Lull 1044C-54 Operation Manual

Operation & Safety

An Oshkosh Corporation Company

Manual

Keep this manual with machine at all times.

Model

1044C-54

Series II

S/N 0160037900 & After

31200608

Revised

September 30, 2014

CALIFORNIA PROPOSITION 65

BATTERY WARNING

Battery posts,

terminals and related

accessories contain

lead and lead compounds,

chemical known to the

State of California

to cause cancer and

reproductive harm.

WASH HANDS

AFTER HANDLING!

CALIFORNIA PROPOSITION 65

EXHAUST WARNING

Diesel Engine exhaust and

some of its constituents

are known to the State of

California to cause cancer,

birth defects and other

reproductive harm.

Revision Log

Revision Log

February 23, 2009 - A - Original Issue of Manual

September 25, 2009 - B - Revised pages b, 1-5, 1-6, 2-3, 2-4, 3-3, 3-4, 3-5, 3-17,
3-19, 4-1, 4-2, 7-2, 7-5, 7-11, 7-14, 7-16, 7-17, 7-23, 7-24, 8-1, 8-2 & 9-1.

December 21, 2010 - C - Revised pages 7-18, 9-2 & 9-4.

September 30, 2014 - D - Revised pages 1-6, 1-7, 5-2, 5-14 thru 5-39 & 9-4.

REVISION LOG

a31200608

Read This First

Read This First

This manual is a very important tool! Keep it with the machine at all times.

The purpose of this manual is to provide owners, users, operators, lessors, and
lessees with the precautions and operating procedures essential for the safe and
proper machine operation for its intended purpose.

Due to continuous product improvements, JLG Industries, Inc. reserves the right to
make specification changes without prior notification. Contact JLG Industries, Inc.
for updated information.

Operator Qualifications

The operator of the machine must not operate the machine until this manual has
been read, training is accomplished and operation of the machine has been
completed under the supervision of an experienced and qualified operator.
Operation within the U.S.A. requires training per OSHA 1910.178.

Operators of this equipment must possess a valid, applicable driver’s license, be in
good physical and mental condition, have normal reflexes and reaction time, good
vision and depth perception and normal hearing. Operator must not be using
medication which could impair abilities nor be under the influence of alcohol or any
other intoxicant during the work shift.

In addition, the operator must read, understand and comply with instructions
contained in the following material furnished with the telehandler:

• This Operation & Safety Manual

• Telehandler Safety Manual (ANSI only)

• All instructional decals and plates

• Any optional equipment instructions furnished

The operator must also read, understand and comply with all applicable Employer,
Industry and Governmental rules, standards and regulations.

Modifications

Any modification to this machine must be approved by JLG.

b 31200608

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: [phone]

E-mail

[e-mail]

c31200608

Read This First

Other Publications Available

Service Manual..........................................................................................31200079

Illustrated Parts Manual.............................................................................31200069

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 31200608

Table of Contents

TABLE OF CONTENTS

Revision Log

Read This First

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

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

Other Publications Available .............................................. d

Table of Contents

Section 1 - General Safety Practices

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

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

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

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

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

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

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

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

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

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

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

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

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

Table of Contents

Section 2 - Pre-Operation and Inspection

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

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

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

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

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

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

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

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

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

Section 3 - Controls and Indicators

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

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

Instrument Panel and Switches ......................................3-4

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

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

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

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

Front Joystick ................................................................3-10

Middle Joystick..............................................................3-11

i31200608

Table of Contents

Outrigger Joysticks ....................................................... 3-12

Frame Level Joystick.................................................... 3-13

Heater and Air Conditioning Controls (if equipped)...... 3-14

Accessory Control Lever (if equipped) ......................... 3-15

3.3 Steer Modes ...................................................................... 3-16

Steer Mode Change ..................................................... 3-16

3.4 Rear Oscillation Lock System ........................................... 3-17

3.5 Drive Lockout System ....................................................... 3-18

3.6 Boom/Transfer Extend Lock System ................................. 3-19

3.7 Operator Seat.................................................................... 3-20

Adjustments.................................................................. 3-20

Seat Belt ....................................................................... 3-21

3.8 Indicators ........................................................................... 3-22

Boom Angle and Extension Indicators.......................... 3-22

Transfer Carriage Extension......................................... 3-22

Section 4 - Operation

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

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

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

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

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

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

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

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

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

Transporting a Load ....................................................... 4-6

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

Placing a Load................................................................ 4-7

Disengaging a Load........................................................ 4-7

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

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

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

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

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

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

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

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

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

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

Section 5 - Attachments

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

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

5.3 JLG Supplied Attachments.................................................. 5-2

ii 31200608

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

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

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

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

Example ..........................................................................5-7

5.6 Attachment Installation ........................................................5-9

Hydraulic Operated Attachment ....................................5-11

5.7 Adjusting/Moving Forks......................................................5-12

5.8 Attachment Operation ........................................................5-13

Carriage w/Forks...........................................................5-14

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

Side Shift Carriage ........................................................5-18

Dual Fork Positioning Carriage .....................................5-20

Fork Extension ..............................................................5-22

Swing Carriage .............................................................5-24

Mast Carriage ...............................................................5-26

Mast Carriage w/Side Tilt ..............................................5-28

Fork Mounted Hook ......................................................5-30

Truss Boom...................................................................5-32

Bucket ...........................................................................5-34

Grapple Bucket .............................................................5-36

Personnel Work Platform ..............................................5-38

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

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 Hour Maintenance Schedule .......................7-3

50, 250 & 1st 500 Hour Maintenance Schedule .............7-4

500, 1000 & 2000 Hour Maintenance Schedule .............7-5

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

10 Hour Lubrication Schedule.........................................7-6

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

250 Hour Lubrication Schedule.......................................7-8

7.5 Operator Maintenance Instructions....................................7-10

Fuel System ..................................................................7-10

Air Intake System ..........................................................7-12

iii31200608

Table of Contents

Engine Oil ..................................................................... 7-14

Hydraulic Oil ................................................................. 7-15

Engine Cooling System ................................................ 7-16

Tires.............................................................................. 7-18

Hydraulic Return Filter.................................................. 7-21

Transmission Oil........................................................... 7-22

Battery .......................................................................... 7-23

Section 8 - Additional Checks

8.1 Rear Oscillation Lock System ............................................. 8-1

8.2 Boom/Transfer Extend Lock System ................................... 8-2

Section 9 - Specifications

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

Capacities....................................................................... 9-1

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

Performance ................................................................... 9-3

Dimensions..................................................................... 9-4

Index

Inspection, Maintenance and Repair Log

iv 31200608

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.

WARNIN G 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 listed in this manual could result in machine damage, property
damage, personal injury or death.

1-131200608

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 31200608

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 raise boom unless frame is level (0 degrees), unless otherwise noted 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.)

1-331200608

Section 1 - General Safety Practices

OH2291

OH20911

OH2221

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

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

• Always wear the seat belt.

• Keep head, arms, hands, legs and all other body parts inside operator’s cab at all
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 31200608

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 attempt to use telehandler frame-leveling to compensate for load swing.

• Keep heavy part of load closest to attachment.

• Never drag the load; lift vertically.

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 surface or
the boom more than 45°.

• DO NOT exceed walking speed.

