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Operation 31200172

1. 91143290 80603037 80603037 91553072 E 12345678910 80603037 91143282 VIEW B B 0 0092 VIEW 31200172 2 5 Section 2 Pre Operation and Inspection 2 3 WALK AROUND INSPECTION 18 1 2 17 3 16 4 1 15 14 13 5 6 7 t o 8 11 9 10 2 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 wear pads for presence of grease Pivot pins secure hydraulic hoses undamaged not leaking 2 Left Outrigger Pins secure hydraulic hoses and cylinder undamaged not leaking 3 Front Axle Pivot pins secure hydraulic hoses unda
2. 0 0371 The Lubrication and Maintenance Decal 1 contains instructions that must be followed to keep this product in good operating condition The Operation amp Safety Manual and Service Manual contain more detailed service information with specific instructions Clothing and Safety Gear Wear all the protective clothing and personal safety devices issued to you or called for by job conditions DO NOT wear loose clothing or jewelry that can get caught on controls or moving parts 31200172 74 Section 7 Lubrication and Maintenance 7 2 GENERAL MAINTENANCE INSTRUCTIONS Prior to performing any service or maintenance on the telehandler follow the shut down procedure on page 4 4 unless otherwise instructed Ensure telehandler is level for proper fluid readings Clean lubrication fittings before lubricating After greasing telehandler cycle all functions several times to distribute lubricants Perform this maintenance procedure without attachment installed Apply a light coating of engine oil to all linkage pivot points ntervals shown are for normal usage and conditions Adjust intervals for abnormal usage and conditions Drain engine and gear cases after operating when oil is hot Check all lubricant levels when lubricant is cool For ease of filling hydraulic reservoir use a funnel with a hose or flexible tube for best results Note Be certain
3. OX0180 1 Be sure all cylinders are fully retracted and machine is level 2 Perform Shut Down Procedure on page 4 4 3 Check level of hydraulic oil at the sight gauge 6 on the hydraulic tank b The oil level should be visible in the gauge window 4 If hydraulic oil is low open the tank cover and remove oil fill cap 7 from filler neck Add hydraulic fluid to bring oil up to the upper mark on the sight gauge 5 Replace hydraulic oil fill cap 6 Close and secure the tank cover 31200172 7 13 Section 7 Lubrication and Maintenance Tires A Tire Air Pressure Check 1 0 6 9 QUOTE OW1040 1 Perform Shut Down Procedure on page 4 4 2 Remove valve stem cap 3 Check tire pressure 4 Add air if required 14 00 x 24 G 2 L 2 Bias Ply Traction 12 Ply 65 psi 4 5 bar 14 00 x 24 G 2 L 2 Radial 1 70 psi 4 8 bar 14 00 x 24 G 3 L 3 Bias Ply Rock 12 70 psi 4 8 bar 5 Replace valve stem cap B Tire Damage For pneumatic tires when any cut rip or tear is discovered that exposes sidewall or tread area cords in the tire measures be taken to remove the product from service immediately Arrangements must be made for replacement of the tire or tire assembly For polyurethane foam filled tires when any of the following are discovered measures
4. 2340046 Fork Pallet 2x6x60 in Before S N 0160037689 90601015 Fork Pallet 2x6x60 in Before S N 0160037689 91163269 Fork Dual Taper 2 36x6x60 in S N 0160037689 amp After 2340039 Fork Pallet 2x6x72 in Before S N 0160037689 90553018 Fork Pallet 2x6x72 in Before S N 0160037689 91123132 Fork Dual Taper 2x6x72 in S N 0160037689 amp After 1001092391 Use Side Tilt Carriage Attachment Capacity Chart To determine maximum capacity refer to Telehandler Attachment Fork Capacity on page 5 3 lt 7 oe Nae 7 lt 2 1 3 a 2 OX0311 5 20 31200172 Section 5 Attachments The joystick 1 controls lift lower and extend retract movement of the boom The tilt lever 2 controls the carriage tilt Move lever back to tilt up Move lever forward to tilt down To Side Tilt The auxiliary hydraulic lever 3 controls the carriage side tilt Move lever up to side tilt left Move lever down to side tilt right Installation Procedure Referto Attachment Installation on page 5 11 A 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 te
5. 98 8 in 2510 mm Cab Width 1 5 223 31 GER ie ve doh a diet depo dae 32 7 in 831 mm Track Width eee etes e 83 in 2108 mm Wheelbase m e e db emere tees 135 in 3429 mm Length at Front Wheels 189 6 in 4816 mm Overall Length less 241 3 in 6129 mm Ground Clearance eee eoe etie ania nein 20 8 in 528 mm Outside Turning Radius senem 175 in 4445 mm Maximum Gross Vehicle Weight no attachment 33 779 Ib 15 322 kg Maximum Front Axle Weight no attachment boom level and fully retracted 17 058 Ib 7737 kg Maximum Rear Axle Weight no attachment boom level and fully retracted 16 721 Ib 7585 kg Maximum Ground Bearing Pressure 177 Ib in 12 4 kg cm 9 4 31200172 A Additional Checks 8 1 Adjusting Moving Forks 5 15 Approved Attachments 5 1 Attachment Installation 5 11 Attachment Operation 5 16 Attachment Tilt 3 8 3 9 3 11 Attachments 22 5 1 Auxiliary Hydraulics 3 9 3 11 AXIOS oisi ee RD REUS 9 1 B 222 7 19 Boom Angle Indicator
6. 6 1 Transmission Control Lever 3 7 Transport ie ere 4 12 2 2 2 0 4 11 Transporting a Load 4 6 Transporting a Suspended Load 4 9 Travel 1 6 Truss 5 34 Walk Around Inspection 2 6 Warm Up 2 8 Wheel Installation 7 16 Wheel Lug Nut sees 9 2 Wheel Replacement 7 15 WINDOWS nme 2 10 31200172 Inspection Maintenance and Repair Log Serial Number Date Comments Inspection Maintenance and Repair Log Date Comments AL TRANSFER OF OWNERSHIP An Oshkosh Corporation Company To Product Owner If you now own but ARE NOT the original purchaser of the product covered by this manual we would like to know who you are For the purpose of receiving safety related bulletins it is very important to keep JLG Industries Inc updated with the current ownership of all JLG products JLG maintains owner information for each JLG product and uses this informatio
7. Approx 623 Ib 283 kg FOAM iioc eet ain AR Ge eerta Approx 720 Ib 327 kg TOI QUO scc occid c etf ttr tel emet 350 400 Ib ft 475 543 Nm 9 2 31200172 Section 9 Specifications Performance Maximum Lift Capacity 10 000 Ib 4536 kg Maximum Lift 044 0 55 ft 16 8 m Capacity at Maximum Height Outriggers Engaged 2 5 000 Ib 2268 kg Outriggers Not 4 000 Ib 1814 kg Maximum Forward 42 ft 12 8 m Capacity at Maximum Forward Reach Outriggers Engaged Before S N 0160037689 3 000 Ib 1361 kg S N 0160037689 amp 2 400 Ib 1089 kg Outriggers Not 0 40 4 O Ib 0 kg Reach at Maximum 8 5 ft 2 6 m Maximum Travel Speed sese 19 mph 30 6 kmph Towing Capacily 5 EE a tepido utei e en 10 000 Ib 4536 kg Framie Leveling 5 I dee RAKE ce dr p i ere 8 degrees Maximum Travel Grade Gradeability ae ble RENI ea ni I 45 Side Slope rade duse e ined 8 75 31200172 9 3 Section 9 Specifications Dimensions Overall Height 2 5 sleet tete eee tod 98 in 2489 mm Overall
8. 3 16 Boom Extension Indicator 3 16 Boom Head Mounted Winch 5 40 Boom Joystick 3 8 B cket epe 5 36 1 1 9 1 Capacity 5 3 Capacity Chart 5 10 5 6 Capacity Indicator Locations 5 4 Carriage w Forks 5 18 Chemical Hazards 1 13 Cold Weather Starting Aids 4 2 3 2 Cooling System 9 1 D D cals 2 3 2 2 9 4 Disengaging a Load 4 7 Disengaging a Suspended Load 4 10 Driving Hazards on Slopes 1 9 31200172 E Electrical Hazards 1 2 Emergency Exit from Enclosed 6 2 Emergency Lowering of Boom 6 2 Emergency Procedures 6 1 Engine Normal Operation 4 4 Startitig eet etm 4 1 Engine Coolant Level 7 18 Engine Crankcase Oil 9 1 Engine Oil Level 7 12 F Fall Hazardg deren 1 12 Fork Mounted Hook 5 30 5 32 Frame 3 9 3 11 Fuel 7 8 Fuel 9 1
9. 4 3 Normal Engine 4 4 Shut Down Procedure sssseeenenee 4 4 4 2 Operating with a Non Suspended Load 4 5 Lift Load Safely sss 4 5 Picking Up a 4 5 Transporting Load 4 6 Leveling 4 6 Placing 4 7 Disengaging 4 7 4 3 Operating with a Suspended 4 8 Lift Load 4 8 Picking Up a Suspended 4 8 Transporting a Suspended 4 9 Leveling 4 9 Placing a Suspended 4 10 Disengaging a Suspended Load 4 10 4 4 Loading and Securing for 4 11 BU 4 11 Minnie 4 12 Section 5 Attachments 5 1 Approved Attachments 5 1 5 2 Unapproved 5 2 5 3 Telehandler Attachment Fork Capacity 5 3 5 4 Use of the Capacity 5 4 Capacity Indicato
10. 7 18 aie ano net ei eme 7 19 iii Table of Contents Section 8 Additional Checks Section 9 Specifications 9 1 Product 0 4 4 8 9 1 Fluid and Lubrication Capacities 9 1 ree 9 2 9 3 DIMENSIONS eere nie fete aa s Ho ho ave ees 9 4 Index Inspection Maintenance and Repair Log iv 31200172 Section 1 General Safety Practices SECTION 1 GENERAL SAFETY PRACTICES 1 4 HAZARD CLASSIFICATION SYSTEM Safety Alert System and Safety Signal Words A DANGER fi DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury A WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION 8 CAUTION indicates a potentiality hazardous situation which if not avoided may result in minor or moderate injury 1 2 GENERAL PRECAUTIONS A 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 31200172 1 1 Section 1 General Safety Practices 1 3 OPERATION SAFETY Electrical Hazards OS T e This machine is not insulated and does not provide pr
11. 3 6 Performance 9 3 Personnel Work Platform 5 41 5 42 Picking Up a Load 4 5 Picking Up a Suspended Load 4 8 Pinch Points and Crush Hazards 1 10 Placing a 1 4 7 Placing a Suspended Load 4 10 Pre Operation Check and Inspection epe ts 2 1 R Restriction 7 10 Return Filter Indicator 7 17 2 S Safety 2 3 Safety Practices 1 1 Safety Signal Words 1 1 Seat 3 15 Service Maintenance Schedule TO EQUI rrr tco 7 3 1000 7 5 1500 2 0 tees 7 5 16 50 HOUr 5 anne 7 3 250 Hour eR 7 4 Se 7 4 500 et 7 4 Shut Down Procedure 4 4 Side Tilt Carriage 5 20 Specifications ss 9 1 Swing 5 22 T Tip Over 1 3 oct 7 14 9 2 Air 7 14 Damage 7 14 7 15
12. 90553005 Fork Dual Taper 1 75x7x60 in S N 0160037689 amp After 2340046 Fork Pallet 2x6x60 in Before S N 0160037689 90601015 Fork Pallet 2x6x60 in Before S N 0160037689 91163269 Fork Dual Taper 2 36x6x60 in S N 0160037689 amp After 2340039 Fork Pallet 2x6x72 in Before S N 0160037689 90553018 Fork Pallet 2x6x72 in Before S N 0160037689 91123132 Fork Dual Taper 2x6x72 in S N 0160037689 amp After 1001092391 100 Drywall Swing Carriage Before S N 0160037689 90555013 Use Swing Carriage Attachment Capacity Chart To determine maximum capacity refer to Telehandler Attachment Fork Capacity on page 5 3 lt A 7 4 1 3 O 2 Ze E OX0301 m o 5 22 31200172 Section 5 Attachments The joystick 1 controls lift lower and extend retract movement of the boom The tilt lever 2 controls the carriage tilt Move lever back to tilt up Move lever forward to tilt down To Swing The auxiliary hydraulic lever 3 controls the carriage swing Move lever up to swing left Move lever down to swing right Installation Procedure Referto Attachment Installation on page 5 11 A WARNING CRUSH HAZARD Always level fork
