Operation 31200070
Contents
1. SS Tilting Attachment Up Pulling back on the front joystick tilts the attachment upwards Tilting Attachment Down Pushing forward on the front joystick tilts the attachment downwards 19 INSTRUMENTS AND CONTROLS Rear Joystick The rear joystick controls boom elevation and extension An auxiliary function is also available by pressing the button on top of the handle See Auxiliary Controls on page 22 for further information Extending the Transfer Carriage Moving the front joystick to the right extends the transfer carriage Lowering the Boom Moving the rear joystick forward lowers the boom Retracting the Transfer Carriage Moving the front joystick to the left retracts the transfer carriage Raising the Boom Pulling back on the rear joystick raises the boom 20 INSTRUMENTS AND CONTROLS Extending the Boom Moving the rear joystick to the right extends the boom Retracting the Boom Moving the rear joystick to the left ret2. 26 SHUTDOWN PROCEDURES Correct shutdown is important to the safe operation of the vehicle Always follow these steps 1 Come to a full stop 2 Set the park brake 3 Lower boom to the ground DO NOT leave the operator s compartment while the vehicle is supporting a load 4 Place transmission shift selector in NEUTRAL position Place the neutral lock lever to NEUTRAL LOCK position 5 Idle engine for 1 3 minutes for gradual cooling This is especially important for turbocharged engines 6 Shut off engine 7 After the engine is shut off move all hydraulic levers If any vehicle movement is detected a problem MAY exist and your supervisor should be advised immediately DO NOT put the vehicle into service until the problem has been fixed 8 Remove ignition key 9 Lock anti vandalism covers and closures 10 Dismount 11 Block wheels if on a slope or incline TRAVELING ACAUTION When traveling over rough terrain soft ground or wet icy surfaces slow down and shift to a lower gear Travel only at speeds that permit stopping in a safe manner When traveling keep forks as low as possible while maintaining safe clearance with the ground L Start and stop vehicle to check brakes L Check park brake by holding on hill L Check the three steering modes Round Front Wheel Oblique GENERAL OPERATING PROCEDURES FOLLOW SAFE OPERATING PROCEDURES AWARN
3. 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 JLG Latino Americana Ltda JLG Industries UK Ltd JLG France SAS P O Box 5119 Rua Eng Carlos Stevenson Bentley House Z l de Baulieu 11 Bolwarra Road 80 Suite 71 Bentley Avenue 47400 Fauillet Port Macquarie 13092 310 Campinas SP Middleton France N S W 2444 Brazil Greater Manchester Phone 33 0 5 53 88 31 70 Australia Phone 55 193 295 0407 M24 2GP Fax 33 0 5 53 88 31 79 Phone 61 265 811 111 Fax 55 193 295 1025 England Fax 61 265 810 122 Phone 44 0 161 654 1000 Fax 44 0 161 654 1001 JLG Deutschland GmbH JLG Equipment Services Ltd JLG Industries Italia s r l JLG Europe B V Max Planck Str 21 Rm 1107 Landmark North Via Po 22 Polaris Avenue 63 D 27721 Ritterhude Ihlpohl 39 Lung Sum Avenue 20010 Pregnana Milanese MI 2132 JH Hoofddorp Germany Sheung Shui N T Italy The Netherlands Phone 49 0 421 69 350 20 Hong Kong Phone 39 029 359 5210 Phone 31 0 23 565 5665 Fax 49 0 421 69 350 45 Phone 852 2639 5783 Fax 39 029 359 5845 Fax 31 0 23 557 2493 Fax 852 2639 5797 JLG Polska JLG Industries Scotland Plataformas Elevadoras JLG Sverige AB UI Krolewska Wright Business Centre JLG Iberica S L Enkopingsvagen 150 00 060 Warsawa 1 Lonmay Road Trapadella 2 Box 704 Poland Queenslie Glasgow G33 4EL P I Castellbisb
4. Note Before you begin your workday take time to check V your vehicle and have all systems in good operational condition Check the following Y Warning decals special instructions service lubrication schedule and operators manuals Make sure they are legible and stored in the proper location NEVER operate without a legible load chart Engine oil level Add oil as required Radiator coolant level Add coolant as required Hydraulic fluid level Add hydraulic fluid as required Hydraulic hoses and hose connections for wear or leaks Repair or replace any damaged hoses or connections Condition of boom chain system Transmission oil cooler and engine radiator for dirty fins Back up alarm and horn Structural and weld damage Forks for welded repairs cracks wear and misalignment Wo e D LEER MS S AWARNING Never repair forks by welding Never use forks with welded repairs Forks may break and falling load or forks may cause death or serious injury v Tires for cuts bulges correct tire pressure and proper ballast content v Loose hardware v All wheel lugs v Service and park brakes for proper operation v All instruments gauges and indicator lights v The steering left and right v All control levers for proper operation Y Keep engine and radiator clean and free of dirt and flammable material v The condition and operation of the seat belt and its mounts v Steps pedals and non sk
5. Planetary Hub Tractor Hydraulic Fluid Mobilfluid 424 Grease Points Grease Lithium based 1 Consult engine manufacturers Operator s Manual for additional information 36 ENGINE OIL SPECIFICATIONS John Deere Engines Use the table below to select the oil viscosity based on expected air temperature range during the period between oil changes Consult the John Deere Operator s Manual for additional information Note New John Deere engines use special break in oil for the initial period of operation Consult engine Operator s Manual for additional information Engine Oil Selection Chart John Deere Engine Oil John Deere Temperature Range C Oil Grade Temperature Range F SAE 5W 30 22 to 86 F 30 to 30 C SAE 10W 30 4 to 86 F 20 to 30 C SAE 15W 40 5 to 122 F 15 to 50 C SAE 30W 32 to 86 F 0 to 30 C SAE 40W 50 to 104 F 10 to 40 C Arctic Oil e g MIL L 46167B Approved Engine Oil Specifications Below 22 F Below 30 C API CD CE CCMC Specification D4 D5 SAE 5W 30 SAE 10W 30 SAE 15W 40 SAE 30W SAE 40W MIL L 46167B FLUID amp LUBRICANT SPECIFICATIONS TRANSMISSION OIL SPECIFICATIONS The following table shows approved lubricants and associated temperature ranges for use with ZF 4WG series transmission Transmission Oil Selection Chart ZF 4WG 98TC Trans
6. FEET 30 METERS 4 SAMPLE LOAD CHART CONSULT LOAD CHART MOUNTED IN MACHINE FOR YOUR MACHINE S MODEL AND OPTIONAL ATTACHMENT CAPACITIES 8 7 6 5 3 2 1 0 R1025 VERTICAL SCALE SHOWS DISTANCE ABOVE AND BELOW GROUND LEVEL HORIZONTAL SCALE SHOWS DISTANCE FROM FRONT WHEELS BOOM ANGLE SCALE REPRESENTS THE BOOM ANGLE RELATIVE TO LEVEL GROUND LETTERED ARCS SHOW THE AMOUNT OF BOOM EXTENSION AND THE ROTATION OF THE BOOM AT THESE EXTENSIONS G LOAD AREAS SHOW MAXIMUM RATED LOAD CAPACITIES EACH AREA DEFINES THE CAPACITY THAT MAY BE LIFTED AND PLACED FOR EASE OF READING HEAVY LINES AND DIFFERENT COLORS SEPARATE THESE AREAS TRANSACTION AREA SHOWS THE ADDITIONAL 80 INCH AREA THAT MAY BE REACHED BY MOVING THE TRANSFER CARRIAGE WITH A FULLY EXTENDED BOOM THE AREA FILLED WITH RED DOTS SHOWS WHERE THE REAR AXLE IS LOCKED AND FRAME TILT AND DRIVE ARE DISABLED See Lift the Load Safely on page 27 40 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 An Oshkosh Corporation Company JLG Industries Inc
7. Know how to use a first aid kit and fire extinguisher VEHICLE STABILITY Your JLG vehicle is proven to be stable when properly operated However improper operation faulty maintenance unauthorized modifications or poor housekeeping may cause instability Some Conditions that Affect Stability Ground and surface conditions Surface grade Weight and configuration of the attachment Improper tire inflation and ballast content Operator judgement Excessive tilting of the fork carriage or other attachments with an elevated load can cause vehicle instability The amount of allowable tilt is governed by conditions such as boom elevation weight of load and terrain STARTING SAFETY Before Starting the Engine Important Warn all others in the area that you are going to start the vehicle 1 Check underneath and around the vehicle and make sure all personnel are clear 2 Be properly seated and seat belt secured 3 Set the park brake 4 Make sure shift selector is locked in the NEUTRAL position 5 Apply the brakes SAFETY OPERATION SAFETY Before Leaving the Vehicle Unattended L Safe operation is the responsibility of the operator Stop the engine L Improper use of the vehicle can lead to dangerous Block the wheels if parked on an incline situations for yourself those around you the e Lower the boom vehicle and the work area You must have safe working habits and be aware
