JLG G6-42A Operator Manual

4 (1)
Operation & Safety
An Oshkosh Corporation Company
Manual
Original Instructions
Keep this manual with machine at all times.
Model
G6-42A
31200149
Revised
August 8, 2011
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

Revision Log
April 28, 2006 - A - Original Issue of Manual January 14, 2009 - B - Revised manual. January 5, 2010 - C - Revised covers and pages b, 1-5 , 1- 6, 2-1 , 3-7, 3-13 , 4-1, 4-2 ,
4-3, 4-5, 4-7, 4-10, 5-3, 5-4, 5-5, 5-18, 5-19, 5-20, 5-22, 5-24, 5-26, 5-28, 5-30 thru 5-34, 5-36, 5-38, 5-39, 5-40, 5-42, 7-2, 7-3, 7-5, 7-16, 7-21, 9-1 & 9-2.
December 21, 2010 - D - Revised pages 7-14, 9-3 & 9-5. March 31, 2011 - E - Revised pages 1-9, 2-3, 2-6 thru 2-11, 2-13, 2-15, 3-1 thru 3-5,
3-7 thru 3-15, 3-18, 4-1 thru 4-4, 4-10, 4-11, 5-5, 5-19, 5-20, 5-22, 5-24, 5-25, 5-26, 5-30, 5-32, 5-34, 5-36, 5-38, 5-42, 6-1, 7-1 thru 7-15, 7-19 thru 7-23, 9-1 & 9-2.
August 8, 2011 - F - Revised pages 2-6 & 2-9.
REVISION LOG
a31200149

Read This First

Read This First
This manual is a very important tool! Keep it with the machine at all times. The purpose of this manual is to provide owners, users, operators, lessors, and
lessees with the precautions and operating procedures essential for the safe and proper machine operation for its intended purpose.
Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without prior notification. Contact JLG Industries, Inc. for updated information.
Operator Qualifications
The operator of the machine must not operate the machine until this manual has been read, training is accomplished and operation of the machine has been completed under the supervision of an experienced and qualified operator. Operation within the U.S.A. requires training per OSHA 1910.178.
Operators of this equipment must possess a valid, applicable driver’s license, be in good physical and mental condition, have normal reflexes and reaction time, good vision and depth perception and normal hearing. Operator must not be using medication which could impair abilities nor be under the influence of alcohol or any other intoxicant during the work shift.
In addition, the operator must read, understand and comply with instructions contained in the following material furnished with the telehandler:
• This Operation & Safety Manual
• Telehandler Safety Manual (ANSI only)
• All instructional decals and plates
• Any optional equipmen t instr uctions furnished
The operator must also read, understand and comply with all applicable Employer, Industry and Governmental rules, standards and regulations.
Modifications
Any modification to this machine must be approved by JLG.
b 31200149
Read This First
This product must comply with all safety related bulletins. Contact JLG Industries, Inc. or the local authorized JLG representative for information regarding safety­related bulletins which may have been issued for this product.
JLG Industries, Inc. sends safety related bulletins to the owner of record of this machine. Contact JLG Industries, Inc. to ensure that the current owner records are updated and accurate.
JLG Industries, Inc. must be notified immediately in all instances where JLG products have been involved in an accident involving bodily injury or death of personnel or when damage has occurred to personal property or the JLG product.
FOR:
• Accident Reporting and Product Safety Publications
• Current Owner Updates
• Questions Regarding Product Applications and Safety
• Standards and Regulations Compliance Information
• Questions Regarding Product Modifications
CONTACT:
Product Safety and Reliability Department JLG Industries, Inc. 13224 Fountainhead Plaza Hagerstown, MD 21742 USA
or Your Local JLG Office (Addresses on back cover)
In USA
Toll Free: 1-877-JLG-SAFE (1-877-554-7233)
Outside USA
Phone: +1-717-485-6591
E-mail
ProductSafety@JLG.com
c31200149
Read This First
Other Publications Available
Service Manual......................................... ................................. ...... ..........31200151
Illustrated Parts Manual....................................... ...... ................................9147 400 1
Note: The following standards may be referenced in this manual: ANSI is compliant to ANSI/ITSDF B56.6 AUS is compliant to AS 1418.19 CE is compliant to EN1459 Refer to the machine Serial Number Plate to identify the applicable compliance standard.
d 31200149

