Operation_31200537_11-11-10_CE_English.pdf

Operation & SafetyManual

Original InstructionsKeep this manual with machine at all times.

Agrovector40.8 & 40.9

31200537

RevisedNovember 11, 2010

Revision Log

31200537

Revision Log

REVISION LOGSeptember 30, 2008 - A - Original Issue of ManualNovember 11, 2010 - B - Revised manual.a

Read This First

b

Read This FirstThis 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, andlessees with the precautions and operating procedures essential for the safe andproper machine operation for its intended purpose.

Due to continuous product improvements, JLG Industries, Inc. reserves the right tomake specification changfor updated information.

Operator Qualificat

The operator of the macbeen read, training is completed under the sOperation within the U.S.Operators of this equipmgood physical and mentavision and depth percepmedication which could iother intoxicant during theIn addition, the operatocontained in the following This Operation & Safe Telehandler Safety Ma All instructional decals Any optional equipme

The operator must also rIndustry and Governmen

Modifications

Any modification to this31200537

es without prior notification. Contact JLG Industries, Inc.

ions

hine must not operate the machine until this manual hasaccomplished and operation of the machine has beenupervision of an experienced and qualified operator.A. requires training per OSHA 1910.178.ent must possess a valid, applicable drivers license, be inl condition, have normal reflexes and reaction time, goodtion and normal hearing. Operator must not be using

mpair abilities nor be under the influence of alcohol or any work shift.

r must read, understand and comply with instructions material furnished with the material handler:ty Manualnual (ANSI only) and platesnt instructions furnishedead, understand and comply with all applicable Employer,tal rules, standards and regulations.

machine must be approved by JLG.

Read This First

31200537

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 thismachine. Contact JLG Industries, Inc. to ensure that the current owner records areupdated and accurate.

JLG Industries, Inc. muproducts have been invpersonnel or when dama

FOR: Accident Reporting an Current Owner Updat Questions Regarding Standards and Regula Questions Regarding

CONTACT:Product SafeJLG Industri13224 FountHagerstown,USA

or Your Loca(Addresses oIn USA:Toll Free: 1

Outside USPhone: +

E-mail:ProductSafec

st be notified immediately in all instances where JLGolved in an accident involving bodily injury or death ofge has occurred to personal property or the JLG product.

d Product Safety Publicationses

Product Applications and Safetytions Compliance Information

Product Modifications

ty and Reliability Departmentes, Inc.ainhead Plaza MD 21742

l JLG Officen back cover)

-877-JLG-SAFE (1-877-554-7233)A:1-717-485-6591

[email protected]

Read This First

d

Other Publications Available

Service Manual............................................................................................31200206Illustrated Parts Manual...............................................................................31200204

Note: The following stanANSI is compliant to ANSAUS is compliant to AS 1CE is compliant to EN145Refer to the machine Serstandard.31200537

dards may be referenced in this manual:I/ITSDF B56.6418.199ial Number Plate to identify the applicable compliance

Table of Contents

31200537

TABLE OF CONTENTSRevision LogRead This First

Operator Qualifications ......................................................bModifications ......................................................................bOther

Table of ContentsSection 1 - General

1.1 Hazard CSafety

1.2 General P1.3 Operation

ElectriTip OvTravelLoad FLiftingDrivingPinch Fall HaChem

Section 2 - Pre-Ope2.1 Pre-Oper2.2 Safety De2.3 Walk-Aro2.4 Warm-Up

WarmOpera

2.5 Operator 2.6 Windows

Cab DRear W

Section 3 - Controls3.1 General ..3.2 Controls .

InstrumDisplaKeypaIgnitioPark B

Table of Contentsi

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

Safety Practiceslassification System ..............................................1-1 Alert System and Safety Signal Words................1-1recautions ............................................................1-1 Safety..................................................................1-2cal Hazards ...........................................................1-2er Hazard..............................................................1-3 Hazard .................................................................1-6alling Hazard........................................................1-7

Personnel .............................................................1-8 Hazards on Slopes .............................................1-9

Points and Crush Hazards ..................................1-10zard....................................................................1-12

ical Hazards.........................................................1-13ration and Inspectionation Check and Inspection...................................2-1cals.......................................................................2-3und Inspection.......................................................2-6 and Operational Checks......................................2-8-Up Check .............................................................2-8tional Check ..........................................................2-8Cab .......................................................................2-9............................................................................2-10oor Window.........................................................2-10

indow ................................................................2-10 and Indicators..............................................................................3-1..............................................................................3-2ent Panel.............................................................3-4

y Screen................................................................3-6d............................................................................3-8n ..........................................................................3-10rake ....................................................................3-11

Table of Contents

ii

Parking Procedure........................................................ 3-11Transmission Control Lever.......................................... 3-12Load Stability Indicator (LSI) ........................................ 3-14Steering Column Adjuster............................................. 3-17Joystick......................................................................... 3-18Armrest and Right Hand Console................................. 3-22Acces

3.3 Anti Thef3.4 Steer Mo

ManuaAll WhMode

3.5 Operator AdjustSeat B

3.6 Boom IndBoom

Section 4 - Operatio4.1 Engine ...

StartinBatterNormaShut-D

4.2 OperatingLift LoPickinTranspLevelinPlacinDiseng

4.3 OperatingLift LoPickinTranspLevelinPlacinDiseng

4.4 Road Op4.5 Loading a

TiedowLifting31200537

sory Control Lever .............................................. 3-24t ........................................................................... 3-25des ...................................................................... 3-26l Steering Alignment Mode Change................... 3-26eel Assisted Steering AlignmentChange............................................................... 3-27Seat.................................................................... 3-28ments.................................................................. 3-28elt ....................................................................... 3-30icators ................................................................ 3-31Extension ........................................................... 3-31n

.............................................................................. 4-1g the Engine ......................................................... 4-1y Boosted Starting................................................. 4-2l Engine Operation ............................................... 4-3own Procedure .................................................... 4-3 with a Non-Suspended Load .............................. 4-4

ad Safely............................................................... 4-4g Up a Load .......................................................... 4-4orting a Load ....................................................... 4-5g Procedure......................................................... 4-5

g a Load................................................................ 4-6aging a Load........................................................ 4-6 with a Suspended Load...................................... 4-7

ad Safely............................................................... 4-7g Up a Suspended Load ....................................... 4-7orting a Suspended Load .................................... 4-8g Procedure......................................................... 4-8

g a Suspended Load............................................. 4-9aging a Suspended Load .................................... 4-9

eration ................................................................. 4-10nd Securing for Transport.................................. 4-11n........................................................................ 4-11

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

Table of Contents

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Section 5 - Attachments and Hitches5.1 Approved Attachments ........................................................5-15.2 Unapproved Attachments ....................................................5-15.3 JLG Supplied Attachments ..................................................5-25.4 Telehandler/Attachment/Fork Capacity................................5-45.5 Use of the Capacity Chart....................................................5-5

CapacSamplExamp

5.6 AttachmeQuick Hydra

5.7 Adjusting5.8 Attachme

CarriaSide SFork EFork MTruss BuckeMulti-PGrappConcr

5.9 Hitches...Pin HiPin HiPin HiAuto HPiton FHydra

Section 6 - Emerge6.1 Towing a

MovinMovin

6.2 Emergen6.3 Cab Emeiii

ity Indicator Locations...........................................5-5e Capacity Chart ...................................................5-6le ..........................................................................5-7nt Installation ........................................................5-9Attach....................................................................5-9ulic Operated Attachment....................................5-14/Moving Forks......................................................5-15nt Operation........................................................5-16ge w/Forks...........................................................5-17hift Carriage........................................................5-18xtension ..............................................................5-20ounted Hook ......................................................5-22

Boom...................................................................5-24t ...........................................................................5-26urpose Bucket ....................................................5-28

le Bucket .............................................................5-30ete Bucket - Fork Mounted ..................................5-32............................................................................5-34tch - CUNA C (Italy).............................................5-34tch - CUNA D2 (Italy)...........................................5-35tch........................................................................5-36itch .....................................................................5-37rame and Auto Hitch..........................................5-38

ulic Hitch..............................................................5-39ncy Procedures Disabled Product..................................................6-1g Short Distances ..................................................6-1g Longer Distances ...............................................6-1cy Lowering of Boom.............................................6-2rgency Exit ............................................................6-2

Table of Contents

iv

Section 7 - Lubrication and Maintenance7.1 Introduction.......................................................................... 7-1

Clothing and Safety Gear ............................................... 7-17.2 General Maintenance Instructions....................................... 7-27.3 Service and Maintenance Schedules .................................. 7-3

