JLG G6-42A Operator Manual

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Operation & Safety

An Oshkosh Corporation Company

Manual

Original Instructions

Keep this manual with machine at all times.

Model

G6-42A

S/N 0160003986 & After

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

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

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

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.

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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

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

Grease

Grease Grease

Grease

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

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

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

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

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 °

0°

10°

20°

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

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

VIEW C-C

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

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

1001118911 B

IF EQUIPPED

1000

1001130782

S/N 0160040678 & AFTER

91473217

BEFORE S/N 0160040678

1001114982

1001118911 B

IF EQUIPPED

1000

CAPACITY

CHARTS

1001131745A

1001131745 (IF EQUIPPED WITH TILT ON JOYSTICK)

1001109459

1001109459C

1001108847

(IF EQUIPPED WITH

RH SWAY)

91413061

1001108836

(IF EQUIPPED WITH

RH TILT/SWAY)

1001108836B

S/N 0160040169 & After, If Equipped

2-6 31200149

Section 2 - Pre-Operation and Inspection

OY2100

1706850A

CRUSHING HAZARD

Keepothers

awaywhile operating.

Loweringboom or falling load could

causedeath or serious injury.

WARNING

1706850

1706306A

1706306

1706299A

CONTACTING

POWERLINES

willresult in death

orserious injury.

1706299

4109801

1706296

4109801

91563220

9156-3220 REV A

4100181

1706301A

1706301

91563220

9156-3220 REV A

4100181

DO NOT use Ether or other high energy starting aids.

Engine equipped with Pre-heating system.

ENGINE EXPLOSION could result in death or serious injury.

1706300C

1706300

1001109053

2.5 GPM

9.5 lpm

MAX

1001109053 REV A

1706301A

1706301

VIEW A-A

VIEW B-BVIEW C-C

VIEW D-D

S/N 0160040169 THRU 0160040677

S/N 0160040678 & AFTER

2-731200149

Section 2 - Pre-Operation and Inspection

OY2110

1706302

-1 0

0°

10°

20°

70°

80°

1706302

-10

4105262

1706298A

1706298

1706302

91553072

1706302

VIEW E-E

VIEW F-F

2-8 31200149

Section 2 - Pre-Operation and Inspection

OY2121

91163028

91163028REV.B

1001130802 1001130920

1001118911 B

IF EQUIPPED

1000

1001130782

S/N 0160040678 & AFTER

91473217

BEFORE S/N 0160040678

1001114982

1001118911 B

IF EQUIPPED

1000

CAPACITY

CHARTS

1001131745A

1001131745 (IF EQUIPPED WITH TILT ON JOYSTICK)

1001109459

1001109459C

1001108847

(IF EQUIPPED WITH

RH SWAY)

91413061

1001108836

(IF EQUIPPED WITH

RH TILT/SWAY)

1001108836B

1706283

1706287

1706289

1706293

1705881

1001092878

(ENCLOSED CAB)

1701640

(S/N 0160040678

& AFTER)

1701640

1706098

(PERKINS ENGINE

BEFORE S/N 0160040678)

1706098B

1001092878

(OPEN CAB)

ISO (S/N 0160040169 & After, If Equipped)

2-931200149

Section 2 - Pre-Operation and Inspection

OY2130

4109801

1706281

91563220

9156-3220 REV A

4100181

1706285

91563220

9156-3220 REV A

4100181

1001109053

2.5 GPM

9.5 lpm

MAX

1001109053 REV A

1706098

1706098B

1706285

1706288

1706284

1001092877

VIEW A-A

VIEW B-BVIEW C-C

VIEW D-D

S/N 0160040169 THRU 0160040677

S/N 0160040678 & AFTER

2-10 31200149

Section 2 - Pre-Operation and Inspection

OY2140

1706282

1706292

91553072

1706292

-1 0

0°

10°

20°

70°

80°

-10

4105262

1706292

VIEW E-E

VIEW F-F

2-1131200149

Section 2 - Pre-Operation and Inspection

OY0182

2.3 WALK-AROUND INSPECTION

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

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

1. Boom Sections and Lift, Tilt, Extend/Retra ct, Compensating (Slave) Cylin ders

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

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

2. Front Axle hydraulic hoses undamaged, not leaking.

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

4. Mirrors

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

- Clean and undamaged.

2-12 31200149

Section 2 - Pre-Operation and Inspection

5. Cab and Electrical -

• General appearance; no visible damage.

• Frame level indicator and window glass undamaged and clean.

• Gauges, switches, joysticks, foot controls and horn operational.

• Emerg ency escape hammer in place (enclosed cab only).

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

6. Air Cleaner check for clogged condition. Replace element as required.

7. Main Control Valve

(Before S/N 0160040678) - Air cleaner element condition indicato r,

- See Inspection Note.

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

9. Stabilizer Cylinder leaking.

10. Rear Axle - Steer cylinders undamaged, not leaking; pivot pins secure; hydraulic hoses undamaged, not leaking.

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

12. Engine Compartm ent

• Air Cleaner (S/N 0160040678 & After) - Air cleaner element condition

indicator, check for clogged condition. Replace element as required.

• Drive belts, check condition and replace as required.

• Engine mounts - See inspection note.

• Battery cables tight, no visible damage or corrosion.

• Engine cover properly secured.

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

14. Frame Level Cylinder

15. Attachment - Properly installed, see See “Attachment Installation” on

page 5-13.