Table of Contents

TABLE OF CONTENTS
Revision Log Read This First
Operator Qualifications......................................................b
Modifications......................................................................b
Other Publications Available..............................................d
Table of Contents Section 1 - General Safety Practices
1.1 Hazard Classification System..............................................1-1
Safety Alert System and Safety Signal Words................1-1
1.2 General Precautions............................................................1-1
1.3 Operation Safety..................................................................1-2
Electrical Hazards...........................................................1-2
Tip Over Hazard..............................................................1-3
Travel Hazard ............................................. ...... ....... ...... .1-6
Load Falling Hazard........................................................1-7
Lifting Personnel .............................................................1-8
Driving Hazards on Slopes .............................................1-9
Pinch Points and Crush Hazards..................................1-10
Fall Hazard....................................................................1-12
Chemical Hazards.........................................................1-13
Table of Contents
Section 2 - Pre-Operation and Inspection
2.1 Pre-Operation Check and Inspection...................................2-1
2.2 Safety Decals.......................................................................2-3
ANSI................................................................................2-3
ISO (S/N 0160040169 & After, If Equipped) ............ ...... .2-9
2.3 Walk-Around Inspection.....................................................2-12
2.4 Warm-Up and Operational Checks....................................2-14
Warm-Up Check ...........................................................2-14
Operational Check ........................................................2-14
2.5 Operator Cab.....................................................................2-15
2.6 Windows ............................................................................2-16
Cab Door Window (if equipped)....................................2-16
Section 3 - Controls and Indicators
3.1 General................................................................................3-1
3.2 Controls ...............................................................................3-2
Dash Controls and Indicators..........................................3-4
Ignition ............................................................................3-6
Park Brake ......................................................................3-7
Parking Procedure ..........................................................3-7
i31200149
Table of Contents
Transmission Control Lever............................................ 3-8
Boom Joystick .............................................................. 3-10
Frame Level and Attachment Tilt (if equipped)
Joystick......................................................................... 3-11
Auxiliary Hydraulic Joystick (if equipped) ..................... 3-12
Right Hand Panel (S/N 0160040678 & After)...............3-14
Heater and Air Conditioning Controls
(Before S/N 0160040678, if equipped)......................... 3-15
Accessory Control Lever (if equipped) ......................... 3-16
3.3 Steer Modes...................................................................... 3-18
Steer Mode Change ..................................................... 3-18
3.4 Operator Seat.................................................................... 3-19
Adjustments.................................................................. 3-19
Seat Belt....................................................................... 3-21
3.5 Boom Angle and Extension Indicators .............................. 3-22
Section 4 - Operation
4.1 Engine................................................................................. 4-1
Starting the Engine......................................................... 4-1
Cold Weather Starting Aids............................................ 4-2
Extreme Cold Weather Starting (if equipped)................. 4-3
Battery Boosted Starting................................................. 4-4
Normal Engine Operation.............. ....... ...... ....... ...... ....... 4-5
Shut-Down Procedure .................................................... 4-5
4.2 Operating with a Non-Suspended Load .............................. 4-6
Lift Load Safely............................................................... 4-6
Picking Up a Load ................... ...... ....... ...... ....... ...... ....... 4- 6
Transporting a Load ................ ...... ................................. 4-7
Leveling Procedure......................................................... 4-7
Placing a Load................................................................ 4-8
Disengaging a Load........................................................ 4-8
4.3 Operating with a Suspended Load...................................... 4-9
Lift Load Safely............................................................... 4-9
Picking Up a Suspended Load....................................... 4- 9
Transporting a Suspended Load ............................. ..... 4 -10
Leveling Procedure....................................................... 4-10
