JLG 1043, Operation & Safety Manual

Page 1: ...Operation Safety Manual Original Instructions Keep this manual with machine at all times An Oshkosh Corporation Company Models 642 943 1043 1055 1255 31211031 Revised August 31 2015 ...

Page 2: ...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 ...

Page 3: ...SION LOG April 17 2015 A Original Issue of Manual August 31 2015 B Revised cover and pages d 2 1 2 4 thru 2 13 2 16 3 3 3 5 3 8 3 11 3 16 3 17 4 5 4 7 5 2 5 3 5 37 5 39 5 40 5 43 7 6 7 8 thru 7 13 7 15 7 16 7 19 7 23 9 1 thru 9 6 9 8 thru 9 12 ...

Page 4: ...equires 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 ad...

Page 5: ...d 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 Prod...

Page 6: ...ompliance standard Machine Configuration Two configurations of each machine are included in this manual Determine if machine is equipped with Ultra Low Sulfur Fuel Decal as indicated below If equipped with Ultra Low Sulfur decal all specific references to this machine configuration will be referred to as Ultra Low Sulfur ULS from this point forward If not equipped with Ultra Low Sulfur decal all s...

Page 7: ...d 1 8 Lifting Personnel 1 9 Driving Hazards on Slopes 1 10 Pinch Points and Crush Hazards 1 11 Fall Hazard 1 13 Chemical Hazards 1 14 1 4 ClearSky if equipped 1 15 Federal Communications Commission FCC Information for Users 1 15 Section 2 Pre Operation and Inspection 2 1 Preparation Inspection and Maintenance 2 1 2 2 Pre Operation Check and Inspection 2 2 2 3 Safety Decals 2 4 ANSI if equipped 2 4...

Page 8: ...isplay if equipped 3 18 Home Screen 3 19 Main Menu Screen 3 20 Attachment Selection Screen 3 22 Communication Error Screen 3 23 3 4 Anti Theft Functionality if enabled 3 24 Instrument Panel Input 3 24 Multifunction Display Input 3 25 3 5 Steer Modes 3 26 Manual Steering Alignment Mode Change 3 26 3 6 Operator Seat 3 27 Adjustments 3 27 Seat Belt 3 28 3 7 Boom Angle and Extension Indicators 3 29 3 ...

Page 9: ...ating with a Suspended Load 4 11 Lift Load Safely 4 11 Picking Up a Suspended Load 4 11 Transporting a Suspended Load 4 12 Leveling Procedure 4 12 Placing a Suspended Load 4 13 Disengaging a Suspended Load 4 13 4 5 Loading and Securing for Transport 4 14 Tie Down 4 14 Lifting 4 15 Section 5 Attachments 5 1 Approved Attachments 5 1 5 2 Unapproved Attachments 5 1 5 3 JLG Supplied Attachments 5 2 5 4...

Page 10: ... Bucket Fork Mounted 5 36 Trash Hopper Fork Mounted 5 38 Coupler Mounted Hook 5 40 Fork Mounted Hook 5 42 Truss Boom 5 44 Material Handling Arm 5 46 Personnel Work Platform Fork Mounted 5 48 Section 6 Emergency Procedures 6 1 Towing a Disabled Product 6 1 Moving Short Distances 6 1 Moving Longer Distance 6 1 6 2 Emergency Lowering of Boom 6 2 6 3 Emergency Exit from Enclosed Cab 6 3 Inside Cab 6 3...

Page 11: ... 8 250 Hour Lubrication Schedule 7 10 1000 Hour Lubrication Schedule 7 12 7 5 Operator Maintenance Instructions 7 15 Engine Maintenance Components 7 15 Fuel System 7 18 Emission System if equipped for ULS 7 20 Engine Oil 7 21 Air Intake System 7 22 Tires 7 24 Hydraulic Oil 7 26 Transmission Oil 7 27 Brake Fluid 7 28 Engine Cooling System 7 29 Windshield Washer System if equipped 7 30 Section 8 Add...

Page 12: ...Table of Contents vi 31211031 ...

Page 13: ...avoided may result in minor or moderate injury 1 2 GENERAL PRECAUTIONS Hydraulic cylinders are subject to thermal expansion and contraction This may result in changes to the boom and or attachment position while the machine is stationary Factors affecting thermal movement can include the length of time machine is stationary hydraulic oil temperature ambient air temperature and boom and or attachme...

Page 14: ...ectrical lines apparatus or any energized exposed or insulated parts according to the Minimum Approach Distance MAD Allow for machine movement and electrical line swaying Maintain a clearance of at least 10 ft 3m between any part of the machine and its occupants their tools and their equipment from any electrical line or apparatus carrying up to 50 000 volts One foot additional clearance is requir...

Page 15: ...tached to the machine The minimum approach distance shall be reduced to a distance within the designed working dimensions of the insulating barrier This determination shall be made by a qualified person in accordance with the employer local or governmental requirements for work practices near energized equipment DANGER Do not maneuver machine or personnel inside prohibited zone MAD Assume all elec...

Page 16: ...se the capacity charts located in cab DO NOT exceed rated lift capacity Be sure that the ground conditions are able to support the machine Be aware of wind conditions Wind may cause load swing and dangerous side loads DO NOT raise boom unless frame is level 0 degrees unless otherwise noted on capacity chart DO NOT level machine with boom attachment above 4 ft 1 2 m AUS DO NOT level machine with lo...

Page 17: ...pecifications for proper fill ratio and pressure requirements for tires equipped with ballast Always wear seat belt Keep head arms hands legs and all other body parts inside operator s cab at all times If 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 OH2291 OH20911 OH2221 ...

Page 18: ...load DO NOT attempt to use telehandler frame leveling to compensate for load swing Keep heavy part of load closest to attachment Never drag the load lift vertically When driving with a suspended load Start travel turn and stop slowly to prevent load from swinging DO NOT extend boom DO NOT raise the load more than 300 mm 11 8 in above ground surface or the boom more than 45 DO NOT exceed walking sp...

Page 19: ... 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 m...

Page 20: ... 31211031 Load Falling Hazard Never suspend load from forks or other parts of carriage weldment Use only approved lift points DO NOT burn or drill holes in fork s Forks must be centered under load and spaced apart as far as possible OW0130 ...

Page 21: ...tices 1 9 31211031 Lifting Personnel When lifting personnel USE ONLY an approved personnel work platform with proper capacity chart displayed in the cab DO NOT drive machine from cab when personnel are in platform O 0171 W O 0921 D ...

Page 22: ... 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...

Page 23: ...Pinch Points and Crush Hazards Stay clear of pinch points and rotating parts on the telehandler Stay clear of moving parts while engine is running Keep clear of steering tires and frame or other objects Keep clear from under boom OW0210 OW0220 OW0230 ...

Page 24: ...afety Practices 1 12 31211031 Keep clear of boom holes Keep arms and hands clear of attachment tilt cylinder Keep hands and fingers clear of carriage and forks Keep others away while operating OW0240 OW0250 OW0260 OW0960 ...

Page 25: ... maintain 3 point contact when mounting or dismounting Never grab control levers or steering wheel when mounting or dismounting the machine DO NOT get off the machine until the shutdown procedure on page 4 5 has been performed DO NOT carry riders Riders could fall off machine causing death or serious injury OW0280 OW0290 ...

Page 26: ... or service the fuel system near an open flame sparks or smoking materials Engine fuel is flammable and can cause a fire and or explosion Hydraulic Fluid DO NOT attempt to repair or tighten any hydraulic hoses or fittings while the engine is running or when the hydraulic system is under pressure Stop engine and relieve trapped pressure Fluid in the hydraulic system is under enough pressure that it...

Page 27: ...uipment does cause harmful interference to radio or television reception which can be determined by turning the equipment off and on the user is encouraged to try to correct the interference by one or more of the following measures Reorient or relocate the receiving antenna Increase the separation between the equipment and receiver Connect the equipment into an outlet on a circuit different from t...

Page 28: ...tion with any other antenna or transmitter in order to satisfy FCC RF exposure requirements for mobile transmitting devices Important To comply with the FCC RF exposure limits and to satisfy the categorical exclusion requirements for mobile transmitters the requirements described in the following section Antenna Installation must be met Antenna Installation A minimum separation distance of eight i...