8 & 1st 50 Hour Maintenance Schedule ......................... 7-350, 251000 &

7.4 Lubricatio8 Hou50 Ho

7.5 Operator Fuel SAir IntaEngineHydraTires..Brake TransmEngineBatterWinds

Section 8 - Addition8.1 General..8.2 Load Sta8.3 Boom Int

Section 9 - Specific9.1 Product S

Fluid aTires..PerforDimenDeclarNoise

IndexInspection, Mainten31200537

0 & 500 Hour Maintenance Schedule................... 7-4 1500 Hour Maintenance Schedule..................... 7-5n Schedules ......................................................... 7-6

r Lubrication Schedule .......................................... 7-6ur Lubrication Schedule ........................................ 7-7Maintenance Instructions ..................................... 7-8ystem.................................................................... 7-8ke System ......................................................... 7-10 Oil ..................................................................... 7-12

ulic Oil ................................................................. 7-13............................................................................ 7-14System ............................................................... 7-16ission ................................................................ 7-17 Cooling System ................................................ 7-18

y .......................................................................... 7-19hield Washer System.......................................... 7-20al Checks

.............................................................................. 8-1bility Indicator Test ................................................ 8-1erlock .................................................................... 8-2ationspecifications......................................................... 9-1nd Lubrication Capacities .................................... 9-1.............................................................................. 9-2mance................................................................... 9-3sions..................................................................... 9-4ation of Vibration .................................................. 9-5Emission Level ..................................................... 9-5

ance and Repair Log

Section 1 - General Safety Practices

31200537

SECTION 1 - GENERAL SAFETY PRACTICES

1.1 HAZARD CLASSIFICATION SYSTEM

Safety Alert System and Safety Signal Words

DANGER indicates an iresult in death or serious

WARNING indicates a presult in death or serious

CAUTION indicates a poresult in minor or modera

1.2 GENERAL PR

Before operation, read safety precautions listeddamage, personal injury1-1

mminently hazardous situation which, if not avoided, willinjury.

otentially hazardous situation which, if not avoided, couldinjury.

tentiality hazardous situation which, if not avoided, mayte injury.

ECAUTIONS

WARNINGand understand this manual. Failure to comply with the in this manual could result in machine damage, property or death.


1-2

1.3 OPERATION SAFETY

Electrical Hazards

This machine is not ibeing near electrical c

NEVER operate theoverhead or undergrensuring the appropri

Always check for pow Follow employer, lo

powerlines.31200537

nsulated and does not provide protection from contact orurrent. telehandler in an area where overhead power lines,ound cables, or other power sources may exist withoutate power or utility company de-energizes the lines.er lines before raising the boom.cal and governmental regulations for clearance from


31200537

Tip Over Hazard

General For additional load requirements, refer to the appropriate capacity chart.

Never use an attachminstalled on the teleha

Understand how to pr DO NOT exceed rated Be sure that the groun

DO NOT raise boom ucapacity chart.

DO NOT level machin(AUS - DO NOT leveground surface.)1-3

ent without the appropriate JLG approved capacity chartndler.operly use the capacity charts located in cab. lift capacity.d conditions are able to support the machine.

nless frame is level (0 degrees), unless otherwise noted on

e with boom/attachment above 1,2 m (4 ft).l machine with load more than 300 mm (11.8 in) above


1-4

MAINTAIN proper timaintained, this mach

Refer to manufacturequirements for tires

Always wear the seat Keep head, arms, han

times.

If the telehandler starts to

DO NOT JUMP BRACE YOURSELF a KEEP YOUR SEAT B HOLD ON FIRMLY LEAN AWAY FROM T31200537

re pressure at all times. If proper tire pressures are notine could tip over.rers specifications for proper fill ratio and pressure equipped with ballast.

belt.ds, legs and all other body parts inside operators cab at all

tip over:

nd STAY WITH THE MACHINEELT FASTENED

HE POINT OF IMPACT


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Non-Suspended Load

DO NOT drive with bo

Suspended Load

Tether suspended loa Weight of all rigging (s Beware of wind. Wi

dangerous side loads DO NOT attempt to us Keep heavy part of loa Never drag the load; l

When driving with a s Start, travel, turn a DO NOT extend b DO NOT raise the

the boom more tha DO NOT exceed w1-5

om raised.

ds to restrict movement.lings, etc.) must be included as part of load.

nd can cause a suspended load to swing and cause - even with tag lines.e telehandler frame-leveling to compensate for load swing.d closest to attachment.

ift vertically.uspended load:nd stop slowly to prevent load from swinging.oom.

load more than 300 mm (11.8 in) above ground surface orn 45.alking speed.


1-6

Travel Hazard

Steering characteristisettings of the telehan

DO NOT change stewhile telehandler is st

Visually verify proper Ensure that adequate

swing. Look out for and avoid

a spotter if you DO NO Before moving be sur When driving, retract

maintaining visibility o Always look in the dire Always check boom

obstructions. Position When driving in high

selectable).

2-Wheel Front Steer 4-Wheel Circle Steer 4-Wheel Crab Steer31200537

cs differ between steer modes. Identify the steer modedler being operated.

er modes while traveling. Steer modes must be changedationary.wheel alignment after each steer mode change. clearance is provided for both rear tail swing and front fork

other personnel, machinery and vehicles in the area. UseT have a clear view.

e of a clear path and sound horn.boom and keep boom/attachment as low as possible whilef mirrors and maximum visibility of path of travel. ction of travel.

clearances carefully before driving underneath overhead attachment/load to clear obstacles.speed, use only front wheel steer (if steering modes are


31200537

Load Falling Hazard

Never suspend load fr DO NOT burn or drill h Forks must be centere1-7

om forks or other parts of carriage.oles in fork(s).d under load and spaced apart as far as possible.


1-8

Lifting Personnel

When lifting personnewith proper capacity c

DO NOT drive machin31200537

l, USE ONLY a JLG approved personnel work platform,hart displayed in the cab.

e from cab when personnel are in platform.


31200537

Driving Hazards on Slopes

To maintain sufficient trac

When unloaded, the pointed downhill.

When loaded, the fropointed uphill.

For additional travel re To avoid overspeedin

downshift to a lower gslow speed. DO NOT

Avoid excessively stedrive across excessiv

Avoid turning on a slodownhill.

DO NOT park on a slo1-9

tion and braking capabilities, travel on slopes as follows:rear of the machine is the heavy end. Drive with forks

nt of the machine is the heavy end. Drive with the forks

quirements, refer to the appropriate capacity chart.g the engine and drivetrain when driving down slopes,ear and use the service brake as necessary to maintain ashift into neutral and coast downhill.ep slopes or unstable surfaces. To avoid tip over DO NOTely steep slopes under any circumstances.pe. Never engage inching or shift to Neutral when going

pe.


1-10

Pinch Points and Crush Hazards

Stay clear of pinch points and rotating parts on the telehandler.

Stay cle

Keep clea31200537

ar of moving parts while engine is running.

r of steering tires and frame or other objects.

Keep clear from under boom.


31200537

Keep arm

Keep ha

1-11

Keep clear of boom holes.

s and hands clear of attachment tilt cylinder.

nds and fingers clear of carriage and forks.

Keep others away while operating.


1-12

Fall Hazard

Enter using the propecontact when mountiwheel when mounting

DO NOT get off the mperformed.

DO NOT carry ridersinjury.31200537

r hand holds and steps provided. Always maintain 3-pointng or dismounting. Never grab control levers or steering or dismounting the machine.achine until the shutdown procedure on page 4-3 has been

. Riders could fall off machine causing death or serious


31200537

Chemical Hazards

Exhaust Fumes

DO NOT operate machine in an enclosed area without proper ventilation. DO NOT operate the machine in hazardous environments unless approved for

that purpose by JLG engine exhaust can ca

If spark arrestors areorder.

DO NOT fill the fuel taor smoking materialsexplosion.

DO NOT attempt to engine is running or w

Stop engine and relieenough pressure that

DO NOT use your hansearch for leaks. Wea1-13

and site owner. Sparks from the electrical system and theuse an explosion.

required, ensure they are in place and in good working

Flammable Fuel

nk or service the fuel system near an open flame, sparks. Engine fuel is flammable and can cause a fire and/or

Hydraulic Fluid

repair or tighten any hydraulic hoses or fittings while thehen the hydraulic system is under pressure.

ve trapped pressure. Fluid in the hydraulic system is under it can penetrate the skin.d to check for leaks. Use a piece of cardboard or paper to

r gloves to protect hands from spraying fluid.