- Properly inflated and secured; no loose or missing lug

(if equipped) - Pins secure ; hydr aulic hos es und amage d, not

- Properly inflated and secured; no loose or missing lug

- Pins secure; hydraulic hoses undamaged, not leaking.

2-1331200149

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 clo sed while engine is running

except when checking transmission oil level and hydraulic filter condition indicator.

Operational Check

When engine warms, perform an operational check:

1. Service brake and parking brake operation.

2. Forward and reverse travel.

3. Each gear.

4. Steering in both directions with engine at low idle (steering lock to lock will not be reached). Check in each steering mode.

5. Horn and back-up alarm. Must be audib le from ins ide operato rs cab with en gine running.

6. All joystick functions - operate smoothly and correctly.

7. Perform any additional checks described in Section 8.

8. Hydraulic filter condition indicator.

2-14 31200149

Section 2 - Pre-Operation and Inspection

2.5 OPERATOR CAB

The telehandler is equipped with an open or enclosed ROPS/FOPS cab.

WARNING

Never operate telehandler unless the overhead guard, cab structure and right side glass or screen are in goo d condition. Any modification to this machine mus t be approved by JLG to assure compliance with ROPS/FOPS certification for this cab/machine configuration. If the overhead guard or cab structure is damaged, the CAB CANNOT BE REPAIRED. It must be REPLACED.

2-1531200149

Section 2 - Pre-Operation and Inspection

OAL0011

2.6 WINDOWS

Keep all windows and mirrors clean and unobstructed.

Cab Door Window (if equipped)

• Cab doo r (1) must be closed during operation.

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

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

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

2-16 31200149

Section 3 - Controls and Indicators

SECTION 3 - CONTROLS AND INDICATORS

3.1 GENERAL

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

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

NOTICE

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

3-131200149

Section 3 - Controls and Indicators

OY2160

3.2 CONTROLS

Before S/N 0160040678

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

2. Instrument Panel

3. Steering Wheel

machine in the corresponding direction. Three steering modes are available. See “Steer Modes” on page 3-18.

4. Frame Level Indicato condition of the telehandler.

5. Accessory Control Lever

6. Boom Joystick

7. Frame Level and Attachment Tilt (if equipped) Joystick

8. Heater and Air Conditioning Controls

9. Accelerator Pedal

speed.

10. Service Brake Pedal speed.

11. Ignition Switch

12. Auxiliary Hydraulic Joystick

3-2 31200149

: See page 3-4.

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

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

(if equipped): See page 3-16.

: See page 3-10.

: Pressing down the pedal increases engine and hydraulic

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

: Key activated. See page 3-6.

(if equipped): See page3-12.

: See page 3-11.

(if equipped): See page 3-15.

S/N 0160040678 & After

OY2150

Section 3 - Controls and Indicators

1. Transmission Control Lever

2. Instrument Panel

3. Steering Wheel

: See page 3-4.

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

: See page 3-8.

machine in the corresponding direction. Three steering modes are available. See “Steer Modes” on page 3-18.

4. Frame Level Indicator condition of the telehandler.

5. Accessory Control Lever (if equipped): See page 3-16.

6. Right Hand Panel

7. Boom Joystick

8. Frame Level and Attachment Tilt (if equipped) Joystick

9. Accelerator Pedal

: Enables the operator to determine the left to right level

: See page 3-14.

: See page 3-10.

: See page 3-11.

: Pressing down the pedal increases engine and hydraulic

speed.

10. Service Brake Pedal: The further the pedal is depressed, the slower the travel speed.

11. Ignition Switch: Key activated. See page 3-6.

12. Auxiliary Hydraulic Joystick

: See page 3-12.

3-331200149

Section 3 - Controls and Indicators

OY0084

145

6712

8131011

145

6712

2 3

891011

BEFORE S/N 0160031634

S/N 0160031634 THRU

0160040677

Dash Controls and Indicators

Before S/N 0160040678

1. Hourmeter

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

hours.

2. Boom Work Light Switch

3. Beacon Light Switch

4. Park Brake Switch

5. 4-in-1 Gauge

(Before S/N 0160031634, if equipped): On/Off switch.

(if equipped): On/Off switch.

: See page 3-7 for details.

a. Engine Coolant Temperature Gauge b. Engine Oil Pressure Gauge c. Fuel Gauge d. Voltmeter indicates alternator output and battery condition.

6. Horn Button

7. Steer Select Switch

: Depress button to sound horn.

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

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

8. Work Light Switch

9. Driving Lights Switch

10. Windshield Wiper Control

(if equipped): On/Off switch.

(Before S/N 0160031634, if equipped): On/Off switch.

(if equipped): Two speed rotary switch. Depress to

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

11. Engine Pre-Heat Switch

(Perkins Only): Depress to engag e engin e pre- heat. At temperatures below 32°F (0°C), do not start until engine is preheated. Auxiliary Electrics Sw itches (John Deere, if equipped): Enables functions of attachments that require auxiliary electrics. See Section 5- Attachments for approved attachments and control instructions.

12. Transmission Temperature Light too high. Bring machine to a stop, lower boom and attachment to ground. Idle machine until the transmission temperature light goe s o ut, the n s hut off engine. Determine cause and correct before continued use.

13. Hazard Light Switch

(S/N 0160031634 thru 0160040677, if equipped): On/Off

: Illuminates when transmission temperature is

switch.