Page 29: ... the machine is used in a severe manner Inspection and Maintenance Type Frequency Primary Responsibility Service Qualification Reference Pre Operation Inspection Beginning of each work shift or at each change of operator User or Operator User or Operator Operation Safety Manual Pre Delivery Inspection see note Before each sale lease or rental delivery Owner Dealer or User Qualified Mechanic Servic...

Page 30: ...tion Safety Manual and AEM Safety Manual ANSI only located in cab manual holder 5 Walk Around Inspection See page 2 12 for details 6 Fluid Levels Check fluids including fuel diesel exhaust fluid DEF hydraulic oil engine oil and coolant When adding fluids refer to Section 7 Lubrication and Maintenance and Section 9 Specifications to determine proper type and intervals Before removing filler caps or...

Page 31: ... see page 2 14 of all systems in an area free of overhead and ground level obstructions See Section 3 Controls and Indicators for more specific operating instructions WARNING If telehandler does not operate properly immediately bring machine to a stop lower boom and attachment to ground and stop the engine Determine cause and correct before continued use ...

Page 32: ...4109801 1706302B WARNING PINCH POINTS could crush or cut causing death or serious injury Keep clear of pinch points 4109801 1001195855 1706302 ENGLISH 1001163223 ENGLISH FRENCH 1706301C ROTATING PARTS could crush or cut causing death or serious injury 1706301 ENGLISH 1001163222 ENGLISH FRENCH 1706300C Pre 1706300 ENGLISH 1001163212 ENGLISH FRENCH 1001173422 642 943 1043 1001191487 INSIDE FRAME K8 ...

Page 33: ...vidual load ratings stamped on forks if equipped Use lowest capacity of all ratings As released from factory this truck meets design specifications in ANSI ITSDF B56 6 2011 Manufactured by JLG Industries Inc McConnellsburg PA 17233 9533 USA Maximum Weight Without Attachments lbs kg Maximum Capacity lbs kg Serial Number Year Of Manufacture Model 4109801 4109801 1706296C 1706296 ENGLISH 1001163174 E...

Page 34: ...jury 1706306A 1706299B CONTACTING POWER LINES will result in death or serious injury 1706306 ENGLISH 1001163285 ENGLISH FRENCH 1706850 ENGLISH 1001163304 ENGLISH FRENCH 1706299 ENGLISH 1001163210 ENGLISH FRENCH 1001125387 ENGLISH 1001163355 ENGLISH FRENCH 8005870 IF EQUIPPED WITH ENCLOSED CAB 8005870C 1 2 CHARTS NOT PRESENT IF EQUIPPED WITH MULTIFUNCTION DISPLAY STOP 1001181531 1001180276 CAPACITY...

Page 35: ...63321 ENGLISH FRENCH 1706851A AVOID CRUSHING If machine tips Jumping out could result in serious injury death or 1706768 ENGLISH 1001163300 ENGLISH FRENCH 1706768B Riders could fall off machine causing death or serious injury No riders WARNING 1001140322 IF EQUIPPED 1001181543 1001181537B 1001181537 IF EQUIPPED 1001188372 1001200101A 1001200101 1001172035_A 1001172035 1001191229 INSIDE PANEL 10011...

Page 36: ... OD0980 VIEW UNDER ENGINE COVER O 0070 C 4109801 4109801 1001195855 1001191487 INSIDE FRAME K8 30A K7 30A K6 30A F12 30A F11 30A F10 30A F9 25A F8 30A F7 15A F6 25A F5 80A F4 80A F3 80A F1 200A F2 150A 1001191487 A 1706292 1706285 1706098 1001184632 1001173422 642 943 1043 110hp 82kW 2500 RPM 1001173422_B 1001172037 1055 1255 ...

Page 37: ...W 4109801 4109801 1706281 1001154575 1001154575A Refer to load capacity chart for truck with attachment and individual load ratings stamped on forks if equipped Use lowest capacity of all ratings As released from factory this truck meets design specifications in ANSI ITSDF B56 6 2011 Manufactured by JLG Industries Inc McConnellsburg PA 17233 9533 USA Maximum Weight Without Attachments lbs kg Maxim...

Page 38: ...B F N R 91163028 1001094708B 8005870 IF EQUIPPED WITH ENCLOSED CAB 8005870C 1 2 CHARTS NOT PRESENT IF EQUIPPED WITH MULTIFUNCTION DISPLAY STOP 1001181531 1706288 1001092877 1706284 3m 1001180276 CAPACITY CHARTS XXXXX 1001180276 A D LB FT Nm 500 10 250 50 250 D LB FT Nm 50 RAS 642 943 1043 1001205468 1055 1255 1001180278 ...

Page 39: ...1188372 1001200101A 1001200101 1001172035_A 1001172035 1001092878 1706293 1706283 1706289 1706287 1001191229 INSIDE PANEL 1001191229 B 30A 15A 15A 15A 15A 15A 15A 10A 10A 10A 10A 5A 5A 5A 5A 5A F10 F9 F8 F7 F6 F5 F4 F3 F2 F1 25A 25A 10A 10A 10A 10A 10A 10A 10A 5A F20 F19 F18 F17 F16 F15 F14 F13 F12 F11 10A F27 F26 F25 F24 F23 F22 F21 ...

Page 40: ...ed 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 OD1040 1 2 3 4 5 6 7 8 9 11 13 15 16 14 10 12 ...

Page 41: ...ware 7 Wheel Tire Assembly Properly inflated and secured no loose or missing lug nuts Inspect for worn tread cuts tears or other discrepancies 8 Rear Axle Stabilizer Cylinder Pins secure hydraulic hoses undamaged not leaking 9 Wheel Tire Assembly Properly inflated and secured no loose or missing lug nuts Inspect for worn tread cuts tears or other discrepancies 10 Rear Axle Steer cylinders undamage...

Page 42: ...al check 1 Service brake and parking brake operation 2 Forward and reverse travel 3 Each gear 4 Steering in both directions with engine at low idle steering lock to lock will not be reached Check in each steering mode 5 Horn and back up alarm Must be audible from inside operators cab with engine running 6 All joystick functions operate smoothly and correctly 7 Perform any additional checks describ...

Page 43: ...ification to this machine must be approved by JLG to assure compliance with ROPS FOPS certification for this cab machine configuration If the overhead guard or cab structure is damaged the CAB CANNOT BE REPAIRED It must be REPLACED WARNING Never drill cut and or weld to cab Any modification to this machine must be approved by JLG to assure compliance with machine configuration If unauthorized dril...

Page 44: ... clean and unobstructed Cab Door Window 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 using lever 3 and secure it in the latch 4 Press release 4 inside cab or 5 outside cab to unlatch window O 0190 C 2 1 4 3 5 ...

Page 45: ...Section 2 Pre Operation and Inspection 2 17 31211031 Rear Window Lift lever 6 and push to open the rear window 7 Lift lever and pull to close OD0030 7 6 ...

Page 46: ...Section 2 Pre Operation and Inspection 2 18 31211031 This Page Intentionally Left Blank ...

Page 47: ...Section 3 Controls and Indicators 3 1 31211031 SECTION 3 CONTROLS AND INDICATORS 3 1 GENERAL This section provides the necessary information needed to understand control functions ...

Page 48: ...Section 3 Controls and Indicators 3 2 31211031 3 2 CONTROLS OD1050 STOP 1001181531A OD0100 3 2 1 5 8 6 11 14 15 10 12 9 7 4 13 ...

Page 49: ...ipped See Section 5 Attachments or Section 7 Lubrication and Maintenance b Multifunction Display if equipped See page 3 18 7 Accessory Control lever if equipped See page 3 14 8 Right Dash Control Panel See page 3 9 9 Joystick See page 3 16 10 Left Dash Control Panel See page 3 8 11 Service Brake Pedal Further pedal is pressed the slower the travel speed 12 Ignition Switch Key activated See page 3 ...

Page 50: ...ot corrected machine interruption or damage may result When an indicator illuminates GREEN or BLUE or if a gauge is in the green zone important information regarding safe operation is being displayed 1 All Wheel Steer Illuminates when all wheel steer is active 2 Two Wheel Steer Illuminates when two wheel steer is active 3 Crab Steer Illuminates when crab steer is active NOTICE EQUIPMENT DAMAGE Whe...