1-14

Th31200537

is Page Intentionally Left Blank

Section 2 - Pre-Operation and Inspection

31200537

SECTION 2 - PRE-OPERATION AND INSPECTION

2.1 PRE-OPERATION CHECK AND INSPECTIONNote: Complete all required maintenance before operating unit.

The pre-operation check or at each change of ope

1. Cleanliness - Checkobjects. Report any l

2. Structure - Inspect tmetal cracks or othe

3. Safety Decals - Ensreplace as required.

4. Operation and Safemanual holder.

5. Walk-Around Inspe6. Fluid Levels - Chec

transmission fluid an7 - Lubrication and Mproper type and interand grease away fromcomponent life.

7. Attachments/Accesthe telehandler. If proattachment or accesmaintenance instruct

FALL HAZARD. Use exreach. Use an approved

PARENT METAL 2-1

and inspection, performed at beginning of each work shiftrator, should include the following: all surfaces for leakage (oil, fuel or battery fluid) or foreign eakage to the proper maintenance personnel.he machine structure for dents, damage, weld or parent r discrepancies.

ure all safety decals are legible and in place. Clean or See page 2-3 for details.ty Manuals - Operation & Safety Manual located in cab

ction - See page 2-6 for details.k fluids, including fuel, brake fluid, hydraulic oil, engine oil, d coolant. When adding fluids, refer to Section aintenance and Section 9 - Specifications to determine vals. Before removing filler caps or fill plugs, wipe all dirt the ports. If dirt enters these ports, it can severely reduce

sories - Ensure correct capacity charts are installed on vided, reference the Operation & Safety Manual of each

sory installed for specific inspection, operation and ions.

WARNINGtreme caution when checking items beyond your normal ladder.

CRACK WELD CRACK


2-2

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

If telehandler does notlower boom and attachmcorrect before continued31200537

WARNING operate properly, immediately bring machine to a stop,

ent to ground and stop the engine. Determine cause and use.


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2.2 SAFETY DECALSEnsure all DANGER, WARNING, CAUTION and instructional decals and propercapacity charts are legible and in place. Clean and replace as required.

2-3

VIEW A-A

A

A


2-4

'('

'

VIEW B-B

B

B31200537

!"#$%&

VIEW OF FRONT TIEDOWN POINTS


31200537

!

"

LOAD CHARTS

VIEW OFREAR WINDOW2-5

)

C

C

VIEW C-C(S/N 1160005993 & AFTER INCLUDING

1160005949 & 1160005950)


2-6

2.3 WALK-AROUND INSPECTION

Begin your walk-around i(counterclockwise when vINSPECTION NOTE: Onparts, that they are securin addition to any other cattachment for cracks, ex

1. Boom Sections and L Check front, top, s Pivot pins secure;

2. Front Axle - Steer cyequipped); hydraulic

3. Boom Prop (if equipp4. Wheel/Tire Assembly

nuts. Inspect for wor

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nspection at item 1, as noted below. Continue to your rightiewed from top) checking each item in sequence. all components, make sure there are no loose or missingely fastened and no visible leaks or excessive wear existsriteria mentioned. Inspect all structural members includingcessive corrosion and other damage.ift, Tilt, Extend/Retract, Compensating (Slave) Cylinders -

ide and rear wear pads for presence of grease. hydraulic hoses undamaged, not leaking. linders undamaged, not leaking; pivot pins secure (if hoses undamaged, not leaking.ed) - See inspection note. - Properly inflated and secured; no loose or missing lug

n tread, cuts, tears or other discrepancies.


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5. Work Lights (if equipped) - Clean and undamaged.6. Mirrors - Clean and undamaged.7. Cab and Electrical -

General appearance; no visible damage. Frame level indicator(s) and window glass undamaged and clean. Gauges, switches, Check seat belt fo

buckles or loose m8. Wheel Chock (if equ9. Wheel/Tire Assembly


10. Rear Axle - Steer cylhydraulic hoses unda

11. LSI Sensor - See ins

12. Wheel/Tire Assemblynuts. Inspect for wor

13. Boom Sensor (S/N 1See inspection note.

14. Engine Compartmen Drive belts, check Engine mounts - S Air cleaner elemen

element as require Main control valve Battery cables tigh Engine cover close

15. Air Precleaner - Che16. Wheel/Tire Assembly


17. Frame Level Cylindenot leaking.

18. Attachment - Properl2-7

joystick, foot controls and horn operational.r damage, replace belt if frayed or cut webbing, damagedounting hardware.

ipped) - See inspection note. - Properly inflated and secured; no loose or missing lug

n tread, cuts, tears or other discrepancies.

inders undamaged, not leaking; pivot pins secure; maged, not leaking.pection note.

- Properly inflated and secured; no loose or missing lug n tread, cuts, tears or other discrepancies.

160005993 & After including 1160005949 & 1160005950) -

t - condition and replace as required.ee inspection note.t condition indicator, check for clogged condition. Replaced. - See inspection note.t, no visible damage or corrosion.d and properly secured.

ck and clean as required.

- Properly inflated and secured; no loose or missing lug n tread, cuts, tears or other discrepancies.

r (if equipped) - Pins secure; hydraulic hoses undamaged,

y installed, see Attachment Installation on page 5-9.


2-8

2.4 WARM-UP AND OPERATIONAL CHECKS

Warm-Up Check

During warm-up period, check:1. Heater, defroster and

2. Check all lighting sys3. Adjust mirror(s) for m

Operational Check

When engine warms, per1. Service brake and pa

2. Forward and reverse

3. Each gear.4. Steering in both direc

be reached). Check 5. Horn and back-up ala

running. 6. All joystick functions 7. Perform any addition

CUT/CRUSH/BURN Hexcept when checking t31200537

windshield wiper (if equipped).tems (if equipped) for proper operation.aximum visibility.

form an operational check:

rking brake operation. travel.

tions with engine at low idle (steering lock to lock will not in each steering moderm. Must be audible from inside operators cab with engine

- operate smoothly and correctly.

al checks described in Section 8.

WARNINGAZARD. Keep covers closed while engine is runningransmission oil level.


31200537

2.5 OPERATOR CABThe telehandler is equipped with an enclosed ROPS/FOPS cab.

WARNINGCRUSH HAZARD. Nevstructure are in good approved by JLG to ascab/machine configuratmust be REPLACED.2-9

er operate telehandler unless the overhead guard and cabcondition. Any modification to this machine must besure compliance with ROPS/FOPS certification for thision. If damaged, the CAB CANNOT BE REPAIRED. It


2-10

2.6 WINDOWSKeep all windows clean and unobstructed.

Cab Door Window

Cab door (1) must be During operation the c Open the cab door wi Press the release butt

Rear Window

Lift lever (4) and push Lift lever and pull to cl

31200537

closed during operation.ab door window (2) must either be latched open or closed.

ndow and secure it in the latch.on (3) inside the cab to unlatch the window.

to open the rear window (5).ose.

Section 3 - Controls and Indicators

31200537

SECTION 3 - CONTROLS AND INDICATORS

3.1 GENERALThis section provides the necessary information needed to understand controlfunctions.

Note: The manufactureroperation. The user and opractices.3-1

has no direct control over machine application and perator are responsible for conforming with good safety


3-2

3.2 CONTROLS

1. Park Brake: See pag2. Accelerator Pedal: P

speed.

3. Service Brake Pedalspeed.

4. Ignition Switch: Key 5. Hydraulic Quick Atta

to hydraulically lock o

6. Transmission Contro7. Frame Level Indicato

condition of the teleh

8. Steering Column Adj

31200537

e 3-11.ressing down the pedal increases engine and hydraulic

: The further the pedal is depressed, the slower the travel

Activated. See page 3-10.ch Switch (if equipped): Used in conjuction with the joystick r unlock an attachment.

l Lever: See page 3-12.r: Enables operator to determine the left to right level andler.

uster: See page 3-17.


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9. Steering Wheel: Turning the steering wheel to the left or right steers the machine in the corresponding direction. Three steering modes are available. See Steer Modes on page 3-26.

10. Instrument Panel: See page 3-4.11. Accessory Control Lever: See page 3-24.12. LSI Indicator: See pa

13. Keypad: See page 314. Joystick: See page 315. Armrest and Right H16. Hydraulic Hitch Safe

on hydraulic hitch. S3-3

ge 3-14.-8.

-18.

and Console: See page 3-22.ty Hook Release (if equipped): Pull to release safety hooks ee page 5-39 for control instructions.