Placing a Suspended Load........................................... 4-11
Disengaging a Suspended Load .................................. 4-11
4.4 Loading and Securing for Transport.................................. 4-12
Tiedown........................................................................ 4-12
Lifting............................................................................ 4-13
ii 31200149
Section 5 - Attachments
5.1 Approved Attachments ........................................................5-1
5.2 Unapproved Attachments ....................................................5-2
5.3 JLG Supplied Attachments ..................................................5-3
Before S/N 0160037722 .................................................5-3
S/N 0160037722 & After.................................................5-5
5.4 Telehandler/Atta chmen t/For k Capacity..... ....... ...... ....... ...... .5-6
5.5 Use of the Capacity Chart....................................................5-7
Capacity Indicator Locations...........................................5-7
Sample Capacity Chart ...................................................5-8
Example........................................................................5-12
5.6 Attachment Installation ......................................................5-13
Hydraulic Operated Attachment....................................5-16
5.7 Adjusting/Moving Forks......................................................5-17
5.8 Attachment Operation........................................................5-18
Carriage with Forks.......................................................5-19
Side Tilt Carriage ..........................................................5-20
Swing Carriage .............................................................5-22
Dual Fork Positioning Carriage.....................................5-24
Mast Carriage ............................................. ...... ....... .....5 -2 6
Mast Carriage with Swing and Side Shift
(Before S/N 0160037722) .............................................5-28
Mast Carriage with Side Tilt
(S/N 0160037722 & After).............................................5-30
Fork Mounted Hook ......................................................5-32
Truss Boom...................................................................5-34
Bucket...........................................................................5-36
Grapple Bucket .............................................................5-38
Personnel Work Platform - Quick Switch Mounted
(Before S/N 0160037722) .............................................5-40
Personnel Work Platform - Fork Mounted.....................5-42
Boom Head-Mounted Winch
(Before S/N 0160037722) .............................................5-44
Table of Contents
Section 6 - Emergency Procedures
6.1 Towing a Disabled Product..................................................6-1
Moving Short Distances.......... ....... ...... ....... ....................6-1
Moving Longer Distances ................................. ....... .......6-1
6.2 Emergency Lowering of Boom.............................................6-2
6.3 Emergency Exit from Enclosed Cab....................................6-2
iii31200149
Table of Contents
Section 7 - Lubrication and Maintenance
7.1 Introduction.......................................................................... 7-1
Clothing and Safety Gear ............................................... 7-1
7.2 General Maintenance Instructions....................................... 7-2
7.3 Service and Maintenance Schedule.................................... 7-3
10, 1st 50 & 50 Hour Maintenance Schedule................. 7-3
1st 250, 250 & 500 Hour Maintenance Schedule........... 7-4
1000, 1500 & 2000 Hour Maintenance Schedule........... 7-5
7.4 Lubrication Schedules......................................................... 7-6
50 Hour Lubrication Schedule........................................ 7-6
250 Hour Lubrication Schedule...................................... 7-7
1000 Hour Lubrication Schedule.................................... 7-8
7.5 Operator Maintenance Instructions ................................... 7-10
Fuel System.................................................................. 7-10
Air Intake System ......................................................... 7-12
Engine Oil..................................................................... 7-14
Hydraulic Oil................................................................. 7-15
Tires.............................................................................. 7-16
Transmission Oil........................................................... 7-19
Hydraulic Return Filter (Before S/N 0160040678)........ 7-20
Engine Cooling System ................................................ 7-21
Battery.......................................................................... 7-23
Windshield Washer System (if equipped)..................... 7-24
Section 8 - Additional Checks Section 9 - Specifications
9.1 Product Specificatio ns............................................ ...... ....... 9- 1
Capacities....................................................................... 9-1
Tires................................................................................ 9-3
Performance................................................................... 9-4
Dimensions..................................................................... 9-5
Index Inspection, Maintenance and Repair Log
iv 31200149

