JLG TF6-42 Operator Manual

Operation & Safety and

Service Manual

Triple-L™ Trailers

3121224

October 11, 2012

ANSI

®

FOREWORD

FOREWORD

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 trailer operation for its intended purpose. It is important to stress proper trailer usage at all times. All information in this manual must be read and understood before any attempt is made to operate the trailer.

Because the manufacturer has no direct control over trailer operation and application, proper safety practices are the responsibility of the owners, users, operators, lessors, and lessees.

All instructions in this manual are based upon the use of the trailer under proper operating conditions, with no deviations from the original design. Any alteration or modification of the trailer is strictly forbidden without written approval from JLG Industries, Inc.

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.

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FOREWORD

SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

This is the Safety Alert Symbol. It is used to alert you to the potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death

The Safety Alert Symbol will be used with the appropriate Safety Signal Word of “DANGER” “WARNING” or “CAUTION” to a potential hazard and designate a level of seriousness. The Safety Signal Words are inserted throughout this manual in Black/White. On the machine, the Safety Signal Words will have either a Red, Orange, or Yellow background as part of a safety sign or decal. The “DANGER”, “WARNING”, and “CAUTION” Safety Signal Words, definitions, and associated colors are as follows:

INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH, IF

NOT AVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS

SIGNAL WORD IS USED IN THE MOST EXTREME CASES. WHEN

INSTALLED ON THE, TRAILER. THIS SIGNAL WORD WILL HAVE A

RED BACKGROUND AS PART OF A DECAL.

INDICATES A POTENTIALITY HAZARDOUS SITUATION WHICH, IF

NOT AVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH.

WHEN INSTALLED ON THE TRAILER, THIS SIGNAL WORD WILL

HAVE AN ORANGE BACKGROUND AS PART OF A DECAL.

INDICATES A POTENTIALITY HAZARDOUS SITUATION WHICH IF

NOT AVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY. IT

MAY ALSO BE USED TO ALERT AGAINST UNSAFE PRACTICES.

WHEN INSTALLED ON THE TRAILER, THIS SIGNAL WORD WILL

HAVE A YELLOW BACKGROUND AS PART OF A DECAL.

The “IMPORTANT” Safety Signal Word may also appear in this manual or on the machine. This Safety Signal Word typically will not appear with the Safety Alert Symbol, but contains important information that must be followed for safe and proper operation, The “IMPORTANT” Safety Signal Word definition and associated color is as follows.

INDICATES INFORMATION OR A COMPANY POLICY THAT

RELATES DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSON-

NEL OR PROTECTION OF PROPERTY.

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FOREWORD

ALL SAFETY-RELATED BULLETINS MUST BE ACCOMPLISHED ON THIS PRODUCT. JLG INDUSTRIES, INC. MAY HAVE ISSUED SAFETYRELATED BULLETINS FOR THIS JLG PRODUCT. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG DEALER FOR INFORMATION REGARDING SAFETY-RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS PRODUCT.

FOR THE PURPOSE OF RECEIVING SAFETY-RELATED BULLETINS, IT IS IMPORTANT THAT THE CURRENT OWNER OF THIS UNIT

ENSURES JLG INDUSTRIES, INC. HAS UPDATED OWNERSHIP INFORMATION. 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 SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROPERTY OR THE JLG PRODUCT.

FOR :

•Accident Reporting

•Product Safety Publications

•Current Owner Updates

•Questions Regarding Product Safety

•Standards and Regulations Compliance Information

•Questions Regarding Special Product Applications

•Questions Regarding Product Modifications

CONTACT :

Product Safety and Reliability Department

JLG Industries, Inc.

1 JLG Drive

McConnellsburg, PA 17233

Toll Free: 877-JLG-SAFE

877-554-7233

E-mail: [e-mail]