Page 51: ...talytic Reduction SCR if equipped Illuminates when stationary cleaning is required Flashes during cleaning process See page 4 6 for details 15 Low Diesel Emission Fluid DEF if equipped for ULS Illuminates when DEF is low 16 High Engine Temperature Illuminates when engine temperature is high 17 Engine Fault Critical Illuminates when critical engine fault exists 18 Engine Fault Warning Illuminates w...

Page 52: ...abled See page 3 17 c Do Not Shut Off Engine Illuminates when stationary exhaust system cleaning is required See page 4 6 2 Driving Direction and Gear Displays current driving condition d Direction Forward F Neutral N or Reverse R e Gear First 1 Second 2 Third 3 or Fourth 4 3 Operating Hours Displays total hours of telehandler operation Displays when ignition is in ON position and engine is not st...

Page 53: ...mbols Transmission Oil Temperature Indicator Illuminates when transmission temperature is high Air Cleaner Restriction Indicator Illuminates when air cleaner requires maintenance Low Battery Indicator Illuminates when battery is at low charge or charging system is not functioning properly System Distress Indicator Illuminates when critical machine and engine faults exist Maintenance Required Indic...

Page 54: ...r inside the cab While deactivated air is circulated from outside the cab 3 Park Brake Switch On Off switch See page 3 11 for details 4 Coupler Switch if equipped Used in conjunction with joystick to hydraulically lock or unlock an attachment See page 5 11 for details 5 HVAC Fan Speed if equipped Adjustable rotary switch 6 HVAC Temperature Control Switch if equipped Adjustable rotary switch O 0170...

Page 55: ... relieve pressure in auxiliary hydraulic circuit See page 5 12 8 Road Lights Switch if equipped On Off switch 9 Boom Ride Control Switch if equipped On Off switch While enabled and travelling 3 mph 5 kph or faster the system acts to improve boom control over rough terrain Depress switch again to disable boom ride control 10 Auxiliary Electric Switch if equipped On Off switch 11 Steer Select Switch...

Page 56: ...ition 1 Voltage available for all electrical functions Wait to start engine until preheat indicator on instrument panel goes out Position 1 Engine run Position 2 Engine start In the event the engine does not start rotate key to position 0 then back to position 2 to re engage the starter STOP OD0160 1 0 2 ...

Page 57: ...priate parking area 2 Follow Shut Down Procedure on page 4 5 WARNING MACHINE ROLL AWAY HAZARD In the event of engine failure apply constant pressure to service brake pedal while activating the park brake to the ON position WARNING MACHINE ROLL AWAY HAZARD Always move park brake switch to ON position lower boom to ground and stop engine before leaving cab WARNING CRUSH HAZARD Turning engine off app...

Page 58: ... back up alarm will automatically sound Drive in reverse and turn only at slow rates of speed Unless transmission disconnect button is activated see page 3 17 do not increase engine speed with the transmission in forward or reverse and the service brake pressed in an attempt to get quicker hydraulic performances This could cause unexpected machine movement WARNING TIP OVER CRUSH HAZARD Bring teleh...

Page 59: ...hand grip to select gear The Transmission is equipped with four forward and three reverse gears Select appropriate gear for task being performed Use a lower gear for transporting a load Use a higher gear only when driving unloaded for longer distances Slow down prior to downshifting Do not downshift more than one gear at a time OD0180 1st 2nd 3rd 4th ...

Page 60: ... right turn signal The lever must be manually returned to the center position to deactivate either turn signal The lever will not cancel automatically after a turn Pull lever up 3 to switch between low and high beam headlights Front Windshield Wiper Rotate hand grip 4 to activate front windshield wiper O Off I Continuous or II Fast Push hand grip 4 towards column to activate windshield wiper fluid...

Page 61: ... up to raise outriggers Use the outriggers to increase stability and or load capacity and in leveling telehandler Study capacity charts to determine maximum load capacities with and without outriggers WARNING TIP OVER HAZARD Outriggers increase stability and load capacity only if they are used properly Using outriggers on soft surfaces could cause telehandler to tip over Always ensure surface can ...

Page 62: ...icators 3 16 31211031 Joystick Verify the joystick decal located inside the cab matches the machine controls The joystick controls the boom attachment tilt auxiliary hydraulic and transmission disconnect functions O 1231 D 1 2 3 ...

Page 63: ... of attachments that require the hydraulic supply for operation See Section 5 Attachments for approved attachments and control instructions Transmission Disconnect Transmission disconnect is controlled by button 3 Note Verify functionality of Transmission Disconnect prior to operation While applying service brake depress and release button to enable transmission disconnect function and disengage t...

Page 64: ...e previous menu or screen The screen will not change if already at the home screen 3 Attachment Select Button The attachment select button will display a menu of attachments See page 3 22 4 Navigation Button The navigation button has four arrow buttons to navigate up down left or right A center button allows operator to make a selection confirmation 5 Main Menu Button The main menu button displays...

Page 65: ...figuration a large gray question mark displays Contact your dealer or service representative for assistance 2 Outrigger position Select appropriate capacity chart dependent on outrigger position 3 Real time clock 4 Maintenance status if enabled Green No maintenance required Yellow Maintenance required 5 Attachment part numbers Press right navigation button to display list of attachment part number...

Page 66: ...he menu Note Telehandler must be stopped and park brake applied before menu can be accessed Note Scroll down or up to view all items Machine Set Up Machine set up allows the operator to view how the machine is configured Brand Model Engine Transmission etc See Service Manual OD1940 OD1950 Operator Tools ...

Page 67: ...e telehandler Access Level The access level input screen will prompt the operator to enter a 5 digit number The access level will allow the operator or technician the appropriate level of access to read and or modify display and control system set up data See Service Manual Operator Tools Operator tools accesses the anti theft settings tire selections and type of units displayed Error Messages Thi...

Page 68: ...achment in order to display the applicable capacity chart 1 Press the Attachment Select button to access the types of attachments 2 Select the type of attachment Note Scroll down or up to view all items 3 Select the specific attachment to be used The applicable capacity chart will then be displayed on the home screen OD2050 OD2060 Fork 4 X 8 ...

Page 69: ... 31211031 Communication Error Screen Screen displays if the multifunction display cannot communicate with the machine Wait a few moments and restart the machine If the communication error continues to display contact the local dealer OD1900 ...

Page 70: ...nual for information Instrument Panel Input Code entry is accomplished using information provided in the instrument panel display 1 Turn ignition switch to position 1 If anti theft is active the display 1 will prompt the operator for a numeric code 2 Use the left button 2 to select the first digit Press button to increase number Number will increase from 0 thru 9 then roll over to 0 3 Press the ri...

Page 71: ...pt the operator for a numeric code 2 Press the top or bottom of the navigation button to select the first digit 3 Press the right of the navigation button to move to the next digit 4 Continue until the code is complete Press the center of the navigation button to confirm code 5 If an incorrect code is entered the display will prompt the operator again for the numeric code 6 If the correct code is ...

Page 72: ...ng service brake If front steer mode 2 is active and rear wheels are aligned go directly to step 4 2 With circle steer 1 or crab steer 3 mode active turn the steering wheel until the left rear wheel 4 is aligned with the side of the machine 3 Select front steer mode 2 4 Turn the steering wheel until the left front wheel 5 is aligned with the side of the machine 5 Wheels are now aligned Select desi...

Page 73: ...ments Prior to starting the engine adjust seat for position and comfort 1 Suspension Use the knob 6 to adjust the suspension to appropriate weight setting 2 Fore Aft Use lever 7 to move seat fore and aft 3 Seat Belt Always fasten seat belt 8 during operation O 2040 D 6 7 8 ...

Page 74: ...tangled 2 With back straight in the seat couple the retractable end male end of the belt into the receptacle buckle end of the belt 3 With belt buckle positioned as low on the body as possible pull the retractable end of the belt away from the buckle until it is tight across the lap 4 To release belt latch press red button on the buckle and pull free end from buckle OH20912 ...

Page 75: ... boom Use these indicators to determine boom extension when using the capacity chart see Use of the Capacity Chart on page 5 5 The boom angle indicator 2 is located on the left side of the boom Use this indicator to determine the boom angle when using the capacity chart see Use of the Capacity Chart on page 5 5 A B C OD0660 40 30 20 5 0 10 10 60 80 70 1 2 ...