Section 1 - General Safety Practices

DANGER
OW0010
WARNING
OW0021
CAUTION
OW0031
SECTION 1 - GENERAL SAFETY PRACTICES

1.1 HAZARD CLASSIFICATION SYSTEM Safety Alert System and Safety Signal Words

DANGER indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION indicates a potentiality hazardous situation which, if not avoided, may result in minor or moderate injury.

1.2 GENERAL PRECAUTIONS

WARNING
Before operation, read and understand this manual. Failure to comply with the safety precautions lis ted in thi s m anu al c oul d res ult in ma ch ine dam age , prop erty damage, personal injury or death.
1-131200149
Section 1 - General Safety Practices
OW0040
10 FT
(3 M)

1.3 OPERATION SAFETY Electrical Hazards

• This machine is not insulated and does not provide protection from contact or being near electrical current.
NEVER operate the telehandler in an area where overhead power lines, overhead or underground cables, or other power sources may exist without ensuring the appropriate power or utility company de-energizes the lines.
• Always check for power lines before raising the boom.
• Follow employer, local and governmental regulations for clearance from powerlines.
1-2 31200149
Section 1 - General Safety Practices
OW0050
OW0080
OW0100
4 FT
(1,2 M)

Tip Over Hazard

General
• For additional load requirements, refer to the appropriate capacity chart.
• Never use an attachment without the appropriate JLG approved capacity chart installed on the telehandler.
• Understand how to properly use the capacity charts located in cab.
DO NOT exceed rated lift capacity.
• Be sure that the ground conditions are able to support the machine.
DO NOT rai se boom unles s frame is lev el (0 degrees ), unless othe rwise not ed on capacity chart.
DO NOT level machine with boom/attachment above 4 ft (1,2 m). (AUS - DO NOT level machine with load more than 11.8 in (300 mm) above ground surface.)
1-331200149
Section 1 - General Safety Practices
OH2291
OH20911
OH2221
MAINTAIN proper tire pressure at all times. If proper tire pressures are not maintained, this machine cou ld tip ov er.
• Refer to manufacturer’s specifications for proper fill ratio and pressure requirements for tires equipped with ballast.
• Always wear the seat belt.
• Keep head, arms, han ds, le gs and al l ot her bo dy part s inside op erator’s ca b at al l times.
If the telehandler starts to tip over:
DO NOT JUMP
• BRACE YOURSELF and STAY WITH THE MACHINE
• KEEP YOUR SEAT BELT FASTENED
•HOLD ON FIRMLY
• LEAN AWAY FROM THE POINT OF IMPACT
1-4 31200149
Non-Suspended Load
OW0060
OW0150
DO NOT drive with boom raised.
Suspended Load
Section 1 - General Safety Practices
• Tether suspended loads to restrict movement.
• Weight of all rigging (slings, etc.) must be included as part of load.
• Beware of wind. Wind can cause a suspended load to swing and cause dangerous side loads - even with tag lines.
DO NOT a ttemp t to us e teleh andle r frame-l eveling to com pens ate for load sw ing.
• Keep heavy part of load closest to attachment.
• Never drag the load; lift vertically. When driving with a suspended load:
Start, travel, turn and stop slowly to prevent load from swinging.
DO NOT extend boom.
DO NOT raise the load more than 11.8 in (300 mm) above ground surfac e or the boom more than 45°.
DO NOT exceed walking speed.
1-531200149
Section 1 - General Safety Practices
OAL2030
2-Wheel Front Steer 4-Wheel Circle Steer 4-Wheel Crab Steer

Tr avel Hazard

• Steering characteristics differ between steer modes. Identify the steer mode settings of the telehandler being operated.
DO NOT change steer modes while traveling. Steer modes must be changed while telehandler is stationary.
• Visually verify proper wheel alignment after each steer mode change.
• Ensure that adequate clearance is provided for both rear tail swing and front fork swing.
• Look out for and avoid other personnel, machinery and vehicles in the area. Use a spotter if you DO NOT have a clear view.
• Before moving be sure of a clear path and sound horn.
• When driving, retract boom and keep boom/attachment as low as possible while maintaining visibility of mirrors and maximum visibility of path of travel.
• Always look in the direction of travel.
• Always check boom clearances carefully before driving underneath overhead obstructions. Position attachment/load to clear obstacles.
• When driving in high speed, use only front wheel steer (if steering modes are selectable).
1-6 31200149
Section 1 - General Safety Practices
OW0130

Load Falling Hazard

• Never suspend load from forks or other parts of carriage.
DO NOT burn or drill holes in fork(s).
• Forks must be centered under load and spaced apart as far as possible.
1-731200149
Section 1 - General Safety Practices
OW0170
OW0190

Lifting Personnel

• When lifting personnel, USE ONLY a JLG approved personnel work platform, with proper capacity chart displayed in the cab.
DO NOT drive machine from cab when personnel are in platform.
1-8 31200149
Section 1 - General Safety Practices
OW0200