13. T o Ox0281 The joystick 1 controls lift lower extend retract movement of the boom The auxiliary hydraulic lever 3 controls the winch Move lever up to lower cable Move lever down to raise cable A WARNING CRUSH HAZARD Maintain a minimum of three wraps of wire rope on the cable drum at all times Failure to comply could cause object or load to fall 5 40 31200172 Section 5 Attachments Personnel Work Platform Before S N 0160037689 The operator and personnel in platform must read and understand the separate personnel work platform manual prior to installing and using a platform Preparation and Setup 1 Check to ensure the personnel platform is securely attached at the quick switch or is securely attached to the forks and or carriage if using fork mounted personnel work platform Follow installation procedure on page 5 11 for JLG quick switch mounted personnel work platforms Ensure the telehandler is on a firm surface and is level Engage the park brake Blocking the wheels is also recommended Level the platform both side to side frame level and front to back attachment tilt Keep area under the platform free from personnel When personnel are on platform the operator must remain seated in cab with personnel in direct line of sight DO NOT lift or carry persons in the bucket or on forks A WARNING FALL HAZARD Never tilt the pla
14. A 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 6 31200172 Section 3 Controls and Indicators Transmission Control Lever OX0083 3 Transmission control lever 4 engages forward or reverse travel Lift and push lever forward for forward travel lift and pull lever rearward for reverse travel Move lever to centered position for neutral When traveling in reverse the back up alarm will automatically sound Drive in reverse and turn only at slow rates of speed Do not increase engine speed with the transmission in forward or reverse the service brake depressed in an attempt to get quicker hydraulic performances This could cause unexpected machine movement A 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 31200172 3 7 Section 3 Controls and Indicators Boom Joystick IF EQUIPPED Ox0060
15. 1 Perform Shut Down Procedure on page 4 4 2 Locate air cleaner 1 and check restriction indicator 2 If red band is visible filter s must be replaced 3 Remove dust from vacuator valve 3 by squeezing bottom of valve to allow loose particles to fall out Note Only remove canister cover to service the elements as restriction indicator indicates Excessive access to check an element can lead to premature element failure 7 10 31200172 Section 7 Lubrication and Maintenance B Element Change as restriction indicator indicates 1 Unlock air cleaner cover 4 turn counterclockwise and remove from air cleaner canister 5 Remove outer primary element 6 and inspect for damage Damaged elements should not be reused Thoroughly clean the interior of the air cleaner canister and vacuator valve Replace inner safety element 7 after every third primary element change If replacing the inner safety element at this time carefully slide the element out and replace with new element Slide the new primary element over the inner element making sure the sealing edge is flush with the base of the air cleaner Position air cleaner cover in place turn clockwise and lock into position Depress button on restriction indicator to reset Note An inner safety element should never be washed or reused Always install a new element 31200172 7 11 Section 7 Lubrication and Maintenance Engine Oil A Engine O
16. The boom joystick 1 controls the boom and attachment tilt if equipped functions Boom Functions Move the joystick back to lift boom move joystick forward to lower boom move joystick right to extend boom move joystick left to retract boom The speed of boom functions depends upon the amount of joystick travel in corresponding direction Increasing engine speed will also increase function speed For two simultaneous boom functions move the joystick between quadrants For example moving the joystick forward and to the left will lower and retract boom simultaneously Attachment Tilt if equipped Tilt control is actuated by the switch 2 Depress the rear of the switch to tilt up depress the front of switch to tilt down A 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 8 31200172 Section 3 Controls and Indicators Right Hand Levers if equipped A ATTACHMENT TILT 2 FRAME LEVEL AUXILIARY HYDRAULICS LEFT DOWN AUXILIARY HYDRAULICS AUXILIARY OxX0660 HYDRAULICS The right hand levers control attachment tilt frame level or auxiliary hydraulics Attachment Tilt if equipped The attachment tilt lever 3 controls attachment tilt Move lever forward to tilt down move lever b
17. on the attachment ID Plate Note This is a sample capacity chart only DO NOT use this chart use the one located in your operator cab A WARNING TIP OVER HAZARD All loads shown on rated capacity chart are based on machine being on firm ground with frame level see page 4 6 the forks being positioned evenly on carriage the load being centered on forks proper size tires being properly inflated and the telehandler being in good operating condition 5 6 31200172 Section 5 Attachments To identify the proper capacity chart on telehandlers equipped with outriggers refer to the following icons which may be located on the capacity chart Use when lifting a load with outriggers up Use when lifting a load with outriggers down 4 2 31200172 57 Section 5 Attachments S N 0160037689 amp After This Capacity Chart may be used with this model ONLY The telehandler model is indicated on the boom or chassis Model is used for demonstration purposes only Attachment type weight and dimensions must be equal to or less than the data shown Boom Angle OY1520 Load zones indicate the Load center must maximum weight that be equal to or less may be safely lifted than value shown Note This is a sample capacity chart only DO NOT use this chart use the one located in your operator cab A WARNING TIP OVER HAZARD All loa
18. 2 2 8 Operational 2 8 Operator 2 9 e Re s 2 10 Cab Door Window if 2 10 Controls and Indicators wai eset 3 1 Controls 3 2 Dash Controls 3 3 INNON ET 3 5 Park Brakes aie edd tees 3 6 Parking Procedure 3 6 Transmission Control 3 7 Boom 3 8 Right Hand Levers if 3 9 Table of Contents Outrigger 3 10 Left Hand Lever if 3 11 Heater if 3 12 3 3 Operator 2 000 0 3 13 3 13 Seat Bell ceeds nese 3 15 3 4 Boom Angle and Extension Indicators 3 16 Section 4 Operation 4 1 Engine niece certe ce eec ed e bee eade 4 1 Starting the 4 1 Cold Weather Starting Aids 4 2 Battery Boosted
19. 2 Check hydraulic return filter indicator with engine at normal operating temperature 3 Have an assistant open the tank cover 4 With the engine at full throttle and the assistant observing the indicator 2 located on the hydraulic return filter 1 extend and retract the boom 10 to 12 ft 3 0 to 3 7 m The bar gauge should be within the green area 5 Replace filter before the gauge reaches the red area on the indicator If it reaches the red area the filter is too dirty and hydraulic oil is bypassing the filter 6 Close and secure the tank cover 31200172 7 17 Section 7 Lubrication and Maintenance Engine Cooling System A Engine Coolant Level Check 50 0980 OW1070 JOHN DEERE ENGINE CUMMINS ENGINE 1 2 fh 4 H ne rT OX0641 1 Perform Shut Down Procedure on page 4 4 2 Open the engine cover 3 John Deere When coolant is cool remove cap 1 Check coolant level in radiator Cummins Check coolant level in overflow bottle 2 When coolant is hot bottle should be 1 2 to 3 4 full When coolant is cool bottle should be 1 4 to 1 2 full 4 If coolant is low add coolant 50 50 mixture of ethylene glycol and water as required 5 Replace cap 6 Close and secure the engine cover 7 18 31200172
20. Description P N Fork Mounted 91565094 Use Fork Mounted Hook 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 o o Ox0261 The joystick 1 controls lift lower extend retract movement of the boom The tilt lever 2 controls the fork mounted hook tilt Move lever back to tilt up Move lever forward to tilt down Installation Procedure Refer to Attachment Installation on page 5 11 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 5 32 31200172 Section 5 Attachments Operation Pallet or lumber forks of an appropriate load rating must be used Do not use with cubing or block forks Weight of rigging must be included as part of total load being lifted Do not use fork mounted hook with attachments capable of rotating i e side tilt and swing carriages without disabling the rotation feature s 31200172 5 33 Section 5 Attachments Truss Boom Description P N Truss Boom 10 ft Before S N 0160037689 90455011 Truss Boom 10 ft w winch Before S N 0160037689 90455012 Truss Boom 10 ft w winch reevin
21. Fuel Water Separator 7 9 G General Maintenance 7 2 Grapple 5 38 H Hazard Classification System 1 1 Heatet tes 3 12 Hydraulic Level 7 13 Hydraulic Operated Attachment 5 14 Hydraulic System 9 1 Ignition ere 3 5 L Left Hand 3 11 Leveling Procedure 4 6 4 9 Lifting Personnel 1 8 Load Falling Hazard 1 7 1 Index Lubrication and Maintenance 7 1 Lubrication Schedule 250 HOUF sienna 7 7 SO HOU eei 7 6 M Mast 5 24 Mast Carriage w Side Tilt 5 28 Mast Carriage w Swing and 5 26 Operating with Non Suspended 4 5 Operating with Suspended Load 4 8 Operation Men ttt 4 1 Operational 2 8 Operator 2 9 Operator Maintenance Instructions 7 8 Operator 3 13 Outrigger 3 10 Park 3 6 Parking Procedure
22. John Deere Engine 10 11 5 2 3 46 z 0 11 22 40 7 S 7 111109 OX0034 Park Brake Indicator See page 3 6 for details 4 in 1 Gauge a Engine Coolant Temperature Gauge b Engine Oil Pressure Gauge c Fuel Gauge d Voltmeter indicates alternator output and battery condition Heater Switch if equipped See page 3 12 for details Shutdown Override Switch Depress and release to delay 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 Hourmeter Indicates total time of engine operation in hours and tenths of hours 4x2 4x4 Switch Engages and disengages rear wheel drive motors Rear drive motors are engaged for four wheel drive Park Brake Switch See page 3 6 for details Auxiliary Electrics Switches if equipped Enables functions of attachments that require auxiliary electrics See Section 5 Attachments for approved attachments and control instructions 4x4 Indicator Illuminates when four wheel drive is engaged The indicator will not illuminate when park brake is applied Check Engine Indicator Illuminates for 30 seconds before engine shuts down when a Shutdown fault is detected Indi
23. OX0321 The joystick 1 controls lift lower and extend retract movement of the boom The tilt lever 2 controls the mast tilt Move lever back to tilt up Move lever forward to tilt down To Swing Pull Swing Switch 5 located on dash panel 4 to activate Swing function The auxiliary hydraulic lever 3 controls the carriage swing Move lever up to swing left Move lever down to swing right 5 26 31200172 Section 5 Attachments To Raise Lower Mast Pull Mast Raise Lower Switch 6 located on dash panel to activate Mast Raise Lower function The auxiliary hydraulic lever controls the mast raise lower function Move lever up to lower Move lever down to raise To Side Shift Push Side Shift Switch 7 located on dash panel to activate Side Shift function The auxiliary hydraulic lever controls the carriage side shift Move lever up to shift left Move lever down to shift right Installation Procedure Referto Attachment Installation on page 5 11 A 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 A WARNING CRUSH HAZARD Do not use mast to push or pull objects or load Failure to comply could cause object or load to fall Operation Always lower forks fully in mast and position forks straight ahead before engaging load To drive with a load