Page 76: ...f objects Pulsing alarm sounds when an object is in range of Reverse Sensing System Alarm increases in frequency as object becomes closer If alarm sounds at a frequency of eight pulses per second 8 Hz an object is detected within 5 feet 1 5 m Stop reverse direction of machine by applying service brake Perform Shut Down Procedure on page 4 4 Check and clear area behind machine of objects before pro...

Page 77: ...e multifunction display home screen when the telehandler is running and transmission is in reverse The display automatically returns to the standard home screen when transmission is shifted out of reverse NOTICE EQUIPMENT MALFUNCTION Always keep camera lens clean or camera may not operate normally Camera may not operate normally at extremely high or low temperatures OD1910 EXAMPLE ...

Page 78: ...ervice brake is not applied and transmission is in gear Rear axle will respond slowly to changes in terrain and frame level functions normally RAS indicator 2 will be off Locked Mode With boom above 40 3 and activating one or more of following functions RAS system is in Locked Mode Park brake switch engaged Transmission control lever in Neutral Service brake pedal depressed Rear axle is locked and...

Page 79: ...starting motor Release key immediately when engine starts If engine fails to start within 20 seconds release key and allow starting motor to cool for a few minutes before trying again 4 After engine starts observe indicators If indicators remain on for more than five seconds stop engine and determine cause before restarting engine Note If engine preheat indicator flashes after engine starts accele...

Page 80: ...raulic tank heater to one extension cord and the battery and block heaters to the other extension cord Connect each extension cord to separate A C power supplies with a minimum rating of 15 Amps each 4 Allow the heating components to operate a minimum of 12 hours prior to machine operation 5 Follow start up procedure on page 4 1 and allow engine to idle 20 minutes 6 Operate all boom functions cont...

Page 81: ...posite end of positive jumper cable to positive post of booster battery Connect negative jumper cable to negative post on booster battery Connect opposite end of negative jumper cable to ground point on machine 2 Follow standard starting procedures Remove cables in reverse order after machine has started WARNING BATTERY EXPLOSION HAZARD Never jump start or charge a frozen battery as it could explo...

Page 82: ... is noticed park machine in safe position and perform shut down procedure Report condition to your supervisor or maintenance personnel Avoid prolonged idling If engine is not being used turn it off If prolonged idling is required park brake applied and all controls in neutral engine idle may increase if any of the following conditions are present Driving lights on Air conditioning on Ambient tempe...

Page 83: ... transmission to Neutral 3 Lower forks or attachment to ground 4 Operate engine at low idle for 3 to 5 minutes DO NOT over rev engine 5 Shut off engine and remove ignition key 6 Exit telehandler properly 7 Purge indicator 4 will illuminate until DEF is purged from the system Do not turn key 5 to off while indicator is illuminated 8 Turn off electrical master switch 9 Block wheels if necessary OD17...

Page 84: ...nt System Automatic Exhaust System Cleaning ATS is an automatic exhaust cleaning system and will perform as required without any operator interaction High Exhaust System Temperature HEST 1 Indicator may illuminate during exhaust system cleaning WARNING HIGH EXHAUST TEMPERATURE Keep flammables and people away from hot exhaust O 1031 D 1 2 ...

Page 85: ...60 minutes Note Stationary exhaust system cleaning will stop and may be incomplete if any controls are inadvertently moved or activated If stationary exhaust cleaning is interrupted HEST 1 and Do Not Turn Off Engine 3 indicators will turn off and SCR Indicator 2 will stop blinking and illuminate solid To restart stationary exhaust system cleaning depress service brake and disengage park brake Retu...

Page 86: ...terrain Adjust travel speed and reduce amount of load if conditions warrant Avoid lifting double tiered loads Make sure load is clear of any adjacent obstacles Adjust spacing of forks so they engage the pallet or load at maximum width See Adjusting Moving Forks on page 5 13 Approach load slowly and squarely with fork tips straight and level NEVER attempt to lift a load with just one fork NEVER ope...

Page 87: ...e level indicator s to determine whether machine must be leveled prior to lifting load If equipped level machine with frame level switch see page 3 3 or outrigger controls see page 3 3 or 3 15 4 Move boom attachment to 4 ft 1 2 m off ground AUS Move boom so forks are no more than 11 8 in 300 mm above ground surface Important things to remember Never raise boom attachment more than 4 ft 1 2 m above...

Page 88: ...ty Chart on page 5 5 Align forks at level the load is to be placed then position boom slowly until load is just above area where it is to be placed Lower the boom until the load rests in position and the forks are free to retract Disengaging a Load Once the load has been placed safely at the landing point proceed as follows 1 With forks free from weight of load boom can be retracted 2 Lower carria...

Page 89: ...tions 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 operator cab for telehandler attachment combination you are using Only use approved lifting devices rated for lifting of load Identify proper lifting points of load taking into consideration center of gravity and load stability E...

Page 90: ... and operator must remain in constant communication verbal or hand and be in visual contact with operator at all times Never place guide persons between suspended load and telehandler Only transport 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 shift transmission to NEUTRAL 3 Observe level indica...

Page 91: ... on page 5 5 Align load at level the load is to be placed then position boom slowly until load is just above area where it is to be placed Ensure that guide persons and operator remain in constant communication verbal or hand when placing load Disengaging a Suspended Load Never place guide persons between suspended load and telehandler Once at destination of load ensure to bring telehandler to a c...

Page 92: ...5 Do not tiedown front of boom Note User assumes all responsibility for choosing proper method of transportation and tie down devices making sure equipment used is capable of supporting weight of vehicle being transported and that all manufacturer s instructions and warnings regulations and safety rules of their employer Department of Transportation and or any other local state or federal provinci...

Page 93: ...vated The machine must remain level at all times while being lifted Machine must never be lifted by any point on the boom Take care not to let cables chains slings etc contact any part of the vehicle during lift The appropriate lifting locations are the axle beams inboard of the kingpins Take care as not to damage the tie rod assemblies Ensure that the boom is retracted and lowered Ensure that the...

Page 94: ...Section 4 Operation 4 16 31211031 This Page Intentionally Left Blank ...

Page 95: ...ulics and electrics If any of the above conditions are not met do not use attachment Telehandler may not be equipped with proper capacity chart or attachment may not be approved for the model telehandler being used Contact JLG or a local distributor for further information 5 2 UNAPPROVED ATTACHMENTS Do not use unapproved attachments for the following reasons Range and capacity limitations for will...

Page 96: ...X X X 180 SwingCarriage 72in 1829mm 1001104992 X X DualForkPositioningCarriage 50in 1270mm 7301295 X X X X DualForkPositioningCarriage 50in 1270mm 1001189211 X 8ftMastCarriage 50in 1270mm 1001108668 X X X X X SideTilt8ftMastCarriage 50in 1270mm 1001108669 X X X X X Fork Pallet 2 36x4x48in 60x100x1220mm 2340045 X X X X Fork Pallet 2 36x5x48in 60x127x1220mm 2340038 X X X X X Fork Lumber 1 6x5 9x60in...

Page 97: ...X X X X X TrashHopper ForkMounted 1001195082 X X X X X TrussBoom 12ft 3658mm 1001099902 X X X X X TrussBoom 15ft 4572mm 1001099901 X X X X X TrussBoomw Winch 3ft 3658mm 1001100967 X X X X X TrussBoomw Winch 12ft 3658mm 1001099351 X X X X X MaterialHandlingArm 6 7 13 2ft 2007 3941mm 1001176515 X X X X X Platform ForkMounted ASME 1001103637 X X X X X Platform ForkMounted ASME French 1001103736 X X X...

Page 98: ...3 Total attachment capacity is multiplied by number of forks on attachment if equipped up to maximum capacity of attachment Maximum capacity as indicated on the proper capacity chart See Approved Attachments on page 5 1 When load rating of telehandler differs from capacity of the forks or attachment the lower value becomes the overall load capacity Use the proper capacity chart to determine maximu...

Page 99: ...er where load is to be placed 5 On capacity chart find the line for height and follow it over to distance 6 Number in 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 load zone must be equal to or greater than weight of load to be lifted Determine limits of load zone on capacity chart and ...