3-4

Instrument Panel

1. Low Fuel Indicator: I

2. Fuel Gauge: Indicate3. Left Turn Signal Indic4. Display Screen: See5. Right Turn Signal Ind6. Engine Temperature7. Engine Temperature

engine temperature i8. Continuous Auxiliary

auxiliary hydraulics a

9. Trailer Turn Signal In10. Clutch Lock Indicato

11. High Beam Indicator12. Anti Theft Indicator: I

theft feature is active

13. Maintenance Indicatomaintenance is requ

14. Engine Preheat Indictemperature is reachindicator goes out.

15. Park Brake Indicator

31200537

lluminates and buzzer sounds briefly when fuel level is low.

s amount of fuel in fuel tank.

ator: Illuminates when left turn signal is active. page 3-6.icator: Illuminates when right turn signal is active.

Gauge: Indicates engine operating temperature. Warning Indicator: Illuminates and buzzer sounds when s too high. Hydraulics Indicator: Illuminates when continuous re active.

dicator: Illuminates when trailer turn signal is activated.r: Illuminates when clutch lock feature is engaged.: Illuminates when high beam lights are on.lluminates and buzzer sounds briefly at start-up when anti . Enter anti theft code, see page 3-25.r: Illuminates and buzzer sounds briefly when

ired.

ator: With ignition key in position II, illuminates until start ed. At temperatures below 0 C (32 F), do not start until

: Illuminates when park brake is applied. See page 3-11.


31200537

16. System Distress Indicator: Illuminates and buzzer sounds when critical machine and engine faults exist.

17. Engine Fault Critical Indicator: Illuminates and buzzer sounds when a critical engine fault exists.

18. Engine Fault Warning Indicator: Illuminates and buzzer sounds when engine is operating outside the

19. Air Filter Restriction filter(s) require maint

20. Engine Oil Pressure pressure is too low.

21. Battery Charge Indicsystem is not functio

22. Transmission Oil Temtransmission oil temp

23. Steering Pressure Inpressure is too low.

24. Hydraulic Filter Restwhen hydraulic filter

Note: All indicators (excesystem start up.

EQUIPMENT DAMAGindicator illuminates (exlower boom and attachmcorrect before continued3-5

normal range.Indicator: Illuminates and buzzer sounds briefly when air enance.

Indicator: Illuminates and buzzer sounds when engine oil

ator: Illuminates when battery is at low charge or charging ning properly.perature Indicator: Illuminates and buzzer sounds when erature is too high.dicator: Illuminates and buzzer sounds when steering

riction Indicator: Illuminates and buzzer sounds briefly requires maintenance.

pt high beam and turn signals) perform a bulb check at

WARNINGE. When the engine fault, system distress or a redcept park brake), immediately bring machine to a stop,ent to ground and stop the engine. Determine cause and use.


3-6

Display Screen

1. Joystick Mode: Displby the machine owneService Manual for ina. Loader Joystick P

active. See pageb. Lift Joystick Patte

See page 3-18.2. Speed (if equipped)

(km/h) or miles per h3. Driving Direction and

a. Direction - Forwab. Gear - First (1), S

4. Engine Speed: Displ5. Operating Hours: Dis6. Boom Angle: Display7. Continuous Auxiliary

a. Continuous Auxiwhen continuo5 - Attachments

b. Steering Mode CModes on page

8. Anti Theft Code Entrystart. See Anti Theft

DISPLAY SHOWN WITH CONTINUOUS AUXILIARY HYDRAULICS ACTIVE

DISPLAY SHOWN WITH ANTI THEFT ACTIVE AT SYSTEM START31200537

ays current joystick mode. Joystick mode can be changed r in Operator Tools Menu (level 2 password required). See formation.attern - Displays loader joystick pattern icon on left when3-20.rn - Displays lift joystick pattern icon on right when active.

- Telehandler travel speed displayed in kilometers per hour our (m/h). Gear: Displays current driving condition.rd (F), Neutral (N) or Reverse (R).econd (2), Third (3) or Fourth (4).ays engine speed in revolutions per minute (rpm).plays total hours of telehandler operation.

s boom angle in degrees. 0 degrees indicates horizontal. Hydraulics and Steering Mode Change:liary Hydraulics - Displays flow value (-100% to +100%)us auxiliary hydraulics is activated. See Sectionand Hitches for details.hange - Assists with steering mode change. See Steer3-26 for details.: If active, the four digit code must be entered after system on page 3-25 for details.


31200537

9. Menus: Menus displamodification of somebuttons on the keypaa. Help - Displays a

arrows to cycle with an asterisk.

b. Operator Tools - Alignment Mode access code req

Machine Spe Engine Tem

displayed. Steering Alig

to be used wc. Personalities - V

access code reqd. Access Level - C

Operator (Le Customer (Le Service (Leve

e. Diagnostics - Vief. System Test - Pe

g. Machine Setup -required to modi

h. Calibrations - Cus

3-7

y fault codes and other machine information while allowing operating parameters. Depress and hold the C and OK d to access menus.ctive fault code. Depress OK button again and use keypadthrough the last 25 fault codes. Active faults are denoted

Speed, Temperature and Oil Pressure units and Steeringcan be modified by the operator. Customer or Service leveluired to modify additional items.ed - Select units (km/h or m/h) to be displayed.perature - Select units (Celsius or Fahrenheit) to be

nment Mode - Select mode (manual or all wheel assisted)hen changing steering modes, see page 3-26.iew performance parameters. Customer or Service leveluired to modify parameters.ode entry determines access level.vel 3) - No code required.vel 2) - See Service Manual for information.l 1) - Manufacturer service representative only.

w diagnostic information.rforms test of all system inputs and outputs. View machine configurations. Service level access codefy configurations.tomer or Service level access code required.


3-8

Keypad

1. C (Clear or escape):interface one level duone second to exit.

2. Up/Down Arrows: Usselections and chang

3. OK (Enter): Use in coinputs.

4. Steer Mode: Three sSteer and 4-Wheel CSee page 3-26.Note: If machine is sat restart.

5. LSI Override: Momenwhile activated. Deprmomentarily disable

6. Bucket Mode: LED li

7. Joystick Function: LEoutrigger functions apublic roads. See R

Note: All LEDs perform a

TIP OVER HAZARD. Eequipment and/or cause

31200537

Use in conjuction with display screen. Returns user ring navigation. If at top level menu, depress and hold for

e in conjuction with display screen. Navigate menu e adjustable values.njuction with display screen. Confirms user interface

teer modes available: 4-Wheel Circle Steer, 2-Wheel Front rab Steer. Illuminated LED indicates current steer mode.

hut-down during steer mode change, it must be completed

tarily disables the automatic function cut-out. LED flashes ess and hold up to 30 seconds while operating joystick to the automatic function cut-out.

t while activated. Increases response to boom functions.

D lit while activated. Boom, auxiliary hydraulics and re enabled. Deactivate this function before traveling on oad Operation on page 4-10. bulb check at system start up.

WARNINGxceeding lift capacity of the telehandler could damage the tip over.


31200537

Th3-9



3-10

Ignition

Position 0 - Engine of Position I - Voltage av Position II - Engine p

engine until preheat in Position III - Engine s

position 0 then back toNote: Key is removable

31200537

f.ailable for all electrical functions. reheat at temperatures below 0 C (32 F). Wait to startdicator on instrument panel goes out.tart. In the event the engine does not start, rotate key to position III to re-engage the starter.

in the 0 and P positions.


31200537

Park Brake

The park brake lever (1) c Pull lever back to app Squeeze release (2) a

Parking Procedure

1. Using service brake,2. Follow Shut-Down P

MACHINE ROLL-AWAposition, lower boom to

CRUSH HAZARD. Appabruptly and could causthe park brake.

3-11

ontrols the application and release of the park brake.

ly park brake.nd push lever forward to release park brake.

stop telehandler in an appropriate parking area.rocedure on page 4-3.

WARNINGY HAZARD. Always move park brake switch to "ON"ground and stop engine before leaving cab.

WARNINGlying park brake while traveling will cause unit to stope load loss. To stop the machine in an emergency, apply

8, 9, 12 & 13M


3-12

Transmission Control Lever

Direction of Travel Selection

Transmission control leve

Push lever forward forlever to centered posi

Forward or reverse tra When traveling in reve Drive in reverse and t If clutch lock switch is

with the transmissionan attempt to get quicmachine movement.

TIP OVER/CRUSH HAshifting transmission coreduce stability and/or c31200537

r (1) engages forward or reverse travel. forward travel; pull lever rearward for reverse travel. Movetion for Neutral.vel can be selected while in any gear.rse, the back-up alarm will automatically sound.

urn only at slow rates of speed. activated (see page 3-22), do not increase engine speed

in forward or reverse and the service brake depressed inker hydraulic performances. This could cause unexpected

WARNINGZARD. Bring telehandler to a complete stop before

ntrol lever. A sudden change in direction of travel couldause load to shift or fall.


31200537

Gear Selection

Gear selection is located

Twist hand grip to sele Select the appropriat

when transporting alonger distances.