1-531200608

Section 1 - General Safety Practices

OAL2030

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

Travel 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).

• Telehandlers equipped with solid tires should not be used in applications
requiring excessive roading or driving extended distances. In the event an
application requires excessive roading or driving expanded distances, JLG
recommends the use of telehandlers not equipped with solid tires.

1-6 31200608

Section 1 - General Safety Practices

OW0130

Load Falling Hazard

• Never suspend load from forks or other parts of carriage weldment. Use only
JLG approved lift points.

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

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

1-731200608

Section 1 - General Safety Practices

OW0170

OW0190

Lifting Personnel

• When lifting personnel, USE ONLY an 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 31200608

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.

1-931200608

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 31200608

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.

1-1131200608

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 off the machine until the shutdown procedure on page 4-4 has been
performed.

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

1-12 31200608

Section 1 - General Safety Practices

OW0300

OW0950

Chemical Hazards

Exhaust Fumes

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

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

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 hydraulic hoses or fittings while the
engine is running or when the hydraulic system is under pressure.

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

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

1-1331200608

Section 1 - General Safety Practices

This Page Intentionally Left Blank

1-14 31200608

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 leakage (oil, fuel or battery fluid) or foreign
objects. Report any leakage to the proper maintenance personnel.

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

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 (as required) are located in cab manual holder.

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

6. Fluid Levels - Check fluids, including fuel, hydraulic oil, engine oil, transmission
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 capacity charts are installed on
the telehandler. If provided, reference the Operation & Safety Manual of each
attachment or accessory installed for specific inspection, operation and
maintenance instructions.

2-131200608

Section 2 - Pre-Operation and Inspection

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

WARNING

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

2-2 31200608

Section 2 - Pre-Operation and Inspection

OV0091

10135092

DISCONNECT BATTERY

CAUTION

BEFORE SERVICING

10135092

TIRE BALLAST

REQUIRED

REFER TO LUBRICATION SCHEDULE

10124751

FT FT

150

cmcm

160170cm180cm190cm200

cm

65

10438305

10121319

SHUT DOWN ENGINE

BEFORE ANY SERVICE

DONT BE
CARELESS

TIRE BALLAST

REQUIRED

REFER TO LUBRICATION SCHEDULE

10124751

10121319

SHUT DOWN ENGINE

BEFORE ANY SERVICE

DONT BE

CARELESS

TIRE BALLAST

REQUIRED

REFER TO LUBRICATION SCHEDULE

10124751

TIRE BALLAST

REQUIRED

REFER TO LUBRICATION SCHEDULE

10124751

1705883

7301379

7301380

7301379

7301380

HYDRAULIC

OIL ONLY

10120988

HYDRAULIC BREATHER

DO NOT FILL

10139619

DIESEL

FUEL ONLY

CHECK & FILL ON LEVEL GROUND

10120989

10135092

DISCONNECT BATTERY

CAUTION

BEFORE SERVICING

10135092

2.5 GPM

9.5 lpm

MAX

1001109053 REV A

1001109053

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

A

VIEW A-A

A

CAB SIDE VIEW OF FRAME

TANK SIDE VIEW OF FRAME

TOP VIEW OF HYDRAULIC

AND FUEL TANKS

VIEW B-B

(IF EQUIPPED WITH CUMMINS ENGINE)

BB

VIEW OF BATTERY BOX

(IF EQUIPPED WITH

JOHN DEERE ENGINE)

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.

2-331200608

Section 2 - Pre-Operation and Inspection

OV0100

DO NOT OPERATE MACHINE WHEN

LOW BRAKE PRESSURE LIGHT IS ON.

10124906

10167809

Carry load in low position.

CAUTION

10167810

Consult operators manual before
using drive lockout override switch.

WARNING

10167808

Stabilizer System Operation

 With boom below 20°, rear axle oscillates freely.
 With boom between 20° and 40°:

Transmission is limited to first or second gear.

Rear axle is in restricted oscillation mode.
Frame tilt function operates at reduced speed at any boom

angle above 20°.

 With boom above 40°:

Transmission is locked out and rear axle oscillation is locked to frame.
Frame tilt function still operates at reduced speed.

 With boom above 40° and foot switch depressed:

Transmission is limited to first gear.
Rear axle is in very restricted oscillation mode.

 Fully depressing brake pedal locks rear axle at any boom angle.

10135193

PULL TO APPLY

PUSH TO RELEASE

PARKING BRAKE

10135193

10135082

TRANSMISSION

DECLUTCH

HAZARD
LIGHTS

10138460

(IF EQUIPPED)

BEACON

LIGHT

10139648

(IF EQUIPPED)

WORK

LIGHTS

10138409

(IF EQUIPPED)

ROOF
WIPER

10139610

(IF EQUIPPED)

10138377

(IF EQUIPPED)

STROBE

LIGHT

WINDSHIELD

WIPER

10138410

(IF EQUIPPED)

ROUND STEER

FRONT WHEEL STEER

OBLIQUE STEER

10112750

10130487

FRAME

TILT
LEFT

FRAME

TILT

RIGHT

10135091

FORK TILT DOWN

FORK TILT UP

TRANSFER

IN

AUXILIARY

PRESS AND HOLD BUTTON FOR AUXILIARY FUNCTION

TRANSFER

OUT

AUXILIARY

10135090

BOOM DOWN

BOOM UP

BOOM IN

AUXILIARY

PRESS AND HOLD BUTTON FOR AUXILIARY FUNCTION

BOOM OUT

AUXILIARY

10138929

RAISE LOWER

RIGHT

RAISE LOWER

LEFT

OUTRIGGERS

10438304

cm

102030

FT

10

110 90

FT

3

120

FT

4

100

PRESSURE TEST PORTS

PUMP 1 PUMP 2

LOCK (G1)

REAR OSC. REAR OSC.

LOCK (G2)

BRAKES STEERING PILOT

ACCUM.

10339962

LUBRICATION SCHEDULE.

11. TIRES MUST BE CALCIUM CHLORIDE FILLED! REFER TO

FIND OUT FORK CAPACITY BEFORE USING MACHINE.

10. NEVER LIFT LOADS HEAVIER THAN THE CAPACITY OF THE FORKS.

9. KEEP THE WORK AREA CLEAN OF DEBRIS.

AND IN PLACE.

8. OPERATE ONLY WITH GUARDS AND SAFETY EQUIPMENT FUNCTIONING

MANUFACTURER'S PRIOR WRITTEN APPROVAL.

7. DO NOT MODIFY OR ALTER THIS MACHINE WITHOUT THE

OR MOVING THE MACHINE.

6. EVALUATE GROUND-BEARING CONDITIONS BEFORE MAKING LIFTS

FROM THE CYLINDERS.

THROUGH FULL STROKE IN EACH DIRECTION TO ELIMINATE AIR

TILT-FRAME CYLINDER AND FORK-CARRIAGE TILT CYLINDER

5. TWICE DAILY, WITH THE FORKS NEAR GROUND ELEVATION, CYCLE

MANUAL AND THE LUBRICATION SCHEDULE.

4. SERVICE THE MACHINE AS RECOMMENDED IN THE OPERATOR'S

THIS MACHINE AS A WORK PLATFORM.