Page 100: ... size tires being properly inflated and the telehandler being in good operating condition OD1060 xxxxx XX XX XX XX XX XX XX XX XX XX XX XX XX XX XXXXXX XXXXXX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XXXXXX XXXXXX XXXXXX Attachment P N XXXXXXXXXX xx in XXXXXXXXXX xx in XXXXXXXXXX xx in XXX lbs MAX XX MAX XXXXXX XXXXX This Capacity Chart may be used with this model ONLY The telehandler model is...

Page 101: ... for model xxxx 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 Note This is a sample capacity chart only DO NOT use this chart use the one located in your operator cab Load Weight Distance Height OK to Lift 1 5750lb 2608kg 25 ft 7 62 m 10 ft 3 m Yes 2 4900lb 2223kg 30 ft 9 2m 30...

Page 102: ...Section 5 Attachments 5 8 31211031 This Page Intentionally Left Blank ...

Page 103: ... coupler 5 Lock Pin 6 Coupler attachment tilt control in cab see page 3 16 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 OD0540 1 2 3 4 5 6 3 5 6 MECHANICAL HYDRAULIC ...

Page 104: ...Align attachment pin with recess in attachment Raise boom slightly to engage attachment pin in recess 3 Tilt coupler forward to engage attachment 4 Lift retainer pin 2 and insert lock pin 1 completely through coupler Release retainer pin and ensure lock pin is secure 5 If attachment is equipped connect auxiliary hydraulic hoses See Hydraulic Operated Attachment on page 5 12 6 If equipped connect a...

Page 105: ...pler switch 3 on left control panel At the same time press roller switch 4 up to engage lock pin Press roller switch 4 down to disengage lock pin 5 Raise boom to eye level and visually check that lock pins protrude through holes on both sides of coupler If lock pins do not protrude through holes place attachment on ground and return to step 2 6 If attachment is equipped connect auxiliary hydraulic...

Page 106: ... page 5 9 2 Lower attachment to ground 3 Press and hold auxiliary decompression switch 1 on right control panel for three seconds to relieve pressure at both auxiliary fittings 2 4 Perform Shut Down Procedure on page 4 5 5 Connect attachment hoses to both auxiliary fittings OD0860 OY1720 2 1 ...

Page 107: ...king bolt 3 Elevate attachment to approximately 5 ft 1 5 m and tilt carriage forward until fork heel is free from attachment 4 Stand at side of carriage To slide fork toward center of carriage push fork near fork eye To slide fork toward edge of carriage pull fork near fork eye To avoid pinching do not place fingers or thumb between fork and carriage structure 5 If equipped tighten fork locking bo...

Page 108: ...chment if it is equipped with a manual holder NOTICE EQUIPMENT DAMAGE Some attachments may contact front tires or machine structure when the boom is retracted and the attachment is rotated Improper use of attachment may result in attachment or machine structural damage NOTICE EQUIPMENT DAMAGE Avoid contact with any structure or object when lifting a load Maintain clearance around boom structure an...

Page 109: ...Roller switch 2 controls carriage tilt Press roller switch down to tilt up Press roller switch up to tilt down Installation Procedure Refer to Attachment Installation on page 5 9 Equipment Damage Precautions Do not use forks as a lever to pry material Excessive prying forces could damage forks or machine structure Do not attempt to lift loads that are attached or connected to another object OY0690...

Page 110: ...t Fork Capacity on page 5 4 Joystick 1 controls movement of the boom Roller switch 2 controls carriage tilt Press roller switch down to tilt up Press roller switch up to tilt down To Side Shift Roller switch 3 controls carriage side shift Press roller switch down to shift right Press roller switch up to shift Left OAL1540 OD0880 OD0380 OD0370 OD0390 2 3 1 ...

Page 111: ...recautions 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 WARNING CRUSH HAZARD Do not use side shift to push or pull objects or load Failure to comply could cause object or load to fall ...

Page 112: ...nt Fork Capacity on page 5 4 Joystick 1 controls movement of the boom Roller switch 2 controls carriage tilt Press roller switch down to tilt up Press roller switch up to tilt down To Side Tilt Roller switch 3 controls carriage side tilt Press roller switch down to side tilt right Press roller switch up to side tilt left OAL1550 OD0880 OD0370 OD0400 OD0390 2 3 1 ...

Page 113: ...ad and engage load Raise load slightly and level carriage side to side Travel in accordance with 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 WARNING CRUSH HAZARD Do not...

Page 114: ...achment Fork Capacity on page 5 4 Joystick 1 controls movement of the boom Roller switch 2 controls carriage tilt Press roller switch down to tilt up Press roller switch up to tilt down To Swing Roller switch 3 controls carriage swing Press roller switch down to swing right Press roller switch up to swing left OU2150 OD0880 OD0410 OD0370 OD0390 2 3 1 ...

Page 115: ...ine structure Do not attempt to lift loads that are attached or connected to another object WARNING CRUSH HAZARD Always level forks horizontally and telehandler frame before swinging load to side Swinging unlevel forks could cause load to slide off forks WARNING CRUSH HAZARD Do not use swing carriage to push or pull objects or load Failure to comply could cause object or load to fall WARNING CRUSH...

Page 116: ...Attachment Fork Capacity on page 5 4 Joystick 1 controls movement of the boom Roller switch 2 controls carriage tilt Press roller switch down to tilt up Press roller switch up to tilt down To Fork Position Roller switch 3 controls fork position Press roller switch down to shift forks in Press roller switch up to shift forks out OZ3670 OD0880 OD0420 OD0370 OD0390 2 3 1 ...

Page 117: ...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 WARNING CRUSH HAZARD Do not use fork positioning to push or pull objects or load Failure to comply could cause object or load to fall ...

Page 118: ...Fork Capacity on page 5 4 Joystick 1 controls movement of the boom Roller switch 2 controls carriage tilt Press roller switch down to tilt up Press roller switch up to tilt down To Raise Lower Mast Roller switch 3 controls raise lower movement of mast Press roller switch down to raise Press roller switch up to lower OY0580 OD0880 OD0430 OD0370 OD0390 2 3 1 ...

Page 119: ...ents set forth in Section 1 General Safety Practices Use a signal person to assist in positioning of load if necessary Equipment Damage Precautions Do not use forks as a lever to pry material Excessive prying forces could damage forks or machine structure Do not attempt to lift loads that are attached or connected to another object WARNING CRUSH HAZARD Do not use mast to push or pull objects or lo...

Page 120: ...ment Fork Capacity on page 5 4 Joystick 1 controls movement of the boom Roller switch 2 controls carriage tilt Press roller switch down to tilt up Press roller switch up to tilt down To Raise Lower Mast Roller switch 3 controls raise lower movement of mast Press roller switch down to raise Press roller switch up to lower OY0580 OD0880 OD0430 OD0370 OD0390 2 3 1 ...

Page 121: ...ng load To drive with a load lower forks fully in mast and travel in accordance with requirements set forth in Section 1 General Safety Practices Use a signal person to assist in positioning of load if necessary Equipment Damage Precautions Do not use forks as a lever to pry material Excessive prying forces could damage forks or machine structure Do not attempt to lift loads that are attached or c...

Page 122: ... 4 Joystick 1 controls movement of the boom Roller switch 2 controls pipe grapple tilt Press roller switch down to tilt up Press roller switch up to tilt down To Open Close Pipe Grapple Roller switch 3 controls the open close movement of the pipe grapple Press roller switch down to close grapple Press roller switch up to open grapple OH5660 O 1650 D OD0880 OD0370 OD0390 2 3 1 ...

Page 123: ...nce with requirements set forth in Section 1 General Safety Practices Open pipe grapple and unload material from forks Equipment Damage Precautions Except for lifting or unloading material the boom must be fully retracted for all operations Do not use forks as a lever to pry material Excessive prying forces could damage forks or machine structure Do not use pipe grapple as a lever to pry material ...

Page 124: ...e when equipped with fork extensions may be reduced to the capacity indicated on the fork extensions If the load exceeds the capacity of the fork extension contact JLG to obtain forks and or fork extensions of the proper load rating and length Joystick 1 controls movement of the boom Roller switch 2 controls carriage tilt Press roller switch down to tilt up Press roller switch up to tilt down OZ07...

Page 125: ...ent fork arm blade length stamped into the fork extension Secure the fork extensions to the forks by sliding the fork extensions onto the parent forks and install the retaining pin behind the vertical shank of the fork Operation Heavy part of load must be against carriage backrest Do not allow load center of gravity to be in front of tip of the supporting fork Do not pick up a load or pry material...