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FOREWORD

TRAILER IDENTIFICATION

TRAILER NUMBER	MODEL NUMBER	SERIAL NUMBER	VIN NUMBER
1
2
3
4
5
6
7
8
9
10
11
12

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NEW PRODUCT WARRANTY

NEW PRODUCT WARRANTY

1.WARRANTY. JLG Industries, Inc. (“Manufacturer”) warrants each new product made by it to be free from defects in material or workmanship for twelve months from the date of initial sale, lease, rental, or other disposition of such product. Manufacturer further warrants the structural elements of each new product made by it, as defined in its then current warranty policies and procedures, to be free from defects in material or workmanship for one year from the date of initial sale, lease, rental or other disposition of such product. Manufacturer agrees only to repair or replace at its own expense, F.O.B. the place or places of manufacturer, any part or parts of the product found to be defective in material or workmanship, provided Manufacturer is notified of such defect or defects within the applicable warranty period and given a reasonable time to correct the defect. In no case shall any warranty extend to defects in materials, components, or services furnished by third parties or to the erection or installation of the product performed by third parties. Defects caused by chemical action or the presence of abrasive materials and defects arising following the operation beyond rated capacity or the improper use or application of any products shall not be considered defects within the scope of the above mentioned warranty. If any repairs or alterations are made or any parts are replaced during the periods covered by any warranty above mentioned by other than an authorized Manufacturer’s Distributor in accordance with authorized Manufacturer’s service manuals or with other than parts, accessories, or attachments authorized by Manufacturer for use in its products, customer shall pay for such repairs or parts without recourse against Manufacturer, and Manufacturer shall be relieved of responsibility for fulfillment of the above mentioned warranty with respect to parts or components for all repairs, alterations, or replacements so made. Manufacturer’s obligations under this warranty shall at all times be subject to its then current warranty policies and procedures. The above mentioned warranty shall not apply to replacement or service parts made by and sold by Manufacturer, with any obligation of the Manufacturer to such parts governed solely by Manufacturer’s then current warranty policies and procedures.

2.DISCLAIMER AS TO CONSEQUENTIAL OR SPECIAL DAMAGES. Under no circumstances shall Manufacturer be liable for any consequential or special damages which any person firm, corporation, or other entity may suffer or claim to suffer or incur or claim to incur as a result of any defect in the product or in any correction or alteration thereof made or furnished by Manufacturer or others. “Consequential”

or “special damages” as used herein includes but is not limited to costs of transportation, lost sales, lost orders, lost profits, lost income, increased overhead, labor and material costs, and costs of manufacturing variances and operational inefficiencies.

3.MAXIMUM LIABILITY. The maximum liability of Manufacturer under the exclusive warranty set forth herein shall be the amount paid to Manufacturer with respect to the product to which such warranty applies.

4.EXCLUSIVE AND ENTIRE WARRANTY. This warranty constitutes Manufacturer’s entire warranty as to the product and it is expressly agreed that the remedies of customer and those claiming under customer as stated in this warranty are exclusive. Manufacturer does not assume (and has not authorized any other person to assume on its behalf) any other warranty or liability in connection with any product covered by this warranty.

NOTE: Manufacturer expressly disclaims any and all other warranties of any kind whatsoever as to the product furnished hereunder, including but not limited to express or implied warranties as to merchantibility, fitness for particular purposes sold, description or quality of the product furnished hereunder.

5.NOTICE OF OCCURRENCE. This warranty shall be void if, upon the occurrence of any incident involving any product made by Manufacturer and resulting in any personal injury or property damage, customer shall fail to notify Manufacturer within 48 hours of such occurrence or permit Manufacturer and its representatives to have immediate access to such product and all records of or within the control of customer relating to the product and occurrence.

6.LIMITATION OF LIABILITY. The limitation of liability provisions herein shall apply to any and all claims or suits brought against Manufacturer including any claim based upon negligence, breach of contract, breach of warranty, strict liability, or any other legal theories upon which liability may be asserted against Manufacturer.

NOTE: Manufacturer may at any time amend the foregoing form of warranty without prior notice.

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NEW PRODUCT WARRANTY

REVISION LOG

Original Issue - May 23, 2003

Revised - August 7, 2003

Revised - March 3, 2004

Revised September 30, 2004 (Edited to 0010598 Rev 7, 0010599 Rev 9, 0010600 Rev 6, 0010601Rev 9, 0010602 Rev 10)

Revised - October 4, 2004

Revised - February 25, 2005

Revised - June 27, 2005

Revised - August 22, 2005

Revised - May 24, 2006

Revised - August 28, 2006

Revised - December 5, 2007

Revised - January 17, 2008

Revised - December 21, 2010

Revised - October 11, 2012

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TABLE OF CONTENTS

TABLE OF CONTENTS

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a NEW PRODUCT WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .e REVISION LOG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .f

SECTION 1 - SAFETY PRECAUTIONS

1.1 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 1.2 Local and National Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 1.3 Major Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 1.4 Reporting Safety Defects. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5 1.5 Safety Warning Labels on Your Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

SECTION 2 - TRAILER OPERATION

2.1 Trailer Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.2 Trailer Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

2.3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

2.4 Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

2.5 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

2.6 Battery (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2.7 Deck Alarm System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2.8 Tow Vehicle And Hitch Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