3. THIS MACHINE IS NOT EQUIPPED TO LIFT PERSONNEL. NEVER USE

FORKS ABOVE EYE LEVEL MAY CAUSE THE MACHINE TO TIP OVER.

KEPT AT OR BELOW EYE LEVEL POSITION. TRAVELING WITH THE

2. WHEN TRAVELING WITH OR WITHOUT LOADS, THE FORKS MUST BE

KEEP THE OPERATOR'S MANUAL WITH THE MACHINE.

THOROUGHLY FAMILIAR WITH THE OPERATOR'S MANUAL! ALWAYS

1. DO NOT OPERAE THIS MACHINE UNTIL YOU HAVE READ AND ARE

NOTICE

10220963

10220963

STOP RAISE LOAD LOWER LOAD

TILT FORKS RIGHT TILT FORKS LEFT TILT FORKS UP

TILT FORKS DOWN MOVE LOAD BACKWARD MOVE LOAD FORWARD

FORKLIFT SIGNALS

INSTRUCTIONS TO SIGNALMAN

1. ONLY ONE PERSON TO BE SIGNALMAN.

2. MAKE SURE THE OPERATOR CAN SEE YOU AND IS ABLE TO ACKNOWLEDGE THE SIGNAL GIVEN.

3. SIGNALMAN MUST WATCH THE LOAD, THE OPERATOR IS WATCHING YOU.

4. NEVER RAISE OR LOWER THE LOAD OVER THE OTHER WORKMEN. WARN THEM TO KEEP OUT OF THE WAY.

5. WATCH FOR OVERHEAD LINES OR OTHER OBSTRUCTIONS.

10239617

10239617

1. DO NOT OPERATE THIS MACHINE UNTIL YOU HAVE READ AND ARE
THOROUGHLY FAMILIAR WITH THE OPERATOR'S MANUAL! ALWAYS
KEEP THE OPERATOR'S MANUAL WITH THE MACHINE.

2. WHEN TRAVELING, FORKS MUST BE AT OR BELOW EYE LEVEL POSITION.
NEVER TRAVEL WITH BOOM RAISED. FAILURE TO LOWER BOOM BEFORE
TRAVELING COULD CAUSE MACHINE TO TIP AND RESULT IN SERIOUS INJURY
OR DEATH.

3. ALWAYS LIFT & CARRY LOADS WITHIN MANUFACTURER'S RECOMMENDED
CAPACITY. REFER TO LOAD CHART ON RIGHT SIDE OF OPERATOR'S

4. DO NOT USE THE MACHINE IF MALFUNCTIONING-REPAIR FIRST.

5. FAULTY MAINTENANCE, CARELESSNESS, LACK OF OPERATOR TRAINING,
IMPROPER OPERATING PRACTICES, ETC. WILL AFFECT THE SAFETY AND
CAPACITY OF THIS MACHINE.

6. ALWAYS LEVEL MACHINE BEFORE LIFTING A LOAD. IF LEVEL INDICATOR IS
DAMAGED OR MISSING, REPLACE BEFORE USING MACHINE.

7. DO NOT USED FRAME TILT TO POSITION LOADS-LOWER LOAD TO A SAFE
HEIGHT, REPOSITION MACHINE, LEVEL MACHINE AND RELIFT TO NEW
POSITION.

8. WATCH FOR OVERHEAD OBSTRUCTIONS BEFORE AND WHILE MAKING A LIFT,
ESPECIALLY ELECTRICAL WIRES. SERIOUS INJURY OR DEATH CAN RESULT
FROM CONTACT WITH ELECTRICAL WIRES.

COMPARTMENT.

CAUTION

10220964

10220964

10139033

CAUTION

OUTRIGGERS PROVIDE A SUBSTANTIAL
INCREASE IN STABILITY
IF BOOM COAPACITIES ARE EXCEEDED WITH
OUTRIGGERS DOWN, STRUCTURAL DAMAGE
MAT CCUR BEFORE MACHINE INSTABILITY.
CONSULT LOAD CHART FOR RATED
CAPACITIES. DO NOT EXCEED RATED
LIFT CAPACITIES.

1001103932

LUBRICATE BOOM WEAR PADS AND SLIDE AREAS MONTHLY WITH
EP LITHIUM-BASED GREASE OR DRY-FILM LUBRICANT.

P/N 1706502 (A)

12

8

79 6

20

12

192221133

235423

198132117

25

17

24211824

1116

1722

16 10

241514

SERVICE/LUBRICATION SCHEDULE

MODEL 1044C-54 SERIES II

20 20

SEE OTHER SIDE OF THIS CARD FOR ADDITIONAL INFORMATION

SYSTEM CAPACITIES AND PRESSURES

HYDRAULIC RESERVOIR 47 GALS

FUEL TANK 36 GALS

COOLING SYSTEM 18 QTS

ENGINE CRANKCASE  DEERE 4 CYL. 14 QTS

TRANSMISSION  DRAIN/REFILL (APPROX.) 19 QTS

ACCUMULATOR (NITROGEN PRECHARGE)

TIRES  14.00 × 24

PER TIRE

400425 PSI

WET DISK BRAKES

HYDRAULIC SYSTEM & RESERVOIR 65 GALS

PRESSURE 65 PSI
HYDRO-FILL TIRES SHOULD BE FILLED TO
APPROXIMATELY 75% FULL (55 GALLONS/596LB)
OF CALCIUM CHLORIDE TIRE FILL.

FRONT AXLE

DIFFERENTIAL 9.5 QTS

PLANETARY HUB (EACH) 54 OZ

REAR AXLE

DIFFERENTIAL 10.5 QTS

PLANETARY HUB (EACH) 40.5 OZ

APPROXIMATED WEIGHTS:

14.00 x 24 12 PLY SGG RB G2 BIAS BELTED
HYDRO-FILLED

925 LBS

FOAM-FILLED

1050 LBS

14.00 x 24 GLA2 STEEL BELTED RADIAL
HYDRO-FILLED

1000

LBS

FOAM-FILLED

1125 LBS

*

=
C =

CF =
R =
CLN =

SHORTEN SERVICE INTERVALS
ACCORDINGLY WHEN OPERATING
UNDER DUSTY OR SEVERE
CONDITIONS.

14

BOOM PIVOT

15

HOIST PIVOTS

16

TILT CYLINDER PIVOTS

INSPECT ALL FLUID SYSTEMS AND
CHANGE FLUID WHEN FLUID SHOWS
TRACES OF CONTAMINATION
OR HIGH TEMPERATURES,
EVIDENCED BY STRONG ODOR,
DISCOLORATION, OR SEPARATION