Page 126: ... Chart To determine maximum capacity refer to Telehandler Attachment Fork Capacity on page 5 4 Joystick 1 controls movement of the boom Roller switch 2 controls bucket tilt Press roller switch down to tilt up Press roller switch up to tilt down OZ0730 OD0870 OD0460 OD0390 1 2 ...

Page 127: ...Practices 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 str...

Page 128: ... 5 4 Joystick 1 controls movement of the boom Roller switch 2 controls grapple bucket tilt Press roller switch down to tilt up Press roller switch up to tilt down To Open Close Grapple Roller switch 3 controls the open close movement of the grapple Press roller switch down to close grapple Press roller switch up to open grapple OZ1450 OD0880 OD0480 OD0460 OD0390 2 3 1 ...

Page 129: ...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 dama...

Page 130: ...ent Capacity Chart To determine maximum capacity refer to Telehandler Attachment Fork Capacity on page 5 4 Joystick 1 controls movement of the boom Roller switch 2 controls bucket tilt Press roller switch down to tilt up Press roller switch up to tilt down O 2070 D OD0870 OD0460 OD0390 1 2 ...

Page 131: ...n to dump load Fork mounted bucket weight must be included as part of total load being lifted Do not use with mast carriage attachment Do not use fork mounted bucket with attachments capable of rotating i e side tilt and swing carriages without disabling the rotation feature s Equipment Damage Precautions Except for lifting or dumping a load the boom must be fully retracted for all bucket operatio...

Page 132: ... Capacity Chart To determine maximum capacity refer to Telehandler Attachment Fork Capacity on page 5 4 Joystick 1 controls movement of the boom Roller switch 2 controls trash hopper tilt Press roller switch down to tilt up Press roller switch up to tilt down OD1630 OD1640 OD0870 OD0390 1 2 ...

Page 133: ...equirements set forth in Section 1 General Safety Practices To release gate tilt fork mounted trash hopper down approximately 10 degrees and engage bottom bumper on edge of dumpster The gate will open allowing the contents to slide out Tilt fork mounted trash hopper back to close and secure the gate Do not use with mast carriage attachment Do not use fork mounted trash hopper with attachments capa...

Page 134: ...er to Telehandler Attachment Fork Capacity on page 5 4 Suspend loads in accordance with requirements set forth in Section 1 General Safety Practices Joystick 1 controls movement of the boom Roller switch 2 controls coupler mounted hook tilt Press roller switch down to tilt up Press roller switch up to tilt down OC0130 OC0140 OD0870 OD0390 1 2 ...

Page 135: ...Section 5 Attachments 5 41 31211031 Installation Procedure Refer to Attachment Installation on page 5 9 Operation Weight of rigging must be included as part of total load being lifted ...

Page 136: ... refer to Telehandler Attachment Fork Capacity on page 5 4 Suspend loads in accordance with requirements set forth in Section 1 General Safety Practices Joystick 1 controls movement of the boom Roller switch 2 controls carriage tilt Press roller switch down to tilt up Press roller switch up to tilt down OY0640 OD0870 OD0450 OD0390 1 2 ...

Page 137: ...stall the retaining pin behind the vertical shank of the fork Operation Pallet or lumber forks of an appropriate load rating must be used Do not use with cubing or block forks Fork mounted hook and rigging weight must be included as part of total load being lifted Do not use with mast carriage attachment Do not use fork mounted hook with attachments capable of rotating i e side tilt and swing carr...

Page 138: ...e with requirements set forth in Section 1 General Safety Practices Joystick 1 controls movement of the boom Roller switch 2 controls truss boom tilt Press roller switch down to tilt up Press roller switch up to tilt down Winch Control if equipped Roller switch 3 controls truss boom mounted winch Press roller switch down to lower cable Press roller switch up to raise cable OY0570 OD0880 OD0520 OD0...

Page 139: ...o Attachment Installation on page 5 9 Operation Weight of rigging must be included as part of total load being lifted 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 ...

Page 140: ...ty refer to Telehandler Attachment Fork Capacity on page 5 4 Suspend loads in accordance with requirements set forth in Section 1 General Safety Practices Joystick 1 controls movement of the boom Roller switch 2 controls material handling arm tilt Press roller switch down to tilt up Press roller switch up to tilt down OH5670 OD1660 OD0870 OD0390 1 2 ...

Page 141: ...Secure adjustable arm in desired position using the retaining pin Operation Weight of rigging must be included as part of total load being lifted WARNING CRUSH HAZARD Ensure adjustable arm is properly secured using the retaining pin prior to lifting load Failure to comply could cause object or load to fall ...

Page 142: ...ler Attachment Fork Capacity on page 5 4 The operator and personnel in platform must read and understand the separate personnel work platform manual prior to installing and using a platform Joystick 1 controls movement of the boom Roller switch 2 controls platform tilt Press roller switch down to tilt up Press roller switch up to tilt down OY1610 OD0470 OD0340 OD0390 1 2 ...

Page 143: ...up 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 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 ...

Page 144: ...Section 5 Attachments 5 50 31211031 This Page Intentionally Left Blank ...

Page 145: ...ieval devices are not intended for on road trailer towing applications 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 If it is only necessary to move telehandler a short dis...

Page 146: ...with on an individual basis Contact the local dealer for specific instructions Secure the telehandler using the following procedures 1 Clear the area around telehandler of all personnel 2 Apply the parking brake Place the transmission 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 5 See Service Manu...

Page 147: ...M ENCLOSED CAB In an emergency the rear window can be used to exit the telehandler Inside Cab Remove the latch pin 1 The window is then free to swing open Outside Cab if equipped Remove the knob 2 securing window The window is then free to swing open OZ0240 1 OD1250 2 ...

Page 148: ...Section 6 Emergency Procedures 6 4 31211031 This Page Intentionally Left Blank ...

Page 149: ...wed to keep this product in good operating condition Operation Safety Manual and Service Manual contain more detailed service information with specific instructions If equipped with Multifunction Display refer to page 3 18 for navigation information Clothing and Safety Gear Wear all protective clothing and personal safety devices issued to you or called for by job conditions DO NOT wear loose clot...

Page 150: ...bute lubricants Perform this maintenance procedure without attachment installed Apply a light coating of engine oil to all linkage pivot points Intervals shown are for normal usage and conditions Adjust intervals for abnormal usage and conditions Check all lubricant levels when lubricant is cool with the exception of the transmission fluid For ease of filling hydraulic reservoir use a funnel with ...

Page 151: ...ine Coolant Level Drain Fuel Water Separator Check Fuel Level EVERY 10 Check Tire Condition Pressure Check Brake Fluid Level Check Engine Oil Level Check Hydraulic Oil Level Check Wheel Lug Nut Torque Check DEF Level if equipped for ULS 1 50 st Check Transmission Oil Level Additional Checks Section 8 Check Air Cleaner Check Boom Chain Tension ...

Page 152: ...t MPG Lubrication Schedule Check Axle Oil Level Check Wheel End Oil Levels Check Transfer Case Fluid Level Change Axle Oil Change Transfer Case Fluid Change Wheel End Oil Check Boom Wear Pads Check Washer Fluid 50 EVERY Lubrication Schedule MPG Change Transmission Fluid and Filter Check Boom Chains RAS Check RAS System ...

Page 153: ...Change Axle Oil Check Boom Chain Tension Check Air Intake System 750 EVERY Change Hydraulic Filters Change Hydraulic Tank Breather Change Transmission Fluid and Filter Check Park Brake MPG Lubrication Schedule Change Transfer Case Fluids Check Wheel Lug Nut Torque Check Fan Belt Check Battery Change Fuel Filters Change Engine Oil and Filter ...

Page 154: ... 4000 5000 Hour Maintenance Schedule O 1292 D 5000 EVERY 4000 EVERY 2000 EVERY Engine Valve Lash Adjustment 1500 EVERY Change Hydraulic Fluid and Filters Change Engine Coolant Change DEF Tank Filter if equipped for ULS Change DEF Pump Filter if equipped for ULS ...

Page 155: ...Section 7 Lubrication and Maintenance 7 7 31211031 This Page Intentionally Left Blank ...