Slow down prior to dotime.

3-13

on the twist grip handle (2) of transmission control lever.ct gear.

e gear for the task being performed. Use a lower gear load. Use a higher gear only when driving unloaded for

wnshifting. Do not downshift more than one gear at a

*!$

+

!,


3-14

Load Stability Indicator (LSI)

Before S/N 1160005993

The LSI (1) provides viswhen machine is static on

Green LED (2) will illu When approaching fo

green (3), then yellow The warning buzzer s As the telehandler rea

illuminates, the automdisabled (i.e. boom lift

Press button (6) to diwill illuminate. If lastwarning buzzer sound

Test LSI (8) at the bChecks.

WARNINGTIP OVER HAZARD. The LSI considers only longitudinal stability limitations,observe all operating ptelehandler could dama

31200537

excluding 1160005949 & 1160005950

ual and audible indication of forward stability limitations firm, level surface.

minate when LSI power is on.rward stability limitations LEDs progressively illuminate,

(4) and finally red (5).ounds as the first red LED illuminates.ches forward stability limitations and the second red LEDatic function cut-out is activated. Certain functions are

, extend, etc). Retract boom to re-enable functions.sable the warning buzzer. When disabled, yellow LED (7) red LED illuminates, disable button is overridden ands.eginning of each work shift. See Section 8 - Additional

arameters. Failure to follow operating parameters of thege the equipment and/or cause tip over.

-


31200537

S/N 1160005993 & After including 1160005949 & 1160005950

The LSI (9) provides viswhen machine is static on

Green LED (10) will ill When approaching fo

green (11), then orang If the red LED illumina

The LSI has two modes:Active Mode As the telehandle

illuminates, the auand outrigger funand boom lift (CE

In some instanceoperated close tocertain functionsjoystick to neutraLEDs to stop flash

Passive Mode The orange LED

The boom is f The park brak

forward or rev When approachin

is provided and tdisabled.

3-15

ual and audible indication of forward stability limitations firm, level surface.

uminate when LSI power is on.rward stability limitations LEDs progressively illuminate,e (12) and finally red (13).tes the warning buzzer also sounds.

r reaches forward stability limitations and the red LED (13)tomatic function cut-out is activated. All boom, frame levelctions are disabled except for boom retract (CE & AUS)). Retract boom to re-enable functions.s the LSI system may slow down or stop boom functions if forward stability limitations. When LEDs begin to flash,

can not be operated. Retract boom and/or return thel position for a short period to allow system to reset anding before proceeding with operation.

(15) illuminates when either of the following occurs:ully retracted.e is not applied and transmission control lever is in the

erse position.g forward stability limitations, visual and audible indicationhe automatic function cut-out and/or slow down feature is


3-16

Travel in accordance with the requirements set forth in Section 1 - GeneralSafety Practices.

Test LSI (14) at the beginning of each work shift. See Section 8 - AdditionalChecks.

When placing a load, ensure axles are not fully steered in either direction.

TIP OVER HAZARD. buzzer sounds, retractcorrect before continued31200537

WARNINGIf the green, orange and red LEDs flash and warning and lower boom immediately. Determine cause and use.


31200537

Steering Column Adjuster

Follow Shut-Down Pr Turn lever (1) counter Place steering column Turn lever clockwise t

TIP OVER/CRUSH HAshifting transmission coreduce stability and/or c3-17

ocedure on page 4-3.clockwise to unlock. in desired position.o lock.

WARNINGZARD. Bring telehandler to a complete stop before

ntrol lever. A sudden change in direction of travel couldause load to shift or fall.


3-18

Joystick

Lift Joystick Pattern

Verify the lift joystick patdecal located inside the c

The joystick (1) controlsfunctions.

Boom Functions

Move the joystick bacjoystick right to extend

The speed of boom corresponding directispeed.

For two simultaneousexample; moving the simultaneously.

31200537

tern icon (2) is active on the display (1) and the joystickab matches the machine controls.

the boom, attachment, auxiliary hydraulics and outrigger

k to lift boom; move joystick forward to lower boom; move boom; move joystick left to retract boom.functions depends upon the amount of joystick travel inon. Increasing engine speed will also increase function

boom functions, move the joystick between quadrants. Forjoystick forward and to the left will lower and retract boom


31200537

Attachment Functions

Attachment tilt is controlle

Push the roller switchtilt attachment up.

Auxiliary Hydraulic Fun

Auxiliary Hydraulics butthydraulic supply for operboom attachment functiolower functions. See Secand control instructions.

WARNINGTIP OVER/CRUSH HAZARD. Rapid, jerky operation of controls will cause rapid,jerky movement of the load. Such movements could cause the load to shift or fallor could cause the machine to tip over.3-19

d by the roller switch (2). up to tilt attachment down; push the roller switch down to

ctions

ons (3 & 4) control functions of attachments that requireation. Buttons (3) can be used simultaneously with normalns. Button (4) must be used independently of boom lift/

tion 5 - Attachments and Hitches for approved attachments


3-20

Loader Joystick Pattern

Verify the loader joystick decal located inside the c

The joystick (1) controlsfunctions.

Boom Functions

Move the joystick bac Extend/retract is con

extend boom; push ro The speed of boom

corresponding directispeed.

For two simultaneousexample; moving theattachment up simulta

31200537

pattern icon (3) is active on the display (1) and the joystickab matches the machine controls.

the boom, attachment, auxiliary hydraulics and outrigger

k to lift boom; move joystick forward to lower boom.trolled by the roller switch (2). Push roller switch up toller switch down to retract boom.functions depends upon the amount of joystick travel inon. Increasing engine speed will also increase function

boom functions, move the joystick between quadrants. For joystick forward and to the left will lower boom and tiltneously.


31200537

Attachment Functions

Attachment tilt is controlle

Move joystick right to Auxiliary Hydraulic Fun

Auxiliary Hydraulics butthydraulic supply for operboom attachment functiolower functions. See Secand control instructions.

WARNINGTIP OVER/CRUSH HAZARD. Rapid, jerky operation of controls will cause rapid,jerky movement of the load. Such movements could cause the load to shift or fallor could cause the machine to tip over.3-21

d by the joystick.tilt down; move joystick left to tilt up.ctions

ons (3 & 4) control functions of attachments that requireation. Buttons (3) can be used simultaneously with normalns. Button (4) must be used independently of boom lift/

tion 5 - Attachments and Hitches for approved attachments


3-22

Armrest and Right Hand Console

1. Frame Level Switch right side of switch toframe left. Frame levboom retracted switcwith boom fully retrac

2. Hazard Light Switch:3. Beacon Light Switch

beacon on cab roof.

4. Clutch Lock Switch: engaged while depresystem and have tra

5. Boom Work Lights S6. Front/Rear Auxiliary

auxiliary hydraulics.

7. Rear Wiper Switch: O

8. Driving Lights Switch9. Rear Work Lights Sw

10. Front Work Lights Sw11. Power Outlet: 12V re

12. Auxiliary Electrics (if auxiliary electric featuattachments and con

31200537

(if equipped): Controls the left to right frame level. Depress rotate frame right; depress left side of switch to rotate el operable with boom below 20 degrees. If equipped with h, frame level operable with boom below 20 degrees or ted and between 20 and 55 degrees.

On/Off switch.

(if equipped): On/Off switch. Place magnetic base of Power supplied by 12V receptacle at rear left of cab roof.

Depress front of switch to activate and keep transmission ssing service brake. Depress back of switch to deactivate nsmission disengage while depressing service brake.witch (if equipped): On/Off switch.Hydraulics Switch: Depress front of switch to activate front Depress back of switch to activate rear auxiliary hydraulics.

n/Off switch.

(if equipped): On/Off switch.itch (if equipped): On/Off switch.itch (if equipped): On/Off switch.ceptacle.

equipped): On/Off switch. Depress button to activate re. See Section 5 - Attachments and Hitches for approved trol instructions.


31200537

13. Continuous Auxiliary Hydraulics Switch:

a. Depress and release front of switch for continuous operation of hydraulicpowered attachments. Set continuous auxiliary hydraulic level (-100% to100%) within 10 seconds using the keypad up/down arrow buttons (seepage 3-8). See Section 5 - Attachments and Hitches for approvedattachments and control instructions.

b. Relieves auxiliary

Heater and Air Conditio

14. Fan Speed Switch: A

15. Recycle/Fresh Air Sw16. Temperature Control

17. Air Conditioning Swit3-23

hydraulic circuit pressure. See page 5-14.

ning Controlsdjustable rotary switch.itch (if equipped): Adjustable rotary switch.