3-4 31200149

Section 3 - Controls and Indicators

OAL2430

12 3

678

4 5

S/N 0160040678 & After

1. Transmission Temperature Light: Illuminates when transmission temperature is

too high. Bring machine to a stop, lower boom and attachment to ground. Idle machine until the transmission temperature light goe s o ut, the n s hut off engine. Determine cause and correct before continued use.

2. Engine Pre-Heat Indicator Light position. Light goes out when start temperature is reached. Do not start until light goes out.

3. Steer Select Switch

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

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

4. Park Brake Switch

5. Horn Button

: See page 3-7 for details.

: Depress button to sound horn.

6. Auxiliary Electrics Switches require auxiliary electrics. See Section 5 - Attachments for approved attachments and control instructions.

7. Warning and Check Engine Lights engine fault and/or parameter that is outside of acceptable range. Engine may derate.

8. 3-in-1 Gauge and Display

a. Engine Coolant Temperature Gauge b. Engine Oil Pressure Gauge c. Fuel Gauge d. Display - Displays engine operating hours, battery voltage and engine rpm.

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

: Illuminates with ignition key in the “RUN”

(if equipped): Enab les funct ions of a ttachments that

: Any combination of i llum ination indic ate s an

3-531200149

Section 3 - Controls and Indicators

ACC

RUN

START

OFF

OY0052

Ignition

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

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

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

3-6 31200149

Section 3 - Controls and Indicators

OY0123

BEFORE S/N 0160040678 S/N 0160040678 & AFTER

Park Brake

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

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

• With switch in "O N" 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 eng ine of f applies t he park brak e. Applyin g park brak e

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

Parking Procedure

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

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

3-731200149

Section 3 - Controls and Indicators

OY0034

Transmission Control Lever

Direction of Travel Selection

Transmission control lever (1) engages forward or revers e travel.

• Lift and push lever forward for forward travel; lift and pull lever rearward for reverse tr avel. Move lever to centered position for neutral.

• Forward or reverse travel can be selected while in any gear.

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

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

• Do not increase engine spee d with the transmi ssion in forw ard or reverse and th e service brake depressed in an attempt to get quicker hydraulic performances. This could cause unexpected machine movement.

WARNING

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

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

3-8 31200149

Section 3 - Controls and Indicators

OY0043

1st

2nd

3rd

4th

OY0551

Gear Selection

Gear selection is located on the twist grip handle (2) of transmission control lever.

• Twist hand grip to select gear.

• Select the appropriate gear for the task being performed. Use a lower gear when transporting a load. Use a higher gear only when driving unloaded for longer distances.

• Slow down prior to downshifting. Do not downshift more than one gear at a

time.

Neutral Lock Lever (Before S/N 0160040678)

• To lock transmission control lever in the neutral position, place transmission

• To unlock, move neutral lock lever to position “D” (4).

control lever in neutral position and move neutral lock lever (2) to position “N” (3).

3-931200149

Section 3 - Controls and Indicators

OAL0792

TILT SPEED CONTROL

IF EQUIPPED

(S/N 0160040678 & AFTER)

(BEFORE S/N 0160040678)

Boom Joystick

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 boo m fu nc tion s, move the joystick be tween quadrants. For example; moving the joystick forward and to the left w ill lower and retract boom simultaneously.

Attachment Tilt Function (if equipped)

Tilt control is ac tuated by the switch (2).

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

• Use knob (3) to regulate the speed of the tilt. Rotate knob counter-clockwise to increase speed; rotate knob clockwise to decrease speed.

WARNING

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

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

3-10 31200149

Section 3 - Controls and Indicators

OY2180

Frame Level and Attachment Tilt (if equipped) Joystick

The rear joystick (4) controls the left to right frame level and attachment tilt (if equipped) functions.

Frame Level

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

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

WARNING

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

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

Attachment Tilt Function

• Move the joystick forward to tilt down, move the joystick back to tilt up.

WARNING

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

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

3-1131200149

Section 3 - Controls and Indicators

OY0154

Auxiliary Hydraulic Joystick (if equipped)

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

3-12 31200149

Section 3 - Controls and Indicators

This Page Intentionally Left Blank

3-1331200149

Section 3 - Controls and Indicators

OAL0542

Right Hand Panel (S/N 0160040678 & After)

Heater and Air Conditioning Controls (if equipped)

1. Air Vent: Two individually adjustable round vents.

2. Air Louver

3. 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.

4. Temperature Control Switch: Adjustable rotary switch.

5. Fan Speed: Four-position rotary switch.

6. Air Conditioning Switch

7. Air Louver

8. Recirculation Vent

operating air conditioning.

Other Controls (if equipped)

9. Work Light Switch

10. Beacon Light Switch

11. Hazard Light Switch: On/Off switch.

12. Windshield Wiper and Washer Switch

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

13. Attachment Tilt Speed Switch

: Three individually adjustable air louvers.

: On/Off switch.

: Two individually adjustable air louvers.

: Open louvers when operating heat. Close louvers when

: On/Off switch.

: Two speed rotar y switc h. Depre ss to

: See page 3-10.

3-14 31200149

Section 3 - Controls and Indicators

OAL0801

Heater and Air Conditioning Controls (Before S/N 0160040678, if equipped)

1. Air Vent: Two individually adjustable round vents.

2. Air Louver

3. Defroster Fan

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

4. Temperature Control Switch

5. Fan Speed

6. Air Conditioning Switch: On/Off switch.

7. Air Louver

8. Recirculation Vent

heat. Close louvers when operating air conditioning.