Page 156: ...Section 7 Lubrication and Maintenance 7 8 31211031 7 4 LUBRICATION SCHEDULES 50 Hour Lubrication Schedule 642 943 1043 O 0010 C 50 EVERY ...

Page 157: ...Section 7 Lubrication and Maintenance 7 9 31211031 1055 1255 OD1300 50 EVERY B B B B B B ...

Page 158: ...Section 7 Lubrication and Maintenance 7 10 31211031 250 Hour Lubrication Schedule 642 943 1043 250 EVERY O 0020 C ...

Page 159: ...Section 7 Lubrication and Maintenance 7 11 31211031 1055 1255 250 EVERY OD1310 ...

Page 160: ...Section 7 Lubrication and Maintenance 7 12 31211031 1000 Hour Lubrication Schedule 642 943 1043 1000 EVERY O 0030 C ...

Page 161: ...Section 7 Lubrication and Maintenance 7 13 31211031 1055 1255 1000 EVERY OD1320 ...

Page 162: ...Section 7 Lubrication and Maintenance 7 14 31211031 This Page Intentionally Left Blank ...

Page 163: ...TRUCTIONS Engine Maintenance Components If Equipped for ULS 1 Surge Tank See page 7 29 2 Transmission Fluid Dipstick See page 7 27 3 Primary Fuel Filter See page 7 18 4 Engine Oil Cap See page 7 21 5 Engine Oil Dipstick See page 7 21 6 Air Cleaner See page 7 22 O 0681 D 5 1 3 4 2 6 ...

Page 164: ...1211031 If Equipped for LS 1 Surge Tank See page 7 29 2 Transmission Oil Dipstick See page 7 27 3 Primary Fuel Filter See page 7 18 4 Engine Oil Cap See page 7 21 5 Engine Oil Dipstick See page 7 21 6 Air Cleaner See page 7 22 OC0120 4 1 5 6 3 2 ...

Page 165: ...Section 7 Lubrication and Maintenance 7 17 31211031 This Page Intentionally Left Blank ...

Page 166: ...perform Shut Down Procedure on page 4 5 3 Turn fuel tank cap 8 to remove from filler neck 4 Add fuel as needed 5 Replace fuel tank cap Note Replenish diesel fuel at end of each work shift to minimize condensation NOTICE EQUIPMENT DAMAGE Do not allow machine to run out of fuel during operation See Engine Operation Maintenance Manual for details prior to servicing 10OW0970 OW0990 OD0690 OD0710 8 7 ...

Page 167: ... Down Procedure on page 4 5 2 Open engine cover 3 Loosen drain cock 2 on underside of fuel filter 1 and allow all water to drain into a glass until clear fuel is visible Tighten drain cock 4 Close and secure engine cover 10OW0970 OW1000 OC0110 OD0730 1 2 IF EQUIPPED FOR ULS IF EQUIPPED FOR LS 1 2 ...

Page 168: ...of Instrument Panel in cab 2 If DEF is low proceed to DEF source and perform Shut Down Procedure on page 4 5 3 Turn DEF tank cap 2 to remove 4 Add DEF as needed 5 Replace DEF tank cap NOTICE EQUIPMENT DAMAGE Do not allow machine to run out of Diesel Emission Fluid DEF during operation See the Engine Operation Maintenance Manual for details prior to servicing 10OW0970 OD1350 OD1340 OD1330 2 1 ...

Page 169: ...5 2 Open engine cover 3 Remove dipstick 3 and check oil mark Oil should be between full 4 and add 5 marks of dipstick 4 Replace dipstick 5 If oil is low remove oil fill cap 6 and add oil to bring oil up to full mark in crosshatch area 6 Replace oil fill cap 7 Close and secure engine cover 10OW0970 OW1020 OD0740 O 0751 D 6 3 5 4 ...

Page 170: ... engine cover 3 Remove dust from vacuator valve 1 by squeezing bottom of valve to allow loose particles to fall out 4 Close and secure engine cover NOTICE EQUIPMENT DAMAGE Only remove air cleaner cover to service elements Excessive access to check elements can lead to premature element and or engine failure 10OW0970 OW1010 OD0780 1 2 3 4 ...

Page 171: ...Replace inner safety element 4 every third primary element change or if primary element was found to be damaged If replacing inner safety element at this time carefully slide element out and replace with new element 7 Slide new primary element over inner safety element making sure sealing edge is flush with base of air cleaner 8 Position air cleaner cover in place and lock into position 9 Close an...

Page 172: ...s in 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 above noted criteria tire must be inspected daily to ensure damage has not propagated beyond allowable criteria C Tire and Wheel Replacement Machines equipped with pneumatic tires from manufacturer must use pneumatic replacements Machines equipped with foam ...

Page 173: ...ng stability E Wheel Installation Torque lug nuts after first 50 hours and after each wheel installation Note If machine is equipped with directional tire assemblies wheel and tire assemblies must be installed with directional tread pattern arrows facing in 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 i...

Page 174: ...ggers if equipped are fully raised and machine is level 2 Perform Shut Down Procedure on page 4 5 3 Allow hydraulic oil to cool Check fluid level at sight gauge 4 Oil level should be visible in gauge window 4 Remove fill cap 5 Add fluid to bring oil up to the center of the sight gauge 5 Replace hydraulic oil fill cap 10OW0970 OW1030 OD0720 4 5 ...

Page 175: ...al operating temperature 2 Apply park brake shift transmission to Neutral and lower attachment to ground 3 Open engine cover 4 Remove dipstick 1 and check fluid mark Fluid should be between the full 2 and add 3 marks within crosshatched area of dipstick 5 If fluid is low add fluid as required 6 Replace dipstick 7 Close and secure engine cover 10OW0970 OW1050 OD0770 1 OD0750 3 2 ...

Page 176: ...d Level Check 1 Perform Shut Down Procedure on page 4 5 2 Check the brake fluid level 1 Fluid should be between Max and Min 2 marks on brake reservoir 3 If fluid is low remove the product from service See Service Manual for information 10OW0970 OD1380 OD1360 1 MAX MIN OD1370 2 ...

Page 177: ...Check coolant level in surge tank 3 Coolant should be between Full and Add 4 marks on surge tank 4 If coolant is low allow fluid to cool 5 Remove surge tank cap 5 slowly Add coolant as required 6 Replace surge tank cap 7 Close and secure engine cover Note When filling coolant maximum fill rate is 2 5 gallon per minute 9 5 liter per minute 10OW0970 OW1070 OD0760 5 4 3 ...

Page 178: ...if equipped A Windshield Washer Fluid Level Check 1 Perform Shut Down Procedure on page 4 5 2 Remove reservoir cap 3 3 Windshield washer fluid should be visible in the reservoir 4 If washer fluid level is low add fluid as needed 5 Replace reservoir cap 50OW0980 OAL2040 OD0820 3 ...

Page 179: ...and is functional when machine is moving in reverse direction Note The use of a construction cone or similar object must be used to test the Reverse Sensing System 4 Verify operation with no objects in detection zone No audible alarm 5 Verify operation when object is in range of approximately 9 to 15 ft 2 7 to 4 5 m Produces pulsing audible alarm at a frequency of one per second 1 Hz 6 Verify oper...

Page 180: ...Section 8 Additional Checks 8 2 31211031 This Page Intentionally Left Blank ...

Page 181: ...4 20 45 Mobilfluid LT 75W 80 40 14 40 10 Axle Differential and Wheel End Mobilfluid 424 10W 30 4 115 20 46 Mobilfluid LT 75W 80 40 0 40 20 API GL4 with LS Additives or API GL5 with LS Additives SAE90 SAE90LS 32 115 0 46 80W 90 4 115 20 46 75W 90 40 115 40 46 75W 40 50 40 10 Hydraulic System Mobilfluid 424 10W 30 6 114 15 45 Exxon Univis HVI 40 100 40 40 Boom Wear Pad Grease Extreme Pressure Grease...

Page 182: ...iodiesel Blend of 1 diesel and 2 diesel fuels winterized 2 Cold Weather B5 Biodiesel with Winter Conditioner Diesel Exhaust Fluid ISO22241 1 32 5 Urea Brake Fluid Mobil ATF D M 40 114 40 45 Air Conditioning Refrigerant R 134 a Tetrafluoroethane Compartment or System Type and Classification Viscosities Ambient Temperature Range F C Min Max Min Max ...