Driving Hazards on Slopes

To maintain sufficient traction and braking capabilities, travel on slopes as follows:
• When unloaded, drive with forks pointed downhill.
• When loaded, drive with the forks pointed uphill.
• For additional travel requirements, refer to the appropriate capacity chart.
• To avoid overspeeding the engine and drivetrain when driving down slopes, downshift to a lower gear and use the service brake as necessary to maintain a slow speed. DO NOT shift into neutral and coast downhill.
• Avoid excessively steep slopes or unstable surfaces. To avoid tip over DO NOT drive across excessively steep slopes under any circumstances.
• Avoid turning on a slope. Never engage “inching” or shift to “Neutral” when going downhill.
DO NOT park on a slope.
1-931200149
Section 1 - General Safety Practices
OW0210
OW0220
OW0230

Pinch Points and Crush Hazards

Stay clear of pinch points and rotating parts on the telehandler.
• Stay clear of moving parts while engine is running.
• Keep clear of steering tires and frame or other objects.
• Keep clear from under boom.
1-10 31200149
Section 1 - General Safety Practices
OW0240
OW0250
OW0260
OW0960
• Keep clear of boom holes.
• Keep arms and hands clear of attachment tilt cylinder.
• Keep hands and fingers clear of carriage and forks.
• Keep others away while operating.
1-1131200149
Section 1 - General Safety Practices
OW0280
OW0290

Fall Hazard

• Enter using the proper hand holds and steps provided. Always maintain 3-point contact when mounting or dismounting. Never grab control levers or steering wheel when mounting or dismounting the machine.
DO NOT get o f f th e m ac hi ne until the shutdown procedure on pa ge4-5 has been performed.
DO NOT carry riders. Riders could fall off machine causing death or serious injury.
1-12 31200149
Section 1 - General Safety Practices
OW0300
OW0950

Chemical Hazards

Exhaust Fumes
DO NOT operate machine in an enclosed area without proper ventil ation.
DO NOT operate the machine in hazardous environments unless approved for that purpose by JLG and site owner. Sparks from the electrical system and the engine exhaust can cause an explosion.
• If spark arrestors are required, ensure they are in place and in good working order.
Flammable Fuel
DO NOT fill the fuel tank or service the fuel system near an open flame, sparks or smoking materials. Engine fuel is flammable and can cause a fire and/or explosion.
Hydraulic Fluid
DO NOT attempt to repair or tighten any hydra ulic hoses or fittin gs while t he engine is running or when the hydraulic system is under pressure.
• Stop engine and relieve trapped pressure. Fluid in the hydraulic system is under enough pressure that it can penetrate the skin.
DO NOT use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks. Wear gloves to protect hands from spraying fluid.
1-1331200149
Section 1 - General Safety Practices
This Page Intentionally Left Blank
1-14 31200149