: Three individually adjustable air louvers.

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

: Adjustable rotary switch

: Four-position rotary switch.

(S/N 0160038331 & After): Two individually adjustable air louvers.

(S/N 0160038331 & After): Open louvers when operating

3-1531200149

Section 3 - Controls and Indicators

OY0761

Accessory Control Lever (if equipped)

Before S/N 0160031634

The accessory control lever (1) operates the turn signals, hi/low beams and hazard lights.

Tu rn Signal

• Push the lever (2) forward to activate the left turn signal.

• Pull the lever back to activate the right turn signal.

• The lever must be manually returned to the center position to deactivate either turn signal. The lever will not cancel automatically after a turn.

High/Low Beam

• With driving lights on, depress button (3) to switch between low and high beam.

Hazard Lights

• Depress button (4) to activate hazard lights.

3-16 31200149

Section 3 - Controls and Indicators

OY1790

S/N 0160031634 & After

The accessory control lever (5) operates the turn signals, parking lights and headlights.

Tu rn Signal

• Push the lever forward (6) to activate the left turn signal.

• Pull the lever back (7) to activate the right turn signal.

• The lever must be manually returned to the center position to deactivate either turn signal. The lever will not cancel auto ma tic all y afte r a turn.

Parking Lights and Headlights

• Turn the twist grip (8) of the lever counterclockwise to the first position (9) to turn on the parking lights.

• Turn the twist grip to the second position (10) to turn on the headlights.

• Raise/lower the lever to switch between low beam and high beam.

• Turn the twist grip clockwise to the OFF position (11) to turn all lights off.

3-1731200149

Section 3 - Controls and Indicators

OAL2030

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

OAL2790

1 2 3

BEFORE S/N 0160040678

S/N 0160040678 & AFTER

OAM2400

4 5

3.3 STEER MODES

Three steer modes are available for operator use.

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

Steer Mode Change

1. Bring machine to a stop using service brake w hile either ci rcle st eer mode (1) or crab steer mo de (3) is selected.

2. Turn the steering wheel until the left rear wheel (4) is ali gned with the side of the machine.

3. Select front steer mode (2).

4. Turn the steering wheel until the left front wheel (5) is aligned with the side of the machine.

5. Wheels are now aligned. Select desired steer mode.

3-18 31200149

Section 3 - Controls and Indicators

OY1800

3.4 OPERATOR SEAT Adjustments

Prior to starting engine adjust seat for position and comfort.

Before S/N 0160015458

1. Fore/Aft

2. Seat Belt

seat belt is available.

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

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

3-1931200149

Section 3 - Controls and Indicators

OW0480

S/N 0160015458 & After

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

1. Suspension

: Use knob to adjust suspension to the appropriate setting. Turn

clockwise to increase stiffness. Turn counterclockwise to reduce sti f fn es s.

2. Fore/Aft

3. Arm Rest

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

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

4. Seat Belt: Always fasten seat belt during operation. If required, a 3 in (76 mm) seat belt is available.

3-20 31200149

Section 3 - Controls and Indicators

OH20912

Seat Belt

Fasten seat belt as follows:

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

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

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

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

3-2131200149

Section 3 - Controls and Indicators

OX0541

-1 0

0°

30°

40°

50°

60°

70°

3.5 BOOM ANGLE AND EXTENSION INDICATORS

• The boom angle indicator (1) is located on the left side of the boom. Use this indicator to determine the boom angle when using the capacity chart (see “Use of the Capacity Chart” on page 5-7).

• The boom extension indicators (2) are located on the left side of the boom. Use these indicators to de termin e boom exte nsion when us ing th e cap acity chart (see “Use of the Capacity Chart” on page 5-7).

3-22 31200149

Section 4 - Operation

SECTION 4 - OPERATION

4.1 ENGINE Starting the Engine

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

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

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

2. (Before S/N 0160040678) If equipped with Perk ins eng ine and the te mperature is below 32° F (0° C), turn the ignition switch to “RUN”. Depress and hold engine pre-heat switch for approx im atel y 10 secon ds. (S/N 0160040678 & After) Turn the ignition switch to “RUN” position and wait until engine pre-heat indicator light goes out.

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

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

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

Note: Engine will not st art u nle ss tran sm is si on 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.

4-131200149

Section 4 - Operation

Cold Weather Starting Aids

John Deere Engine

JLG approved starting aids employ ether. If your telehandler is equipped with an ether starting aid, the followi ng app lie s:

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

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

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

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

WARNING

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

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

Perkins or Cummins Engine

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

WARNING

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

4-2 31200149

Section 4 - Operation

OY1971

Extreme Cold Weather Starting (if equipped)

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

1. Machine must be equipped with heating c omponent s and extrem e cold weather fluids. See Section 9 - Specifications for fluid details.

2. (Before S/N 0160040678) Locate two yellow heating component extension cords stored in engine compartment. (S/N 0160040678 & After) Lo cate two yellow extension cords stored behind seat in cab. Connec t engin e bloc k heate r to one e xtens ion co rd and th e batte ry, oil pan and hydraulic tank heaters into the other extension cord.