2.9 Coupling and Uncoupling the Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

2.10 Loading the Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

2.11 Lift Tie Down Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

2.12 Towing Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

2.13 Pre-Tow Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16

2.14 Breaking-in a New Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17

SECTION 3 - ACCESSORIES

3.1	Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3-1
3.2	Scissor Lift chocks (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3-3

SECTION 4 - SERVICE AND MAINTENANCE

4.1	Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-1
4.2	Inspections, Service & Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-1
4.3	Inspection and Service Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-2
4.4	Bleeding Surge Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-10
4.5	Trailer Connection to Tow Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-11
4.6	Tongue Jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-11
4.7	Lights and Signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-12
4.8	Trailer Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-12
4.9	Wheel Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-14
4.10	Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-14
4.11	Unsealed Bearings (Hubs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-15
4.12	Deck Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-16
4.13	Tire and Wheel Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-17
4.14	Tire Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-20

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TABLE OF CONTENTS (Continued)

LIST OF FIGURES

FIGURE NO.

TITLE

PAGE NO.

1-1. VIN Label & Tire Information Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4 1-2. Decal Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6 2-1. Trailer Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 2-2. Vehicle Identification Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 2-3. Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8 2-4. Lift Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13 3-1. Battery Charger Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 3-2. Tie Down Attach Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3 3-3. Chock Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4 4-1. Jacking Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2 4-2. Hydraulic Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4 4-3. Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5 4-4. 12 Volt Motor/Pump Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6 4-5. Electric Brakes with Parking Brake Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8 4-6. Hydraulic Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9 4-7. Trailer Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12 4-8. Trailer Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13 4-9. Dual, Quadra Spring Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14 4-10. Flex Ride Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15 4-11. Suspension Camber Setting (Fixed). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15 4-12. Tire Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19

LIST OF TABLES

TABLE NO.

TITLE

PAGE NO.

1-1 Decal Location Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

2-1 Trailer Model Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2-2 Production Option and Accessory Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

3-1 Chock Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

4-1 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4-2 Motor/Pump Amperage Draw (No Load in Trailer). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

4-3 Tire Inflation Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17

4-4 Tire Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

4-5 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25

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SECTION 1 - SAFETY PRECAUTIONS

SECTION 1. SAFETY PRECAUTIONS

1.1 SAFETY INFORMATION

Safety Information, Alert Symbols, and

Signal Words

An owner’s manual that provides general trailer information cannot cover all of the specific details necessary for the proper combination of every trailer, tow vehicle and hitch. Therefore, you must read, understand and follow the instructions given by the tow vehicle and trailer hitch manufacturers, as well as the instructions in this manual.

Triple-L™ Trailers are built with components produced by various manufacturers. Some of these items have separate instruction manuals that were originally shipped with the product. Where this manual indicates that you should read another manual, and you do not have that manual, call JLG to obtain a copy.

The safety information in this manual is denoted by the safety alert symbols and signal words listed below:

INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT

AVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE A RED BACKGROUND.

INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. THIS

DECAL WILL HAVE AN ORANGE BACKGROUND.

INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY. IT MAY

ALSO ALERT AGAINST UNSAFE PRACTICES. THIS DECAL WILL

HAVE A YELLOW BACKGROUND.

INDICATES PROCEDURES ESSENTIAL FOR SAFE OPERATION. THIS DECAL WILL HAVE A GREEN BACKGROUND.

1.2 LOCAL AND NATIONAL REGULATIONS

In many regions, a trailer is considered a motor vehicle. As such, there are regulations (height, width, brakes etc.) that must be followed by the owner and operator. It is the responsibility of the trailer owner and operator to determine which regulations apply and to comply with these requirements.

1.3 MAJOR HAZARDS

Safe and proper usage of the trailer is essential to avoid accidents. Unsafe use; separation of trailer from tow vehicle; and loss of control of the trailer or trailer/tow vehicle combination can result in death or serious injury. Common causes for trailer accidents include:

a.Driving too fast for conditions

b.Failure to adjust handling while towing a trailer

c.Trailer improperly coupled to the hitch

d.Incorrect use of safety chains

e.Incorrect use of breakaway brake

f.Mismatch of trailer and hitch

g.Unsafe tires, lug nuts or wheels

h.Overload

i.Unsafe load distribution

j.Shifting cargo

k.Inappropriate cargo

l.Inoperable brakes, lights or mirrors

m.Modifying the trailer

n.Inadequate tow vehicle or towing hitch

o.Not properly maintaining the trailer structure.

Driving too Fast for Conditions

With ideal road conditions, the maximum speed when safely towing a trailer is 55 mph. If you drive too fast, the trailer tires will overheat and possibly blowout. As your speed increases, you are more likely to suddenly lose control. Never exceed 55 mph while towing the trailer.