Section 2 - Pre-Operation and Inspection

OAH1000
PARENT METAL CRACK WELD CRACK
SECTION 2 - PRE-OPERATION AND INSPECTION

2.1 PRE-OPERATION CHECK AND INSPECTION

Note: Complete all required maintenance before operating unit.
WARNING
FALL HAZARD. Use extreme caution when checking items beyond your normal
reach. Use an approved ladder.
The pre-operation check and inspection, performed at beginning of each work shift or at each change of operator, should include the following:
1. Cleanliness - Check all surfaces for leaka ge (oil, fuel or battery fluid) or fo reign objects. Report any leakage to the proper maintenance personnel.
2. Structure - Inspect the machine structure for dents, damage, weld or parent metal cracks or other discrepancies.
3. Safety Decals - Ensure all safety decals are legible and in place. Clean or replace as required. See page 2-3 for details.
4. Operation and Safety Manuals - Operation & Safety Manual and AEM Safety Manual (ANSI only) are located in cab manual holder.
5. Walk-Around Inspection - See page2-12 for details.
6. Fluid Levels - Check fluids, includi ng fuel, hydr aulic o il, eng ine oil , transm ission fluid and coolant. When adding fluids, refer to Section 7 - Lubrication and Maintenance and Section 9 - Specifications to determine proper type and intervals. Before removing filler caps or fill plugs, wipe all dirt and grease away from the ports. If dirt enters these ports, it can severely reduce component life.
7. Attachments/Accessories - Ensure correct capa cit y cha rts are ins tal led on the telehandler. If provided, reference the Operation & Safety Manual of each attachment or accessory installed for specific inspection, operation and maintenance instructions.
2-131200149
Section 2 - Pre-Operation and Inspection
8. Oper ational Check - Once the walk-around inspection is complete, perform a warm-up and operational check (see page 2-14) of all systems in an area free of overhead and ground level obstructions. See Section 3 - Controls and Indicators for more specific operating instructions.
WARNING
If telehandler does not operate properly, immediately bring machine to a stop, lower boom and attachm ent to grou nd and st op th e engine . Deter mine c ause an d correct before continued use.
2-2 31200149
Section 2 - Pre-Operation and Inspection
OY0951
1705881
91143283
9114-3283
NO RIDERS PERMITTED ON HANDLER.
OPERATOR ONLY IN MACHINE
WHILE RUNNING.
RIDERS COULD FALL OFF MACHINE
CAUSING SERIOUS INJURY OR DEATH.
91143286
9114-3286
DIESEL FUEL IS FLAMMABLE
EXTINGUISH ALL OPEN FLAME AND
SMOKING MATERIALS WHEN REFUELING
INJURY OR DEATH COULD RESULT
FROM FIRE.
91083492
91143282
9114-3282
STAY CLEAR OF PINCH POINT AREA
ANYTIME ENGINE IS RUNNING. BEING IN PINCH POINT AREA COULD CAUSE SERIOUS INJURY OR DEATH.
91143282
9114-3282
STAY CLEAR OF PINCH POINT AREA
ANYTIME ENGINE IS RUNNING. BEING IN PINCH POINT AREA COULD CAUSE SERIOUS INJURY OR DEATH.
DO NOT use Ether or other high energy starting aids.
Engine equipped with Pre-heating system.
ENGINE EXPLOSION could result in death or serious injury.
1706300C
1706300
(PERKINS ENGINE
ONLY )
9151-3201 REV. (-)
91513201
(IF EQUIPPED WITH
TILT ON JOYSTICK)
90553027
9055-3027 REV. A
READ AND UNDERSTAND THE FOLLOWING PRIOR TO LIFTING PERSONNEL.
WHEN LIFTING PERSONNEL USE ONLY A GRADALL MANUFACTURED PERSONNEL WORK PLATFORM.