3. Connect each extension cord to separate A/C power supplies with a minimum rating of 15 Amps each.

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

5. Locate recirculation hoses stored behind seat in cab.

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

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

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

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

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

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

12. Machine is ready for operation.

4-331200149

Section 4 - Operation

OW0530

Battery Boosted Starting

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

• Never allow vehicles to touch.

• Ensure boosting vehicle engine is running.

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

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

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

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

• Follow standard starting procedures.

• Remove cables in reverse order after machine has started.

WARNING

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

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

4-4 31200149

Section 4 - Operation

Normal Engine Operation

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

• Be alert for unusual noises or vibration. When an unusual condition is noticed, park machine in safe positi on 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 igni tion key.

6. Exit telehandler properly

7. Block wheels (if necessary).

4-531200149

Section 4 - Operation

4.2 OPERATING WITH A NON-SUSPENDED LOAD Lift Load Safely

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

WARNING

TIP OVER HAZARD. Exceeding lift capacity o f th e tel eh and ler cou ld dam ag e the

equipment and/or cause tip over.

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

Picking Up a Load

• Note the conditions of t he te rrai n. Ad jus t tra ve l sp eed and reduce amount of load if conditions warrant.

• Avoid lifting double-tiered loads.

• Make sure load is clear of any adjacent obstacles.

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

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

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

4-6 31200149

Section 4 - Operation

OW0540

Tr ansporting a Load

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

Leveling Procedure

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

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

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

4. Move boom/attachment to 4 ft (1,2 m) off ground. (AUS - Move boom so forks are no more than 11.8 in (300 mm) above ground surface.)

Important things to remember:

• Never raise the boom/attachment more than 4 ft (1,2 m) above ground unless telehandler is level. (AUS - Never raise the forks more than 11.8 in (300 mm) above ground surface unless telehandler is level.)

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

4-731200149

Section 4 - Operation

Placing a Load

Before placing any load be sure that:

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

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

• Use the capacity chart to determine safe boom extension range. See “Use of the Capacity Chart” on page 5-7.

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

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

Disengaging a Load

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

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

2. Lower the carriage.

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

4-8 31200149

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 o f th e tel eh and ler cou ld dam ag e 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 t he te rrai n. Ad jus t tra vel sp eed 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 l ifti ng po ints o f th e load, taking into consideration the c en ter o f gravity and load stability.

• Ensure to always properly tether loads to restrict movement.

• Refer to See “Use of the Capacity C hart” o n page5-7. for proper lifting guidelines in addition to the appropriate capacity chart in the operator cab.

4-931200149

Section 4 - Operation

OW0130

OZ3160

Tr ansporting a Suspended Load

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

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

Important things to remember:

• Ensure the boom is fully retracted.

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

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

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

• Never place the guide pe rsons between the suspended load and th e te lehandler.

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

Leveling Procedure

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

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

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

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

4-10 31200149

Section 4 - Operation

Placing a Suspended Load

Before placing any load be sure that:

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

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

• Use the capacity chart to determine safe boom extension range. See “Use of the Capacity Chart” on page 5-7.

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

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

Disengaging a Suspended Load

• Never place the guide pe rsons between the suspended load and th e te lehandler.

• Once at the destination of the lo ad, ensu re to bring the telehandler to a complete stop and apply the park brake prior to disengagement of the lifting devices and tethers.

4-1131200149

Section 4 - Operation

OY1820

4.4 LOADING AND SECURING FOR TRANSPORT

Tiedown

1. Level the telehandler prior to loading.

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

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

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

5. Do not tie down front of boom.

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

WARNING

TELEHANDLER SLIDE HAZARD. Before loading telehandler for transport,

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

4-12 31200149

Section 4 - Operation

Lifting

• When lifting machine, it is very im portant 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.

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Section 4 - Operation

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4-14 31200149

Section 5 - Attachments

SECTION 5 - ATTACHMENTS

5.1 APPROVED ATTACHMENTS

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

Before S/N 0160037722

• The attachment model /op tion num be r on th e 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.

• Hydrauli cally powered attachme nts must only be used on mach ines 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 0160037722 & 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.

• Hydrauli cally powered attachme nts must only be used on mach ines 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.

5-131200149

Section 5 - Attachments

5.2 UNAPPROVED ATTACHMENTS

Do not use unapproved attachme nts for the follow i ng reas on s:

• 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 abil ity of a non- appro ved at tach ment to perfor m its inten ded fu nctio n safe ly 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 31200149

Section 5 - Attachments

5.3 JLG SUPPLIED ATTACHMENTS Before S/N 0160037722

Attachment Part Number

Carriage, 48 in (1220 mm) 91405073 X Carriage, 50 in (1270 mm) 1170019 X Carriage, 60 in (1524 mm) 1170022 X Carriage, 72 in (1829 mm) 91405074 X

Carriage, 72 in (1829 mm) 1170025 X Carriage, Drywall 72 in (1829 mm) 91405077 X Side Tilt Carriage, 48 in (1220 mm) 91405101 X Side Tilt Carriage, 72 in (1829 mm) 91405079 X

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

6 ft Mast Carriage, 48 in (1220 mm) 91405060 X 6 ft Mast Carriage, 72 in (1829 mm) 91405061 X