8. Override Switch 15 General Fluid and Lubricant Specifications Transmission Declutch Switch 16 36 Steer Mode Selector 16 Engine Oil Specifications 36 Front Wheel Steer Mode 17 John Deere Engines n na 36 Round Steer Mode 17 Transmission Oil Specifications 37 Oblique Steer Mode ei Fuel Requirements 0 000 eee 37 Synchronizing Straightening the Wheels 17 General 37 Joystick Controls 0 000 Po quart ur cac top heh NO TN General Description 19 Sonn Dele Engines sues egeat on Front Joystick sss esse eee 19 Service Lubrication Schedule 38 Rear Joystick 20 Auxiliary Controls 00005 22 Sample Load Chart usse 40 TABLE OF CONTENTS SAFETY DANGER WARNING amp CAUTION WHAT THEY MEAN Hazards are identified by the Safety Alert Symbol and followed by a signal word Danger Warning or Caution A DANGER The signal word DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious personal injury AWARNING The signal word WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious personal injury ACAUTION The signal word CAUTION indicates a potentially hazardous situation wh
9. another vehicle at intersections blind spots or other dangerous locations Avoid running over loose objects and debris Additional Safety Instructions Maneuver the vehicle carefully Do not cause the load to shift or the vehicle to tip Slow down for wet and slippery surfaces and changes in terrain Turn the steering wheel smoothly and slow down when turning Do not make sharp turns at high speeds Take special care when traveling without a load The vehicle is more susceptible to tipping over on its side Do not continue to operate the vehicle if an unsafe condition is found Stop the vehicle and report the condition to the designated authority Never make repairs or adjustments unless you are authorized to do so Always keep your hands and feet inside the cab Never reach into the boom or attachments Understand the limitations of the vehicle and drive safely Watch for pedestrians especially when backing up or turning and where pedestrians may step into the path of the vehicle The vehicle may add to the overall sound level of the work area Give consideration to the sound exposure of those working around you If a fuel leak is found do not operate the vehicle until the problem is fixed When approaching areas where vision is obstructed always slow down and sound the horn Report all accidents involving personnel building structures and equipment to your supervisor or as directed Use cauti
10. clearance you have under power lines and telephone lines All local state provincial and federal regulations must be met before approaching power lines overhead or underground cables or other power sources with any part of your vehicle Do not operate the vehicle near energized power lines Always contact the electrical power company when operating near power lines The lines should be moved insulated disconnected or de energized and grounded before operating in the area Keep all parts of the vehicle at least 10 feet away from power lines BEFORE OPERATING THE MACHINE KEEP ALL PARTS OF lt MACHINE AT LEAST 10 FEET FROM POWER LINES CONTACTING ENERGIZED POWER LINES WILL CAUSE DEATH OR SERIOUS PERSONAL INJURY PLAN YOUR WORK Before you operate know how and where you will travel turn and pickup lift and place loads Choose a smooth level route to prevent possible tipover or loss of load If possible avoid crossing Ruts Ditches Curbs Exposed railroad tracks Note When these conditions cannot be avoided keep the load as low as possible and travel very slowly and with extreme caution Know where there are any blind corner conditions on the worksite Before turning a blind corner stop sound your horn and proceed slowly Always maintain safe distances between your vehicle and other equipment that may be on the worksite Know the weights of all loads you may be expected to transpo
11. e Left Outrigger Outrigger Controls The outrigger control levers are located just in front of the frame tilt control lever Moving an outrigger control lever to the right will lower the outrigger moving it to the left will raise it ACAUTION IF BOOM CAPACITIES ARE EXCEEDED WITH Frame Tilt Control OUTRIGGERS DOWN STRUCTURAL The frame tilt control is used to level the vehicle laterally DAMAGE MAY OCCUR CONSULT LOAD side to side up to 10 left or right The lateral angle of CHART FOR RATED CAPACITIES DO NOT the vehicle relative to level ground is shown on the EXCEED RATED LIFT CAPACITIES frame level indicator see Frame Level Indicator on page 23 The control is functional only while the engine is running The control lever 1 is equipped with a safety lock to prevent unintentional operation Lift the lock ring 2 to unlock the lever and allow it to be moved left or right Return the control lever to center position and release lock ring to secure lever The lever can be moved either left or right tilting the frame accordingly To level the frame move the lever in the direction you want the ball in the frame level indicator to move 24 INSTRUMENTS AND CONTROLS 25 GENERAL OPERATING PROCEDURES STARTING PROCEDURES Before operating walk completely around the vehicle Make certain no one is under it on it or close to it Let all other workers and bystanders know yo
12. of hazardous The vehicle is considered attended when the operator working conditions is less than 25 feet from the vehicle and it remains in the operator s view L Thoroughly read and understand this entire manual Follow all safety rules and practices The vehicle is considered unattended when the explained in this manual operator is 25 feet or more from the vehicle and the vehicle is in the operator s view or whenever the L The vehicle must be checked every day or at the vehicle is not in the operator s view start of each shift See Check the Equipment on page 8 L To meet the requirements of different operating conditions JLG offers optional lighting packages for your vehicle Do not operate the vehicle if it is not equipped with lights when conditions require them If your vehicle is not equipped with the proper lights contact your authorized JLG dealer for available lighting packages L If operating in an enclosed or partially enclosed environment make sure there is enough ventilation Engine exhaust fumes can be deadly Never stand or walk under a raised boom Do not allow to you and those around you if precautions are not others to do so taken Questions about the air quality in the working environment and sampling methods should be directed to a qualified person W1008 f Never allow passengers on the vehicle Never operate the vehicle controls while you are outside the cab You must be properl
13. override switch 2 is located on the cab floor to the left of the brake pedal See Stability Systems on page 32 before using this switch PARK BRAKE CONTROL Service Brake Pedal Push brake pedal 1 down to slow or stop vehicle DRIVE LOCKOUT OVERRIDE FOOT SWITCH Park Brake Control Pull knob 3 out toward you to engage the park brake Push knob in to disengage the park brake Important Always stop the vehicle with service brakes before engaging park brake Do not use the park brake to slow or stop the vehicle EXCEPT in an emergency Note When park brake is engaged transmission will default to NEUTRAL regardless of shift selector Drive Lockout Override Foot Switch position 14 SHIFT SELECTOR l X Shift Selector The shift selector is located on the steering wheel column It controls vehicle travel direction and transmission speed range Direction Control Vehicle travel direction is controlled by moving the shift lever to one of three positions FORWARD F Move the lever fully forward to select forward vehicle movement NEUTRAL N Move the lever to the center position to disengage the transmission The engine may be started only when the transmission is in NEUTRAL REVERSE R Move the lever fully rearward to select reverse vehicle movement Speed Range Selection The transmission has four speed ranges in forward and three in reverse To select different transmission