Switch: Adjustable rotary switch.ch (if equipped): On/Off switch.


3-24

Accessory Control Lever

Turn Signals and Low/High Beam Headlights

Push accessory contr Pull lever backward (3 The lever must be ma

turn signal. The lever Pull lever up (4) to sw

Front Windshield Wiper

Rotate hand grip (5) toI - Fast

Depress end of lever Depress button (7) to

31200537

ol lever (1) forward (2) to activate left turn signal.) to activate right turn signal.nually returned to the center position to deactivate either

will not cancel automatically after a turn.itch between low and high beam headlights.

and Horn

activate front windshield wiper, O - Off, J - Continuous or

(6) to activate windshield wiper fluid.sound horn.

.


31200537

3.3 ANTI THEFTMachines with the anti theft feature active require entering a numeric code beforeoperation to prevent unauthorized use. Code entry is accomplished using the displayand keypad.

1. Turn ignition switch tthe operator for a nu

2. Use the up/down arr

3. Depress OK button (4. Continue until the co

5. If an incorrect code iprompt the operator

6. If the correct code is

Note: If the anti theft feamay be viewed or changepassword required). See

3-25

o position I. If anti theft is active, the display (1) will prompt meric code.

ow buttons (2) to select the first digit.3) to confirm and move to the next digit.de is complete.

s entered, the buzzer will sound briefly and the display will again for the numeric code. entered, normal start up can continue.

ture is active and the current access code is not known, it d by the machine owner in Operator Tools Menu (level 2 Service Manual for information.


3-26

3.4 STEER MODESThree steer modes are available for operator use.

Note: 2-Wheel Front Ste

Manual Steering Al

If manual steering alignmpage 3-7), use the followiNote: Steer mode will ch

1. Bring machine to a strear wheels are align

2. With circle steer (1) othe left rear wheel (4

3. Select front steer mo4. Turn the steering wh

the machine.

5. Wheels are now alig

2-Wheel Front Steer 4-Wheel Circle Steer 4-Wheel Crab Steer31200537

er mode is required for travel on public roads.

ignment Mode Change

ent mode is active under the Operator Tools menu (seeng procedure for steer mode change. ange immediately after selection.

op using service brake. If front steer mode (2) is active and ed, go directly to step 4.

r crab steer (3) mode active, turn the steering wheel until ) is aligned with the side of the machine.de (2).eel until the left front wheel (5) is aligned with the side of

ned. Select desired steer mode.


31200537

All Wheel Assisted Steering Alignment Mode Change

If all wheel assisted steering alignment mode is active under the Operator Toolsmenu (see page 3-7), use the following procedure for steer mode change.

1. Bring machine to a stop using service brake.

2. Select desired steer

Note: Selected steer moscreens until the change mode LED will illuminate

3. Turn the steering whskipped if changing fcentered.

4. Turn the steering whskipped if changing t

5. Wheels are now alig

3-27

mode: circle steer (1), front steer (2) or crab steer (3).de LED will flash and display will show steering alignment is complete. After steering alignment is complete, steer solid.

eel until the rear wheels are centered (6). This step will be rom front steer mode and rear wheels are already

eel until the front wheels are centered (7). This step will be o front steer mode.ned and steer mode change is complete (8).


3-28

3.5 OPERATOR SEAT

AdjustmentsPrior to starting the engine adjust seat for position and comfort.

Mechanical Suspension

1. Backrest: Use handle

2. Fore/Aft: Use handle

3. Suspension: Use han4. Weight: Displays cur5. Lumbar Support: Use

6. Seat Belt: Always fas7. Height: Pull up on bo

31200537

Seat

to adjust backrest angle. to move seat fore and aft.

dle to adjust suspension to the appropriate weight setting.rent weight setting. knob to adjust lumbar support.ten seat belt during operation.th sides of seat to adjust height.


31200537

Pneumatic Suspension Seat

1. Backrest Angle: Use2. Fore/Aft: Use handle

3. Suspension: Use kno

4. Height: Use knob to 5. Lumbar Support: Use

6. Seat Belt: Always fas

7. Fore/Aft Isolator: Use3-29

handle to adjust backrest angle. to move seat fore and aft.

b to adjust suspension to the appropriate weight setting.adjust height to the appropriate setting. knob to adjust lumbar support.ten seat belt during operation. handle to lock or unlock.


3-30

Seat Belt

Fasten seat belt as follow

1. Grasp both free endsor entangled.

2. With back straight ininto the receptacle (b

3. With belt buckle posiend of the belt away

4. To release belt latch,buckle.31200537

s:

of the belt making certain that belt webbing is not twisted

the seat, couple the retractable end (male end) of the belt uckle) end of the belt.tioned as low on the body as possible, pull the retractable from the buckle until it is tight across the lap. depress red button on the buckle and pull free end from


31200537

3.6 BOOM INDICATORS

Boom Extension

The boom extension ithese indicators to detUse of the Capacity C

3-31

ndicators (1) are located on the left side of the boom. Useermine boom extension when using the capacity chart (seehart on page 5-5).


3-32

Th31200537


Section 4 - Operation

31200537

SECTION 4 - OPERATION

4.1 ENGINE

Starting the Engine

This machine can be ope45C (0F to 113F). Conconditions.

1. Make sure all controheater, defroster, etc

2. Turn ignition switch t3. Turn ignition switch t

for preheat indicator

4. Turn ignition switch timmediately when enrelease key and allowagain.

5. After engine starts, ofor more than five seengine.

6. Warm up engine at aNote: Engine will not stabrake is applied.

UNEXPECTED MOVEMlever is in neutral and tReleasing park brake imove abruptly.

ENGINE EXPLOSION.starting.4-1

rated under normal conditions in temperatures of -18C tosult JLG for operation outside this range or under abnormal

ls are in Neutral and all electrical components (lights, .) are turned off. Set parking brake.o position I. If active, enter anti theft code.

o position II. If the temperature is below 0 C (32 F), wait on instrument panel to go out.o position III to engage starting motor. Release key gine starts. If engine fails to start within 20 seconds, starting motor to cool for a few minutes before trying

bserve engine oil pressure indicator. If indicator remains on conds, stop engine and determine cause before restarting

pproximately 1/2 throttle.

rt unless transmission control lever is in Neutral and park

WARNINGENT HAZARD. Always ensure that transmission control

he service brake is applied before releasing park brake.n either forward or reverse could cause the machine to

WARNING Do not spray ether into air intake for cold weather


4-2

Battery Boosted Starting

If battery-boost starting (j Never allow vehicles t Ensure boosting vehic Connect the positive ( Connect the opposite

booster battery. Connect the negative Connect opposite end

away from discharged Follow standard starti Remove cables in rev

BATTERY EXPLOSIONas it could explode. Kefrom the battery. Lead Wear safety glasses.31200537

ump-start) is necessary, proceed as follows:o touch.le engine is running.+) jumper cable to positive (+) post of discharged battery. end of positive (+) jumper cable to positive (+) post of

(-) jumper cable to negative (-) post on booster battery. of negative (-) jumper cable to ground point on machine battery.

ng procedures.erse order after machine has started.

WARNING HAZARD. Never jump start or charge a frozen batteryep sparks, flames and lighted smoking materials awayacid batteries generate explosive gases when charging.


31200537

Normal Engine Operation

Observe instrument panel and display frequently to be sure all systems arefunctioning properly.

Be alert for unusual noises or vibration. When an unusual condition isnoticed, park machine in safe position and perform shut-down procedure. Reportcondition to your supe

Avoid prolonged idli

Shut-Down Procedu

When parking the telehanfrom other equipment and

1. Apply the park brake

2. Shift the transmissio

3. Lower forks or attach

4. Operate engine at lo5. Shut off engine and r6. Exit telehandler prop

7. Turn off electrical ma

8. Block wheels (if nece4-3

rvisor or maintenance personnel.ng. If the engine is not being used, turn it off.

re

dler, park in a safe location on flat level ground and away/or traffic lanes..

n to Neutral.

ment to the ground.w idle for 3 to 5 minutes. DO NOT over rev engine.emove ignition key.erly.

ster switch (if equipped).ssary).


4-4

4.2 OPERATING WITH A NON-SUSPENDED LOAD

Lift Load Safely

You must know the weight and load center of every load you lift. If you are notsure of the weight and load center, check with your supervisor or with thesupplier of the materia

Know the rated load cthe telehandler to detransport and place a

Picking Up a Load

Note the conditions ofif conditions warrant.