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

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

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

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

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

Fork, Pallet 2.25x4x48 in (57x101x1220 mm) 91513206 X Fork, Pallet 2.36x4x48 in (60x101x1220 mm) 2340045 X Fork, Pallet 2.25x5x48 in (57x127x1220 mm) 91563141 X Fork, Pallet 2.36x5x48 in (60x127x1220 mm) 2340038 X Fork, Pallet 1.75x6x48 in (44x152x1220 mm) 91403361 X

Fork, Pallet 2x4x48 in (50x101x1220 mm) 91403362 X Fork, Pallet 2x6x48 in (50x152x1220 mm) 91403363 X Fork, Pallet 2x6x60 in (50x152x1524 mm) 91403360 X Fork, Pallet 2x6x60 in (50x152x1524 mm) 91403365 X

Fork, Lumber 2.25x6x60 in (57x152x1524 mm) 91563142 X Fork, Dual T aper 1.75x7x60 in (44x178x1524 mm) 2340046 X Fork, Dual T aper 2.36x6x60 in (60x152x1524 mm) 2340039 X

Fork, Dual T aper 2x6x72 in (50x152x1830 mm) 1001092391 X

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

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

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

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

Bucket, 60 in - 0.75 yd Bucket, 74 in - 1.25 yd

3 3

91405054 X 91405055 X

Applicable

Model

G6-42A

5-331200149

Section 5 - Attachments

Attachment Part Number

Bucket, 102 in -1.25 yd

Grapple Bucket, 96 in -1.75 yd

Hook, Fork Mounted 90553036 X Hook, Fork Mounted 91565094 X

Truss Boom, 10 ft (3048 mm) 91405083 X

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

Truss Boom, 15 ft (4572 mm) 91405082 X

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

Winch, Boom Head-Mounted 91405024 X

Platform, Quick Switch Mounted 91415025 X Platform, Fork Mounted (ASME)

Platform, Fork Mounted (ASME - French)

Platform, Fork Mounted (ISO)

Applicable

Model

G6-42A

91405071 X

0930021 X

1001092280 X 1001103637 X 1001097072 X 1001103736 X 1001096306 X 1001103730 X

5-4 31200149

Section 5 - Attachments

S/N 0160037722 & After

Attachment Part Number

Carriage, 50 in (1270 mm) 1170021 X Carriage, 60 in (1524 mm) 1170024 X

Carriage, 72 in (1829 mm) 1170027 X Side Tilt Carriage, 50 in (1270 mm) 1170054 X Side Tilt Carriage, 60 in (1524 mm) 1001101956 X Side Tilt Carriage, 72 in (1829 mm) 1170057 X

90° Swing Carriage, 72 in (1829 mm) 1001095418 X

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

8 ft Mast Carriage, 50 in (1270 mm) 1001 108668 X

8 ft Mast Carriage with Side Tilt, 50 in (1270 mm) 1001108669 X

Fork, Pallet 2.36x4x48 in (60x100x1220 mm) 2340045 X

Fork, Pallet 2.36x5x48 in (60x127x1220 mm) 2340038 X Fork, Dual T aper 1.75x7x60 in (44x178x1524 mm) 2340046 X Fork, Dual T aper 2.36x6x60 in (60x152x1524 mm) 2340039 X

Fork, Dual T aper 2x6x72 in (50x152x1830 mm) 1001092391 X

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

Bucket, 72 in - 1.0 yd Bucket, 96 in - 1.5 yd

Bucket, 102 in - 2.0 yd

Grapple Bucket, 96 in - 1.75 yd

Hook, Fork Mounted 90553036 X Hook, Fork Mounted 91565094 X

Truss Boom, 12 ft (3658 mm) 1001099902 X

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

Truss Boom, 15 ft (4572 mm) 1001099901 X

Platform, Fork Mounted (ASME)

Platform, Fork Mounted (ASME - French)

Platform, Fork Mounted (ISO)

3 3

1001100822 X 1001100823 X 1001100824 X

0930020 X

1001092280 X 1001103637 X 1001097072 X 1001103736 X 1001096306 X 1001103730 X

Applicable

Model

G6-42A

5-531200149

Section 5 - Attachments

OW0550

5.4 TELEHANDLER/ATTACHMENT/FORK CAPACITY

Prior to installing the att achme nt ve rify it is ap proved an d th e teleh andle r is eq uippe d 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 ma ximum l oad ce nter ( 3). Total attachme nt cap acity 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 f orks , all forks should be used in matched pairs, block forks used in matched sets.

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

5-6 31200149

WARNING

Section 5 - Attachments

OY1510

-10

DO NOT GO NEAR LEAKS

10814B

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

BOOM

EXTENSION

INDICATOR

BOOM ANGLE

INDICATOR

ATTACHMENT

IDENTIFICATION

PLATE

FORK

WEIGHT

STAMP

5.5 USE OF THE CAPACITY CHART

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

1. An approved attachment. See “Approved Attachments” on page5-1.

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 teleha ndler where the load is to be

placed.

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

distance.

6. The number in the load zone where the two cross is the maximum capacity for

this lift. If the two cross at a division between zones, the smaller number must be used.

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

Capacity Indicator Locations

5-731200149

Section 5 - Attachments

XXXX-XXXX

48" & 72"

CARRIAGES

MODEL XXXXX

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

RATED CAPACITY @ 2 FT. LOAD CENTER

48'

44'

40'

36'

32'

28'

24'

20'

16'

12'

-4'

-8'

69°

60°

50°

40°

30°

20°

10°

0°

-6°

9000 LBS

7000 LBS

6000 LBS

5000 LBS

40 00 LBS

3000 LBS

2000 LBS

1100 LBS

DEDUCT 350 LBS

FROM ALL CAPACITIES

WHEN MACHINE IS

EQUIPPED WITH WINCH

36'

0'4'8'

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

OWO650

This Capacity Chart may be used with this model ONLY.