14. speed ranges rotate the selector handle to the desired position Speed ranges may be selected while the vehicle is moving in forward or reverse Note The transmission requires 3 seconds immediately after engine start for self diagnostics Always wait at least 3 seconds after engine start before engaging transmission The following table shows the maximum travel speed forward or reverse See note below for each position on the selector ZF 4WG 98 TC Speeds POSITION SPEED 1 4 2 mph 2 7 0 mph 3 16 5 mph 4 21 5 mph Note If the fourth speed range is selected while traveling in reverse the transmission will remain in third INSTRUMENTS AND CONTROLS Neutral Lock F t N y R Neutral Lock The shift selector is equipped with a neutral lock 4 To lock the shift lever in the NEUTRAL position 1 Place the lever in the NEUTRAL position 2 Move the neutral lock lever to the N NEUTRAL LOCK position To unlock move the neutral lock lever to the D DRIVE position SHUTDOWN OVERRIDE SWITCH TRANSMISSION DECLUTCH Shutdown Override Switch The shutdown override switch 5 is an internally lighted rocker switch located on the instrument panel located below the gauge cluster Pressing the forward side of the switch delays engine shutdown for 30 seconds The switch resets the shutdown timer to 30 seconds and may be used repeatedly However continuously holding
15. the switch will not reset the 30 second timer 15 INSTRUMENTS AND CONTROLS TRANSMISSION DECLUTCH SWITCH ot TRANSMISSION DECLUTCH Transmission Declutch Switch The transmission declutch switch 1 is an internally lighted rocker switch located on the instrument panel below the gauge cluster Pressing the forward side of the switch activates the transmission declutch feature when the foot brake pedal is applied This feature eliminates the need to shift to NEUTRAL before operating the hydraulic system at high engine speeds When the transmission is declutched the drivetrain is disconnected and the hydraulic system has full engine power To use the Transmission Declutch Feature 1 The transmission must be in first or second speed range forward or reverse The declutch feature will not operate when the transmission is in third speed range 2 Press the forward side of the transmission declutch switch 3 Press the service brake pedal or pull the park brake knob 4 The switch will illuminate to show the transmission clutch has disengaged Press the rear side of the switch to deactivate the declutch feature AWARNING Apply park brake or service brake and return engine to idle before deactivating declutch feature Deactivating declutch feature above idle will cause machine to move abruptly 16 STEER MODE SELECTOR OBLIQUE STEER cc H H ke 7 x mr E ke 2 fo E Wa ROUN
16. your area John Deere Engines Use of regular sulfur off highway diesel fuel is recommended If low sulfur on highway diesel fuel is used John Deere Diesel Fuel Conditioner TY22030 must be added Use of low sulfur fuel without the specified conditioner may cause premature failure of the engine s fuel system components and void the warranty 37 SERVICE LUBRICATION SCHEDULE 38 SERVICE LUBRICATION SCHEDULE SYSTEM CAPACITIES AND PRESSURES 47 GALS TIRES 14 00 x 24 65 GALS PRESSURE 36 GALS HYDRO FILL TIRES SHOULD BE FILLED TO 18 OTS APPROXIMATELY 75 FULL 55 GALLONS 596LB HYDRAULIC RESERVOIR HYDRAULIC SYSTEM amp RESERVOIR FUEL TANK COOLING SYSTEM PER TIRE 65 PSI OF CALCIUM CHLORIDE TIRE FILL 14 QTS ENGINE CRANKCASE DEERE 4 CYL APPROXIMATED WEIGHTS TRANSMISSION DRAIN REFILL APPROX 19 QTS FRONT AXLE DIFFERENTIAL PLANETARY HUB EACH REAR AXLE DIFFERENTIAL PLANETARY HUB EACH ACCUMULATOR NITROGEN PRECHARGE WET DISK BRAKES HYDRO FILLED 9 5 QTS FOAM FILLED 54 OZ HYDRO FILLED 10 5 QTS FOAM FILLED 40 5 OZ 400 425 PSI 14 00 x 24 12 PLY SGG RB G2 BIAS BELTED 925 LBS 1050
17. 1 in the gauge and light cluster See above figure W1057 AWARNING Do not disconnect or bypass proximity switches Bypassing proximity switches may result in death or serious personal injury W1056 On models equipped with a standard carriage the boom extension distance is approximately 25 feet On models equipped with an optional tower the distance is approximately 21 feet The boom extension distance is sensed by a proximity switch installed in the outer boom section Never disconnect or bypass the proximity switch At this point the left and right outriggers must both be lowered to the ground to allow the boom or transfer carriage to be extended further See Outrigger Controls on page 24 for information on outrigger operation 34 STABILITY SYSTEMS 35 FLUID amp LUBRICANT SPECIFICATIONS GENERAL FLUID AND LUBRICANT SPECIFICATIONS General Fluid amp Lubricant Specifications System or Component Fuel System Fluid or Lubricant Specification See Fuel Requirements Hydraulic System Tractor Hydraulic Fluid Mobilfluid 424 Engine Cooling System See engine manufacturer s operating manual Engine Oil See Engine Oil Specifications Transmission See Transmission Oil Specifications Differential Tractor Hydraulic Fluid Mobilfluid 424
18. ALWAYS check the load chart mounted 7 in the vehicle before lifting a load Lift only within the capacity of the vehicle as shown by the load chart If possible plan to load unload and turn on flat level ground If not level use frame tilt See Frame Tilt Control on page 24 to level vehicle before raising the boom Level indicator MUST be centered Be sure there is enough clearance overhead and all around for lifting and traveling Watch the front and rear clearances when turning If loads are to be handled several times place stacking blocks under loads For sideshift equipped vehicles center the forks and carriage before lifting Inspect load to be lifted Approach the load slowly and squarely with fork tips straight and level Adjust pallet forks as necessary Fully engage the load by moving the transfer carriage slowly forward until the load touches the fork carriage backrest Tilt the forks back to position the load for travel then lift the load only enough to clear obstacles Fully retract the transfer carriage TRANSPORT THE LOAD SAFELY When transporting the load Keep the forks tilted back with boom retracted and the load close to the ground Keep the load as low as possible Never carry the load above eye level Where the load will obstruct the operator s vision itis recommended that the vehicle be operated in REVERSE looking backwards in the direction of travel Travel at a slower spee
19. D STEER Steer Mode Selector There are three steer modes available on your vehicle 2 Oblique Steer Crab Steer 3 Front Wheel Steer 2 Wheel Steer 4 Round Steer 4 Wheel Steer To select a steer mode turn the steer mode selector so the handle aligns with a selection on the adjacent plate You will feel the selector slip into a detent or catch when the desired mode is selected ACAUTION Never change steer modes while the vehicle is moving The wheels can become misaligned and cause loss of control Always stop the vehicle completely and synchronize straighten and align the wheels before changing steer mode See Synchronizing Straightening the Wheels on page 17 INSTRUMENTS AND CONTROLS Front Wheel Steer Mode Front Wheel Steer Mode Front Wheel Steer mode also known as 2 Wheel Steer mode allows the operator to steer the vehicle in a conventional manner The front wheels of the vehicle steer and the rear wheels remain in position Use this mode when traveling on flat surfaces at higher speeds Front Wheel Steer mode should not be used in confined and congested areas Important Synchronize straighten and align the wheels before engaging Front Wheel Steer mode Round Steer Mode Round Steer Mode Round Steer mode also known as 4 Wheel S