24. 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 N Attachments Accessories Ensure correct capacity charts are installed on the telehandler If provided reference the Operation amp Safety Manual of each attachment or accessory installed for specific inspection operation and maintenance instructions 31200172 24 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 A 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 31200172 Section 2 Pre Operation and Inspection 2 2 SAFETY DECALS Ensure all DANGER WARNING CAUTION and instructional decals and proper capacity charts are legible and in place Clean and replace as required 1705882 1705881 S N 0160003969 S N 0160036260 thru 0160035922 amp After 91303
25. Cummins Ehgine racconti 22 quarts 20 8 liters Type Of 50 50 ethylene glycol amp water Hydraulic System System Capacity anc s cede dence ettet gestus 50 gallons 189 liters Reservoir Capacity to Full 30 gallons 113 5 liters Type 22 2 4242 Mobilfluid 424 Tractor Hydraulic Fluid ISO 46 Axles Housing Capacity Front Axle 16 5 quarts 15 6 liters Hub Capacity Front and Rear Axle 1 5 quarts 1 4 liters Type of Mobilfluid 424 Tractor Hydraulic Fluid ISO 46 31200172 9 1 Section 9 Specifications Tires 14 00 x 24 G 2 L 2 Bias Ply Traction 12 Ply Meee beue 65 psi 4 5 bar Water and Calcium Chloride Approx 623 Ib 283 kg FOAM CET Approx 720 Ib 327 kg 14 00 x 24 G 2 L 2 Radial 1 Star Pneumatic tec de e eee ca 70 psi 4 8 bar Water and Calcium Chloride Approx 623 Ib 283 kg andae ae tet Approx 720 Ib 327 kg 14 00 x 24 G 3 L 3 Bias Ply Rock 12 Ply ERI DE 70 psi 4 8 bar Water and Calcium Chloride
26. 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 amp Safety Manual Telehandler Safety Manual as required Allinstructional 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 31200172 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 safety related bulletins which may have been issued for this product JLG Industrie
27. lower forks fully in mast keep forks pointed forward and travel in accordance with the requirements set forth in Section 1 General Safety Practices e 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 31200172 5 27 Section 5 Attachments Mast Carriage w Side Tilt S N 0160037689 amp After Description P N 8 ft Mast Carriage with Side Tilt 1001108669 Fork Block 2x2x48 2340037 Fork Pallet 2 36x4x48 in 2340045 Fork Pallet 2 36x5x48 2340038 9Y09 Fork Dual Taper 1 75x7x60 2340046 Fork Dual Taper 2 36x6x60 2340039 Fork Dual Taper 2 6 72 1001092391 Use Mast Carriage Attachment Capacity Chart To determine maximum capacity refer to Telehandler Attachment Fork Capacity on page 5 3 2 7 r 7 A 0X0750 The joystick 1 controls lift lower and extend retract movement of the boom The tilt lever 2 controls the mast tilt M
28. must be taken to remove the product from service immediately Arrangements must be made for replacement of the tire or tire assembly a smooth even cut through the cord piles which exceeds 3 in 7 5 cm in total length any tears or rips ragged edges in the cord plies which exceeds 1 in 2 5 cm in any direction any punctures which exceed 1 in 2 5 cm in diameter If a tire is damaged but within the above noted criteria the tire must be inspected daily to ensure the damage has not propagated beyond the allowable criteria 7 14 31200172 Section 7 Lubrication and Maintenance C Tire and Wheel Replacement It is recommended that a replacement tire to be the same size ply and brand as originally installed Refer to the appropriate parts manual for ordering information If not using an approved replacement tire the replacement tires must have the following characteristics Equal or greater ply load rating and size of original Tire tread contact width equal or greater than original Wheel diameter width and offset dimensions equal to the original Approved for the application by the tire manufacturer including inflation pressure and maximum tire load Unless specifically approved by JLG do not replace a foam filled or ballast filled tire assembly with a pneumatic tire Due to size variations between tire brands when selecting and installing a replacement tire ensure both tires on the axle are the same The r
29. 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 A WARNING ENGINE EXPLOSION Do not use ether for cold weather starting 4 2 31200172 Section 4 Operation Battery Boosted Starting A OW0530 If battery boost starting jump start is necessary proceed as follows Never allow vehicles to touch Connect the positive jumper cable to positive post of discharged battery Connect the opposite end of positive jumper cable to positive post of booster battery Connect the negative jumper cable to negative post on booster battery Connect opposite end of negative jumper cable to ground point on machine away from discharged battery Follow standard starting procedures Remove cables in reverse order after machine has started A 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 31200172 4 3 Section 4 Operation Normal Engine Operation Observe instrument panel frequently to be s
30. tilt 4 Keep area under platform free from personnel 5 When personnel are on platform the operator must remain seated in cab with personnel in direct line of sight 6 DO NOT lift or carry persons in a bucket or on forks A WARNING FALL HAZARD Never tilt the platform forward rearward or level the machine when the platform is occupied 31200172 5 43 Section 5 Attachments This Page Intentionally Left Blank 5 44 31200172 Section 6 Emergency Procedures SECTION 6 EMERGENCY PROCEDURES 6 1 TOWING A DISABLED PRODUCT The following information assumes the telehandler cannot be moved under its own power Before moving the telehandler read all of the following information to understand options available Then select the appropriate method Machine mounted retrieval devices provide suitable means to attach a tow chain or tow bar only in the event the telehandler becomes stuck or disabled Retrieval devices are not intended for trailer towing devices The steering system permits manual steering if engine or power assist feature fails however steering will be slow and will require much greater force DO NOT attempt to tow a telehandler that is loaded or the boom attachment is raised above 4 ft 1 2 m Moving Short Distances f it is only necessary to move telehandler a short distance less than 100 ft 30 m it is permissible to use a vehicle of sufficient capacity to tow the uni
31. 00172 Section 5 Attachments Operation Raise or lower boom to appropriate height and open grapple for loading material from stockpile Align telehandler with face of stockpile and drive slowly and smoothly into pile to load bucket Tilt bucket up far enough to retain load close grapple and back away from pile Travel in accordance with requirements set forth in Section 1 General Safety Practices Open grapple and tilt bucket down to dump load Equipment Damage Precautions Except for lifting or dumping a load the boom must be fully retracted for all bucket operations Do not corner load bucket Distribute material evenly within the bucket Bucket capacity charts are for evenly distributed loads only Do not use bucket as a lever to pry material Excessive prying forces could damage bucket or machine structure Do not attempt to load material which is hard or frozen This could cause severe damage to quick switch or machine structure Do not use bucket for back dragging This could cause severe damage to quick switch and retraction cables chains 31200172 5 39 Section 5 Attachments Boom Head Mounted Winch Before S N 0160037689 P N 91165011 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 b
32. 047 TO 90553028 80603022 A DANGER s OX0780 VIEW A A 31200172 2 3 Section 2 Pre Operation and Inspection 91143280 91 91169130 S N 0160027211 BEFOR thru 0160035922 91143284 S N 01 50030260 91143282 91143281 91143280 BEFORE S N 0160027211 91083492 91143288 91143286 BEFORE BEFORE 91143282 S N 0160036260 S N 0160036260 91143162 A ej WARNING 1706300 S N 0160036260 amp AFTER VIEW OF CAB DASH WARNING 91143182 DO NOT ENGAGE PARK WHILE MACHINE IS IN STATIC BRAKE ONLY 91163212 91343016 g FORWARD TRACTION LOCK SWITCH mq em CAPACITY NEUTRAL ex CHARTS ect REVERSE MUST BE 91163028 91088314 1143126 91033089 S N 0160036260 OX0102 2 4 31200172 Section 2 Pre Operation and Inspection 91143282 4105262 80603037 A WARNING
33. 37689 90455049 Bucket 72 in 1 0 yd S N 0160037689 amp After 1001100822 Bucket 74 in 1 25 yd Before S N 0160037689 90555020 Bucket 74 in 2 0 yd Before S N 0160037689 90453039 Bucket 96 in 1 5 yd S N 0160037689 amp After 1001100823 Bucket 102 in 2 0 yd S N 0160037689 amp After 1001100824 Concrete Hopper 0 75 yd Before S N 0160037689 91123115 OZ0730 Use Appropriate Bucket Capacity Chart To determine maximum capacity refer to Telehandler Attachment Fork Capacity on page 5 3 d reme rz A 1 ED The joystick 1 controls lift lower and extend retract movement of the boom The tilt lever 2 controls bucket tilt Move lever back to tilt up Move lever forward to tilt down Installation Procedure Referto Attachment Installation on page 5 11 5 36 31200172 Section 5 Attachments Operation Raise or lower boom to appropriate height for loading material from stockpile Align telehandler with face of stockpile and drive slowly and smoothly into pile to load bucket Tilt bucket up far enough to retain load and back away from pile Travel in accordance with requirements set forth in Section 1 General Safety Practices Tilt bucket down to dump load Equipment Damage Precautions Except for lifting or dumping a load t
34. 722 kg 18 ft 5 5 12 ft 3 7 m Yes 2 4000 Ib 1814 kg 30 ft 9 1 m 26 ft 7 9 m NO 3 7500 Ib 3402 kg 8 ft 2 4 m 24 ft 7 3 m Yes 4 5750 Ib 2608 kg 12 ft 3 7 m 44 ft 13 4 m NO Example 4 Example 3 Example 2 Example 1 OY1710 Note This is a sample capacity chart only DO NOT use this chart use the one located in your operator cab 5 10 31200172 Section 5 Attachments 5 5 ATTACHMENT INSTALLATION BEFORE S N 0160037689 S N 0160037689 amp AFTER 1 2 X OX0680 Attachment Attachment Pin Recess 1 2 3 Attachment Pin 4 Lock Pin 5 Retaining Pin 6 Quick Switch attachment tilt control in cab see page 3 8 A 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 31200172 5 11 Section 5 Attachments Before S N 0160037689 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 secured in out position with retainer pin 2 Align attachment pin with recess in attachment Raise boom slightly to engage attachment pin in recess 3 Tilt quick switch f
35. 89 90453002 Fork Pallet 2 25x4x48 in Before S N 0160037689 90453048 Fork Pallet 2 36x5x48 in S N 0160037689 amp After 2340038 Fork Pallet 2x6x48 in Before S N 0160037689 90553005 Fork Dual Taper 1 75x7x60 in S N 0160037689 amp After 2340046 Fork Pallet 2x6x60 in Before S N 0160037689 90601015 Fork Pallet 2x6x60 in Before S N 0160037689 91163269 Fork Dual Taper 2 36x6x60 in S N 0160037689 amp After 2340039 Fork Pallet 2x6x72 in Before S N 0160037689 90553018 Fork Pallet 2x6x72 in Before S N 0160037689 91123132 Fork Dual Taper 2x6x72 in S N 0160037689 amp After 1001092391 Use Mast Carriage Attachment Capacity Chart To determine maximum capacity refer to Telehandler Attachment Fork Capacity on page 5 3 OX0291 5 24 31200172 Section 5 Attachments The joystick 1 controls lift lower and extend retract movement of the boom The tilt lever 2 controls the mast tilt Move lever back to tilt up Move lever forward to tilt down To Raise Lower Mast The auxiliary hydraulic lever 3 controls the movement of the mast Move lever up to lower Move lever down to raise Installation Procedure Refer to Attachment Instal