17

QUICK ATTACH PIVOT

18

OSCILLATION PIVOTS

19

FRAME TILT CYLINDER

20

REAR AXLE LOCK CYLINDER

21

22

23

24

25

DRIVE SHAFT SLIP

YOKES

TRANSFER ROLLERS

1ENGINE OIL

SEE ENGINE MANUAL

CF*CFC

2ENGINE OIL FILTER R*R

3FUEL FILTER(S)/WATER SEP. RC

4TRANSMISSION FLUID CF*CFC

5TRANSMISSION FILTER R*R

6HYD. RESERVOIR FLUID CFC

7HYD. RETURN FILTER R*RC

8HYD. PRESSURE FILTERR*RC

9HYD. TANK BREATHER

R

10AIR CLEANER RC

11ENGINE COOLANT CFC

12AXLE DIFFERENTIAL CFC*CF

13PLANETARY HUBS CFC*CF

2 GREASE FITTINGSLUBE

4 GREASE FITTINGSLUBE

6 GREASE FITTINGSLUBE

1 GREASE FITTINGSLUBE

4 GREASE FITTINGSLUBE

2 GREASE FITTINGSLUBE

2 GREASE FITTINGSLUBE

4 GREASE FITTINGS

LUBE

FIRST HOURS OF OPERATION
CHECK, SERVICE AS
NECESSARY
CHANGE FLUID
REPLACE
CLEAN CAREFULLY

SEE PARTS BOOK

SEE PARTS BOOK

SEE SERVICE MANUAL

SEE PARTS BOOK

SEE PARTS BOOK

SEE PARTS BOOK

SEE OTHER SIDE OF CARD

LUBE

LUBEOUTRIGGERS

9 GREASE FITTINGS

CHAIN GUIDES LUBE 5 GREASE FITTINGS

SEE ENGINE MANUAL

SEE PARTS BOOK

SEE PARTS BOOK

3 GREASE FITTINGS

SEE SERVICE MANUAL

HOURS OF OPERATION

*R

R

SEE PARTS BOOK

HYD. CARTRIDGE FILTER

#

DESCRIPTIONDAILYWEEKLY

50100 2505001000 2000 REMARKS

SEE OTHER SIDE OF CARD

VIEW C-C

C

VIEW OF DASH PANEL

C

VIEW OF

JOYSTICK PANEL

CAPACITY

CHARTS

2-4 31200608

Section 2 - Pre-Operation and Inspection

OV0110

10267807

Do not disconnect or bypass
proximity switches.

Bypassing proximity switches
may result in serious personal
injury or death!

See operators manual for
instructions.

10267807

10116346

4105262

-10

0

10

20

30

40

50

60

7

0

8

0

AB DCEFQRSTU

V

10239784

VIEW OF TRANSFER CARRIAGE

2-531200608

Section 2 - Pre-Operation and Inspection

OV0080

1

2

3

4

5

7

8

9

10

11

12

13

15

16

17

18

14

6

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/Retract, Compensating (Slave) Cylinders

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

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

2. Left Outrigger
leaking.

3. Front Axle
hydraulic hoses undamaged, not leaking.

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

2-6 31200608

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

- Pins secure; hydraulic hoses and cylinder undamaged, not

- Properly inflated and secured; no loose or missing lug

-

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.

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

6. Main Control Valve

(under cab floor) - See Inspection Note.

7. Air Cleaner
condition. Replace element as required.

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

9. Rear Axle Oscillation Cylinder
leaking.

10. Rear Axle
hydraulic hoses undamaged, not leaking.

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

12. Engine Compartment

• Drive belts, check condition and replace as required.

• Engine mounts - See inspection note.

• Battery cables tight, no visible damage or corrosion.

• Engine access doors (if equipped) closed and properly secured.

13. Transfer Carriage
hydraulic hoses undamaged, not leaking.

14. Mirror

15. Wheel/Tire Assembly

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

- Air cleaner element condition indicator, check for clogged

- Properly inflated and secured; no loose or missing lug

- Pins secure; hydraulic hoses undamaged, not

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

- Properly inflated and secured; no loose or missing lug

-

- See inspection note. Transfer carriage cylinder pins secure;

- Clean and undamaged.

- Properly inflated and secured; no loose or missing lug

16. Frame Level Cylinder

17. Right Outrigger

leaking.

18. Attachment

- Pins secure; hydraulic hoses and cylinder undamaged, not

- Properly installed, see “Attachment Installation” on page 5-9.

- Pins secure; hydraulic hoses undamaged, not leaking.

2-731200608

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. Adjust mirror(s) for maximum visibility.

WARNING

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

except when checking transmission oil level.

Operational Check

When engine warms, perform an operational check:

1. Service brake and parking brake operation.

2. Forward and reverse travel.

3. Each gear.

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

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

6. All joystick functions - operate smoothly and correctly.

7. Perform any additional checks described in Section 8.

2-8 31200608

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 good condition. Any modification to this machine must
be approved by JLG to assure compliance with ROPS/FOPS certification for this
cab/machine configuration. If the overhead guard or cab structure is damaged,
the CAB CANNOT BE REPAIRED. It must be REPLACED.

2-931200608

Section 2 - Pre-Operation and Inspection

OV0120

3

2

1

4

2.6 WINDOWS

Keep all windows and mirrors clean and unobstructed.

Cab Door Window (if equipped)

• Cab door (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).

• Pull on knob (4) to unlatch the window.

2-10 31200608

Section 3 - Controls and Indicators

SECTION 3 - CONTROLS AND INDICATORS

3.1 GENERAL

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

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

3-131200608

Section 3 - Controls and Indicators

OV0130

1

2

4

5

6

8

9

10

11

12

15

16

17

7

13

3

14

3.2 CONTROLS

1. Hourmeter: Records and indicates engine operating hours.

2. Transmission Control Lever

3. Horn

4. Steering Wheel

5. Accessory Control Lever

6. Transmission Oil Temperature Gauge

7. Instrument Panel and Switches

8. Ignition Switch

9. Front Joystick

10. Middle Joystick

11. Outrigger Joysticks

: Depress button to sound horn.

machine in the corresponding direction. Three steering modes are available.
See “Steer Modes” on page 3-16.

temperature.

: See page 3-8.

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

(if equipped): See page 3-15.

: See page 3-4.

: Key activated. See page 3-6.

: See page 3-10.

: See page 3-11.

: See page 3-12.

: Indicates transmission oil operating

3-2 31200608

Section 3 - Controls and Indicators

12. Frame Level Joystick: See page 3-13.

13. Park Brake

: See page 3-7.

14. Steer Mode Selector
and 2-wheel steer. See page 3-16.

15. Accelerator Pedal
speed.
(Cummins Engine Only) Accelerator pedal also used to activate Cummins
diagnostic system. See Service Manual for details.

16. Service Brake Pedal: The further the pedal is depressed, the slower the travel
speed.
With service brake pedal fully depressed, the locked mode of the rear oscillation
lock system is activated. See page 3-17.

17. Drive Lockout Override Switch
lockout system. See page 3-18.

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

: Pressing down the pedal increases engine and hydraulic

: Press and hold down to override the drive

3-331200608

Section 3 - Controls and Indicators

OV0033

BOOM/
TRANSFER
EXTEND
LOCK

REAR

OSC
LOCK

BRAKE

TRANSMISSION

DECLUTCH

WATER

°F

100

130

160

190

240

FUEL

F

3/4

1/2

1/4

E

BATT.

10

12

14

16

V

OIL

0

psi

20

40

60

80

PARK BRAKE

P

CHECK ENGINE

1

2

3

4

5

6

7

8

9

10

111213141516

BOOM/
TRANSFER
EXTEND
LOCK

REAR

OSC
LOCK

WATER

°F

100

130

160

190

240

FUEL

F

3/4

1/2

1/4

E

BATT.

10

12

14

16

V

OIL

0

psi

20

40

60

80

P

1

2

3

4

5

17

7

8

9

10

1112131418 1519

CUMMINS ENGINEJOHN DEERE ENGINE

Instrument Panel and Switches

1. Transmission Declutch Indicator: Illuminates when transmission declutch

feature is activated.