20. E AND BOOM AS LEVEL AS POSSIBLE WHILE DRIVING NEVER EXCEED 5 FROM LEVEL LEVEL FRAME SLOWLY AND CAREFULLY FAILURE TO FOLLOW THE INSTRUCTIONS IN THIS MANUAL MAY RESULT IN DEATH OR SERIOUS PERSONAL INJURY OV0070 33 STABILITY SYSTEMS BOOM TRANSFER EXTEND LOCK SYSTEM The boom transfer extend lock system is designed to increase stability of the vehicle by limiting how far the Do not disconnect or bypass the outrigger boom can be extended with the outriggers up cylinder pressure switches Do not restrict outrigger movement to simulate normal outrigger operation Failure to follow these instructions may result in death or serious personal injury SN Soyo WATER BOOM CHECK ENGINE 190 S 460 When both outriggers are lowered to the ground and LOCK P m have made positive contact with it pressure switches in the outrigger cylinders send electrical signals to the PARK BRAKE boom transfer extend lock system The system then unlocks the boom extend and transfer extend functions D The warning lamp will turn off B A CAUTION IF BOOM CAPACITIES ARE EXCEEDED WITH Gauge and Light Cluster OUTRIGGERS DOWN STRUCTURAL When the boom is extended to a specific distance and DAMAGE MAY OCCUR CONSULT LOAD the outriggers are not lowered the system will disable CHART FOR RATED CAPACITIES DO NOT the boom extend and transfer extend functions and light EXCEED RATED LIFT CAPACITIES the Boom Transfer Extend Lock lamp
21. E ons r with caution BEFORE RAI Bees E NEVER TILT FRAME WITH L Avoid panic braking Apply brakes smoothly for a THE BOOM RAISED controlled stop to prevent toppling the load eo MACHINE MAY TIP AND 72 CAUSE DEATH OR SERIOUS PERSONAL INJURY L Slow down for turns ramps dips uneven or slippery surfaces and in congested areas 5 Slowly and carefully raise the load If there is any indication of instability during the lift i e movement leaning swaying stop immediately lower the load move the vehicle to a more stable level position As lift height increases your depth perception decreases Placing the load safely at a high elevation may require a signalman to guide you 28 GENERAL OPERATING PROCEDURES 6 When the load is slightly higher than the landing LIFTING PERSONNEL point SLOWLY stop the lift JLG strongly recommends that you DO NOT use the JLG vehicle as a personnel lift It is designed for material handling ONLY If personnel MUST be lifted lift only in accordance with ASME ANSI B56 6 1992 or later Para 5 15 and with a properly designed work Do not ram the hydraulic lift cylinder to the platform end of its stroke The jolt could spill the load resulting in death or serious personal injury AWARNING 7 Use the transfer carriage to place the load directly over the landing point The transfer carriage allows saf
22. ING ALWAYS LEVEL MACHINE BEFORE RAISING BOOM NEVER TILT FRAME WITH THE BOOM RAISED MACHINE MAY TIP AND CAUSE DEATH OR iB SERIOUS PERSONAL INJURY L ALWAYS check the load chart mounted in the vehicle before lifting a load Lift only within the capacity of the vehicle as shown by the load chart Never tilt the frame when the boom is raised Operate the controls smoothly don t jerk the hydraulic controls or steering wheel Avoid sudden stops starts turns or changes in direction Never cowboy or play games with a vehicle Operate vehicle controls only while seated in the operator s compartment D DD D OO Never leave the operator s seat without first lowering the boom to the ground setting the park brake and placing transmission in NEUTRAL AWARNING Keep all parts of your body inside the operators compartment while operating the vehicle Failure to follow these instructions may result in death or serious personal injury L DO NOT touch lean on or reach through the boom lift mechanism or transfer carriage areas DO NOT permit others to do so Never climb on the boom lift mechanism or transfer carriage L DO NOT operate a malfunctioning vehicle L STAY ALERT Should something break come loose or fail to operate on your vehicle stop work shut down the vehicle and alert your supervisor immediately LIFT THE LOAD SAFELY Important
23. LBS 14 00 x 24 GLA2 STEEL BELTED RADIAL 1000 LBS 1125 LBS HOURS OF OPERATION DESCRIPTION AIR CLEANER ENGINE COOLANT E E 7 nrOYUNDERRVOTS LUB zs m 25 OUTRIGGERS DAILY WEEKLY 50 Oo m 10 a m mr o n A E 2 GREASE FITTINGS 4 GREASE FITTINGS 6 GREASE FITTINGS 1 GREASE FITTINGS 4 GREASE FITTINGS 4 GREASE FITTINGS P 2 GREASE FITTINGS 2 GREASE FITTINGS LUBE 3 GREASE FITTINGS 5 GREASE FITTINGS 9 GREASE FITTINGS 1 1 5 6 c UJ m 17 m r c UJ m o r c D m o m 21 N c Ww m REMARKS SEE ENGINE MANUAL SEE PARTS BOOK SEE PARTS BOOK SEE SERVICE MANUAL SEE PARTS BOOK SEE SERVICE MANUAL SEE PARTS BOOK SEE PARTS BOOK SEE PARTS BOOK SEE PARTS BOOK SEE ENGINE MANUAL SEE OTHER SIDE OF CARD SEE OTHER SIDE OF CARD SEE PARTS BOOK CF FIRST HOURS OF OPERATION C CHECK SERVICE AS NECESSARY CF CHANGE FLUID R REPLACE CLN CLEAN CAREFULLY SHORTEN SERVICE INTERVALS ACCORDINGLY WHEN OPERATING UNDER DUSTY OR SEVERE CONDITIONS INSPECT ALL FLUID SYSTEMS AND CHANGE FLUID WHEN FLUID SHOWS TRACES OF CONTAMINATION OR HIGH TEMPERATURES EVIDENCED BY STRONG ODOR DISCOLORATION OR SEPARATION Ov0060 39 SAMPLE LOAD CHART 6 gt TRaNsacTION 80 203 CM e e e e 90 906 oeoo o e INDICATES REAR e 2000 LBS 900 kg
24. Lesli Operator amp Safety Manual Keep this manual with machine at all times Model 1044C 54 Series II Before S N 0160037900 31200070 Revised February 23 2009 An Oshkosh Corporation Company Revision Log REVISION LOG March 9 2005 A Original Issue of Manual July 12 2005 B Revised pages 6 23 24 27 amp inside rear cover February 23 2009 C Revised covers and pages c 30 amp 31 Read This First This manual is a very important tool Keep it with the machine at all times The purpose of this manual is to provide owners users operators lessors and lessees with the precautions and operating procedures essential for the safe and proper machine operation for its intended purpose Due to continuous product improvements JLG Industries Inc reserves the right to make specification changes without prior notification Contact JLG Industries Inc for updated information Operator Qualifications The operator of the machine must not operate the machine until this manual has been read training is accomplished and operation of the machine has been completed under the supervision of an experienced and qualified operator Operation within the U S A requires training per OSHA 1910 178 Operators of this equipment must possess a valid applicable driver s license be in good physical and mental condition have normal reflexes and reaction time good vision and depth perception and normal hearing Operator m
25. W1056 REAR OSCILLATION LOCK SYSTEM The Rear Oscillation Lock System prevents the frame from rotating on the rear axle System operation With the boom below 20 elevation the rear axle oscillates freely With the boom between 20 and 40 elevation Transmission is limited to first or second gear Rear axle is in restricted oscillation mode Frame tilt function still operates but at a reduced speed when the boom elevation is above 20 With the boom above 40 elevation Transmission is locked out and rear axle oscillation is locked to the frame Frame tilt function still operates but at a reduced speed With the boom above 40 elevation and the drive lockout override switch page 14 pressed down Transmission is limited to first gear Rear axle is in very restricted oscillation mode Fully pressing the brake pedal down locks the rear axle at any boom angle 32 DRIVE LOCKOUT OVERRIDE Important Read and understand the following instructions BEFORE using the Drive Lockout Override System Theory of Normal Operation This vehicle is equipped with a stabilization system that does several things to increase lateral side to side stability When the boom is raised above 20 elevation The transmission is limited to first and second gears The rear oscillation lock cylinder is limited to slow orificed movement The speed of the frame tilt function is limited When the boom is ra
26. ach pivot pin 6 from attachment 7 8 Pull release handle 1 back D C 12 Retract the boom until quick attach 5 is clear of attachment 7 9 The lock pin 2 should engage the attachment clearing the lock plate 3 from the attachment stop 4 30 GENERAL OPERATING PROCEDURES Connecting an Attachment d N 4 cr 1 With quick attach 5 rotated fully downwards 5 Checkto see that the lock plate 3 is engaged extend the boom until quick attach pivot pin 6 is ahead of the attachment stop 4 properly aligned underneath the attachment 7 S r AWARNING Cc B MAKE SURE SECURELY CONNECTED TO QUICK ATTACH 6 ATTACHMENT MAY FALL AND CAUSE SERIOUS 8 PERSONAL INJURY OR DEATH 6 Connect attachment hydraulic hoses if 2 Raise the boom to engage the quick attach pivot equipped pin 6 with the attachment 7 3 Rotate the quick attach 5 upwards to engage the attachment 7 4 Shut off engine 31 STABILITY SYSTEMS SYSTEM SAFETY Never tamper with modify or bypass the stability systems installed on your JLG vehicle Never disconnect or bypass pressure switches or proximity switches AWARNING Do not disconnect or bypass proximity switches Bypassing proximity switches may result in death or serious personal injury