36. Disabled 6 1 Moving Short Distances 6 1 Moving Longer Distances 6 1 Emergency Lowering of 6 2 Emergency Exit from Enclosed 6 2 Lubrication and Maintenance Introduction s 2 tn Eo PR RR ESO 7 1 Clothing and Safety 7 1 General Maintenance Instructions 7 2 Service and Maintenance Schedule 7 3 10 amp 1st 50 Hour Maintenance Schedule 7 3 50 250 amp 500 Hour Maintenance Schedule 7 4 1000 amp 1500 Hour Maintenance Schedule 7 5 Lubrication 7 6 50 Hour Lubrication 7 6 250 Hour Lubrication 7 7 Operator Maintenance 7 8 Fuel SYSTEM 7 8 Air Intake 0000 7 10 Engine antares 7 12 Hydraulic nee 7 13 7 14 Hydraulic Return Filter 7 17 Engine Cooling
37. RE S N 0160037689 S N 0160037689 amp AFTER 3 Connect attachment hoses to both auxiliary fittings 2 5 14 31200172 Section 5 Attachments 5 6 ADJUSTING MOVING FORKS Carriages may have different locations where forks can be positioned Two different methods can be used for repositioning depending upon the carriage structure Note Apply a light coating of appropriate lubricant to ease sliding of forks or fork bar To slide forks 1 Ensure attachment is properly installed See Attachment Installation on page 5 11 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 i Rest forks on ground Remove fork bar Reposition forks Reinstall the fork bar and fork bar retaining mechanism s 31200172 5 15 Section 5 Attachments 5 7 ATTACHMENT OPERATION Capacities and range limits for the telehandler change depending on the attachment in use Separate attachment instructions must be kept in manual holder in cab with this Operation amp Safety Manual An additional copy must be kept with the
38. Read This First TABLE OF CONTENTS Operator Qualifications 1 2222 b 2 2 4 b Other Publications Available d Table of Contents Section 1 1 1 1 2 1 8 Section 2 2 1 2 2 2 3 2 4 2 5 2 6 Section 3 3 1 3 2 31200172 General Safety Practices Hazard Classification System 1 1 Safety Alert System and Safety Signal Words 1 1 General Precautions 1 1 Operation 1 2 Electrical 1 2 Tip Over 0000 1 3 Travel 1 6 Load Falling 0 0 01 1 7 Lifting 1 8 Driving Hazards on Slopes 1 9 Pinch Points and Crush 1 10 Fall 1 12 Chemical 1 13 Pre Operation and Inspection Pre Operation Check and 2 1 safety D6Cals uem ees 2 3 Walk Around 4 224 00 2 6 Warm Up and Operational 2 8 Warm Up
39. Section 7 Lubrication and Maintenance Battery A Battery Check 50 x Ow0980 1080 JOHN DEERE ENGINE CUMMINS ENGINE 3 3 Uu 9 7 D Du reel TT TT Ox0601 1 Perform Shut Down Procedure on page 4 4 2 Remove the front cover 3 Wearing eye protection visually inspect the battery 3 Check terminals for corrosion Replace battery if it has a cracked melted or damaged case 4 Replace the front cover 31200172 7 19 Section 7 Lubrication and Maintenance This Page Intentionally Left Blank 7 20 31200172 Section 8 Additional Checks SECTION 8 ADDITIONAL CHECKS This Page Intentionally Left Blank 31200172 8 1 Section 8 Additional Checks This Page Intentionally Left Blank 8 2 31200172 Section 9 Specifications SECTION 9 SPECIFICATIONS 9 1 PRODUCT SPECIFICATIONS Fluid and Lubrication Capacities Engine Crankcase Oil Capacity with Filter Change John Deere Engine eese 15 5 quarts 14 7 liters Cummins Erigirie 13 7 quarts 13 liters Oil ida tba ae e Reit do dot et 15W 40 CD Fuel Tank GI lo eT 40 gallons 151 4 liters Type ot Fuels n ERR REUTERS te 2 Diesel Cooling System System Capacity John Deere Engine eese 24 8 quarts 23 5 liters
40. XTEND BOOM With both hands clenched point thumbs outward OY1160 RETRACT BOOM With both hands clenched point thumbs inward OY1170 THIS FAR TO GO With hands raised and open inward move hands laterally indicating distance to go TILT FORKS UP With one arm held at side extend other arm upward at about 45 degrees TILT FORKS DOWN With one arm held at side extend other arm downward at about 45 degrees Special Signals When signals for auxiliary equipment functions or conditions not covered are required they shall be agreed upon in advance by the operator and signalman An Oshkosh Corporation Company JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 USA Phone 1 717 485 5161 Customer Support Toll Free 1 877 554 5438 Fax 1 717 485 6417 JLG Worldwide Locations JLG Industries Australia P O Box 5119 11 Bolwarra Road Port Macquarie N S W 2444 Australia Phone 61 265 811 111 Fax 61 265 810 122 JLG France SAS 2 1 de Baulieu 47400 Fauillet France Phone 33 0 5 53 88 31 70 Fax 33 0 5 53 88 31 79 JLG Industries Italia s r l Via Po 22 20010 Pregnana Milanese MI Italy Phone 39 029 359 5210 Fax 39 029 359 5845 JLG Industries Scotland Wright Business Centre 1 Lonmay Road Queenslie Glasgow G33 4EL Scotland Phone 44 0 141 781 6700 Fax 44 0 141 773 1907 JLG Latino Americana Ltda Rua E
41. ack to tilt up Frame Level if equipped The frame level lever 4 controls the left to right frame level Move lever forward to rotate frame left move lever back to rotate frame right A level indicator is located above the front cab window to permit operator to determine whether the telehandler frame is level A 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 Auxiliary Hydraulics if equipped The auxiliary hydraulics lever 4 controls function of attachments that require hydraulic supply for operation See Section 5 Attachments for approved attachments and control instructions 31200172 3 9 Section 3 Controls and Indicators Outrigger Levers fy 4 The rear levers 1 amp 2 control the outriggers The left lever controls the left outrigger and the right lever controls the right outrigger Push levers forward to lower outriggers push levers back 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 A 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
42. an engine fault and or parameter is outside the acceptable range Engine may derate and shutdown Alternator Indicator Illuminates when alternator is not charging Preheat Indicator llluminates with ignition in RUN position Light goes out when start temperature is reached At temperatures below 32 F 0 C do not start until engine is preheated 31200172 Section 3 Controls and Indicators Ignition LCN OX0072 n ACC or RUN position voltage is available for all electrical functions Full clockwise rotation to START engages starter motor e Counter clockwise rotation to OFF stops engine and removes voltage from all electrical functions 31200172 3 5 Section 3 Controls and Indicators Park Brake O O r3 OX0043 Park brake switch controls the application and release of the park brake Indicator light 3 illuminates to indicate brake is applied With the engine running and the park brake switch in OFF position 1 park brakes are disengaged With switch in ON position 2 park brake is engaged and transmission will not engage forward or reverse A WARNING MACHINE ROLL AWAY HAZARD Always move park brake switch to ON position lower boom to ground and stop engine before leaving cab
43. and side to side Use the capacity chart to determine safe boom extension range See Use of the Capacity Chart on page 5 4 Align load at the level load is to be placed then position boom slowly until load is just above area where it is to be placed Ensure that the guide men and operator remain in constant communication verbal or hand when placing the load Disengaging a Suspended Load Never place the guide men between the suspended load and the telehandler Once at the destination of the load ensure to bring the telehandler to a complete stop and apply the park brake prior to disengagement of the lifting devices and tethers 4 10 31200172 Section 4 Operation 4 4 LOADING AND SECURING FOR TRANSPORT Tiedown 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 weig
44. apabilities travel on slopes as follows When unloaded the rear of the machine is the heavy end Drive with forks pointed downhill When loaded the front of the machine is the heavy end Drive with the forks pointed uphill For additional travel requirements refer to the appropriate capacity chart To avoid overspeeding the engine and drivetrain when driving down slopes downshift to a lower gear and use the service brake as necessary to maintain a slow speed DO NOT shift into neutral and coast downhill Avoid excessively steep slopes or unstable surfaces To avoid tip over DO NOT drive across excessively steep slopes under any circumstances Avoid turning on a slope Never engage inching or shift to Neutral when going downhill DO NOT park on a slope 31200172 1 9 Section 1 General Safety Practices Pinch Points and Crush Hazards Stay clear of pinch points and rotating parts on the telehandler 0210 Stay clear of moving parts while engine is running 0220 Keep clear of steering tires and frame or other objects 0230 Keep clear from under boom 1 10 31200172 Section 1 General Safety Practices Y 0240 Keep clear of boom holes i OW0250 Keep arms and hands clear of attachment tilt cylinder 2 OW0260 Keep hands and fingers clear of carriage and forks amp all 4 gt e Ow0960 Keep others
45. attachment if it is equipped with a manual holder Operations described within this section reference right hand attachment tilt and left hand auxiliary hydraulics controls Refer to pages 3 9 or 3 11 if equipped with a different configuration 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 EQUIPMENT DAMAGE Avoid contact with any structure or object when lifting a load Maintain clearance around boom structure and load Failure to maintain clearance may result in attachment or machine structural damage 5 16 31200172 Section 5 Attachments This Page Intentionally Left Blank 31200172 5 17 Section 5 Attachments Carriage w Forks Description P N Carriage 48 in Before S N 0160037689 90455051 Carriage 66 in Before S N 0160037689 90455052 Carriage 72 in Before S N 0160037689 90555008 Fork Block 2x2x48 in Before S N 0160037689 90600390 Fork Pallet 1 75x6x48 in Before S N 0160037689 90601819 Fork Pallet 2x4x48 in Before S N 0160037689 90453002 Fork Pallet 2 25x4x48 in Before S N 0160037689 90453048 Fork Pallet 2x6x48 in Before S N 0160037689 90553005 Fork Pallet 2x6x60 in Before S N 0160037689 90601015 For
46. away while operating 31200172 1 11 Section 1 General Safety Practices 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 OW0280 DO NOT get off the machine until the shutdown procedure on page 4 4 has been performed OWO0290 DO NOT carry riders Riders could fall off machine causing death or serious injury 1 12 31200172 Section 1 General Safety Practices Chemical Hazards Exhaust Fumes DO NOT operate machine 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 f spark arrestors are required ensure they are in place and in good working order Flammable Fuel OW0300 DO NOT fill the fuel tank or service the fuel system near an open flame sparks or smoking materials Engine fuel is flammable and can cause a fire and or explosion Hydraulic Fluid 0950 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 penet
47. cator also flashes engine fault codes See Service Manual for details Alternator Indicator Illuminates when alternator is not charging 31200172 3 3 Section 3 Controls and Indicators Cummins Engine 12 13 14 15 16 17 18 19 20 21 22 23 16 13 14 15 23 17 le 18 12 22 21 20 621 Park Brake Indicator See page 3 6 for details 4 in 1 Gauge e Engine Coolant Temperature Gauge f Engine Oil Pressure Gauge g Fuel Gauge h Voltmeter indicates alternator output and battery condition Heater Switch if equipped See page 3 12 for details Diagnostic Indicator when diagnostic system detects an engine fault Hourmeter Indicates total time of engine operation in hours and tenths of hours 4x2 4x4 Switch Engages and disengages rear wheel drive motors Rear drive motors are engaged for four wheel drive Park Brake Switch See page 3 6 for details Auxiliary Electrics Switches if equipped Enables functions of attachments that require auxiliary electrics See Section 5 Attachments for approved attachments and control instructions 4 4 Indicator Illuminates when four wheel drive is engaged The indicator will not illuminate when park brake is applied Engine Shutdown Indicator to indicate