DECREASE YOUR SPEED AS ROAD, WEATHER AND LIGHTING

CONDITIONS DETERIORATE.

Failure to Adjust Handling While Towing a Trailer

When towing a trailer, your tow vehicle will have decreased acceleration, increased stopping distance, and increased turning radius (which means you must make wider turns to keep from hitting curbs, vehicles, and anything else that is on the inside corner). In addition, you will need a longer distance to pass, due to slower acceleration and increased length.

Be alert for slippery conditions. You are more likely to be affected by slippery road surfaces when driving a tow vehicle with a trailer, than driving a tow vehicle without a trailer.

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Anticipate the trailer “swaying.” Swaying is the trailer reaction to the air pressure wave caused by passing trucks and busses. Continued pulling of the trailer provides a stabilizing force to correct swaying. Do not apply the brakes to correct trailer swaying.

Check rear view mirrors frequently to observe the trailer and traffic.

Use lower gear when driving down steep or long grades. Use the engine and transmission as a brake. Do not ride the brakes, as they can overheat and become ineffective.

Be aware of your trailer height, especially when approaching roofed areas and when around trees.

Hitting a bump or depression in the road surface or running off the shoulder of the road, and then returning to the road surface, can adversely affect the stability of the trailer or towing vehicle.

Rounding a corner or curve at excessive speed can adversely affect the stability of the trailer or towing vehicle.

Trailer Improperly Coupled to the Hitch

It is critical that the trailer be securely coupled to the hitch, and that the safety chains are correctly attached. Uncoupling could result in death or serious injury.

DO NOT MOVE THE TRAILER UNTIL THE COUPLER IS SECURED

AND LOCKED TO HITCH, THE SAFETY CHAINS ARE SECURED

TO THE TOW VEHICLE AND THE TRAILER JACK(S) ARE FULLY RETRACTED.

DO NOT TOW THE TRAILER ON THE ROAD UNTIL THE TIRES

AND WHEELS ARE CHECKED, THE TRAILER BRAKES ARE CHECKED, THE BREAKAWAY CABLE IS CONNECTED TO THE

TOW VEHICLE, THE LOAD IS SECURED TO THE TRAILER AND

THE TRAILER LIGHTS ARE CONNECTED AND CHECKED.

Incorrect Use of Safety Chains

If your trailer comes loose from the hitch for any reason, safety chains are provided so that control of the trailer can still be maintained. The chains originally supplied with the trailer are of proper size. Be sure the chains are not allowed to drag while towing. If links become worn, replace with proper size chain. Always check that the chains are attached to the tow vehicle before towing.

FASTEN CHAINS ONLY TO FRAME OF TOW VEHICLE. DO NOT FASTEN CHAINS TO ANY PART OF THE HITCH UNLESS THE HITCH HAS HOLES OR LOOPS SPECIFICALLY FOR THAT PURPOSE. CROSS CHAINS UNDERNEATH HITCH AND COUPLER

WITH ENOUGH SLACK TO PERMIT TURNING AND TO HOLD

TONGUE UP, IF THE TRAILER COMES LOOSE.

Incorrect Use of Breakaway Brake

When equipped with brakes, a breakaway brake system applies the brakes on your trailer if your trailer comes loose from the hitch for any reason. The safety chains and breakaway brake system must be in good condition and properly rigged to be effective.

THE BREAKAWAY CABLE MUST BE CONNECTED TO THE TOW

VEHICLE; AND NOT TO ANY PART OF THE HITCH. BEFORE TOW-

ING THE TRAILER, TEST THE FUNCTION OF THE BREAKAWAY BRAKE SYSTEM. IF THE BREAKAWAY BRAKE SYSTEM IS NOT WORKING, DO NOT TOW THE TRAILER; HAVE IT SERVICED OR REPAIRED.

Mismatch of Trailer and Hitch

The use of a Weight Carrying Hitch instead of a Weight Distributing Hitch can place too much tongue load on the rear end of the towing vehicle. This combined loading can cause the rear end of the towing vehicle to sag downward and the forward end to be raised upward, causing steering problems and towing vehicle sway at other than slow speeds.

BE SURE YOUR HITCH AND TOW VEHICLE ARE RATED FOR THE

GROSS VEHICLE WEIGHT RATING OF YOUR TRAILER.

Unsafe Tires, Lug Nuts or Wheels

NOTE: Reference Section 4 - Service and Maintenance, Section 4.12, Tire and Wheel Maintenance, and Section 4.13, TIRE SAFETY INFORMATION for complete tire maintenance and safety information.

