMOKING MATERIALS WHEN REFUELING

INJURY OR DEATH COULD RESULT

FROM FIRE.

9114-3286

NO RIDERS PERMITTED ON HANDLER. OPERATOR ONLY IN MACHINE WHILE RUNNING. RIDERS COULD FALL OFF MACHINE

CAUSING SERIOUS INJURY OR DEATH.

STAY CLEAR OF PINCH POINT AREA ANYTIME ENGINE IS RUNNING. BEING IN PINCH POINT AREA COULD CAUSE SERIOUS INJURY OR DEATH.

9114-3282

9114-3283

9114-3282

DO NOT GO NEAR LEAKS

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

10814B

7-6 31200148

Section 7 - Lubrication and Maintenance

** unknown ** ** unknown ** 2 NO

7733-3027

250 Hour Lubrication Schedule

EVERY

250

Mystik Tetrimoly Grease

(NLGI 2 GC-LB)

STAY CLEAR OF PINCH POINT AREA ANYTIME ENGINE IS RUNNING. BEING IN PINCH POINT AREA COULD CAUSE SERIOUS INJURY OR DEATH.

9114-3282

STAY CLEAR OF PINCH POINT AREA ANYTIME ENGINE IS RUNNING. BEING IN PINCH POINT AREA COULD CAUSE SERIOUS INJURY OR DEATH.

9114-3282

DO NOT GO NEAR LEAKS

10814B

7-731200148

Section 7 - Lubrication and Maintenance

7.5 OPERATOR MAINTENANCE INSTRUCTIONS

Fuel System

A. Fuel Level Check

OW0970

OW0990

FUEL

OIL

240

TEMP

VOLT

100

OY0070

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 3-5.

3. Locate fuel tank (2), turn fuel tank cap (3) and remove from filler neck (4). Add diesel fuel as needed. Replace fuel tank cap.

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

7-8 31200148

Section 7 - Lubrication and Maintenance

5-FRONT

B. Drain Fuel/Water Separator

5-FRONT

OX0130

1. Perform “Shut-Down Procedure” on page 4-4.

2. Open the engine cover.

3. Loosen drain cock (4) on underside of fuel filter (5) and allow all water to drain into a glass until clear fuel is visible. Tighten drain cock.

4. Close and secure the engine cover.

7-931200148

Section 7 - Lubrication and Maintenance

Air Intake System

A. Air Filter Restriction Indicator Check

1. Perform “Shut-Down Procedure” on page 4-4.

2. Locate air cleaner (1) and check restriction indicator (2). If red band is visible, filter(s) must be replaced.

3. Remove dust from vacuator valve (3) by squeezing bottom of valve to allow loose particles to fall out.

Note: Only remove canister cover to service the elements as restriction indicator indicates. Excessive access to check an element can lead to premature element failure.

OX0331

7-10 31200148

JLG G6-42A Operator Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Revision Log

Read This First

Table of Contents

Section 1 - General Safety Practices

1.1 HAZARD CLASSIFICATION SYSTEM

Safety Alert System and Safety Signal Words

1.2 GENERAL PRECAUTIONS

1.3 OPERATION SAFETY

Electrical Hazards

Tip Over Hazard

Travel Hazard

Load Falling Hazard

Lifting Personnel

Driving Hazards on Slopes

Pinch Points and Crush Hazards

Fall Hazard

Chemical Hazards

Section 2 - Pre-Operation and Inspection

2.1 PRE-OPERATION CHECK AND INSPECTION

2.2 SAFETY DECALS

2.3 WALK-AROUND INSPECTION

2.4 WARM-UP AND OPERATIONAL CHECKS

Warm-Up Check

Operational Check

2.5 OPERATOR CAB

2.6 WINDOWS

Cab Door Window (if equipped)

Section 3 - Controls and Indicators

3.1 GENERAL

3.2 CONTROLS

Transmission Control Lever

Ignition Switch

Boom Joystick

Attachment Tilt and Frame Sway Lever

Auxiliary Control Joystick (if equipped)

Dash Controls and Indicators

Park Brake Switch

Parking Procedure

Heater

3.3 OPERATOR SEAT

Seat Adjustments

Seat Belt

3.4 BOOM ANGLE AND EXTENSION INDICATORS

3.5 MIRROR

Section 4 - Operation

4.1 ENGINE

Starting the Engine

Cold Weather Starting Aids

Battery Boosted Starting

Normal Engine Operation

Shut-Down Procedure

4.2 OPERATING WITH A LOAD

Lift Load Safely

Picking Up a Load

Transporting the Load

Leveling Procedure

Placing the Load

Disengaging the Load

4.3 OPERATING WITH A SUSPENDED LOAD

Lift Load Safely

Picking Up a Suspended Load

Transporting a Suspended Load

Leveling Procedure

Placing a Suspended Load

Disengaging a Suspended Load

4.4 LOADING AND SECURING FOR TRANSPORT

Tiedown

Lifting

Section 5 - Attachments

5.1 APPROVED ATTACHMENTS

5.2 UNAPPROVED ATTACHMENTS

5.3 TELEHANDLER/ATTACHMENT/FORK CAPACITY

5.4 USE OF THE CAPACITY CHART

Capacity Indicator Locations

Sample Capacity Chart

Example