48. chment to ground and stop the engine Determine cause and correct before continued use 31200172 3 4 Section 3 Controls and Indicators 3 2 CONTROLS VIEW A A 8 11 7136 OX0362 Transmission Control Lever See page 3 7 Steering Wheel Turning the steering wheel to the left or right steers the machine in the corresponding direction Frame Level Indicator Enables the operator to determine the left to right level condition of the telehandler Boom Joystick See page 3 8 Right Hand Levers if equipped See page 3 9 Accelerator Pedal Pressing down the pedal increases engine and hydraulic speed Service Brake Inching Travel Pedal Operates service brakes on front axle Permits slow travel speed while engine speed is kept high for other telehandler functions The further the pedal is depressed the slower the travel speed Left Hand Lever if equipped See page 3 11 Instrument Panel See page 3 3 10 11 12 13 Ignition Switch Key activated See page 3 5 Horn Button Depress to sound horn Outrigger Levers See page 3 10 Traction Lock Pedal Pedal operates traction lock With machine in four wheel drive mode depress and hold down to restore traction when a wheel spins 31200172 Section 3 Controls and Indicators Dash Controls and Indicators
49. d 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 15 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 31200172 4 5 Section 4 Operation Transporting a Load Voting After engaging the load and resting it against the backrest tilt the load back to position it for travel Travel in accordance with the requirements set forth in Section 1 General Safety Practices and Section 5 Attachments 0 0540 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 9 or page 3 11 or if equipped outrigger joysticks see page 3 10 Important things to remember Never raise the boom attachment more than 4 ft 1 2 above gro
50. dL Operation amp Safety Manual Keep this manual with machine at all times Model 544D 10 S N 0160003969 amp After including 0160003856 31200172 Revised January 14 2009 An Oshkosh Corporation Company CALIFORNIA PROPOSITION 65 BATTERY WARNING Battery posts terminals and related accessories contain lead and lead compounds chemical known to the State of California to cause cancer and reproductive harm WASH HANDS AFTER HANDLING CALIFORNIA PROPOSITION 65 EXHAUST WARNING Diesel Engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Revision Log REVISION LOG January 8 2007 A Original Issue of Manual November 25 2008 Revised covers and pages 2 3 2 4 3 4 3 9 3 10 3 11 7 8 and Transfer of Ownership January 14 2009 C Revised manual 31200172 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
51. ds shown on rated capacity chart are based on machine being on firm ground with frame level see page 4 6 the forks being positioned evenly on carriage the load being centered on forks proper size tires being properly inflated and the telehandler being in good operating condition 5 8 31200172 Section 5 Attachments To identify the proper load chart on telehandlers equipped with outriggers refer to the following icons which may be located on the load chart zi Use when lifting a load with outriggers up E OAL1090 Use when lifting a load with outriggers down 2 1100 31200172 5 9 Section 5 Attachments Example A contractor owns a model xxxxx telehandler with a fork carriage He knows this attachment may be used with his model since Before S N 0160037689 The attachment model option number matches the attachment number on the capacity chart The capacity chart is clearly marked for model xxxxx and corresponds with machine configuration being used S N 0160037689 amp After The attachment style weight dimensions and load center match the attachment data on the capacity chart The capacity chart is clearly marked for model xxxxx and corresponds with machine configuration being used Below are examples with various conditions the contractor may encounter and whether or not the load may be lifted Load Weight Distance Height OK to Lift 1 6000 Ib 2
52. e telehandler being operated Ensure that adequate clearance is provided between both rear tail swing and front fork swing Look out for and avoid other personnel machinery and vehicles in the area Use a spotter if you DO NOT have a clear view Before moving be sure of a clear path and sound horn When driving retract boom and keep boom attachment as low as possible while maintaining visibility of mirrors and maximum visibility of path of travel Always look in the direction of travel Always check boom clearances carefully before driving underneath overhead obstructions Position attachment load to clear obstacles When driving in high speed use only front wheel steer if steering modes are selectable 1 6 31200172 Section 1 General Safety Practices Load Falling Hazard 0130 Never suspend load from forks or other parts of carriage DO NOT burn or drill holes in fork s Forks must be centered under load and spaced apart as far as possible 31200172 1 7 Section 1 General Safety Practices an 0170 Lifting Personnel When lifting personnel USE ONLY a JLG approved personnel work platform with proper capacity chart displayed in the cab OWo0190 DO NOT drive machine from cab when personnel are in platform 1 8 31200172 Section 1 General Safety Practices Driving Hazards on Slopes oA ue To maintain sufficient traction and braking c
53. ed Battery Cables tight no visible damage or corrosion Cover properly secured Mirror Clean and undamaged Wheel Tire Assembly Properly inflated and secured no loose or missing lug nuts Inspect for worn tread cuts tears or other discrepancies Frame Level Cylinder Pins secure hydraulic hoses undamaged not leaking Right Outrigger Pins secure hydraulic hoses and cylinder undamaged not leaking Attachment Properly installed See Attachment Installation on page 5 11 31200172 2 7 Section 2 Pre Operation and Inspection 2 4 WARM UP AND OPERATIONAL CHECKS Warm Up Check During warm up period check 1 Heater defroster and windshield wiper if equipped 2 Check all lighting systems if equipped for proper operation 3 Voltmeter should show 13 5 to 14 volts 4 Adjust mirror s for maximum visibility A WARNING CUT CRUSH BURN HAZARD Keep engine cover closed while engine is running except when checking hydraulic filter condition indicator Operational Check When engine warms perform an operational check 1 Service brake and parking brake operation Forward and reverse travel Steering in both directions with engine at low idle Im Horn and back up alarm Must audible from inside operators cab with engine running All joystick functions operate smoothly and correctly 6 Perform any additional checks described in Section 8 7 Hydraulic fil
54. ed 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 31200172 3 15 Section 3 Controls and Indicators 3 4 BOOM ANGLE AND EXTENSION INDICATORS i dp The boom angle indicator 1 is located on the left side of the boom Use this indicator to determine the ied angle when using the capacity chart see Use of the Capacity Chart on page 5 4 OW1220 Boom extension indicators 2 are located on the left side of the boom Use these indicators to determine boom extension when using the capacity chart see Use of the Capacity Chart on page 5 4 3 16 31200172 Section 4 Operation SECTION 4 OPERATION 4 4 ENGINE Starting the Engine This machine can be operated under normal conditions in temperatures of O F to 104 F 20 C to 40 C Consult JLG for operation outside this range or under abnormal conditions 1 Make sure all controls are in Neutral and all electrical components lights heater defroster etc are turned off Set parking brake 2 If equipped with Cummins engine and the temperature is below 32 F 0 C turn the ignition switch to RUN Wait until the preheat indicator light goes out 3 Turn ignition switch to START to engage starting motor Release key immediately w
55. ensure surface can support telehandler and load 3 10 31200172 Section 3 Controls and Indicators Left Hand Lever if equipped AUXILIARY HYDRAULICS LEFT DOWN AUXILIARY HYDRAULICS AUXILIARY HYDRAULICS RIGHT UP FRAME LEVEL ATTACHMENT gt TILT e J OX0222 The left hand lever 3 controls auxiliary hydraulics frame level or attachment tilt Auxiliary Hydraulics if equipped Controls function of attachments that require hydraulic supply for operation See Section 5 Attachments for approved attachments and control instructions Frame Level if equipped Move lever left to rotate frame left move lever right to rotate frame right A level indicator is located in the upper front window frame to permit operator to determine whether the telehandler frame is level A WARNING TIP OVER HAZARD Always move boom as low as possible while allowing for best visibility of right hand mirror before leveling frame Attempting to level machine with boom raised could cause it to tip over Attachment Tilt if equipped Move joystick up to tilt down move joystick down to tilt up 31200172 3 11 Section 3 Controls and Indicators Heater if equipped D 5 o OX0234 1 Defroster Fan Two speed fan Pres
56. er 2 controls the carriage tilt Move lever back to tilt up Move lever forward to tilt down Installation Procedure Refer to Attachment Installation on page 5 11 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 31200172 5 19 Section 5 Attachments Side Tilt Carriage 5 AN OAL1550 Description P N Side Tilt Carriage 48 in Before S N 0160037689 91085058 Side Tilt Carriage 50 in S N 0160037689 amp After 1170054 Side Tilt Carriage 60 in S N 0160037689 amp 1001101956 Side Tilt Carriage 66 in Before S N 0160037689 91305016 Side Tilt Carriage 72 in S N 0160037689 amp 1170057 Fork Block 2x2x48 in Before S N 0160037689 90600390 Fork Block 2x2x48 in S N 0160037689 amp After 2340037 Fork Pallet 1 75x6x48 in Before S N 0160037689 90601819 Fork Pallet 2 36x4x48 in S N 0160037689 amp After 2340045 Fork Pallet 2x4x48 in Before S N 0160037689 90453002 Fork Pallet 2 25x4x48 in Before S N 0160037689 90453048 Fork Pallet 2 36x5x48 in S N 0160037689 amp After 2340038 Fork Pallet 2x6x48 in Before S N 0160037689 90553005 Fork Dual Taper 1 75x7x60 in S N 0160037689 amp After
57. g Before S N 0160037689 90555018 Truss Boom 12 ft S N 0160037689 amp After 1001099902 Truss Boom 12 ft w winch S N 0160037689 amp After 1001099351 Truss Boom 15 ft S N 0160037689 amp After 1001099901 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 q EM a i 4 1 nc n o o Ox0271 The joystick 1 controls lift lower and extend retract movement of the boom The tilt lever 2 controls truss boom tilt Move lever back to tilt up Move lever forward to tilt down Winch Control if equipped The auxiliary hydraulic lever 3 controls the truss boom mounted winch Move lever up to lower cable Move lever down to raise cable 5 34 31200172 Section 5 Attachments Installation Procedure Refer to Attachment Installation on page 5 11 A WARNING CRUSH HAZARD Maintain a minimum of three wraps of wire rope on the cable drum at all times Failure to comply could cause object or load to fall 31200172 5 35 Section 5 Attachments Bucket Description P N Bucket 60 in 0 75 yd Before S N 01600