It is essential to visually inspect the trailer tires and wheels before each tow.

If a tire has a bald spot, bulge, cuts, is showing any cords, or is cracked, replace the tire before towing. If a tire has uneven tread wear, take the trailer to a dealer or service center for diagnosis. Uneven tread wear can be caused by tire imbalance, axle misalignment or incorrect inflation.

Tires with too little tread will not provide adequate tracking on wet roadways and could result in loss of control, leading to death or serious injury.

Improper tire pressure may cause an unstable trailer and could result in a tire blowout and loss of control. Tires must be inspected and inflated in accordance with section 4 of this manual.

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TRAILER TIRES WILL BE INFLATED TO HIGHER PRESSURES

THAN PASSENGER VEHICLE TIRES. UNDER-INFLATED FRONT

TIRES ON THE TOWING VEHICLE COULD CAUSE STEERING PROBLEMS. LOW PRESSURE IN THE REAR TIRES OF THE TOWING VEHICLE COULD CAUSE THE VEHICLE TO SWAY.

Trailer wheels and lug nuts are subjected to significant side loads during tow. Before each tow, visually inspect the lug nuts for loosening. Lug nuts must be tightened to the proper torque in accordance with section 4 of this manual.

Overload

The total weight of the load you put in or on the trailer, plus the empty weight of the trailer itself, must not exceed the trailer's Gross Vehicle Weight Rating (GVWR). If you do not know the empty weight of the trailer, you must measure it at a scale.

Determining the load limits of a trailer includes more than understanding the load limits of the tires alone. On all trailers there is a VIN (Vehicle Identification No.) label and Tire Information Label that is located on the forward half of the left (road) side of the unit. VIN Label indicates the trailer’s Gross Vehicle Weight Rating (GVWR). This is the most weight the fully loaded trailer can weigh. It will also provide the Gross Axle Weight Rating (GAWR). This is the most a particular axle can support. If there are multiple axles, the GAWR of each axle will be provided.

Steps for Determining Correct Load Limit

•Locate the statement, “The weight of cargo should never exceed XXX kg or XXX lbs.,” on your vehicle’s placard.

•This figure equals the available amount of cargo and luggage load capacity.

•Determine the combined weight of luggage and cargo being loaded on the vehicle. That weight may not safely exceed the available cargo and luggage load capacity.

Mfd. By: JLGIndustries, Inc - McConnellsburg, PA--USA Phone 877-JLG-LIFT

MODEL

DATE

PNBV/GVWR (kg/lb)

PNBE/GAWR (ea.axle)(kg/lb)

INFL C

RIMS

TIRES

(KPa/psi)

THIS VEHICLE CONFORMS TO ALL APPLICABLE U.S. FEDERAL MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE.

V.I.N. No.			VEHICLE
			TYPE: TRAILER/REMORQUE
SERIAL NO.				18617D

VIN Label

NOTE: Refer to production options and accessory weight Table 2-2 for weights of various trailer options.

DO NOT LOAD A TRAILER SO THAT THE WEIGHT EXCEEDS THE

TRAILER GROSS VEHICLE WEIGHT RATING (GVWR) OR GROSS

AXLE WEIGHT RATING (GAWR).

The Tire Information Label provides tire and loading information and a statement regarding maximum cargo capacity. Inspect this label.

NOTE: Refer to Figure 1-1. for Tire Information Label and VIN Label location.

TIRE AND LOADING INFORMATION

XXXXXXXXXXXXXX XXXXXXXXXXXXXX

XXXXXXXXXXXXXX XXXXXXXXXXXXXX

	XXXXXXXXXXXXXX	XXXXXXXXXXXXXX
			FD-322

Tire Information Label

Excessive loads and/or under-inflation cause tire overloading and, as a result, abnormal tire flexing occurs. This situation can generate an excessive amount of heat and lead to tire failure. It is the air pressure that enables a tire to support the load, so proper inflation is critical. The proper air pressure may be found on the VIN label and/or on the Tire Information Label. This value should never exceed the maximum cold inflation pressure stamped on the tire.

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2
	1
1.	VIN Label	2.	Tire Information Label
	Figure 1-1. VIN Label & Tire Information Label

Unsafe Load Distribution

Uneven load distribution can cause tire, wheel, axle or structural failure. Be sure your trailer is properly loaded. A proper weight distribution is equal, right to left; and creates a tongue weight that is in the proper range for stable trailer handling (between 10-15% of the total weight of the cargo and the trailer). Towing stability also depends on keeping the center of gravity as low as possible. Load heavy items on the floor and over the axles, but do not exceed the axle load rating (GAWR). When loading additional items, be sure to maintain even side-to-side weight distribution and proper tongue weight.