Page 183: ... LS Additives or API GL5 with LS Additives SAE90 SAE90LS 32 115 0 46 80W 90 4 115 20 46 75W 90 40 115 40 46 75W 40 50 40 10 Hydraulic System Mobilfluid 424 10W 30 6 114 15 45 Exxon Univis HVI 40 100 40 40 Boom Wear Pad Grease Extreme Pressure Grease NLGI Grade 000 31 122 35 50 Cylinder and Axle Grease Multipurpose Grease NLGI Grade 2 5 122 15 50 Boom Chain Lubricant Schaffer 200S Silver Streak Eng...

Page 184: ...l 21 5 L Cooling System System Capacity 5 2 gal 19 7 L Hydraulic System System Capacity 642 No Outriggers 40 2 gal 152 L With Outriggers 41 7 gal 158 L 943 46 5 gal 176 L 1043 48 6 gal 184 L 1055 48 6 gal 184 L 1255 49 9 gal 189 L Reservoir Capacity to Full Mark 23 8 gal 90 L Transmission System Capacity with Filter Change 17 qt 16 1L Transfer Case Capacity 642 943 1043 1 5 qt 1 4 L 1055 1255 1 6 ...

Page 185: ...2 L Rear 14 qt 13 3 L Friction Modifier May be added to axle differentials Must be premixed with axle fluid Not to Exceed 24 oz 709 mL Wheel End Capacity 642 2 1 qt 2 0 L 943 1043 1 8 qt 1 7 L 1055 1255 Front 1 8 qt 1 7 L Rear 1 5 qt 1 4 L Air Conditioning System if equipped System Capacity 2 6 lb 1 2 kg Brake Fluid Capacity 1 1 qt 1 0 L ...

Page 186: ...2 bar 14 00 24 12PR Foam Approx 720 lb 327 kg 1043 400 75 28 16 Ply Pneumatic 76 psi 5 2 bar Foam Approx 570 lb 259 kg 14 00 24 16PR Pneumatic 80 psi 5 52 bar 14 00 24 12PR Foam Approx 720 lb 327 kg 1055 400 75 28 16 Ply Pneumatic 76 psi 5 2 bar Foam Approx 570 lb 259 kg 14 00 24 16PR Pneumatic 80 psi 5 52 bar 14 00 24 12PR Foam Approx 720 lb 327 kg 1255 400 75 28 16 Ply Pneumatic 76 psi 5 2 bar F...

Page 187: ...Section 9 Specifications 9 7 31211031 Wheel Lug Nut Torque 375 25 lb ft 508 34 Nm ...

Page 188: ... 43 ft 13 1 m 1055 1255 55 ft 16 8 m Capacity at Maximum Height 642 Outriggers Engaged 6 000 lb 2722 kg Outriggers Not Engaged 0 lb 0 kg 943 7 000 lb 3175 kg 1043 7 000 lb 3175 kg 1055 Outriggers Engaged 5 000 lb 2268 kg Outriggers Not Engaged 0 lb 0 kg 1255 Outriggers Engaged 5 000 lb 2268 kg Outriggers Not Engaged 0 lb 0 kg Maximum Forward Reach 642 29 ft 8 8 m 943 1043 30 5 ft 9 3 m 1055 1255 4...

Page 189: ...ed 3 500 lb 1588 kg Outriggers Not Engaged 0 lb 0 kg Reach at Maximum Height 642 54 1 in 1375 mm 943 64 3 in 1633 mm 1043 63 7 in 1618 mm 1055 1255 99 5 in 2527 mm Auxiliary Hydraulic Circuit Max Flow 642 18 gpm 68 lpm 943 1043 1055 1255 25 gpm 94 6 lpm Maximum Travel Speed see note 642 21 mph 33 kph 943 1043 19 mph 31 kph 1055 1255 20 mph 32 kph Frame Leveling 10 degrees Maximum Travel Grade boom...

Page 190: ...iggers Engaged 126 25 in 3207 mm Outriggers Not Engaged 100 75 in 2559 mm Maximum Track Width 84 25 in 2140 mm Wheelbase 642 943 1043 135 in 3430 mm 1055 1255 137 5 in 3493 mm Length at Front Wheels 642 Not Available at Publication 943 Not Available at Publication 1043 Not Available at Publication 1055 1255 200 2 in 5086 mm Overall Length no forks 642 227 in 5774 mm 943 1043 236 in 6001 mm 1055 12...

Page 191: ...04 kg Distribution of Maximum Operating Weight no attachment boom level and fully retracted Front Axle 642 No Outriggers Not Available at Publication With Outriggers Not Available at Publication 943 Not Available at Publication 1043 Not Available at Publication 1055 16 435 lb 7455 kg 1255 16 985 lb 7704 kg Rear Axle 642 No Outriggers Not Available at Publication With Outriggers Not Available at Pu...

Page 192: ...t Publication Tires 400 75 28 16 Ply Pneumatic Not Available at Publication Foam Not Available at Publication 14 00 24 16PR Pneumatic Not Available at Publication 14 00 24 12PR Foam Not Available at Publication 1055 Outriggers Not Available at Publication Tires 400 75 28 16 Ply Pneumatic Not Available at Publication Foam Not Available at Publication 14 00 24 16PR Pneumatic Not Available at Publica...

Page 193: ... 5 15 Chemical Hazards 1 14 Controls 3 2 Coolant Level 7 29 Cooling System 9 4 Coupler Mounted Hook 5 40 D DEF Tank 9 4 Dimensions 9 10 Disengaging a Load 4 10 Disengaging a Suspended Load 4 13 Driving Hazards on Slopes 1 10 Dual Fork Positioning Carriage 5 22 E Electrical Hazards 1 2 Emergency Exit from Enclosed Cab 6 3 Emergency Lowering of Boom 6 2 Emergency Procedures 6 1 Engine Extreme Cold W...

Page 194: ...4 8 Operating with a Suspended Load 4 11 Operational Check 2 14 Operator Cab 2 15 Operator Maintenance Instructions 7 15 Operator Seat 3 27 Adjustments 3 27 Outrigger Levers 3 15 P Park Brake 3 11 Parking Procedure 3 11 Performance 9 8 Personnel Work Platform Fork Mounted 5 48 Picking Up a Load 4 8 Picking Up a Suspended Load 4 11 Pinch Points and Crush Hazards 1 11 Pipe Grapple 5 28 Placing a Loa...

Page 195: ... System Cleaning 4 7 Steering Alignment Mode Manual 3 26 Swing Carriage 5 20 T Tip Over Hazard 1 4 Tires 7 24 9 6 Air Pressure 7 24 Damage 7 24 Replacement 7 24 Towing 6 1 Transfer Case 9 4 Transmission Control Direction of Travel 3 12 Gear Selection 3 13 Transmission Disconnect 3 17 Transmission Oil Level 7 27 Transmission System 9 4 Transport Lifting 4 15 Tie Down 4 14 Transporting a Load 4 9 Tr...

Page 196: ...Index 4 31211031 ...

Page 197: ...Inspection Maintenance and Repair Log Serial Number___________________________________ Date Comments Inspection Maintenance and Repair Log ...

Page 198: ...Inspection Maintenance and Repair Log Date Comments ...

Page 199: ...or rented units should not be included on this form Mfg Model ______________________________________________________________ Serial Number ___________________________________________________________ Previous Owner __________________________________________________________ Address _________________________________________________________________ _____________________________________________________...

Page 200: ......

Page 201: ...losed point thumb upward LOWER BOOM With either arm extended horizontally fingers closed point thumb downward MOVE SLOWLY Place one hand motionless in front of hand giving motion signal Raise load slowly shown EXTEND BOOM With both hands clenched point thumbs outward RETRACT BOOM With both hands clenched point thumbs inward THIS FAR TO GO With hands raised and open inward move hands laterally indi...

Page 202: ...3 88 31 79 JLG Deutschland GmbH Max Planck Str 21 D 27721 Ritterhude lhlpohl Germany Phone 49 0 421 69 350 20 Fax 49 0 421 69 350 45 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 Industries Italia s r l Via Po 22 20010 Pregnana Milanese MI Italy Phone 39 029 359 5210 Fax 39 029 359 5845 JLG Europe B V Polari...