Avoid lifting double-tie Make sure load is clea Adjust spacing of fork

Adjusting/Moving For Approach load slowly

attempt to lift a load w NEVER operate teleh

operator cab for the te

TIP OVER HAZARD. Eequipment and/or cause31200537

l.

apacities (refer to Section 5 - Attachments and Hitches) oftermine the operating range in which you can safely lift,load.

the terrain. Adjust travel speed and reduce amount of load

red loads.r of any adjacent obstacles.

s so they engage the pallet or load at maximum width. Seeks on page 5-15. and squarely with fork tips straight and level. NEVERith just one fork.andler without a proper and legible capacity chart in thelehandler/attachment combination you are using.

WARNINGxceeding lift capacity of the telehandler could damage the tip over.


31200537

Transporting a Load

After engaging the loposition it for travel. Section 1 - General S

Leveling Procedure

1. Position machine in b

2. Apply parking brake 3. Observe level indica

to lifting load.4. Move boom/attachm

Important things to rem Never raise the boom

telehandler is level. The combination of fr

over.4-5

ad and resting it against the backrest, tilt the load back toTravel in accordance with the requirements set forth inafety Practices and Section 5 - Attachments and Hitches.

est location to lift or place load.

and move transmission control lever to NEUTRAL.

tor(s) to determine whether machine must be leveled prior

ent to 1,2 m (4 ft) off ground.

ember:

/attachment more than 1,2 m (4 ft) above ground unless

ame leveling and load could cause the telehandler to tip


4-6

Placing a Load

Before placing any load be sure that: The landing point can safely support the weight of the load. The landing point is level; front to back and side to side. Use the capacity char

Capacity Chart on pa Align forks at the leve

just above area where Lower the boom until

Disengaging a Load

Once the load has been p1. With the forks free fr

and/or the telehandlenot change level con

2. Lower the carriage.3. The telehandler can 31200537

t to determine safe boom extension range. See Use of thege 5-5.l load is to be placed, then extend boom slowly until load is it is to be placed.

the load rests in position and the forks are free to retract.

laced safely at the landing point, proceed as follows:om the weight of the load, the boom can be retracted r can be backed away from under the load if surface will dition of telehandler.

now be driven from the landing location to continue work.


31200537

4.3 OPERATING WITH A SUSPENDED LOAD

Lift Load Safely

You must know the weight and load center of every load you lift. If you are notsure of the weight and load center, check with your supervisor or with thesupplier of the materia

Know the rated load cthe telehandler to detransport and place a

Picking Up a Suspe

Note the conditions ofif conditions warrant.

Avoid lifting double-tie Make sure load is clea NEVER operate teleh

operator cab for the te Only use approved lift Identify the proper lifti

gravity and load stabil Ensure to always prop Refer to Use of the C

addition to the approp

TIP OVER HAZARD. Eequipment and/or cause4-7

l.

apacities (refer to Section 5 - Attachments and Hitches) oftermine the operating range in which you can safely lift,load.

nded Load

the terrain. Adjust travel speed and reduce amount of load

red loads.r of any adjacent obstacles.andler without a proper and legible capacity chart in thelehandler/attachment combination you are using.ing devices rated for the lifting of the load.ng points of the load, taking into consideration the center ofity.erly tether loads to restrict movement.apacity Chart on page 5-5 for proper lifting guidelines in

riate capacity chart in the operator cab.

WARNINGxceeding lift capacity of the telehandler could damage the tip.


4-8

Transporting a Suspended Load

Travel in accordanceSafety Practices and

For additional requiroperator cab.

Important things to rem Ensure the boom is fu Never raise the load

boom more than 45. The combination of fr

over.

The guide persons anor hand) and be in vis

Never place the guide Only transport the loa

Leveling Procedure

1. Position machine in b

2. Apply parking brake 3. Observe level indica

to lifting load.4. Move boom so load

and/or boom is raise31200537

with the requirements set forth in Section 1 - GeneralSection 5 - Attachments and Hitches.ements, refer to the appropriate capacity chart in the

ember:

lly retracted.more than 300 mm (11.8 in) above ground surface or the

ame leveling and load could cause the telehandler to tip

d operator must remain in constant communication (verbalual contact with the operator at all times. persons between the suspended load and the telehandler.d at walking speed (0.4 m/s) or less.

est location to lift or place load.

and move transmission control lever to NEUTRAL.

tor(s) to determine whether machine must be leveled prior

is no more than 300 mm (11.8 in) above ground surface d no more than 45.


31200537

Placing a Suspended Load

Before placing any load be sure that: The landing point can safely support the weight of the load. The landing point is level; front to back and side to side. Use the capacity char

Capacity Chart on pa Align load at the level

just above area where Ensure that the guide

(verbal or hand) when

Disengaging a Susp

Never place the guide Once at the destinatio

stop and apply the pathe tethers.4-9

t to determine safe boom extension range. See Use of thege 5-5. load is to be placed, then position boom slowly until load is it is to be placed. persons and operator remain in constant communication placing the load.

ended Load

persons between the suspended load and the telehandler.n of the load, ensure to bring the telehandler to a completerk brake prior to disengagement of the lifting devices and


4-10

4.4 ROAD OPERATION1. Preparation

a. Remove load from attachment.b. Remove any large amounts of dirt from machine.c. Check lights and

Note: Be sure to follow a2. Lower boom. Front e

(12-16 in) above the 3. Fully tilt attachment b

4. Place protective shieforks toward the mac

5. Depress button (2) tocontrolled functions.

6. Deactivating the joyswheel steering (1). S

7. Machine is now read

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mirrors and adjust if necessary.ll local and federal/provincial traffic regulations.dge of attachment should be approximately 30-40 cm ground.ack.

ld over front bucket edge: remove or reposition carriage hine and secure to the carriage.

deactivate joystick function and disable all joystick Joystick function LED will go out.tick function automatically changes steer mode to front ee Steer Modes on page 3-26 for details.y for road operation.


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4.5 LOADING AND SECURING FOR TRANSPORT

Tiedown

1. If equipped, level the

2. Using a spotter, load3. Once loaded, apply p

resting on deck. Movkey.

4. Secure machine to dpoints as shown in th

5. Do not tiedown front

Note: The user assumestransportation and tie-dowsupporting the weight of tinstructions and warningsand federal/provincial law

TELEHANDLER SLIDmake sure deck, rampsFailure to do so could c

4-11

telehandler prior to loading. the telehandler with boom as low as possible.

arking brake and lower boom until boom or attachment is e all controls to Neutral, stop engine and remove ignition

eck by passing chains through the designated tiedown e figure.of boom.

all responsibility for choosing the proper method of n devices, making sure the equipment used is capable of

he vehicle being transported and that all manufacturers , regulations and safety rules of their employer and all local s are followed.

WARNINGE HAZARD. Before loading telehandler for transport, and telehandler wheels are free of mud, snow and ice.

ause telehandler to slide.


4-12

Lifting

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

Make adjustments to the lifting device and equipment to ensure the machine willbe level when elevatelifted.

Ensure that the liftingthe intended purposeweigh machine.

Remove all loose item Lift machine with smo

sudden motions that c31200537

d. The machine must remain level at all times while being

device and equipment is adequately rated and suitable for. See Section 9 - Specifications for machine weight or

s from machine prior to lifting.oth, even motion. Set machine down gently. Avoid quick orould cause shock loads to machine and/or lifting devices.

Section 5 - Attachments and Hitches

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SECTION 5 - ATTACHMENTS AND HITCHES

5.1 APPROVED ATTACHMENTSTo determine if an attachment is approved for use on the specific telehandler you areusing, perform the following prior to installation. The attachment mode

match the attachment The model on the cap The load center of the

on the capacity chart. Hydraulically powered

with auxiliary hydrauliIf any of the above cotelehandler may not be emay not be approved for distributor for further infor

5.2 UNAPPROVEDDo not use unapproved a

Range and capacitynon-approved attachm

An overextended or oand cause serious inju

The ability of a non-acannot be assured.

Use only approved attause with your telehandle5-1

l/option number on the attachment identification plate must number on a capacity chart located in the operator cab.acity chart must match the model telehandler being used. fork (if equipped) must match the load center as indicated

attachments must only be used on machines equippedcs.

nditions are not met, do not use the attachment. Thequipped with the proper capacity chart or the attachment

the model telehandler being used. Contact JLG or the localmation.

ATTACHMENTSttachments for the following reasons: limitations for will fit, homemade, altered, or otherents cannot be established.

verloaded telehandler can tip over with little or no warningry or death to the operator and/or those working nearby.

pproved attachment to perform its intended function safely

WARNINGchments. Attachments which have not been approved forr could cause machine damage or an accident.