58. he boom must be fully retracted for all bucket operations Do not corner load bucket Distribute material evenly within the bucket Bucket capacity charts are for evenly distributed loads only Do not use bucket as a lever to pry material Excessive prying forces could damage bucket or machine structure Do not attempt to load material which is hard or frozen This could cause severe damage to quick switch or machine structure Do not use bucket for back dragging This could cause severe damage to quick switch and retraction cables chains 31200172 5 37 Section 5 Attachments Grapple Bucket S N 0160037689 amp After Description P N Bucket Grapple 96 1 75 0930020 021450 Use Grapple Bucket Capacity Chart To determine maximum capacity refer to Telehandler Attachment Fork Capacity on page 5 3 E D I i i 25 3 O 2 DB 0760 The joystick 1 controls lift lower and extend retract movement of the boom The tilt lever 2 controls grapple bucket tilt Move lever back to tilt up Move lever forward to tilt down To open close grapple The auxiliary hydraulic lever 3 controls the open close movement of the grapple Move lever up to close grapple Move lever down to open grapple Installation Procedure Referto Attachment Installation on page 5 11 5 38 312
59. hen engine starts If engine fails to start within 20 seconds release key and allow starting motor to cool for a few minutes before trying again 4 After engine starts observe oil pressure gauge If gauge remains on zero for more than ten seconds stop engine and determine cause before restarting engine Reference engine manual for minimum pressure at operating temperature 5 Warm up engine at approximately 1 2 throttle Note Engine will not start unless transmission control lever is in Neutral and park brake switch is applied A 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 31200172 4 1 Section 4 Operation Cold Weather Starting Aids John Deere Engine JLG approved starting aids employ ether If your telehandler is equipped with an ether starting aid the following applies Injection of ether is triggered by temperature sensor located on engine At start up temperature sensor on engine will detect if ether is needed Follow normal start up procedure Ether will be automatically injected if needed to keep engine running A second battery is added for additional cold cranking capacity A WARNING ENGINE EXPLOSION If your telehandler is equipped with a cold start aid do
60. ht 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 A 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 31200172 4 11 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 31200172 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 follow
61. il Level Check 1 0 X b OWO970 OW1020 JOHN DEERE ENGINE 4 4 Tli e a 2 Lee en DO P g o o o Y e sE LEY e J CUMMINS ENGINE 4 1 E lt 2 e e OX0610 1 Perform Shut Down Procedure on page 4 4 2 Remove dipstick 1 and check oil mark The oil should be between the full 2 and add 3 marks within the crosshatched area of the dipstick 3 If oil is low open the engine cover remove oil fill cap 4 and add motor oil to bring oil up to the full mark in the crosshatch area 4 Replace oil fill cap and dipstick 5 Close and secure the engine cover Note The standard service interval for engine oil and filter is 250 hours maximum If an extended service interval is desired see your engine manual for specific guidelines for optimizing oil change intervals 7 12 31200172 Section 7 Lubrication and Maintenance Hydraulic Oil A Hydraulic Level Check 10 ri 0970 OW1030
62. ims installed have been designed for stability requirements which consist of track width tire pressure and load capacity Size changes such as rim width center piece location larger or smaller diameter etc without written factory recommendations may result in unsafe condition regarding stability 31200172 7 15 Section 7 Lubrication and Maintenance E Wheel Installation Torque lug nuts before first use and after each wheel removal Note If machine is equipped with directional tire assemblies the wheel and tire assemblies must be installed with the directional tread pattern arrows facing in the direction of forward travel 1 Start all nuts by hand to prevent cross threading DO NOT use a lubricant on threads or nuts 2 Tighten lug nuts in an alternating pattern as indicated in figure Torque to 350 400 Ib ft 475 542 Nm A WARNING TIP OVER HAZARD Lug nuts must be installed and maintained at the proper torque to prevent loose wheels broken studs and possible separation of wheel from the axle 7 16 31200172 Section 7 Lubrication and Maintenance Hydraulic Return Filter A Hydraulic Return Filter Indicator Check 1 0 4 nono OW1060 e OX0170 2 1 Apply park brake shift transmission to Neutral and lower forks or attachment to horizontal position
63. ing prior to installation Before S N 0160037689 The attachment model option number on the attachment identification plate must match the attachment number on a capacity chart located in the operator cab The model on the capacity chart must match the model telehandler being used The load center of the fork if equipped must match the load center as indicated on the capacity chart Hydraulically powered attachments must only be used on machines equipped with auxiliary hydraulics Hydraulically powered attachments that require auxiliary electrics must only be used on machines equipped with auxiliary hydraulics and electrics S N 0160037689 amp After The attachment type weight dimensions and load center must be equal to or less than the data shown on a capacity chart located in the operator cab The model on the capacity chart must match the model telehandler being used Hydraulically powered attachments must only be used on machines equipped with auxiliary hydraulics Hydraulically powered attachments that require auxiliary electrics must only be used on machines equipped with auxiliary hydraulics and electrics If any of the above conditions are not met do not use the attachment The telehandler may not be equipped with the proper capacity chart or the attachment may not be approved for the model telehandler being used Contact JLG or a local distributor for further information 31200172 5 1 Section 5 Attachment
64. ity 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 A WARNING matched sets Never use an attachment without the appropriate JLG approved capacity chart installed on the telehandler 31200172 5 3 Section 5 Attachments 5 4 USE OF THE CAPACITY CHART To properly use the capacity chart See page 5 6 the operator must first determine and or have the following 1 2 3 4 An approved attachment See Approved Attachments on page 5 1 The proper Capacity Chart s Weight of the load being lifted 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 On the Capacity Chart find the line for the height and follow it over to the distance 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 mus
65. k Pallet 2x6x60 in Before S N 0160037689 91163269 Fork Pallet 2x6x72 in Before S N 0160037689 90553018 Fork Pallet 2x6x72 in Before S N 0160037689 91123132 Drywall Carriage 66 in Before S N 0160037689 90455053 Carriage 50 in Before S N 0160037689 1170020 Carriage 50 in S N 0160037689 amp After 1170021 Carriage 60 in Before S N 0160037689 1170023 Carriage 60 in S N 0160037689 amp 1170024 Carriage 72 in Before S N 0160037689 1170026 Carriage 72 in S N 0160037689 amp 1170027 Fork Block 2x2x48 2340037 Fork Pallet 2 36x4x48 in 2340045 Fork Pallet 2 36x5x48 2340038 Fork Dual Taper 1 75 7 60 2340046 Fork Dual Taper 2 36x6x60 2340039 Fork Dual Taper 2 6 72 1001092391 Use Carriage Attachment Capacity Chart To determine maximum capacity refer to Telehandler Attachment Fork Capacity on page 5 3 OX0241 31200172 Section 5 Attachments The joystick 1 controls lift lower and extend retract movement of the boom The tilt lev
66. l can be extended see page 7 12 for details 7 4 31200172 Section 7 Lubrication and Maintenance 1000 amp 1500 Hour Maintenance Schedule Change Front Change Front amp Change Axle Oil Rear Wheel Hydraulic Tank End Oil Breather Change Change Engine Coolant Hydraulic Fluid amp Filters 0 1042 31200172 7 5 Section 7 Lubrication and Maintenance 7 4 LUBRICATION SCHEDULES 50 Hour Lubrication Schedule MX0052 7 6 31200172 Section 7 Lubrication and Maintenance 250 Hour Lubrication Schedule MX0072 31200172 7 7 Section 7 Lubrication and Maintenance 7 5 OPERATOR MAINTENANCE INSTRUCTIONS Fuel System A Fuel Level Check 1 0 X b 5 OWO0970 0990 c 49 OX0212 VIEW OF FUEL TANK FROM TOP OF MACHINE Check fuel gauge 1 located on instrument panel in cab If fuel is low proceed to fuel source and perform Shut Down Procedure on page 4 4 Locate fuel tank 2 turn fuel tank cap 3 and remove from filler neck Add diesel fuel as needed Replace and sec
67. lation on page 5 11 A 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 e 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 31200172 5 25 Section 5 Attachments Mast Carriage w Swing and Side Shift Before S N 0160037689 Description P N 6 ft Mast Carriage 100 Swing 48 in 90455047 Fork Pallet 1 75x4x48 90553008 6 ft Mast Carriage 100 Swing 60 in 90455054 dw Fork Pallet 2x6X60 I 90453045 Use 6 ft Mast Carriage Attachment Capacity Chart To determine maximum capacity refer to Telehandler Attachment Fork Capacity on page 5 3 VIEW A A i 3 SWING MAST X x SIDE SHIFT t sp SWING MAkT 4 6 d 2 UK V L lt
68. lehandler 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 e 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 31200172 5 21 Section 5 Attachments Swing Carriage Si OU2150 Description P N 90 Swing Carriage S N 0160037689 amp After 1001095418 100 Swing Carriage Before S N 0160037689 90455044 180 Swing Carriage Before S N 0160037689 90553024 180 Swing Carriage Before S N 0160037689 91553076 180 Swing Carriage S N 0160037689 amp After 1001104992 Fork Block 2x2x48 in Before S N 0160037689 90600390 Fork Block 2x2x48 in S N 0160037689 amp After 2340037 Fork Pallet 1 75x6x48 in Before S N 0160037689 90601819 Fork Pallet 2 36x4x48 in S N 0160037689 amp After 2340045 Fork Pallet 2x4x48 in Before S N 0160037689 90453002 Fork Pallet 2 25x4x48 in Before S N 0160037689 90453048 Fork Pallet 2 36x5x48 in S N 0160037689 amp After 2340038 Fork Pallet 2x6x48 in Before S N 0160037689
69. maged not leaking 2 6 31200172 4 11 12 13 14 15 16 17 18 Section 2 Pre Operation and Inspection Wheel Tire Assembly Properly inflated and secured no loose or missing lug nuts Inspect for worn tread cuts tears or other discrepancies 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 Emergency escape hammer in place enclosed cab only Check seat belt for damage replace belt if frayed or cut webbing damaged buckles or loose mounting hardware Main Control Valve See Inspection Note Air Cleaner Air cleaner element condition indicator check for clogged condition Replace element as required Wheel Tire Assembly Properly inflated and secured no loose or missing lug nuts Inspect for worn tread cuts tears or other discrepancies Stabilizer Cylinder Pins secure hydraulic hoses undamaged not leaking Rear Axle Steer cylinders undamaged not leaking pivot pins secure hydraulic hoses undamaged not leaking Wheel Tire Assembly Properly inflated and secured no loose or missing lug nuts Inspect for worn tread cuts tears or other discrepancies Engine Compartment Drive belts check condition and replace as required Engine mounts See inspection note Engine cover properly secur