27. al Sur SE 176 27 Jarfalla Phone 48 0 914 320 245 Scotland 08755Castellbisbal Barcelona Sweden Fax 448 0 914 358 200 Phone 44 0 141 781 6700 Spain Phone 46 0 850 659 500 Fax 44 0 141 773 1907 Phone 34 93 772 4 700 Fax 46 0 850 659 534 Fax 34 93 771 1762
28. attempt to mount a moving vehicle 10 BEFORE OPERATING THE MACHINE INSTRUMENTS AND CONTROLS GAUGES AND LIGHTS f S 540 WATER TRANSFER HECK ENGINE EXTEND LOCK PARK BRAKE D TRANSMISSION DECLUTCH Gauge and Light Cluster Note Gauges and indicator lights operate only when the ignition switch is in the ON position 1 Boom Transfer Extend Lock Red lamp lights to show when boom extend and transfer extend functions are locked out because the outriggers are not down See Stability Systems on page 32 2 Park Brake Red lamp lights to show when park brake is applied and goes out when park brake is released See Park Brake Control on page 14 3 Check Engine Red lamp lights and buzzer sounds for 30 seconds before engine shuts down when a Shutdown fault is detected Under normal conditions the light and buzzer will go out quickly after engine start If the light or buzzer does not go out or comes on during vehicle operation shut off engine immediately investigate and repair before operating 4 Engine Water Temperature Registers from 100 to 240 F Normal operating temperature is 180 to 185 F 5 Fuel Level Shows fuel level in fuel tank 6 Rear Oscillation Lock The rear oscillation lock light will come on when the boom angle is above 20 See Stability Systems on page 32 12 7 Low Brake Pressur
29. being driven Operation of the Drive Lockout Override System To operate the Drive Lockout Override System AWARNING Failure to follow the instructions in this manual may result in death or serious personal injury Note These procedures only apply to situations where the boom is above 40 elevation 1 Plan your route of travel The surface must be firm and as level as possible Always avoid rough or steep areas 2 Level the frame before picking up the load If load is suspended slung load make sure tag lines are secure and manned Never let a slung load sway as this may lead to vehicle tipover or injury to personnel 3 With the brakes on move the shift selector to the Forward or Reverse position 4 Using your left foot press and hold down the drive lockout override switch The drive will engage in first gear only and the vehicle may be moved 5 Drive the vehicle very slowly while carefully watching the terrain Make turns smoothly and slowly 6 Use the service brakes to stop the vehicle slowly and smoothly Releasing the Drive Lockout Override Foot Switch will disengage the drive but this will not activate the brakes AWARNING ALWAYS LEVEL MACHINE BEFORE RAISING BOOM WHEN DRIVE LOCKOUT OVERRIDE IS USED TO MOVE MACHINE WITH BOOM ELEVATED FRAME LEVEL CAN CHANGE WITH CHANGING TERRAIN ADJUST FRAME TILT TO KEEP FRAM
30. boom extension The letters on the boom correspond to the lettered zones on the load chart Use this indicator with the boom angle indicator transfer carriage extension indicator if equipped and vehicle load chart to determine correct boom lifting capacities See Sample Load Chart on page 40 TRANSFER CARRIAGE EXTENSION INDICATOR 1L oL TTTLLTTLTTTETTTITTITITIT Transfer Carriage Extension Indicator The transfer carriage extension indicator shows the distance of the carriage from the fully retracted position Use this indicator with the boom angle indicator boom extension indicator and vehicle load chart to determine correct boom lifting capacities See Sample Load Chart on page 40 FRAME LEVEL INDICATOR Frame Level Indicator The Frame Level Indicator shows the lateral side to side angle of the frame relative to level ground Indicator range is from 0 to 10 left or right in increments of one degree When the ball is centered 05 the vehicle is laterally level The frame tilt feature may be used to correct vehicle angles up to 10 to the left or right See Frame Tilt Control on page 24 23 INSTRUMENTS AND CONTROLS AWARNING ALWAYS LEVEL MACHINE BEFORE RAISING BOOM NEVER TILT FRAME WITH THE BOOM RAISED MACHINE MAY TIP AND CAUSE DEATH OR H SERIOUS PERSONAL j INJURY OUTRIGGER CONTROLS Right Outrigger X
31. d and get someone to direct you Avoid excessively steep slopes or unstable surfaces If you must drive on a slope level the vehicle keep the load low and proceed with extreme caution DO NOT under any circumstances drive across excessively steep slopes The vehicle can be levelled side to side a total of 10 in each direction 1896 grade Any slope or grade that exceeds this is considered excessively steep 27 GENERAL OPERATING PROCEDURES U ifa slope is too steep to allow the frame to be SAFELY PLACING THE LOAD leveled do not raise the boom The frame must always be level before raising the boom Elevated or Overhead Placement Important When stacking or placing a load to a W A H N f N G high landing use extreme caution There may be other workers in the immediate When traveling over inclines slopes or area you cannot see Make sure that all bystanders are away from the area ramps where the load could tip or fall Tilt the attachment back and raised only 1 Be sure the landing point can safely support the enough to clear the ground weight of the load The chosen landing location Avoid turning If it cannot be avoided turn oo both front to back and slowly and with extreme caution Travel straight up and down the grades You should know or be able to estimate the When loaded and traveling up or down weight and load center of the load that you will be i lifting If you are unsure of the weight an
32. d load grades travel with the load uphill center of the load check with your supervisor or When unloaded travel only with the forks with the supplier of the material ALWAYS check or attachment downhill the load chart mounted in the vehicle before lifting a load Lift only within the capacity of the vehicle as shown by the load chart Proceed slowly and with extreme caution Do not travel across excessively steep 2 Drive as close as possible to the landing location slopes or unstable surfaces Approach very slowly with the load as low as Failure to follow these instructions may possible result in death or serious personal injury 3 Tilt carriage rearward to cradle the load L Reduce speed and sound horn at blind 4 Level the vehicle using frame tilt BEFORE the intersections exits and when approaching load is raised See Frame Tilt Control on page pedestrians 24 DO NOT raise the load for placement if the forks are tilted to one side If the vehicle cannot be positioned so the load is level before lifting reposition the vehicle The likelihood for vehicle Ll Avoid driving over loose objects and holes in tipover is greatly increased if the load is not level roadway surfaces to prevent losing the load or before lifting tipping the vehicle Ll Avoid crossing ditches curbs or exposed railroad AWARN l NG tracks If crossing cannot be avoided keep the load as low as possible travel very slowly and ALWAYS EE
33. e Red lamp lights and buzzer sounds when service brake hydraulic system pressure drops below the safe operating level Under normal conditions the light and buzzer will go out quickly after engine start If the light or buzzer does not go out or comes on during vehicle operation shut off engine immediately investigate and repair before operating Do not operate vehicle when low brake pressure light or buzzer is on 8 Transmission Declutch Red lamp lights to show when transmission declutch feature is active See Transmission Declutch Switch on page 16 9 Engine Oil Pressure Shows operating engine oil pressure Gauge registers from 0 to 80 PSI Normal operating pressure is 50 to 60 PSI 10 Voltmeter Indicates system voltage Gauge registers from 10 to 16 volts Normal operating voltage range is 14 5 to 15 volts With ignition in ON position and engine off battery voltage is indicated This should normally be 12 6 volts T 280 1 4d 40 N WE 138 320 60 160 TRANS ZOE Transmission Oil Temperature Gauge 11 Transmission Oil Temperature Located on the instrument panel to the left of the Gauge and Light Cluster Registers from 140 to 320 F with Celsius equivalents If the temperature rises above 230 F 110 C stop the vehicle immediately shift to neutral and run the engine at half throttle The temperature should drop quickly If the temperature does not drop shut off engine and i