DO NOT TRANSPORT PEOPLE ON OR INSIDE THE TRAILER. THE

TRANSPORT OF PEOPLE PUTS THEIR LIVES AT RISK AND MAY BE ILLEGAL.

DO NOT TRANSPORT FLAMMABLE, EXPLOSIVE, POISONOUS OR

OTHER DANGEROUS MATERIALS IN YOUR TRAILER.

EXCEPTIONS: FUEL IN THE TANKS OF EQUIPMENT BEING

HAULED; FUEL STORED IN THE TANK OF AN ON-BOARD GENERATOR

MAKE CERTAIN THAT THE TONGUE WEIGHT IS WITHIN THE

ALLOWABLE RANGE. BE SURE TO DISTRIBUTE THE LOAD FRONT-TO-REAR TO PROVIDE PROPER TONGUE WEIGHT, DIS-

TRIBUTE THE LOAD EVENLY, RIGHT AND LEFT, TO AVOID TIRE

OVERLOAD AND KEEP THE CENTER OF GRAVITY LOW.

Shifting Cargo

Since the trailer “ride” can be bumpy and rough, you must secure your cargo so that it does not shift while the trailer is being towed.

TIE DOWN ALL LOADS WITH PROPER SIZED FASTENERS, ROPES, STRAPS, ETC. IF YOUR TRAILER IS ENCLOSED OR EQUIPPED WITH AN OPTIONAL TAILGATE, THE DOORS OR TAILGATE MUST BE SECURELY LATCHED BEFORE TOWING THE TRAILER.

Inoperable Brakes, Lights or Mirrors

Be sure that all of the lights on your trailer are functioning properly before towing your trailer. Lights on a trailer are controlled via a connection to the tow vehicle, generally a multi-pin electrical connector. Check the trailer taillights by turning on your tow vehicle headlights. Check the trailer brake lights by having someone step on the tow vehicle brake pedal while you look at the trailer lights. Have someone activate the tow vehicle’s turn signals to check the trailer’s turn signal lights.

If your trailer has electric brakes, your tow vehicle must have an electric brake controller that sends power to the trailer brakes. Before towing the trailer on the road, you must operate the brake controller while trying to pull the trailer in order to confirm that the electric brakes operate. While towing the trailer at less than 5 mph, manually operate the electric brake controller in the tow vehicle cab. You should feel the operation of the trailer brakes.

Inappropriate Cargo

If your trailer is designed for specific cargo, only carry that cargo in the trailer. A utility trailer must not be used to carry certain items, such as people, containers of hazardous substances or containers of flammable substances.

BEFORE EACH TOW CHECK THAT THE TAILLIGHTS, BRAKE

LIGHTS AND TURN SIGNALS WORK AND CHECK THAT THE

ELECTRIC BRAKES WORK BY OPERATING THE BRAKE CONTROLLER INSIDE THE TOW VEHICLE.

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Standard mirrors usually do not provide adequate visibility for viewing traffic to the sides and rear of towed trailer. You must provide mirrors that allow you to safely observe approaching traffic.

Modifying the Trailer

Essential safety items can be damaged by altering your trailer. Even simply driving a nail or screw to hang something can damage an electrical circuit, hydraulic line or other feature of the trailer.

Before making any alteration to your trailer, contact your dealer or JLG at 1-877-JLG-SAFE (554-7233) between the hours of 8:00 AM and 4:45 PM Eastern Standard time and describe the alteration you are contemplating. Alteration of the trailer structure or modification of mechanical, electrical, hydraulic or other systems on your trailer must be approved by JLG and performed only by qualified technicians who are familiar with the system as installed on your trailer.

Inadequate Tow Vehicle or Towing Hitch

It is essential for the tow vehicle and towing hitch to have a rated towing capacity equal or greater than the trailer Gross Vehicle Weight Rating (GVWR). Vehicle manufacturers will provide you with the maximum capacities of their various models. The hitch ball size must be the same as the coupler size. The height of the hitch ball must equal that of the trailer coupler. If the hitch ball is too small, too large, is underrated, is loose or is worn, the trailer could come loose from the tow vehicle, and could cause death or serious injury.

BE SURE THE HITCH LOAD RATING IS EQUAL TO OR GREATER

THAN THE LOAD RATING OF THE COUPLER. BE SURE THE

HITCH SIZE MATCHES THE COUPLER SIZE. OBSERVE THE

HITCH FOR WEAR, CORROSION AND CRACKS BEFORE COUPLING. REPLACE WORN, CORRODED OR CRACKED HITCH COMPONENTS BEFORE COUPLING THE TRAILER TO THE TOW VEHICLE. BE SURE THE HITCH COMPONENTS ARE TIGHT BEFORE COUPLING THE TRAILER TO THE TOW VEHICLE.