70. n in cases where owner notification is necessary Please use this form to provide JLG with updated information with regard to the current ownership of JLG products Please return completed form to the JLG Product Safety amp Reliability Department via facsimile or mail to address as specified below Thank You Product Safety amp Reliability Department JLG Industries Inc 13224 Fountainhead Plaza Hagerstown MD 21742 USA Telephone 1 717 485 6591 Fax 1 301 745 3713 NOTE Leased or rented units should not be included on this form Mfg Model Serial Number Previous Owner Address Country Telephone Date of Transfer Current Owner Address Country Telephone Who in your organization should we notify Name Title Hand Signals OY1090 EMERGENCY STOP With both arms extended laterally hands open downward move arms back and forth OY1100 STOP With either arm extended laterally hand open downward move arm back and forth OY1110 STOP ENGINE Draw thumb or forefinger across throat RAISE BOOM With either arm extended horizontally fingers closed point thumb upward LOWER BOOM With either arm extended horizontally fingers closed point thumb downward OY1140 MOVE SLOWLY Place one hand motionless in front of hand giving motion signal Raise load slowly shown OY1150 E
71. nal requirements refer to the appropriate capacity chart in the operator cab Important things to remember Ensure the boom is fully retracted Never raise the load more than 11 8 in 300 mm above ground surface or the boom more than 45 The combination of frame leveling and load could cause the telehandler to tip over The guide men and operator must remain in constant communication verbal or hand and be in visual contact with the operator at all times Never place the guide men between the suspended load and the telehandler Only transport the load at walking speed 0 9 mph 0 4 m s or less 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 9 or page 3 11 or if equipped outrigger joysticks see page 3 10 The telehandler is designed to permit leveling the main frame 8 to left or right to compensate for uneven ground conditions 31200172 4 9 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
72. ng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil Phone 55 193 295 0407 Fax 455 193 295 1025 JLG Deutschland GmbH Max Planck Str 21 D 27721 Ritterhude Ihlpohl Germany Phone 49 0 421 69 350 20 Fax 49 0 421 69 350 45 JLG Europe B V Polaris Avenue 63 2132 JH Hoofddorp The Netherlands Phone 31 0 23 565 5665 Fax 31 0 23 557 2493 Plataformas Elevadoras JLG Iberica S L Trapadella 2 Castellbisbal Sur 08755Castellbisbal Barcelona Spain Phone 34 93 772 4 700 Fax 34 93 771 1762 JLG Industries UK Ltd Bentley House Bentley Avenue Middleton Greater Manchester M24 2GP England Phone 44 0 161 654 1000 Fax 444 0 161 654 1001 JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong Phone 852 2639 5783 Fax 852 2639 5797 JLG Polska UI Krolewska 00 060 Warsawa Poland Phone 48 0 914 320 245 Fax 48 0 914 358 200 JLG Sverige AB Enkopingsvagen 150 Box 704 SE 176 27 Jarfalla Sweden Phone 46 0 850 659 500 Fax 46 0 850 659 534
73. ons for proper fill ratio and pressure requirements for tires equipped with ballast 7 2 Nm Always wear the seat belt Keep head arms hands legs and all other body parts inside operator s cab at all times N OH2221 If the telehandler starts to tip over DO NOT JUMP BRACE YOURSELF and STAY WITH THE MACHINE KEEP YOUR SEAT BELT FASTENED HOLD ON FIRMLY LEAN AWAY FROM THE POINT OF IMPACT 1 4 31200172 Section 1 General Safety Practices Non Suspended Load dio a 0060 DO NOT drive with boom raised Suspended Load OWO0150 Tether suspended loads to restrict movement DO NOT raise the load more than 11 8 in 300 mm above ground surface or the boom more than 45 Weight of all rigging slings etc must be included as part of load Start travel turn and stop slowly to prevent load from swinging When driving with the boom raised DO NOT exceed walking speed Beware of wind Wind can cause a suspended load to swing and cause dangerous side loads even with tag lines DO NOT attempt to use telehandler frame leveling to compensate for load swing Keep heavy part of load closest to attachment Never drag the load lift vertically 31200172 1 5 Section 1 General Safety Practices Travel Hazard PIVOT STEER OX0650 Steering characteristics differ between steer modes Identify the steer mode settings of th
74. orward to engage attachment 4 Remove retainer pin and slide lock pin in fully Secure lock pin in locked position using retainer pin 5 If equipped swing attachment saddles down pin in place OY0601 6 If equipped connect auxiliary hydraulic hoses See Hydraulic Operated Attachment on page 5 14 7 If equipped connect auxiliary electric harness 5 12 31200172 Section 5 Attachments S N 0160037689 amp After 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 retainer pin and insert lock pin completely through quick switch Release retainer pin and ensure lock pin is secured 5 If equipped connect auxiliary hydraulic hoses See Hydraulic Operated Attachment on page 5 14 6 If equipped connect auxiliary electric harness 31200172 ov1550 OY1560 OY1570 OY1580 5 13 Section 5 Attachments Hydraulic Operated Attachment 1 Install attachment see page 5 11 2 Lower attachment to ground and perform Shut Down Procedure on page 4 4 BEFO
75. otection from contact or being near electrical current OW0040 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 31200172 Section 1 General Safety Practices Tip Over Hazard General For additional load requirements refer to the appropriate capacity chart x 0050 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 e Be sure that the ground conditions are able to support the machine QS ll OW0080 DO NOT raise boom unless frame is level 0 degrees unless otherwise noted on capacity chart T X F T 0100 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 31200172 1 3 Section 1 General Safety Practices Ded OH2291 MAINTAIN proper tire pressure at all times If proper tire pressures are not maintained this machine could tip over Refer to manufacturers specificati
76. ove lever back to tilt up Move lever forward to tilt down To Side Tilt Press Side Tilt Switch B located on dash panel 4 to activate Side Tilt function The auxiliary hydraulic lever 3 controls the carriage side tilt Move lever up to side tilt left Move lever down to side tilt right 5 28 31200172 Section 5 Attachments To Raise Lower Mast Press Mast Raise Lower Switch 6 located on dash panel to activate Mast Raise Lower function The auxiliary hydraulic lever controls the mast raise lower function Move joystick up to lower Move joystick down to raise Installation Procedure Refer to Attachment Installation on page 5 11 A WARNING CRUSH HAZARD Do not use mast to push or pull objects or load Failure to comply could cause object or load to fall A 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 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 ano
77. r Locations 5 4 Sample Capacity 5 6 RR 5 10 5 5 Attachment 5 11 Hydraulic Operated 5 14 5 6 Adjusting Moving 4 5 15 ii 31200172 5 7 Section 6 6 1 6 2 6 3 Section 7 7 1 7 2 7 3 7 4 7 5 31200172 Table of Contents Attachment 4040 5 16 Carriage 5 18 Side Tilt 5 20 Swing 2 2 5 22 Mast Carriage eee ete eas 5 24 Mast Carriage w Swing and Side Shift Before S N 0160037689 5 26 Mast Carriage w Side Tilt S N 0160037689 amp After 5 28 Fork Mounted Hook Before S N 0160037689 5 30 Fork Mounted Hook S N 0160037689 amp After 5 32 TSS BOOM eeunenn eene eet ite ete antes 5 34 Bucket initia en et ee 5 36 Grapple Bucket S N 0160037689 amp After 5 38 Boom Head Mounted Winch Before S N 0160037689 5 40 Personnel Work Platform Before S N 0160037689 5 41 Personnel Work Platform S N 0160037689 amp After 5 42 Emergency Procedures Towing a
78. rate 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 31200172 1 13 Section 1 General Safety Practices This Page Intentionally Left Blank 1 14 31200172 Section 2 Pre Operation and Inspection SECTION 2 PRE OPERATION AND INSPECTION 2 1 PRE OPERATION CHECK AND INSPECTION Note Complete all required maintenance before operating unit A 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 NN OAH1000 PARENT METAL CRACK WELD CRACK 3 Safety Decals Ensure all safety decals are legible and in place Clean or replace as required See page 2 3 for details 4 Operation and Safety Manuals Operation amp Safety Manual and AEM Safety Manual as required are located in cab manual holder Walk Around Inspection See page 2 6 for details Fluid Levels Check fluids including fuel hydraulic engine oil and coolant
79. s 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 A WARNING Use only approved attachments Attachments which have not been approved for use with your telehandler could cause machine damage or an accident 5 2 31200172 Section 5 Attachments 5 3 TELEHANDLER ATTACHMENT FORK CAPACITY OW0550 Prior to installing the attachment verify it is approved and the telehandler is equipped with the proper capacity chart See Approved Attachments on page 5 1 To determine the maximum capacity of the telehandler and attachment use the smallest of the following capacities Capacity stamped on the attachment identification plate 1 Fork capacities and load centers are stamped on the side of each fork 2 if equipped This rating specifies the maximum load capacity that the individual fork can safely carry at the maximum load center 3 Total attachment capacity is multiplied by the number of forks on the attachment if equipped up to the maximum capacity of the attachment Maximum capac
80. s Inc sends safety related bulletins to the owner of record of this machine Contact JLG Industries Inc to ensure that the current owner records are updated and accurate JLG Industries Inc must be notified immediately in all instances where JLG products have been involved in an accident involving bodily injury or death of personnel or when damage has occurred to personal property or the JLG product FOR Accident Reporting and Product Safety Publications Current Owner Updates Questions Regarding Product Applications and Safety Standards and Regulations Compliance Information Questions Regarding Product Modifications CONTACT Product Safety and Reliability Department JLG Industries Inc 13224 Fountainhead Plaza Hagerstown MD 21742 USA or Your Local JLG Office Addresses on back cover In USA Toll Free 1 877 JLG SAFE 1 877 554 7233 Outside USA Phone 1 717 485 6591 E mail ProductSafety 9 JL G com 31200172 g Read This First Other Publications Available eec 31200170 Illustrated Parts 91364001 Note The following standards may be referenced in this manual ANSI is compliant to ANSIITSDF 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 31200172 Table of Contents Revision Log
81. s horizontally and telehandler frame before swinging load to side Swinging unlevel forks could cause load to slide off forks A 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 A WARNING CRUSH HAZARD Use retaining pin if equipped for locking swing frame to fixed frame when carrying loads greater than 5000 Ib 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 31200172 5 23 Section 5 Attachments Mast Carriage OY0580 Description P N 6 ft Mast Carriage 48 in Before S N 0160037689 90455035 6 ft Mast Carriage 66 in Before S N 0160037689 90455037 8 ft Mast Carriage 50 in S N 0160037689 amp After 1001108668 Fork Block 2x2x48 in Before S N 0160037689 90600390 Fork Block 2x2x48 in S N 0160037689 amp After 2340037 Fork Pallet 1 75x6x48 in Before S N 0160037689 90601819 Fork Pallet 2 36x4x48 in S N 0160037689 amp After 2340045 Fork Pallet 2x4x48 in Before S N 01600376