34. e and easy placement of the load without moving the vehicle Consult load charts for transfer capacity Forks should be level and parallel to the landing surface so that they may be easily retracted from under the load Before retracting the forks check landing point for any excessive bowing cracking noises or other indications of overloading If there is any indication that the landing surface cannot handle the weight of the load place the load ata different location that you know can handle the weight If the landing surface cannot handle the weight of the load pick the load back up lower it to the ground and lift a lighter load 8 Lower the load slowly to place it and relieve the weight from the forks Retract the transfer carriage until the forks are clear of the load Lower and retract the boom BEFORE moving the vehicle 9 The vehicle can now be moved from the landing location to continue work 29 GENERAL OPERATING PROCEDURES QUICK ATTACH Disconnecting an Attachment 1 Come to a complete stop on flat level ground 2 Set the park brake 3 Raise the boom so attachment clears ground 4 Extend the boom a short distance 5 Lower the boom to rest the attachment on level ground 10 Start the engine Fully rotate quick attach 5 6 Shut off engine downwards by using the attachment tilt control 7 Disconnect attachment hydraulic lines if equipped 11 Lower boom enough to clear quick att
35. here are no loose articles that may fall off the fork W1022 Don t overload the vehicle W1023 Never add unauthorized counterweights SAFETY E S o d MIA Ts 4 LF 5 LZ Avoid parking on slopes If it is necessary to park on a slope set the parking brake and block the wheels When Traveling On Inclines e Tilt the attachment back and raise only enough to clear the ground Avoid turning If it cannot be avoided turn slowly and with extreme caution Travel straight up and down grades e When loaded and traveling up or down grades travel only with the load uphill When unloaded travel only with the forks or attachment downhill e Proceed slowly and with extreme caution e Do not travel across excessively steep slopes W1043 Hz ow The vehicle can be levelled side to side a total of 10 in each direction 18 grade Any slope or grade that exceeds this is considered excessively steep W1018 Drive slow and carry the load as low as possible When Traveling on Roadways Make sure the vehicle is equipped with all necessary lights and safety signs required for traveling on roadways Observe all traffic laws and speed limits e Keep to the correct side of the roadway Keep a safe distance from other vehicles e Maintain control of the vehicle at all times e Yield the right of way to pedestrians and emergency vehicles e Do not pass
36. ich if not avoided may result in minor or moderate injury CAUTION The signal word CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in property damage SAFETY STANDARD The ASME ANSI B56 6 safety standard for rough terrain forklift trucks defines safety requirements relating to the design operation and maintenance of these vehicles DECALS The decals on the vehicle provide instructions for safe and correct operation Never make modifications affecting safe operation or capacity without the expressed written approval of JLG When JLG approved modifications are made the user is responsible for seeing that appropriate decals load charts and instructions are changed All plates and decals must be in place and legible at all times OPERATORS PROTECTIVE STRUCTURE This vehicles Operators Protective Structure is equipped with a Roll Over Protective Structure ROPS to guard the operator if the vehicle tips over The Falling Object Protective Structure FOPS is built into the ROPS The FOPS protects the operator from falling objects Despite the protection of the ROPS FOPS it cannot protect the operator from every possible hazard Do not consider the ROPS FOPS a substitute for safe practices and good common sense Any modification to a ROPS FOPS such as welding or drilling holes in the structural members for mounting brackets will affec
37. id surfaces Make sure they are clean and free of dirt grease oil snow and ice v Placement and operation of doors guards and covers Y Cleanliness and operation of mirrors window wipers and work lights Note If there is any indication that faulty equipment exists shutdown safely inform the proper authority and DO NOT operate the vehicle until the problem has been fixed Y Remove or put away tools lunch buckets chains hooks or any other loose objects that could interfere with operation KNOW THE WORK AREA Learn as much as possible about the work area before operation Walk around the worksite and inspect the terrain that you will be travelling on Make a note of surfaces to be avoided including Holes amp Drop offs Obstacles Soft mud amp standing water Oil spills amp slippery surfaces Note If any of the above conditions exist in the work area correct the condition before operating If the condition cannot be corrected avoid operation in the problem area When operating on docks ramps or floors check for weak spots Clear away trash and debris Pick up anything that could puncture a tire When required check the vehicle s maximum fully loaded ground pressure weight if operating on a hollow floor system Watch for conditions that could cause oss of control A collision Tipover Check overhead clearances Know the size of doorways and canopies Know exactly how much
38. ised above 40 elevation The rear axle stabilization cylinder is locked preventing the frame from rotating on the rear axle The transmission is disengaged stopping drive capabilities O_o 9 b f T Mi E oF U J W1052 Diagram 1 Stability Triangle Front axle locked and frame free to rotate on rear axle Diagram 2 Stability Rectangle Front and rear axles locked preventing frame from rotating When the boom angle is below 20 the vehicle operates with a freely oscillating rear axle to negotiate rough terrain See Diagram 1 STABILITY SYSTEMS When the boom angle is above 20 but below 40 the rear axle cylinder is orificed slowing movement of the frame on the rear axle This increases the lateral side to side stability When the boom angle is above 40 the rear axle cylinder locks preventing the frame rotating on the rear axle This changes the stability diagram from a triangle to a rectangle when viewed from above and substantially increases the vehicle s lateral stability See Diagram 2 General Description Drive Lockout Override System The Drive Lockout Override System does two things when engaged with the boom angle above 40 Allows the transmission to be engaged in first gear only Unlocks the rear oscillation lock cylinder and allows very slow orificed movement This increases dynamic lateral stability while the vehicle is
39. lity x25 uad Sg dada Seni 2 Follow Safe Operating Procedures 27 Starting Safety 2 Lift the Load Safely 27 Operation Safety serena in Late ea a ds 3 Transport the Load Safely 27 Before Operating the Machine 8 PASI PACING MIS ROA Sie Ee Ss Check the Equipment 005 8 Elevated or Overhead Placement 28 Know the Work Area 8 Lifting Personnel 29 Plan Your Work o oan eese ain ee EE 9 Quick Attach EE 30 Safe Vehicle Operation 9 Disconnecting an Attachment 30 Know the Rules 9 Connecting an Attachment 31 Protect Yourself 9 Mount and Dismount Properly 10 Stability Systems lslessees 32 Instruments and Controls Ls 12 SEET r Gauges and Lights Ed Kee E A ee e PIAR 12 Rear Oscillation Lock System Dr AY ide ebe a R 32 Ignition Switch 13 Drive Lockout Override Lus 32 Holt EE 13 Theory of Normal Operation 32 Brake Pedal me ierden toi aa ue averted 14 General Description Drive Drive Lockout Override Foot Switch 14 Lockout Override System 33 Park Brake Control 14 Operation of the Drive Shift Selector 15 Lockout Override System IMMER 33 Direction CONN Ol asta Taneka s debet bis 19 Boom Transfer Extend Lock System 34 Speed Range Selection 15 Neutral Locke 15 Fluid amp Lubricant Specifications 36 Shutdown