2. Rear Oscillation Lock Indicator
active. See page 3-17.

: Illuminates when rear oscillation lock system is

3. Low Brake Pressure Indicator

: Illuminates and buzzer sounds when hydraulic

brake pressure is too low.

4. Park Brake Indicator

: Illuminates when park brake is applied. See page 3-7 for

details.

5. Boom/Transfer Extend Lock Indicator

: Illuminates when boom/transfer extend

lock system is active. See page 3-19.

6. Check Engine Indicator

(John Deere Engine): Illuminates and buzzer sounds for
30 seconds before engine shuts down when a “shut-down” fault occurs.
Indicator also flashes engine fault codes. See Service Manual for details.

7. Fuel Gauge

8. Engine Coolant Temperature Gauge

9. Voltmeter

10. Engine Oil Pressure Gauge

11. Strobe Light Switch

12. Windshield Wiper Switch

middle position to turn on wiper. Push and hold bottom of switch to activate

: Indicates amount of fuel in fuel tank.

: Indicates system voltage.

(if equipped): On/Off switch.

(if equipped): Three position switch. Move switch to

: Indicates engine oil operating pressure.

: Indicates engine operating temperature.

washer. Push top of switch to turn off wiper.

3-4 31200608

Section 3 - Controls and Indicators

13. Beacon Light Switch (if equipped): On/Off switch.
Hazard Light Switch

(if equipped): On/Off switch.

14. Work Light Switch
Roof Wiper Switch (if equipped): On/Off switch.

15. Transmission Declutch Switch
declutch function and have transmission declutch while depressing service
brake. Indicator illuminates to indicate transmission has declutched. Depress
bottom of switch to deactivate transmission declutch function and keep
transmission engaged while depressing service brake.

(if equipped): On/Off switch.

: Depress top of switch to activate transmission

WARNING

UNEXPECTED MOVEMENT HAZARD. Always apply park brake or service

brake and return engine to idle before deactivating transmission declutch
function. Deactivating transmission declutch with engine above idle could cause
the machine to move abruptly.

16. Shutdown Override Switch
engine shutdown for 30 seconds. The switch resets the shutdown timer to 30
seconds and may be used repeatedly.
Switch also used to retrieve engine fault codes. See Service Manual for details.

17. Engine Warning Indicator
when critical engine fault is detected.
Indicator also flashes engine fault codes. Diagnose fault using the Cummins
diagnostic system. See Service Manual for details.

18. Engine Air-Intake Preheat Indicator
“RUN” position, illuminates until engine is preheated.

19. Engine Fault Indicator
has detected a fault within the engine. Diagnose fault using the Cummins
diagnostic system. See Service Manual for details.

(John Deere Engine): Depress and release to delay

(Cummins Engine): Illuminates and buzzer sounds

(Cummins Engine): With ignition key in the

(Cummins Engine): Illuminates when diagnostic system

NOTICE

EQUIPMENT DAMAGE. When low brake pressure, check engine or engine
warning indicators illuminate, immediately bring machine to a stop, lower boom
and attachment to ground and stop the engine. Determine cause and correct
before continued use.

3-531200608

Section 3 - Controls and Indicators

OV0140

OFF

RUN

START

Ignition

• In the "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 31200608

Section 3 - Controls and Indicators

OV0150

1

Park Brake

Park brake knob (1) controls the application and release of the park brake.

• Pull knob out to engage park brake. Push knob in to disengage park brake.

• With the engine running and the park brake knob pushed in, park brakes are
disengaged.

• With knob pulled out, park brake is engaged and transmission will not engage
forward or reverse.

WARNING

MACHINE ROLL-AWAY HAZARD. Always pull park brake knob out, lower boom

to ground and stop engine before leaving cab.

WARNING

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

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

Parking Procedure

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

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

3-731200608

Section 3 - Controls and Indicators

OV0160

1

F

R

N

Transmission Control Lever

Direction of Travel Selection

Transmission control lever (1) engages forward or reverse travel.

• Push lever forward for forward travel; pull lever rearward for reverse travel. Move
lever to centered position for neutral.

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

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

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

• If transmission declutch function is not active (see page 3-5), do not increase
engine speed with the transmission in forward or reverse and the service brake
depressed in an attempt to get quicker hydraulic performances. This could cause
unexpected machine movement.

WARNING

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

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

3-8 31200608

Section 3 - Controls and Indicators

OV0170

2

1st

4th

2nd

3rd

OV0180

4

N D3N D

5

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

Neutral lock lever (3) locks transmission control lever.

• To lock the transmission control lever in the neutral position, place the
transmission control lever in neutral and move neutral lock lever to the “N”
position (4).

• To unlock, move the neutral lock lever to the “D” position (5).

3-931200608

Section 3 - Controls and Indicators

OV0190

1

2

Front Joystick

The front joystick (1) controls attachment tilt, transfer carriage and auxiliary hydraulic
functions.

Attachment Tilt Function

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

Transfer Carriage Function

• Move the joystick right to extend transfer carriage; move joystick left to retract
transfer carriage.

• For two simultaneous functions, move the joystick between quadrants. For
example; moving the joystick forward and to the left will tilt attachment down and
retract transfer carriage simultaneously.

Auxiliary Hydraulic Function

• For attachments that require hydraulic supply for operation, press button (2) to
activate auxiliary hydraulics control. The button must be held down while moving
the joystick left or right. See Section 5 - Attachments for approved attachments
and control instructions.

WARNING

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

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

3-10 31200608

Section 3 - Controls and Indicators

OV0200

3

2

IF EQUIPPED

Middle Joystick

The middle joystick (3) controls boom and second auxiliary hydraulic (if equipped)
functions.

Boom Functions

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

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

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

Second Auxiliary Hydraulic Function (if equipped)

• For attachments that require a second hydraulic supply for operation, press
button (2) to activate auxiliary hydraulics control. The button must be held down
while moving the joystick left or right. See Section 5 - Attachments for approved
attachments and control instructions.

WARNING

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

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

3-1131200608

Section 3 - Controls and Indicators

OV0210

1

Outrigger Joysticks

The outrigger joysticks (1) control the outriggers.

• The front joystick controls the right outrigger; the middle joystick controls the left
outrigger.

• Push the joysticks right to lower outriggers; push the joysticks left to raise
outriggers.

• Use outriggers to increase stability and/or load capacity and in leveling the
telehandler. Study capacity charts to determine maximum load capacities, with
and without outriggers.

WARNING

TIP OVER HAZARD. Outriggers increase stability and load capacity only if they

are used properly. Using outriggers on soft surfaces could cause telehandler to
tip over. Always ensure surface can support telehandler and load.

3-12 31200608

Section 3 - Controls and Indicators

OV0220

2

3

Frame Level Joystick

The frame level joystick (2) controls the left to right frame level.

• Lift detent ring (3) and move the joystick left to rotate frame left; lift detent ring
and move the joystick right to rotate frame right.

• A level indicator is located above the front cab window to permit the 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.

3-1331200608

Section 3 - Controls and Indicators

OV0230

1

2

3

4

5

Heater and Air Conditioning Controls (if equipped)

The heater and air conditioning controls are located on the left side of the cab dash.