DO NOT DRIVE MACHINE WITH PERSONNEL IN PLATFORM.
WHEN PERSONNEL ARE IN PLATFORM REMAIN SEATED IN CAB WITH PERSONNEL
IN DIRECT LINE OF SIGHT.
OPERATE CONTROLS LIGHTLY AND CAUTIOUSLY WHEN LIFTING 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.
FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY OR DEATH.
80603022
8060-3022
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.
90553028
8. ON INCLINES, TRAVEL WITH LOAD UP-GRADE.
9. DO NOT USE BOOM AS WALKWAY.
10. USE TWO HANDS WHEN CLIMBING ON MACHINE.
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 JLG 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.
7. WHEN TRAVELING WITH LOAD, FULLY RETRACT BOOM AND PLACE FORKS IN CARRY POSITION (APPROX.12" ABOVE GROUND). TILT CARRIAGE BACK SLIGHTLY TO CRADLE LOAD. USE EXTREME CAUTION WHEN TURNING.
11. USE ONLY A JLG 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.
15. BEFORE ADJUSTING OR SERVICING, PLACE 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 C
FOR SAFE OPERATION OF MACHINE AND TO MINIMIZE RISK OF
SERIOUS INJURY, READ AND OBSERVE THE FOLLOWING:
91323030
9132-3030
NEVER OPERATE MACHINE WITHOUT
CONSULTING PROPER CAPACITY CHART FOR THE
CARRIAGE/FORK COMBINATION BEING USED.
91503102
9150-3102 REV. -
91473217
Diesel Engine
SERVICE INTERVALS
LUBRICATION AND MAINTENANCE
MATERIAL HANDLER
9147-3217 REV(-)
Use this chart in conjunction with the "Lubrication & Maintenance" and "Recommended Lubricants & Capacities" sections of the Owner/Operator Manual.
Service intervals may need to be more frequent than those shown depending upon application severity. Consult your JLG dealer for recommendations. It is recommended that engine oil and filter, transmission lubricant and filter, transfer case lubricant and axle lubricant be changed after first 100 hours on new, or rebuilt units.
LUBRICANT TYPE
OR
SPECIFICATION
Air Cleaner Element Fuel Filter Engine Oil Filter Engine Oil Coolant Diesel Fuel
YEARLY OR
1500 HRS
6 MO. OR 1000 HRS
3 MO. OR 500 HRS
EVERY 5 WKS OR 250 HRS
WEEKLY OR 50 HRS
DAILY OR 10 HRS
Transmission
Lubricant Filter
Transfer Case
Lubricant
Center Section
Axle Lubricant
Planetary Hubs
Filter
Lubricant
Hydraulic System
Breather/Filter
Grease Fittings
Axles (6 Pts. Ea.) Boom Head Pivot (2 Pts.) Boom Pivot (2 Pts.)
Extend Chain Sheave (1 Pt.)
Drive Shafts (1 Pt. Ea.)
Cylinder Pins(13 Pts.)
Quick Switch Pin (1 Pt.) Retract Chain Sheave (1 Pt.)
Boom
Front Bottom Bearing Pads All Other Bearing Pads Extend/Retract Chains
Options And Attachments
Stabilizer Cylinder (3 Pts.) Attachment Pivots And Pins
Tires
13.00-24 12 Ply
13.00R24 Radial
15.5-25 12 Ply
Lug Nut Torque
Torque
Check
Check
Check
Check
Check
Check
Check Check
Check
Check
Check Check
Check
Check
Grease
Grease
Grease
Grease
Grease Grease
Grease
Grease
Grease
Grease
Grease
Grease
Change
Change
Change
Change
Change Change
Change
Change Change
Change Change Change
SAE 15W-40 CH/CI Oil
Ethylene Glycol
No. 2 Diesel Fuel
Mobil 424
Mobil 424
Mobil 424 Mobil 424
Mobil 424
Mystik Tetrimoly Mystik Tetrimoly Mystik Tetrimoly Mystik Tetrimoly Mystik Tetrimoly Mystik Tetrimoly Mystik Tetrimoly Mystik Tetrimoly
Mystik Tetrimoly Mystik Tetrimoly
Mystik Tetrimoly Mystik Tetrimoly
See Manual
65 PSI (448 kPa) 70 PSI (483 kPa) 58 PSI (400 kPa)
350-400 Lb-Ft (475-540 Nm)
Fill
91343016
9134-3016
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.