40. missions Min Oil Temperature for Starting Engine Oil Grade Min Oil Temperature for Engaging Transmission Recommended Mobilfluid 424 4 F 20 C 86 F 30 C Engine Oils SAE 20W 20 14 F 10 C 41 F 5 C SAE 15W 40 5 F 15 C 32 F 0 C SAE 10W 10W 30 10W 40 4 F 20 C 23 F 5 C Automatic Transmission Fluid ATF ATF 22 F 30 C Approved Lubricants Engine Oils 14 F 10 C API CD CE CF SF SG MIL L 2104 C D E MIL L 46152 C D E SAE 10W SAE 10W 30 SAE 10W 40 SAE 15W 40 SAE 20W 20 Automatic Transmission Fluid ATF may only be used at ambient temperatures below 14 F 10 C FUEL REQUIREMENTS General Diesel fuels are blended to meet the local temperature requirements The standard grades are 1 1D for temperatures 22 to 86 F 30 to 30 C 2 2D for temperatures 14 to 122 F 10 to 50 C There are two main classifications of diesel fuel in general use 1 Low sulphur on highway diesel fuel 2 Medium sulfur off highway diesel fuel This fuel contains blue dye The engine manufacturer specifies the diesel fuel requirements Additional information can be found below and in the engine manufacturer s Operator s Manual Consult your local fuel distributor for the properties of the diesel fuels available in
41. nvestigate INSTRUMENTS AND CONTROLS QUARTZ 0 0 00 t P M HOURS Hourmeter 12 Hourmeter Located on the instrument panel to the left of the Gauge and Light Cluster Registers H1021 total hours of vehicle operation Ignition Switch Positions IGNITION SWITCH Note The starter will not engage unless the park brake is applied and the shift selector is placed in the NEUTRAL position The ignition switch has four positions 14 OFF The key may be removed or inserted only at this position The engine and all electrical circuits except the horn circuit are shut down at this position 15 ON All electrical circuits except the engine starter circuit are operational 16 START Activates the engine starter When the key is released the switch will return to the ON position and remain there 17 This position is reserved for future use and currently has no function THROTTLE Ignition Switch Location The ignition switch 13 is located on the dash near the right side Engine Throttle Pedal Push throttle pedal 18 down to increase engine speed 13 INSTRUMENTS AND CONTROLS BRAKE PEDAL AWARNING Read understand and follow the instructions starting on page 32 of this manual BEFORE using the Drive Lockout Override System Failure to follow the instructions in this manual may result in death or serious personal injury The drive lockout
42. o safely operate these vehicles KNOW THE RULES Most employers have rules governing proper operation and maintenance of equipment Before you start work at a new location check with your supervisor or the safety coordinator Ask about rules you may be expected to obey Make sure you understand the rules covering traffic at your jobsite Make sure you recognize and understand the meaning of all signs flags and markings Make sure you understand all hand flag whistle siren or bell signals Make sure you know when to use lights turn signals flashers and horn PROTECT YOURSELF Wear all the protective clothing and personal safety devices issued to you or called for by job conditions You may need A hard hat Safety shoes Safety glasses goggles or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or filter mask BEFORE OPERATING THE MACHINE MOUNT AND DISMOUNT PROPERLY Always use Three Point Contact when mounting or dismounting the vehicle Three Point Contact means that three out of four arms and legs are in contact with the vehicle at all times during mount and dismount Clean your shoes and wipe your hands before mounting vehicle Always use hand hold and step when mounting Never use control levers as a hand hold when mounting or dismounting the vehicle Never step on foot controls when mounting or dismounting the vehicle Never
43. on when operating on ramps platforms trenches and other similar surfaces Keep a clear view of the terrain and where the vehicle is heading Watch out for other vehicles people and structures Where the load will obstruct the operator s vision it is recommended that the vehicle be operated in reverse looking backwards in the direction of travel Travel at a slower speed and get someone to direct you Avoid excessively steep slopes or unstable surfaces If you must drive on a slope level the vehicle keep the load low and proceed with extreme caution Do not under any circumstances drive across excessively steep slopes SAFETY Do not block access to fire lanes or fire equipment Do not jump If a vehicle ever becomes unstable and starts to tip over Brace yourself and stay with the vehicle Keep your seat belt fastened Hold on firmly and lean away from the point of impact Never tamper with modify or bypass the stability systems installed on your JLG vehicle Never disconnect or bypass pressure switches or proximity switches AWARNING Do not disconnect or bypass proximity switches Bypassing proximity switches may result in death or serious personal injury See Stability Systems on page 32 for more information on the stability systems installed on your vehicle BEFORE OPERATING THE MACHINE CHECK THE EQUIPMENT
44. racts the boom 21 INSTRUMENTS AND CONTROLS Auxiliary Controls Auxiliary Controls A switch is located on the top of the front amp rear joysticks under a protective rubber cap Pressing this switch down with your thumb activates the auxiliary function Hold the switch down while moving the joystick left and right Functions for the tilting carriage using the front joystick are shown below as an example Note Releasing the switch while moving the joystick left or right changes the function of the joystick back to the standard joystick controls Rotating Tilt Carriage to Right Tiltin Fri ntrol Holding the button down and moving the front joystick to g Carriage Centre the right rotates an optional tilting carriage to the operator s right Rotating Tilt Carriage to Left Holding the button down and moving the front joystick to the left rotates an optional tilting carriage to the operator s left 22 INSTRUMENTS AND CONTROLS BOOM ANGLE INDICATOR O DEGREES 20 0 Gi Boom Angle Indicator The boom angle indicator shows the angle of the boom relative to level ground Use this indicator with the boom extension indicator transfer carriage extension indicator and vehicle load chart to determine correct boom lifting capacities See Sample Load Chart on page 40 BOOM EXTENSION INDICATOR Boom Extension Indicator typical The boom extension indicator shows the amount of
45. rt before attempting to lift them Avoid loads of loose material if possible Check that loads are properly banded or strapped together If you will be placing loads at high elevations remember your depth perception is decreased because of distance Use a signal person near the point where the load is to be landed Insure that adequate clearance is provided between both rear tail swing and front fork swing of the vehicle to avoid injury to personnel or damage to nearby equipment Know where you will be expected to park your vehicle at the end of the work day preferably in a level area out of traffic If the area is on a slope or incline position the vehicle at right angles to the slope set the parking brake lower the boom to the ground and block the wheels Remember Be alert know that conditions can change Use common sense show that you are a responsible operator Be a defensive operator prevent accidents before they happen SAFE VEHICLE OPERATION For safe operation of this vehicle you must be a qualified and authorized operator To be qualified you must understand the written instructions supplied by the manufacturer have training including actual operation of this vehicle and know the safety rules and regulations for the jobsite An operator must not use drugs or alcohol which can affect his alertness and coordination An operator on prescription or over the counter drugs needs medical approval t