The model of your

telehandleris indicated on

the boom or chassis.

Model XXXXX is used for

demonstration purposes only.

Boom Extension

Indicator (arc)

Load zones indicate

the maximum weight

that may be safely lifted.

These numbers must match the

model/option number stamped

on the attachment ID Plate.

Boom Angle

Sample Capacity Chart

Before S/N 0160037722

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

TIP OVER HAZARD. All loads shown on rated capacity chart are based on machine being on firm ground with frame level (see page 4-7); the forks being positioned evenly on carriage; the load being centered on forks; proper size tires being properly inflated; and the telehandler being in good operating condition.

5-8 31200149

WARNING

Section 5 - Attachments

OAL1090

OAL1100

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

• Use when lifting a load with outriggers up.

• Use when lifting a load with outriggers down.

5-931200149

Section 5 - Attachments

OY1520

XXXXXX

30°

50°

XXXXXXXXXX X

ANSI/ITSDF B56.6-2005

XXXX

LBS

XXXX

LBS

XXXX

BLS

XXXX

SLB

-4

0°

10°

20°

40°

60°

71°

=XXXX XX MAX

< = XX

XXXX XX MAX

XXXXXXXXXXXXXXXXXXXXXXXX

This Capacity Chart may be used with this model ONLY.

The telehandler model is indicated on the boom or chassis.

Model XXXX is used for demonstration purposes only.

Boom Extension

Indicator (arc)

Boom Angle

Load zones indicate the

maximum weight that

may be safely lifted.

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

Attachment type,

weight and

dimensions must

be equal to or less

than the dat a

shown.

S/N 0160037722 & After

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

WARNING

5-10 31200149

Section 5 - Attachments

OAL1090

OAL1100

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

• Use when lifting a load with outriggers up.

• Use when lifting a load with outriggers down.

5-1131200149

Section 5 - Attachments

OY1710

12'

16'

20'

24'

28'32'

36'40'

44'

-4'

12'

16'

20'

24'

28'

32'

36'

40'

44'

48'

52'

56'

60'

48

30°

50°

4000 LBS

10000 LBS

L8000 BS

L6000 BS

5000 BLS

3000 SLB

-4

0°

10°

20°

40°

60°

71°

Example 1

Example 2

Example 3

Example 4

Example

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

Before S/N 0160037722

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

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

S/N 0160037722 & After

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

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

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

Load Weight Distance Height OK to Lift

1 6000 lb (272 2 kg) 18 ft (5,5 m) 12 ft (3,7 m) Yes 2 4000 lb (181 4 kg) 30 ft (9,1 m) 26 ft (7,9 m) NO 3 7500 lb (3402 k g) 8 ft (2,4 m) 24 ft (7,3 m) Y es 4 5750 lb (2608 k g) 12 ft (3,7 m) 44 ft (13,4 m) NO

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

5-12 31200149

5.6 ATTACHMENT INSTALLATION

OY1830

BEFORE S/N 0160037722 S/N 0160037722 & AFTER

1. Attachment

2. Attachment Pin Recess

Section 5 - Attachments

3. Attachment Pin

4. Lock Pin

5. Retaining Pin

6. Quick S witch

(attachment tilt control in cab, see page 3-10 or page 3-11)

WARNING

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

positioned on boom an d is s ecu red by loc k pin an d retai ner pin. Failure to ensure proper installation could permit carriage/attachment/load to disengage.

5-1331200149

Section 5 - Attachments

OY1840

OY1850

OY1860

OY0601

Before S/N 0160037722

This installation p roce dure i s design ed for o ne- person operati on. Prio r to ex iting cab , perform “Shut-Down Procedure” on page 4-5.

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

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

3. Tilt quick switch forward to engage attachment.

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

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

6. If equipped, connect auxiliary hydraulic hoses. See “Hydraulic Operated Attachment” on page5-16.

7. If equipped, connect auxiliary electric harness.

5-14 31200149

Section 5 - Attachments

OY1550

OY1560

OY1570

OY1580

S/N 0160037722 & After

This installation p roce dure i s design ed for o ne- person operati on. Prio r to ex iting cab , perform “Shut-Down Procedure” on page 4-5.

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

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

3. Tilt quick switch forward to engage attachment.

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

5. If equipped, connect auxiliary hydraulic hoses. See “Hydraulic Operated Attachment” on page5-16.

6. If equipped, connect auxiliary electric harness.

5-1531200149

Section 5 - Attachments

OW1230

OY1720

S/N 0160037722 & AFTERBEFORE S/N 0160037722

Hydraulic Operated Attachment

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

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

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

5-16 31200149

Section 5 - Attachments

5.7 ADJUSTING/MOVING FORKS

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

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

To slide forks:

1. Ensure attachment is properly installed. See “Attachment Installation” on page 5-13.

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

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

If removing fork bar is necessary:

1. Rest forks on ground.

2. Remove fork bar.

3. Reposition forks.

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

5-1731200149

Section 5 - Attachments

5.8 ATTACHMENT OPERATION

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

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

Note: Operations descri bed within this sec tion referen ce the atta chment ti lt joysti ck. Refer to page 3-10 if equipped with attachment tilt on boom joystick.