Not Properly Maintaining the Trailer

Structure

Proper maintenance is essential for all trailer structural components to operate properly. Structural components can consist of the trailer deck assembly, deck latching mechanism, suspension, and axle components. To ensure safe and proper operation of the trailer, make sure that the proper maintenance and inspections are performed.

1.4 REPORTING SAFETY DEFECTS

If you believe that your vehicle has a defect that could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying JLG Industries, Inc.

If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or JLG Industries, Inc.

To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-888-327-4236 (TTY: 1-800-424-9153); go to http://www.safercar.gov; or write to:

Administrator

NHTSA

1200 New Jersey Avenue S.E.

Washington, DC 20590

Further information about motor vehicle safety can also be obtained from http://www.safercar.gov or from the JLG PS&R Hotline at 1-877-JLG-SAFE (554-7233) between the hours of 8:00 AM and 4:45 PM Eastern Standard time.

1.5SAFETY WARNING LABELS ON YOUR TRAILER

All decals and safety warning labels are placed on the trailer for a reason. Read, understand, and follow the directions of all the decals. Should the decals become worn or defaced, replace them immediately. Use the appropriate part number and order from your local dealer or direct from the trailer manufacturer.

ALL OF THE LABELS MUST BE ON THE TRAILER AND MUST BE LEGIBLE. REPLACE ANY MISSING OR ILLEGIBLE LABELS. (SEE

FIGURE 1-2., DECAL LOCATION).

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1 12

1

6
7
			13
8	9 10 11	4	12

Figure 1-2. Decal Location

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Table 1-1. Decal Location Legend

Item Number/Model	Decal Number
1	1705809
2	1705782
3
Model UT610	1705761
Model UT612	1705762
Model UT614	1705763
Model EC-10	1705764
Model EC-12	1705765
Model EC-14	1705766
Model 248	1705767
Model UT28	1705768
Model 449	1705769
Model UT49	1705770
Model 4610	1705771
Model UT4610	1705772
Model 1012	1705773
Model 1014	1705774
Model UT912	1705775
Model UT914	1705776
Model 7910	1705777
Model 7612	1705778
Model 7614	1705779
Model 7616	1705780
4	1705810
5	70319
6	70327
7
all except Model 449 & UT49	1707075
	1707076
8
	70322
Model 449 & UT49 only	1001105881
9	70325
10	70323
11	27611
12	1705783
13	70230
14	70317
15*	1705817
16	1706687

*Note: These decals are only available on the following models; 1012/1014/UT912/UT914/EC10/EC12/EC14.

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NOTES:

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SECTION 2 - TRAILER OPERATION

SECTION 2. TRAILER OPERATION

2.1 TRAILER MODELS

Triple-L™ Trailers employ a unique trailer deck design to make loading and unloading easier. The trailer deck can be lowered to the ground while remaining level, allowing equipment to be rolled or driven directly onto the trailer deck.

Table 2-1. Trailer Model Specifications

			VEHICLE		STANDARD BRAKE
	MODEL	DECK SIZE (in)	CAPACITY	AXLE		LIFT	GVWR
					CONFIGURATION
			WEIGHT (lbs)
	248	52 x 96	2200	Single	Optional	Hand Winch	3600 lbs (1633 kg)
	449	52 x 108	5000	Single	Electric	Hydraulic	6810 lbs (3089 kg)
	4610	72 x 120	4500	Single	Electric	Hydraulic	6537 lbs (2965 kg)
	7610	70 x 120	7000	Tandem	Electric - 1 Axle	Hydraulic	9574 lbs (4343 kg)
	7612	70 x 144	7000	Tandem	Electric - 1 Axle	Hydraulic	9750 lbs (4423 kg)
	7614	70 x 168	7000	Tandem	Electric - 1 Axle	Hydraulic	9950 lbs (4513 kg)
	7616	70 x 192	6500	Tandem	Electric - 1 Axle	Hydraulic	9700 lbs (4400 kg)
	1012	70 x 144	10,000	Tandem	Electric - 2 Axles	Hydraulic	13,102 lbs (5943 kg)
	1014	70 x 168	10,000	Tandem	Electric - 2 Axles	Hydraulic	13,342 lbs (6052 kg)
	UT28	52 x 96	2000	Single	Optional	Hand Winch	3790 lbs (1719 kg)
	UT49	52 x 108	4500	Single	Electric	Hydraulic	6460 lbs (2930 kg)
	UT410	70 x 120	4000	Single	Electric	Hydraulic	6800 lbs (3085 kg)
	UT610	70 x 120	6000	Tandem	Electric - 1 Axle	Hydraulic	9740 lbs (4418 kg)
	UT612	70 x 144	6000	Tandem	Electric - 1 Axle	Hydraulic	9903 lbs (4492 kg)
	UT614	70 x 168	6000	Tandem	Electric - 1 Axle	Hydraulic	9720 lbs (4409 kg)
	UT912	70 x 144	9000	Tandem	Electric - 2 Axles	Hydraulic	13,268 lbs (6018 kg)
	UT914	70 x 168	9000	Tandem	Electric - 2 Axles	Hydraulic	13,570 lbs (6155 kg)
	EC10	68 x 120	6000	Tandem	Electric - 2 Axles	Hydraulic	9600 lbs (4345 kg)
	EC12	68 x 126	6000	Tandem	Electric - 2 Axles	Hydraulic	9800 lbs (4445 kg)
	EC14	68 x 150	6000	Tandem	Electric - 2 Axles	Hydraulic	10,320 lbs (4681 kg)