1. Air Vent

2. Heat/Air Conditioning Switch

Depress bottom of switch for heat.

3. Fan Switch

4. Fan Speed Switch

: Three individually adjustable air vents.

: Depress top of switch for air conditioning.

: On/off switch.

: Adjustable rotary switch.

5. Temperature Control Switch

: Adjustable rotary switch.

3-14 31200608

Section 3 - Controls and Indicators

OV0460

2

3

4

1

Accessory Control Lever (if equipped)

The accessory control lever (1) operates the turn signals.

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

• Pull lever back (3) to activate the right turn signal.

• The lever must be manually returned to the center position (4) to deactivate
either turn signal. The lever will not cancel automatically after a turn.

3-1531200608

Section 3 - Controls and Indicators

OAL2030

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

ROUND STEER

FRONT WHEEL STEER

OBLIQUE STEER

ROUND STEER

FRONT WHEEL STEER

OBLIQUE STEER

ROUND STEER

FRONT WHEEL STEER

OBLIQUE STEER

ROUND STEER

FRONT WHEEL STEER

OBLIQUE STEER

12 3

OV0240

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 while either circle steer mode (1) or
crab steer mode (3) is selected.

2. Turn the steering wheel until the left rear wheel (4) is aligned 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.

3-16 31200608

Section 3 - Controls and Indicators

OV0261

BOOM/
TRANSFER
EXTEND
LOCK

REAR

OSC
LOCK

WATER

°F

100

130

160

190

240

FUEL

F

3/4

1/2

1/4

E

BATT.

10

12

14

16

V

OIL

0

psi

20

40

60

80

P

4

2

3

1

3.4 REAR OSCILLATION LOCK SYSTEM

Free Pivot Mode

With boom below 20° (1), the system is in free pivot mode.

• The rear axle pivots freely and frame level functions normally.

• The Rear Oscillation Lock indicator (4) will be off.

Slow Pivot Mode

With boom between 20° and 40° (2), the system is in slow pivot mode.

• The rear axle will respond slowly to changes in terrain and frame level functions
slower than normal.

• The Rear Oscillation Lock indicator (4) will illuminate.

Locked Mode

With boom above 40° (3) or service brake pedal fully depressed, the system is in
locked mode.

• The rear axle is locked and the frame level functions slower than normal.

• The Rear Oscillation Lock indicator (4) will illuminate.

3-1731200608

Section 3 - Controls and Indicators

OV0270

2

3

1

5

3.5 DRIVE LOCKOUT SYSTEM

Normal Mode

With boom below 20° (1), the drive system functions normally.

Restricted Mode

With boom between 20° and 40° (2), the system is in restricted mode.

• The transmission is limited to first and second gear.

Locked Mode

With boom above 40° (3), the system is in locked mode.

• The transmission is disengaged, stopping drive capabilities.

Override Mode

With boom above 40° (3) and the drive lockout override switch depressed and held
down, the system is in override mode.

• The transmission is limited to first gear.

• The rear oscillation lock system is in slow pivot mode. See page 3-17.

3-18 31200608

Section 3 - Controls and Indicators

BOOM/
TRANSFER
EXTEND
LOCK

REAR

OSC
LOCK

WATER

°F

100

130

160

190

240

FUEL

F

3/4

1/2

1/4

E

BATT.

10

12

14

16

V

OIL

0

psi

20

40

60

80

P

3

4

2

5

1

OV0251

3.6 BOOM/TRANSFER EXTEND LOCK SYSTEM

The boom/transfer extend lock system limits boom/transfer carriage extension when
outriggers are not engaged.

Unlocked Mode

With outriggers lowered (1) on firm terrain, boom/transfer extend mode is unlocked
and allows for full boom or transfer carriage extension (2).

• When outriggers are lowered shift travel select lever into neutral, move neutral
lock lever to neutral lock position and engage the parking brake.

• Outriggers can be to adjusted for any changes in outrigger footing.

• The Boom/Transfer Extend Lock indicator (3) will not illuminate.

Locked Mode

With outriggers raised (4), telehandler is in boom/transfer extend lock mode and
limits boom/transfer carriage extension.

• The boom and transfer carriage extension is limited from extending beyond a
point (5) between the “N” and “O” boom extension indicators.

• The Boom/Transfer Extend Lock indicator (3) will illuminate.

3-1931200608

Section 3 - Controls and Indicators

OAL1270

1

2

3

3.7 OPERATOR SEAT

Adjustments

Prior to starting engine adjust seat for position and comfort.

1. Suspension
clockwise to increase stiffness. Turn counterclockwise to reduce stiffness.

2. Fore/Aft

3. Seat Belt

seat belt is available.

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

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

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

3-20 31200608

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.

3-2131200608

Section 3 - Controls and Indicators

OV0290

21

AB DC

-10

0

10

20

30

40

50

6

0

7

0

80

3

OV0280

3.8 INDICATORS

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 5-4).

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

Transfer Carriage Extension

• The transfer carriage indicators (3) are located on the left main frame rail and
right cab wall. Use these indicators to determine transfer carriage extension
when using the capacity chart (see “Use of the Capacity Chart” on page 5-4).

3-22 31200608

Section 4 - Operation

SECTION 4 - OPERATION

4.1 ENGINE

Starting the Engine

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

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

2. If equipped with Cummins engine, turn the ignition switch to “RUN” position and
hold until engine air-intake preheat indicator 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 engine oil pressure gauge. If gauge remains on
zero for more than five seconds, stop engine and determine cause before
restarting engine.

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

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

WARNING

UNEXPECTED MOVEMENT HAZARD. Always ensure that transmission control

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

4-131200608

Section 4 - Operation

Cold Weather Starting Aids

John Deere Engine

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.

Cummins Engine

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

WARNING

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

4-2 31200608

Section 4 - Operation

OW0530

Battery Boosted Starting

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

• Never allow vehicles to touch.

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

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

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

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

• Follow standard starting procedures.

• Remove cables in reverse order after machine has started.

WARNING

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

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

4-331200608

Section 4 - Operation

Normal Engine Operation

• Observe gauges and indicators frequently to be sure all engine systems are
functioning properly.

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

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

Shut-Down Procedure

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

1. Apply the park brake.

2. Shift the transmission to “Neutral.”

3. Lower forks or attachment to the ground.

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

5. Shut off engine and remove ignition key.

6. Exit telehandler properly.

7. Block wheels (if necessary).

4-4 31200608

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 of the telehandler could damage 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 the terrain. Adjust travel speed and reduce amount of load
if conditions warrant.

• Avoid lifting double-tiered loads.

• Make sure load is clear of any adjacent obstacles.

• Adjust spacing of forks so they engage the pallet or load at maximum width. See
“Adjusting/Moving Forks” on page 5-12.

• 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.

4-531200608

Section 4 - Operation

OW0540

Transporting a Load

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

Leveling Procedure

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

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

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

4. Observe level indicator to determine whether machine must be leveled prior to
lifting load. Level machine with frame level joystick (see page 3-13) or outrigger
joysticks (see page 3-12).

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.

The telehandler is designed to permit leveling the main frame 10° to left or right to
compensate for uneven ground conditions.

4-6 31200608

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 and transfer carriage extension
range. See “Use of the Capacity Chart” on page 5-4.