46. t the ROPS FOPS capability to provide the required protection Any modification or repair without the specific written approval of JLG will void the ROPS FOPS certification Contact your authorized JLG dealer before making any modifications or repairs Failure to do so may void the ROPS FOPS certification SAFETY REFUELING SAFETY L Never smoke near the vehicle during refueling L Do not permit anyone to be on the vehicle during refueling L Spilled fuel must be completely absorbed or evaporated before starting the engine L Make sure the fuel cap is in place before starting the engine L Never use an open flame when checking the fuel level in the tank L Never fill the fuel tank with the engine running Make sure you have adequate ventilation during fueling PERSONAL SAFETY Wear all the protective clothing and personal safety devices issued to you or called for by job conditions You may need A hard hat Safety shoes Safety glasses goggles or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or filter mask L Avoid entanglement hazards Do not wear clothing or jewelry that could catch on machinery Keep your hands hair feet and clothing away from moving parts Always keep your hands and feet inside the cab L Know the pinch points and rotating parts on the vehicle L Always know where to get assistance in case of an emergency
47. teer mode allows the front and rear wheels to steer in opposite directions Use Round Steer when tight turning is required This mode is very useful on job sites Oblique Steer Mode aN d Oblique Steer Mode Oblique Steer mode also known as Crab Steer mode enables steering of the front and rear wheels in the same direction V1003 It is generally used to angle the vehicle in tight areas Oblique Steer mode moves the vehicle to the side while moving forward or reverse Synchronizing Straightening the Wheels As different steer modes are selected it is possible for the wheels to become misaligned It is also possible for the wheels to drift out of alignment when traveling over long distances or rough terrain To synchronize straighten and align the wheels 1 Select ROUND steer mode Step 2 2 Turn the steering wheel to the right until it reaches the stop 3 Select FRONT WHEEL steer mode 17 INSTRUMENTS AND CONTROLS D o V1013 Step 4 4 Turn the steering wheel to the left about one turn Step 11 11 Drive the vehicle forward a short distance to check wheel tracking 6 Turn the s
48. teering wheel to the right until it 12 Stop the vehicle and select the desired steer reaches the stop This makes sure the rear mode wheels are fully against right stop 5 Select ROUND steer mode 7 Select FRONT WHEEL steer mode Note The above procedure can also be performed in the left direction Step 8 8 Continue to turn the steering wheel to the right until the wheels reach the stop 9 Select ROUND steer mode Step 10 10 Turn the steering wheel to the left until wheels are pointed straight ahead 18 INSTRUMENTS AND CONTROLS JOYSTICK CONTROLS General Description Joystick The joysticks control hydraulic flow to the associated cylinders Control is proportional The more joystick movement the greater the action The speed of cylinder action is also affected by engine hydraulic pump speed Action is quicker at higher engine speeds Joysticks can be moved in any direction and are not limited to front back left right movement Moving a joystick in a diagonal direction will cause a combination of actions Front Joystick The front joystick controls transfer carriage extension and attachment tilt An auxiliary function is also available by pressing the button on top of the handle See Auxiliary Controls on page 22 for further information
49. ty e 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 OG com Other Publications Available Illustrated Parts Manual 31200069 Service Manual 31200079 Read This First This Page Intentionally Left Blank TABLE OF CONTENTS Revision LOG secre Sines aie eee ERAI RIS a Tilting Carriage Control 22 B Angle Indicator 2 5 23 Read This First eoe uue eese b SE Operator Qualifications liess b Boom Extension Indicator 23 Modifications ccce sss b Transfer Carriage Extension Indicator 23 Other Publications Available C Frame Level Indicator 23 edis Frame Tilt Control llle 24 alely 12 noil AELIAN Eee Danger Warning amp Caution What They Mean 1 Outrigger Controls 24 Sel Ny EE i General Operating Procedures 26 Decals veto Pb eese b endo des Starting Procedures 26 Operators Protective Structure 1 Shutdown Procedures 26 Refueling Gate 2 Personal Safety oues tect om eege 2 Traveling 26 Vehicle Stabi
50. u are preparing to start the vehicle DO NOT start vehicle until everyone is clear To start engine 1 Start on level surface 2 Be properly seated 3 Set park brake 4 Move shift selector to NEUTRAL position Place the neutral lock lever to NEUTRAL LOCK position 5 Apply brakes 6 Turn ignition switch clockwise cranking the engine Do not crank the engine longer than 20 seconds Wait 2 minutes to allow starter to cool down before trying again 7 Allow engine to warm up Note The transmission requires 3 seconds immediately after engine start for self diagnostics Always wait at least 3 seconds after engine start before engaging transmission 8 In cold weather operation progressively move each function a small distance back and forth until full cycle has been accomplished To make sure warm oil reaches the rear carriage tilt cylinders slowly raise and lower the boom several times Failure to cycle the rear carriage tilt cylinders during cold vehicle start up can damage the cylinders and structure 9 Level vehicle move frame tilt full to the right then full to the left then back to level 10 Raise boom full up and full down Extend inner boom full out and retract full in 11 Tilt attachment full down and full back 12 Move transfer carriage full forward and full back Note It is your responsibility to evaluate working conditions and adjust your operation of the vehicle accordingly
51. ust 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 Operator amp Safety Manual Telehandler Safety Manual All instructional decals and plates Any optional equipment instructions furnished The operator must also read understand and comply with all applicable Employer Industry and Governmental rules standards and regulations Modifications Any modification to this machine must be approved by JLG 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 Industries Inc sends safety related bulletins to the owner of record of this machine Contact JLG Industries Inc to ensure that the current owner records are updated and accurate JLG Industries Inc must be notified immediately in all instances where JLG products have been involved in an accident involving bodily injury or death of personnel or when damage has occurred to personal property or the JLG product FOR Accident Reporting and Product Safety Publications Current Owner Updates Questions Regarding Product Applications and Safe
52. y seated in the cab before operating any controls Before Leaving the Cab Bring the vehicle to a full stop e Apply the park brake Lower the boom SAFETY Always check clearances under power lines and overhead structures before driving under them L DO NOT operate the vehicle near energized power lines Always contact the electrical power company when operating near power lines The lines should be moved insulated disconnected or de energized and grounded before operating in the area Keep all parts of the vehicle at least 10 feet away from power lines Contacting electrical power lines WILL result in death or serious personal injury A DANGER KEEP ALL PARTS OF MACHINE AT LEAST 10 FEET FROM POWER LINES CONTACTING ENERGIZED POWER LINES WILL CAUSE DEATH OR SERIOUS PERSONAL INJURY Always check for enough overheard clearance for the boom W1017 X2 8 SE Ensure that correct tire pressure and tire ballast levels are maintained W1014 Never attempt to discharge a load by stopping the vehicle suddenly nest nm Never lift a load using one fork SAFETY Never place loads that exceed scaffold capacity or subject scaffold to unnecessary shock loads ugang Ge Always be aware of load width W1015 Drive carefully and avoid sudden stops and changes of direction Ensure that the load is stable and secure Check to see that t
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