2.2 SAFETY DECALS

Ensure all DANGER, WARNING, CAUTION and instructional decals and proper capacity charts are legible and in place. Clean and replace as required.

ANSI

Before S/N 0160040169
2-331200149
Section 2 - Pre-Operation and Inspection
OY0961
91413061
91413061
80603026
8060-3026
COOLING SYSTEM IS PRESSURIZED.
REMOVE CAP SLOWLY.
HOT FLUID CAN CAUSE BURNS.
91143281
9114-3281
STAY CLEAR OF MOVING PARTS
WHILE ENGINE IS RUNNING. MOVING PARTS CAN CAUSE
SERIOUS INJURY.
91143282
9114-3282
STAY CLEAR OF PINCH POINT AREA
ANYTIME ENGINE IS RUNNING. BEING IN PINCH POINT AREA COULD CAUSE SERIOUS INJURY OR DEATH.
91143280 (BEFORE
S/N 0160027200)
9114-3280
EXHAUST SYSTEMS CAN BE HOT.
KEEP AWAY FROM EXHAUST SYSTEM WHEN HOT.
HOT EXHAUST COMPONENTS CAN CAUSE
SEVERE BURNS.
91403569
ADD
FULL
9140-3569
CHECK OIL LEVEL WITH HANDLER LEVEL AND ALL CYLINDERS RETRACTED.
2.5 GALLON BETWEEN
ADD AND FULL MARKS
HYDRAULIC
OIL LEVEL
91143282
9114-3282
STAY CLEAR OF PINCH POINT AREA
ANYTIME ENGINE IS RUNNING. BEING IN PINCH POINT AREA COULD CAUSE SERIOUS INJURY OR DEATH.
9114-3284
LEAD ACID BATTERIES PRODUCE FLAMMABLE AND
EXPLOSIVE GASES
WHEN CHECKING, TESTING, USING
BOOSTER BATTERY OR CHARGING BATTERIES: * 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
RESULT IN SERIOUS INJURY OR DAMAGE TO THE
ELECTRICAL SYSTEM
91143284
91143285
9114-3285
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
JUMP STARTING INSTRUCTIONS
91143288
R
HYDRAULIC SYSTEM
FILL WITH TRACTOR HYDRAULIC FLUID
For Mobil Product Information, Call 1-800-662-4525.
or equivalent.
9114-3288
VIEW OF CAB DASH
CAPACITY CHARTS
VIEW A-A
AA
2-4 31200149
Section 2 - Pre-Operation and Inspection
OY1251
80603037
8060-3037-A
PINCH POINT
KEEP OUT
REACHING INTO BOOM HOLES AND OTHER PINCH
POINTS CAN CAUSE
SERIOUS INJURY
OR DEATH.
-10 °
10°
20°
3
0
°
4
0
°
5
0
°
6
0
°
70°
80°
80603037
8060-3037-A
PINCH POINT
KEEP OUT
REACHING INTO BOOM
HOLES AND OTHER PINCH
POINTS CAN CAUSE SERIOUS INJURY
OR DEATH.
-10
0
10
20
30
40
50
60
7
0
8
0
4105262
91143282
9114-3282
STAY CLEAR OF PINCH POINT AREA
ANYTIME ENGINE IS RUNNING. BEING IN PINCH POINT AREA COULD CAUSE SERIOUS INJURY OR DEATH.
91143290
9114-3290
ATTCHMENT 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.
80603037
8060-3037-A
PINCH POINT
KEEP OUT
REACHING INTO BOOM
HOLES AND OTHER PINCH
POINTS CAN CAUSE
SERIOUS INJURY
OR DEATH.
91553072
80603037
8060-3037-A
PINCH POINT
KEEP OUT
REACHING INTO BOOM
HOLES AND OTHER PINCH
POINTS CAN CAUSE
SERIOUS INJURY
OR DEATH.
91143282
9114-3282
STAY CLEAR OF PINCH POINT AREA
ANYTIME ENGINE IS RUNNING. BEING IN PINCH POINT AREA COULD CAUSE SERIOUS INJURY OR DEATH.
90553026
9055-3026 REV. A
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.
VIEW B-B
C
VIEW C-C
B
C
B
2-531200149
Section 2 - Pre-Operation and Inspection
OY2091
1705881
1706768
(ENCLOSED CAB)
DO NOT use Ether or other high energy starting aids.
Engine equipped with Pre-heating system.
ENGINE EXPLOSION could result in death or serious injury.
1706300C
1706300
(PERKINS ENGINE
BEFORE S/N 0160040678)
1706768
(OPEN CAB)
1701640
(S/N 0160040678
& AFTER)
1701640
91163028
91163028REV.B
F
N
R
1706304A
RUN-OVER
HAZARD
couldcause
deathor
serious
injury.
1706304
1706767A
1706767
1706851A
1706851
Fasten
seat belt.
1706303A
Operatormust be trained and
mustread and understand
allcapacity charts, operator
andsafety manuals.
1706303
1001130802 1001130920
A
B
1001118911 B
IF EQUIPPED
1000
B
2
B
2
B
2
B
2
2
B
B
2
4
2
A
2
A
2
A
2
A
2
A
A
A
A
A
2
2
2
2
2
A
1001130782
S/N 0160040678 & AFTER
91473217
BEFORE S/N 0160040678
1001114982
A
B
1001118911 B
IF EQUIPPED
1000
B
2
B
2
B
2
B
2
2
B
B
2
4
2
A
2
A
2
A
2
A
2
A
A
A
A
A
2
2
2
2
2
A
CAPACITY
CHARTS
1001131745A
1001131745 (IF EQUIPPED WITH TILT ON JOYSTICK)
1001109459
1001109459C
1001108847
(IF EQUIPPED WITH
RH SWAY)
91413061
91413061
1001108836
(IF EQUIPPED WITH
RH TILT/SWAY)
1001108836B
A
A
S/N 0160040169 & After, If Equipped
2-6 31200149
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