82. s fan switch down for slow speed press switch up for fast speed Return switch to middle position to turn off 2 Heater Fan Switch On Off switch 3 12 31200172 Section 3 Controls and Indicators 3 3 OPERATOR SEAT Adjustments Prior to starting engine adjust seat for position and comfort Before S N 0160016097 OX0013 1 Fore Aft Pull up on handle to move seat fore and aft 2 Seat Belt Always fasten seat belt during operation If required a 3 in 76 mm seat belt is available 3 Arm Rest Arm rest can be moved up or down for comfort 31200172 3 13 Section 3 Controls and Indicators S N 0160016097 amp After 0 ZH OWo480 1 Suspension Use knob to adjust suspension to the appropriate setting Turn clockwise to increase stiffness Turn counterclockwise to reduce stiffness 2 Fore Aft Pull up on handle to move seat fore and aft 3 Arm Rest Arm rest can be moved up or down for comfort 4 Seat Belt Always fasten seat belt during operation If required a 3 in 76 mm seat belt is available 3 14 31200172 Section 3 Controls and Indicators Seat Belt OH20912 Fasten seat belt as follows 1 Grasp both free ends of the belt making certain that belt webbing is not twisted or entangled 2 With back straight in the seat couple the retractable end male end of the belt into the receptacle buckle end of the belt 3 With belt buckle position
83. t 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 BOOM BOOM ANGLE EXTENSION INDICATOR ATTACHMENT INDICATOR IDENTIFICATION FAT 1 hs S 9 o OX0430 5 4 31200172 Section 5 Attachments This Page Intentionally Left Blank 31200172 5 5 Section 5 Attachments Sample Capacity Chart Before S N 0160037689 48 amp 72 CARRIAGES Boom Angle DEDUCT 350 LBS FROM ALL CAPACITIES WHEN MACHINE IS EQUIPPED WITH WINCH This Capacity Chart may be used with this model ONLY The model of your telehandler is indicated the boom or chassis Model XXXXX is used for demonstration purposes only 48 RATED CAPACITY 2 FT LOAD CENTER 44 69 E 6 40 60 36 50 4 RE D 3 Boom Extension o 3 ar m Indicator arc 28 Alo d 3 2 8 0 9 24 30 a zje M S 1 ojs 9 f 20 27 919 m ort 20 1 16 o alo 41 8 12 N 10 8 a 6 di 36 32 28 24 16 12 8 4 USE WITH 1234 5678 48 CARRIAGE be 8765 4321 72 CARRIAGE 0650 These numbers must match the model option number stamped
84. t with no previous preparation Drive wheels will not roll Moving Longer Distances f the telehandler must be moved longer distances it must be loaded onto a trailer of sufficient capacity Contact a local Authorized Distributor for specific instructions if neither of these methods are applicable 31200172 6 1 Section 6 Emergency Procedures 6 2 EMERGENCY LOWERING OF BOOM In the event of total loss of engine power or hydraulic pump failure with an elevated load the situation must be properly evaluated and dealt with on an individual basis Contact a local Authorized Distributor for specific instructions Secure the telehandler using the following procedures 1 Clear the area around telehandler of all personnel 2 Engage the parking brake Place the transmission control lever in NEUTRAL 3 Block all four wheels 4 Section off a large area under the boom with string or tape to restrict any personnel from entering this area 6 3 EMERGENCY EXIT FROM ENCLOSED CAB EMERGENCY EXIT PULL PINS AND PUSH WINDOW OUT TO EXIT D21080 OX0500 n an emergency pull pins at bottom of front window and push window out to exit 6 2 31200172 Section 7 Lubrication and Maintenance SECTION 7 LUBRICATION AND MAINTENANCE 7 1 INTRODUCTION Service the product in accordance with the maintenance schedule on the following pages
85. ter condition indicator 2 8 31200172 Section 2 Pre Operation and Inspection 2 5 OPERATOR CAB The telehandler is equipped with an open or enclosed ROPS FOPS cab A WARNING Never operate telehandler unless the overhead guard and cab structure are in good condition Any modification to this machine must be approved by JLG to assure compliance with ROPS FOPS certification for this cab machine configuration If damaged the CAB CANNOT BE REPAIRED It must be REPLACED 31200172 2 9 Section 2 Pre Operation and Inspection 2 6 WINDOWS Keep all windows and mirrors clean and unobstructed Cab Door Window if equipped OALO011 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 Press latch release button inside the cab or pull on lever 4 outside the cab to unlatch the window 2 10 31200172 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 EQUIPMENT DAMAGE When a red light illuminates immediately bring machine to a stop lower boom and atta
86. tform forward rearward or level the machine when the platform is occupied 31200172 5 41 Section 5 Attachments Personnel Work Platform S N 0160037689 amp After Description P N Personnel Work Platform ANSI 1001103637 Personnel Work Platform ANSI French 1001103736 Personnel Work Platform 50 1001103730 Use Personnel Work Platform Capacity Chart To determine maximum capacity refer to Telehandler Attachment Fork Capacity on page 5 3 The operator and personnel in platform must read and understand the separate personnel work platform manual prior to installing and using a platform r or lt OX0770 The joystick 1 controls lift lower and extend retract movement of the boom The tilt lever 2 controls platform tilt Move lever back to tilt up Move lever forward to tilt down Installation Procedure Referto Attachment Installation on page 5 11 Check to ensure the personnel platform is securely attached to the forks and or carriage 5 42 31200172 Section 5 Attachments Preparation and Setup 1 Ensure the telehandler is on a firm surface and is level 2 Engage the park brake Blocking the wheels is also recommended 3 Level the platform both side to side frame level and front to back attachment
87. ther object 31200172 5 29 Section 5 Attachments Fork Mounted Hook Before S N 0160037689 Description P N Fork Mounted 90553036 Fork Mounted 91565094 Use Appropriate 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 rm orm Ox0261 The joystick 1 controls lift lower and extend retract movement of the boom The tilt lever 2 controls the fork mounted hook tilt Move lever back to tilt up Move lever forward to tilt down Installation Procedure Referto Attachment Installation on page 5 11 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 5 30 31200172 Section 5 Attachments Operation Pallet or lumber forks of an appropriate load rating must be used Do not use with cubing or block forks Weight of fork mounted hook and rigging must be included as part of total load being lifted Do not use fork mounted hook with attachments capable of rotating i e side tilt and swing carriages without disabling the rotation feature s 31200172 5 31 Section 5 Attachments Fork Mounted Hook S N 0160037689 amp After
88. to check boom chain adjustment every 500 hours and adjust as required Chain damage can occur if chain is not adjusted properly A WARNING CUT CRUSH BURN HAZARD Do not perform service or maintenance on the machine with the engine running with the exception of the hydraulic return filter indicator checks 7 2 31200172 Section 7 Lubrication and Maintenance 7 3 SERVICE AND MAINTENANCE SCHEDULE 10 amp 1st 50 Hour Maintenance Schedule EVERY 10 PE 95 ri Check Fuel Air Filter Check Engine Check Hydraulic Level Restriction Oil Level Oil Level Indicator Check Hydraulic Return Filter Indicator Change Front Change Front amp Change Axle Oil Rear Wheel Engine Filter Hydraulic Filter End Oil Check Boom Chain amp Tension 31200172 Check Tire Condition amp Pressure Check Wheel Lug Nut Torque OX0551 Section 7 Lubrication and Maintenance 50 250 amp 500 Hour Maintenance Schedule Drain Fuel Check Engine Check Washer Lubrication Water Coolant Level Battery Fluid Level Schedule Separator if equipped Change Engine Check Front amp Air Filter il and Front Axle Rear Wheel Vacuator Filter Oil Level End Oil Levels Valve Check Boom Check Rear Axle Lubrication Wear Pads Stabilization Schedule Check Boom Change Fuel Check Wheel Cable amp Tension Filter amp Strainer Lug Nut Torque OX0561 Note Engine oil and filter service interva
89. und 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 8 to left or right to compensate for uneven ground conditions 4 6 31200172 Section 4 Operation Placing a Load Before placing any load be sure that The landing point can safely support the weight of the load The landing point is level front to back and side to side Use the capacity chart to determine safe boom extension range See Use of the Capacity Chart on page 5 4 Align forks at the level load is to be placed then extend boom slowly until load is just above area where it is to be placed Lower the boom until the load rests in position and the forks are free to retract Disengaging a Load Once the load has been placed safely at the landing point proceed as follows 1 With the forks free from the weight of the load the boom can be retracted and or the telehandler can be backed away from under the load if surface will not change level condition of telehandler 2 Lower the carriage 3 The telehandler can now be driven from the landing location to continue work 31200172 4 7 Section 4 Operation 4 3 OPERATING WITH A SUSPENDED LOAD Lift Load Safely You must know the weight and load center of ever
90. ure 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 See 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 Shift the transmission to Neutral Lower forks or attachment to the ground Operate engine at low idle for 3 to 5 minutes DO NOT over rev engine Shut off engine and remove ignition key Exit telehandler properly a m Block wheels if necessary 4 4 31200172 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 A 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 spee
91. ure fuel tank cap Note Replenish diesel fuel at end of each work shift to minimize condensation EQUIPMENT DAMAGE Do not allow machine to run out of fuel during operation See Engine Operation amp Maintenance Manual for details prior to servicing 7 8 31200172 Section 7 Lubrication and Maintenance voy B Drain Fuel Water Separator 50 1000 JOHN DEERE ENGINE 5 4 S Poe 0 0130 CUMMINS ENGINE OX0630 1 Perform Shut Down Procedure on page 4 4 2 Open the engine cover 3 Loosen drain cock 4 on underside of fuel filter 5 and allow all water to drain into a glass until clear fuel is visible 4 Tighten drain cock 5 Close and secure the engine cover 31200172 7 9 Section 7 Lubrication and Maintenance Air Intake System 1 A Air Filter Restriction Indicator Check owos7o HZ 1010 3 OX0331
92. y 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 A 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 dentify 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 Referto 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 31200172 Section 4 Operation Transporting a Suspended Load 023160 OW0130 e Travel in accordance with the requirements set forth in Section 1 General Safety Practices and Section 5 Attachments For additio

Operation 31200172

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