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

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

• The transfer carriage can be used to place the load onto the landing point, being
certain the load is within the transfer limits.

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 or transfer carriage can
be retracted.

2. Lower the carriage.

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

4-731200608

Section 4 - Operation

4.3 OPERATING WITH A SUSPENDED LOAD

Lift Load Safely

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

WARNING

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

equipment and/or cause tip over.

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

Picking Up a Suspended Load

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

• Avoid lifting double-tiered loads.

• Make sure load is clear of any adjacent obstacles.

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

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

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

• Ensure to always properly tether loads to restrict movement.

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

4-8 31200608

Section 4 - Operation

OW0130

OZ3160

Transporting 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 and transfer carriage is fully retracted.

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

• 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 persons between the suspended load and the telehandler.

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

4. Observe level indicator to determine whether machine must be leveled prior to
lifting load. Level machine with frame level joystick (see page 3-13) or outrigger
joysticks (see page 3-12).

The telehandler is designed to permit leveling the main frame 10° to left or right to
compensate for uneven ground conditions.

4-931200608

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 and transfer carriage extension
range. See “Use of the Capacity Chart” on page 5-4.

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

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

• The transfer carriage can be used to place the load onto the landing point, being
certain the load is within the transfer limits.

Disengaging a Suspended Load

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

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

4-10 31200608

Section 4 - Operation

OV0300

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 controls 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 local, state or federal/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.

4-1131200608

Section 4 - Operation

Lifting

• When lifting machine, it is very important that the lifting device and equipment is
attached only to designated lifting points. If machine is not equipped with lifting
lugs contact JLG Product Safety for information.

• Make adjustments to the lifting device and equipment to ensure the machine will
be level when elevated. The machine must remain level at all times while being
lifted.

• Ensure that the lifting device and equipment is adequately rated and suitable for
the intended purpose. See Section 9 - Specifications for machine weight.

• Remove all loose items from machine prior to lifting.

• Lift machine with smooth, even motion. Set machine down gently. Avoid quick or
sudden motions that could cause shock loads to machine and/or lifting devices.

4-12 31200608

Section 5 - Attachments

SECTION 5 - ATTACHMENTS

5.1 APPROVED ATTACHMENTS

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

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

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

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

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

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

5.2 UNAPPROVED ATTACHMENTS

Do not use unapproved attachments for the following reasons:

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

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

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

WARNING

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

5-131200608

Section 5 - Attachments

5.3 JLG SUPPLIED ATTACHMENTS

Attachment Part Number

Carriage, 50 in (1270 mm)

Carriage, 60 in (1524 mm)

Carriage, 72 in (1829 mm)

Side Shift Carriage, 50 in (1270 mm) 1001142790 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) 10011086 68 X

8 ft Mast Carriage w/ Side Tilt, 50 in (1270 mm) 1001108670 X

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

Fork, Pallet 2.36x5x48 in(60x127x1220 mm) 2340038 X

Fork, Dual Taper 1.75x7x60 in (44x178x1524 mm) 2340046 X

Fork, Dual Taper 2.36x6x60 in (60x152x1524 mm) 2340039 X

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

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

Fork Extension, 90 in (2286 mm) 1001137512 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

Truss Boom, 12 ft (3658 mm) 1001099902 X

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

Truss Boom, 15 ft (4572 mm) 1001099901 X

Platform, Fork Mounted (ASME) 1001103637 X

Platform, Fork Mounted (ASME - French) 1001103736 X

Platform, Fork Mounted (ISO) 1001103730 X

3

3

3

3

1170021 X

1001146084 X

1170024 X

1001146086 X

1170027 X

1001132514 X

1001146088 X

1001100822 X

1001100823 X

1001100824 X

0930020 X

91565094 X

1001097205 X

Applicable

Model

1044C-54

5-2 31200608

Section 5 - Attachments

OW0550

3

2

1

5.4 TELEHANDLER/ATTACHMENT/FORK CAPACITY

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

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

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

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

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

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

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

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

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

WARNING

5-331200608

Section 5 - Attachments

OV0310

FT FT

150

cmcm

160170cm180cm190cm200

cm

65

-10

0

10

20

30

40

50

60

70

8

0

AB

BOOM

EXTENSION

INDICATOR

BOOM ANGLE

INDICATOR

ATTACHMENT

IDENTIFICATION

PLATE

FORK

WEIGHT

STAMP

TRANSFER CARRIAGE

EXTENSION INDICATORS

5.5 USE OF THE CAPACITY CHART

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

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

2. The proper Capacity Chart(s).

3. Weight of the load being lifted.

4. Load placement information:

a. HEIGHT where the load is to be placed.

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

placed.

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

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

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

Capacity Indicator Locations

5-4 31200608

Sample Capacity Chart

XXXXXXX

XXXXXXXXXX X

=XXXX XX MAX

XX MAX

X

XXXX XX MAX

XXXXXXXXXXXXXXXXXXXXXX

XX

XX

XX

XX

XX

XX

XX

XX

XX

XX

XX

XX

XX

XX

XX

XX

XX

XX

XXXX XX

XXXX XX

XXXX XX

XXXX XX

XXXX XX

XXXX XX

XX

OV0320

This Capacity Chart may be used with this model ONLY.

The telehandler model is indicated on the boom or chassis.

Model XXXXX 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

data shown.

Section 5 - Attachments

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

WARNING

5-531200608

Section 5 - Attachments

OH4410

OH4420

1"

80"

OW0910

0"

OW0920

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

• Use when lifting a load with outriggers up.

• Use when lifting a load with outriggers down.

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

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

5-6 31200608

Section 5 - Attachments

OY1710

0'

4'

8'

12'

16'

20'

24'

28'32'

36'40'

44'

-4'

0'

4'

8'

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°

1

2

3

4

5

6

7

8

9

10

XX

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:

• 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 (2722 kg) 18 ft (5,5 m) 12 ft (3,7 m) Yes

2 4000 lb (1814 kg) 30 ft (9,1 m) 26 ft (7,9 m) NO

3 7500 lb (3402 kg) 8 ft (2,4 m) 24 ft (7,3 m) Yes

4 5750 lb (2608 kg) 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.

5-731200608

Section 5 - Attachments

This Page Intentionally Left Blank

5-8 31200608

5.6 ATTACHMENT INSTALLATION

OY1540

1

2

3

4

5

6

1. Attachment

Section 5 - Attachments

2. Attachment Pin Recess

3. Attachment Pin

4. Lock Pin

5. Retaining Pin

6. Quick Switch

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

WARNING

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

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

5-931200608

Section 5 - Attachments

OY1550

OY1560

OY1570

OY1580

This installation procedure is designed for one-person operation. Prior to exiting cab,
perform “Shut-Down Procedure” on page 4-4.

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 retaining pin and insert lock pin completely
through quick switch. Release retaining pin and
ensure lock pin is secured.

5. If equipped, connect auxiliary hydraulic hoses. See “Hydraulic Operated
Attachment” on page 5-11.

5-10 31200608

Section 5 - Attachments

1

2

OV0330

Hydraulic Operated Attachment

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

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

3. Connect attachment hoses to both auxiliary fittings (1).

4. If equipped, connect attachment hoses to both second auxiliary fittings (2).

5-1131200608

Section 5 - Attachments

5.7 ADJUSTING/MOVING FORKS

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

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

To slide forks:

1. Ensure attachment is properly installed. See “Attachment Installation” on
page 5-9.

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).