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SECTION 2 - TRAILER OPERATION

Production Option and Accessory Weights

Any time a trailer is equipped with a production option or accessory or one of these components is added to a trailer, the weights listed in the following table must be subtracted from the rated vehicle capacity weight.

NOTE: The specified options and accessories must be considered part of cargo weight.

The single axle electric brake and battery are part of the base weight of the single axle trailer and double axle trailer models 248 and UT28.

The dual electric brake and battery are part of the base weight of the 1012 and 1014 models.

Table 2-2. Production Option and Accessory Weights

		HYDRAULIC	HYDRAULIC	ELECTRIC	SPARE	TIRE		RAILS	RAILS
	MODEL	BRAKE	BRAKE	BRAKE			WINCH			GATE
					TIRE	MOUNT		(12 IN)	(24 IN)
		(single axle)	(dual axle)	(dual axle)
	248	19 lbs	--	--	50 lbs	20 lbs	45 lbs	--	--	--
	449	19 lbs	--	--	60 lbs	20 lbs	45 lbs	--	--	--
	4610	19 lbs	--	--	60 lbs	20 lbs	45 lbs	--	--	--
	7610	34 lbs	145 lbs	102 lbs	60 lbs	20 lbs	45 lbs	--	--	--
	7612	34 lbs	145 lbs	102 lbs	60 lbs	20 lbs	45 lbs	--	--	--
	7614	34 lbs	145 lbs	102 lbs	60 lbs	20 lbs	45 lbs	--	--	--
	7616	34 lbs	145 lbs	102 lbs	60 lbs	20 lbs	45 lbs	--	--	--
	1012	--	48 lbs	--	60 lbs	20 lbs	45 lbs	--	--	--
	1014	--	48 lbs	--	60 lbs	20 lbs	45 lbs	--	--	--
	UT28	19 lbs	--	--	50 lbs	20 lbs	45 lbs	90 lbs	108 lbs	38 lbs
	UT49	19 lbs	--	--	60 lbs	20 lbs	45 lbs	90 lbs	108 lbs	38 lbs
	UT410	19 lbs	--	--	60 lbs	20 lbs	45 lbs	100 lbs	117 lbs	49 lbs
	UT610	34 lbs	--	--	60 lbs	20 lbs	45 lbs	100 lbs	117 lbs	49 lbs
	UT612	34 lbs	--	--	60 lbs	20 lbs	45 lbs	111 lbs	129 lbs	49 lbs
	UT614	34 lbs	--	--	60 lbs	20 lbs	45 lbs	123 lbs	141 lbs	49 lbs
	UT912	--	48 lbs	--	60 lbs	20 lbs	45 lbs	111 lbs	129 lbs	49 lbs
	UT914	--	48 lbs	--	60 lbs	20 lbs	45 lbs	123 lbs	141 lbs	49 lbs
	EC10	34 lbs	--	--	60 lbs	20 lbs	45 lbs	--	--	--
	EC12	34 lbs	--	--	60 lbs	20 lbs	45 lbs	--	--	--
	EC14	34 lbs	--	--	60 lbs	20 lbs	45 lbs	--	--	--

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		5	4
	Shown with	3	18
	cover open
	on this side
		6	8

	2
	7
10
15
13
	21
12
	12
16	16
	14

Figure 2-1. Trailer Features

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