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.

5-18 31200149

Carriage with Forks

OY0690

OY2190

Use Carriage Attachment Capacity Chart To determine maximum capacity, refer to “Telehandler/

Attachment/Fork Capacity” on page 5-6.

Section 5 - Attachments

The boom joystick (1) controls lift/lower and extend/retract movement of the boom. The attachment tilt joystick (2) controls fork tilt.

• Move joystick back to tilt up.

• Move joystick forward to tilt down.

Installation Procedure:

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

Equipmen t Damage Pr ecautions:

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

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

5-1931200149

Section 5 - Attachments

OAL1550

OY0382

Side Tilt Carriage

Use Side Tilt Carriage Capacity Chart To determine maximum capacity, refer to “Telehandler/

Attachment/Fork Capacity” on page 5-6.

The boom joystick (1) controls lift/lower and extend/retract movement of the boom. The attachment tilt joystick (2) controls fork tilt.

• Move joystick back to tilt up.

• Move joystick forward to tilt down.

To Side Tilt:

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

• Move joystick up to (side) tilt left.

• Move joystick down to (side) tilt right.

Installation Procedure:

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

5-20 31200149

Section 5 - Attachments

WARNING

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

comply could cause object or load to fall.

Operation:

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

• Level telehandler before side tilting carriage to engage load.

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

• Raise load slightly and level carriage side to side.

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

Equipmen t Damage Pr ecautions:

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

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

5-2131200149

Section 5 - Attachments

OU2150

OY0682

Swing Carriage

Use Swing Carriage Capacity Chart To determine maximum capacity, refer to “Telehandler/

Attachment/Fork Capacity” on page 5-6.

The boom joystick (1) controls lift/lower and extend/retract movement of the boom. The attachment tilt joystick (2) controls fork tilt.

• Move joystick back to tilt up.

• Move joystick forward to tilt down.

To Swing:

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

• Move joystick up to swing left.

• Move joystick down to swing right.

Installation Procedure:

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

5-22 31200149

Section 5 - Attachments

WARNING

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

swinging load to si de. 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 lo ad to fall.

WARNING

CRUSH HAZARD. Use retaining pin (if equippe d) for lo cking sw ing fram e to fixe d

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 fork s poi nte d forward and travel in accordance with the requirements set forth in Section 1 - General Safety Practices.

Equipmen t Damage Pr ecautions:

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

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

5-2331200149

Section 5 - Attachments

OZ3670

OY2200

Dual Fork Positioning Carriage

Use Carriage Attachment Capacity Chart To determine maximum capacity, refer to “Telehandler/

Attachment/Fork Capacity” on page 5-6.

The boom joystick (1) controls lift/lower and extend/retract movement of the boom. The attachment tilt joystick (2) controls fork tilt.

• Move joystick back to tilt up.

• Move joystick forward to tilt down.

To Fork Position:

The auxiliary hydraulic joystick (3) controls the fork position.

• Move joystick up to shift forks out.

• Move joystick down to shift forks in.

Installation Procedure:

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

5-24 31200149

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

Tr avel Hazard

Load Falling Hazard

Lifting Personnel

Driving Hazards on Slopes

Pinch Points and Crush Hazards

Fall Hazard

Chemical Hazards

Section 2 - Pre-Operation and Inspection

2.1 PRE-OPERATION CHECK AND INSPECTION

2.2 SAFETY DECALS

ANSI

ISO (S/N 0160040169 & After, If Equipped)

2.3 WALK-AROUND INSPECTION

2.4 WARM-UP AND OPERATIONAL CHECKS Warm-Up Check

Operational Check

2.5 OPERATOR CAB

2.6 WINDOWS

Cab Door Window (if equipped)

Section 3 - Controls and Indicators

3.1 GENERAL

3.2 CONTROLS

Dash Controls and Indicators

Ignition

Park Brake

Parking Procedure

Transmission Control Lever

Boom Joystick

Frame Level and Attachment Tilt (if equipped) Joystick

Auxiliary Hydraulic Joystick (if equipped)

Right Hand Panel (S/N 0160040678 & After)

Heater and Air Conditioning Controls (Before S/N 0160040678, if equipped)

Accessory Control Lever (if equipped)

3.3 STEER MODES

Steer Mode Change

3.4 OPERATOR SEAT Adjustments

Seat Belt

3.5 BOOM ANGLE AND EXTENSION INDICATORS

Section 4 - Operation

4.1 ENGINE Starting the Engine

Cold Weather Starting Aids

Extreme Cold Weather Starting (if equipped)

Battery Boosted Starting

Normal Engine Operation

Shut-Down Procedure

4.2 OPERATING WITH A NON-SUSPENDED LOAD Lift Load Safely

Picking Up a Load

Tr ansporting a Load

Leveling Procedure

Placing a Load

Disengaging a Load

4.3 OPERATING WITH A SUSPENDED LOAD Lift Load Safely

Picking Up a Suspended Load

Tr ansporting 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 JLG SUPPLIED ATTACHMENTS Before S/N 0160037722

S/N 0160037722 & After

5.4 TELEHANDLER/ATTACHMENT/FORK CAPACITY

5.5 USE OF THE CAPACITY CHART

Capacity Indicator Locations

Sample Capacity Chart