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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.

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.

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Section 5 - Attachments

OY0690

OV0340

2

1

Carriage w/Forks

Use Carriage Attachment Capacity Chart

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

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

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

The front 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 5-9.

Equipment Damage Precautions:

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

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

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Section 5 - Attachments

This Page Intentionally Left Blank

5-1531200608

Section 5 - Attachments

OAL1550

OV0350

2

1

3

Side Tilt Carriage

Use Side Tilt Carriage Attachment Capacity Chart

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

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

The front joystick (2) controls fork tilt.

• Move joystick back to tilt up.

• Move joystick forward to tilt down.

To Side Tilt:

The auxiliary hydraulic button (3) on the front joystick enables carriage side tilt.

• While depressing button move joystick left to (side) tilt left.

• While depressing button move joystick right to (side) tilt right.

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Section 5 - Attachments

Installation Procedure:

• Refer to “Attachment Installation” on page 5-9.

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.

Equipment Damage Precautions:

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

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

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Section 5 - Attachments

OV0670

Side Shift Carriage

Use Side Shift Carriage Attachment Capacity Chart

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

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

The front joystick (2) controls fork tilt.

• Move joystick back to tilt up.

• Move joystick forward to tilt down.

To Side Shift:

The auxiliary hydraulic button (3) on the front joystick enables carriage side shift.

• While depressing button move joystick left to (side) shift left.

• While depressing button move joystick right to (side) shift right.

5-18 31200608

Section 5 - Attachments

Installation Procedure:

• Refer to “Attachment Installation” on page 5-9.

WARNING

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

comply could cause object or load to fall.

Operation:

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

• Level telehandler before side shifting carriage to engage load.

• Side shift 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.

Equipment Damage Precautions:

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

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

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Section 5 - Attachments

OZ3670

OV0680

Dual Fork Positioning Carriage

Use Carriage Load Chart

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

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

The front joystick (2) controls fork tilt.

• Move joystick back to tilt up

• Move joystick forward to tilt down.

To Fork Position:

The auxiliary hydraulic button (3) controls fork position.

• While depressing button, move joystick left to shift forks out.

• While depressing button, move joystick right to shift forks in.

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Section 5 - Attachments

Installation Procedure:

• Refer to “Attachment Installation” on page 5-9.

WARNING

CRUSH HAZARD. Do not use fork positioning to push or pull objects or load.

Failure to comply could cause object or load to fall.

Operation:

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

Equipment Damage Precautions:

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

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

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Section 5 - Attachments

OZ0750

OV0340

2

1

Fork Extension

Use Appropriate Carriage Attachment Capacity Chart

To determine maximum capacity, refer to “Telehandler/Attachment/Fork Capacity” on
page 5-3. The maximum capacity of the carriage when equipped with fork
extensions may be reduced to the capacity indicated on the fork extensions. If the
load exceeds the capacity of the fork extension contact JLG to obtain forks and/or
fork extensions of the proper load rating and length.

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

The front joystick (2) controls fork tilt.

• Move joystick back to tilt up.

• Move joystick forward to tilt down.

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Section 5 - Attachments

Installation Procedure:

• Ensure carriage is properly installed. Refer to “Attachment Installation” on
page 5-9.

• Ensure length and cross section of the parent fork arm is equal to or exceeds the
parent fork arm blade length stamped into the fork extension.

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

Operation:

• Heavy part of load must be against carriage backrest.

• Do not allow load center of gravity to be in front of tip of the supporting fork.

• Do not pick up a load or pry materials with tip of fork extensions.

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Section 5 - Attachments

OU2150

OV0360

2

1

3

Swing Carriage

Use Swing Carriage Attachment Capacity Chart

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

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

The front joystick (2) controls fork tilt.

• Move joystick back to tilt up.

• Move joystick forward to tilt down.

To Swing:

The auxiliary hydraulic button (3) on the front joystick enables the swing function.

• While depressing button move joystick left to swing left.

• While depressing button move joystick right to swing right.

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Section 5 - Attachments

Installation Procedure:

• Refer to “Attachment Installation” on page 5-9.

WARNING

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

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

WARNING

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

Failure to comply could cause object or load to fall.

WARNING

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

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

Operation:

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

Equipment Damage Precautions:

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

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

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Section 5 - Attachments

OY0580

OV0370

2

1

3

Mast Carriage

Use Mast Carriage Attachment Capacity Chart

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

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

The front joystick (2) controls fork tilt.

• Move joystick back to tilt up.

• Move joystick forward to tilt down.

To Raise/Lower Mast:

The auxiliary hydraulic button (3) on the front joystick enables the raise/lower
movement of the mast.

• While depressing button move joystick left to lower.

• While depressing button move joystick right to raise.

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Section 5 - Attachments

Installation Procedure:

• Refer to “Attachment Installation” on page 5-9.

WARNING

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

comply could cause object or load to fall.

Operation:

• Always lower forks fully in mast before engaging load.

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

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

Equipment Damage Precautions:

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

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

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Section 5 - Attachments

OY0590

WARNING

OV0381

Mast Carriage w/Side Tilt

Use Mast Carriage Attachment Capacity Chart

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

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

The front joystick (2) controls fork tilt.

• Move joystick back to tilt up.

• Move joystick forward to tilt down.

To Raise/Lower Mast:

The auxiliary hydraulic button (3) on the front joystick enables the raise/lower
movement of the mast.

• While depressing button move joystick left to lower.

• While depressing button move joystick right to raise.

To Side Tilt:

The auxiliary hydraulic button (4) on the middle joystick enables carriage side tilt.

• While depressing button move joystick left to (side) tilt left.

• While depressing button move joystick right to (side) tilt right.

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Section 5 - Attachments

Installation Procedure:

• Refer to “Attachment Installation” on page 5-9.

WARNING

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

comply could cause object or load to fall.

WARNING

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

comply could cause object or load to fall.

Operation:

• Always lower forks fully in mast before engaging load.

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

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

Equipment Damage Precautions:

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

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

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Section 5 - Attachments

Fork Mounted Hook

Use Appropriate Carriage Attachment Capacity Chart

To determine maximum capacity, refer to “Telehandler/

OY0640

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

Attachment/Fork Capacity” on page 5-3.

2

1

OV0390

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

The front joystick (2) controls fork tilt.

• Move joystick back to tilt up.

• Move joystick forward to tilt down.

5-30 31200608

Section 5 - Attachments

Installation Procedure:

• Ensure carriage is properly installed. Refer to “Attachment Installation” on
page 5-9.

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

Operation:

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

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

• Do not use with mast carriage attachment.

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

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Section 5 - Attachments

OY0570

OV0400

2

1

3

Truss Boom

Use Appropriate Truss Boom Attachment Capacity Chart

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

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

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

The front joystick (2) controls truss boom tilt.

• Move joystick back to tilt up.

• Move joystick forward to tilt down.

Winch Control (if equipped):

The auxiliary hydraulic button (3) on the front joystick enables the truss boom
mounted winch.

• While depressing button move joystick left to lower cable.

• While depressing button move joystick right to raise cable.

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