5-2

5.3 JLG SUPPLIED ATTACHMENTS

Attachment Part Number 40.8 40.9Carriage, 1185 mm 1170028 X XCarriage, 1185 mm 1001107333 X X

Side Shift CarriagFork, 50x100x

Fork, Narrow 50x1Fork, 50x100x

Fork Extension, 5Bucket, 0,Bucket, 1,

Bucket with TeeBucket, Multi-Purp

Bucket, GrappFork Mounted Concre

Concrete Bucket Truss BoomTruss BoomFork Mounte31200537

e, 1200 mm 1170002 X X1200 mm 2340030 X X00x1200 mm 2340041 X X1200 mm 1001100911 X X0x100 mm 1001112559 X X

9 m3 0930015 X X

8 m3 0930016 X X

th, 1,0 m3 4802100 X X

ose, 1,0 m3 0930003 X X

le, 0,8 m3 0930004 X Xte Bucket, 500L 0240158 X XMixer, 500 L 1001106930 X, 3,4 m 0240063 X X, 3,6 m 0240110 X Xd Hook 2700118 X X


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Th5-3



5-4

5.4 TELEHANDLER/ATTACHMENT/FORK CAPACITY

Prior to installing the attacwith the proper capacity c

To determine the maximsmallest of the following c Capacity stamped on Fork capacities and

(if equipped). This ratfork can safely carry amultiplied by the nummaximum capacity of

Maximum capacity aAttachments on page

When the load rating attachment, the lower

Use the proper capacity configurations. Lifting andchart based on machine c

Other than block forks, almatched sets.

Never use an attachmeinstalled on the telehand

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hment verify it is approved and the telehandler is equippedhart. See Approved Attachments on page 5-1.um capacity of the telehandler and attachment, use theapacities:

the attachment identification plate (1).load centers are stamped on the side of each fork (2)ing specifies the maximum load capacity that the individualt the maximum load center (3). Total attachment capacity isber of forks on the attachment (if equipped), up to the

the attachment.s indicated on the proper capacity chart. See Approved

5-1.

of the telehandler differs from the capacity of the forks or value becomes the overall load capacity.chart to determine maximum capacity at various machine placing a load may require use of more than one capacityonfiguration.

l forks should be used in matched pairs, block forks used in

WARNINGnt without the appropriate JLG approved capacity chartler.


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5.5 USE OF THE CAPACITY CHARTTo properly use the capacity chart (see page 5-6), the operator must first determineand/or have the following:

1. An approved attachment. See Approved Attachments on page 5-1.2. The proper Capacity3. Weight of the load be4. Load placement info

a. HEIGHT where thb. DISTANCE from

placed.5. On the capacity char

distance.

6. The number in the lothis lift. If the two crobe used.

The number in the load zto be lifted. Determine thwithin these limits.

Capacity Indicator L

FORK WEIGHT STAMP

ATTACHMENT IDENTIFICATION

PLATE5-5

Chart.ing lifted.

rmation:

e load is to be placed.the front tires of the telehandler where the load is to be

t, find the line for the height and follow it over to the

ad zone where the two cross is the maximum capacity for ss at a division between zones, the smaller number must

one must be equal to or greater than the weight of the loade limits of the load zone on the capacity chart and keep

ocations

BOOMEXTENSION INDICATOR

BOOM ANGLE INDICATOR (inside cab)


5-6

Sample Capacity Chart

Note: This is a sample clocated in your operator c

TIP OVER HAZARD. machine being on firm positioned evenly on cabeing properly inflated;

These numbers must match the model/option number stamped

on the attachment ID Plate.

Boom Angle

This Capacity Chart may be used with this model ONLY.The telehandler model is indicated on the boom or chassis.

Model XXXX is used for demonstration purposes only.31200537

apacity chart only! DO NOT use this chart, use the one ab.

WARNINGAll loads shown on rated capacity chart are based onground with frame level (see page 4-5); the forks beingrriage; the load being centered on forks; proper size tiresand the telehandler being in good operating condition.

!

"

Boom Extension Indicator (arc)

Load zones indicate the maximum weight

that may be safely lifted.


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Example

A contractor owns a model xxxx telehandler with a fork carriage. He knows thisattachment may be used with his model since:

The attachment model/option number, matches the attachment number on thecapacity chart.

The capacity chart imachine configuration

Below are examples wiwhether or not the load m

Note: This is a sample clocated in your operator c

Load Weight1 3.000 kg (6,614 lb2 900 kg (1,984 lbs3 3.750 kg (8,267 lb4 2.500 kg (5,512 lb

Example 1

Example 25-7

s clearly marked for model xxxx and corresponds with being used.

th various conditions the contractor may encounter anday be lifted.

apacity chart only! DO NOT use this chart, use the one ab.

Distance Height OK to Lifts) 3 m (9.8 ft) 3 m (9.8 ft) Yes) 7 m (23 ft) 7,5 m (24.6 ft) NOs) 1,5 m (4.9 ft) 6,75 m (22.1 ft) Yess) 4 m (13.1 ft) 10 m (32.8 ft) NO

!

"

Example 3

Example 4


5-8

Th31200537



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5.6 ATTACHMENT INSTALLATION

Quick Attach

1. Attachment

2. Attachment Pin Rece

3. Attachment Pin

4. Lock Pin

5. Retainer Pin (mecha6. Quick Attach (attach

CRUSH HAZARD. Alwpositioned on boom andproper installation could

MECHANICAL HYDRAULIC5-9

ss

nical quick attach)ment tilt control in cab, see page 3-18 for details)

WARNINGays be certain that carriage or attachment is properly is secured by lock pin and retainer pin. Failure to ensure permit carriage/attachment/load to disengage.


5-10

Mechanical Quick AttachThis installation procedure is designed for one-person operation. Prior to exiting cab,perform Shut-Down Procedure on page 4-3.

1. Tilt quick attach forward to provide clearance. Check to be sure loc

2. Align attachment pinRaise boom slightly trecess.

3. Tilt quick attach back

4. Insert lock pin and se

5. If attachment is equipOperated Attachmen31200537

k pin is out.

with recess in attachment. o engage attachment pin in

to engage attachment.

cure with retainer pin.

ped, connect auxiliary hydraulic hoses. See Hydraulic t on page 5-14.


31200537

Manual Hydraulic Quick AttachThis installation procedure is designed for one-person operation. Prior to exiting cab,perform Shut-Down Procedure on page 4-3.

1. Turn auxiliary hydraulic valve handle (1) back, toward the operator cquick attach function

2. Tilt quick attach forwCheck to be sure loc



5. Press and hold switc(3), at the same timeforward to engage lojoystick back to disen

5-11

ab, to enable hydraulic .

ard to provide clearance. k pin is disengaged.



h (2) and button move joystick ck pin or move gage lock pin.


5-12

6. Raise boom to eye level and visually check that the lock pin protrudes through the hole. If the pin does not protrude through the hole, place the attachment on the ground and return to step 2.

7. Turn auxiliary hydrauaway from the operaattachment auxiliary

8. If attachment is equipOperated Attachmen

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lic valve handle (1) forward, tor cab, to enable hydraulics function.


DISENGAGEDENGAGED


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Hydraulic Quick AttachThis installation procedure is designed for one-person operation.

1. Tilt quick attach forward to provide clearance. Check to be sure lock pin is disengaged.



4. Press and hold switc(3), at the same timeforward to engage lojoystick back to disen

5. Raise boom to eye lecheck that the lock pthe hole. If the pin dothrough the hole, plathe ground and retur

6. If attachment is equipOperated Attachmen5-13



h (2) and button move joystick ck pin or move gage lock pin.

vel and visually in protrudes through es not protrude ce the attachment on n to step 2.


DISENGAGEDENGAGED


5-14

Hydraulic Operated Attachment

1. Install attachment (se2. Lower attachment to

3. Quickly depress andDepress again and h

Note: Depressing of auxwithin two seconds. If buzilluminates, repeat step 3

4. Perform Shut-Down

5. Connect attachment

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e page 5-9). ground. release continuous auxiliary hydraulics switch (1) twice. old to relieve pressure at both auxiliary fittings (2).iliary hydraulics switch three times must be accomplished zer sounds or continuous auxiliary hydraulics indicator . Procedure on page 4-3.hoses to both auxiliary fittings.


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5.7 ADJUSTING/MOVING FORKSCarriages may have different locations where forks can be positioned. Two differentmethods can be used for repositioning, depending upon the carriage structure.Note: Apply a light coating of appropriate lubricant to ease sliding of forks or fork bar.To slide forks:

1. Ensure attachment ispage 5-9.

2. Elevate attachment tfork heel is free from

3. Stand at the side of tpush the fork near thpull the fork near thebetween the fork and

If removing fork bar is n1. Rest forks on ground2. Remove fork bar.

3. Reposition forks.

4. Reinstall the fork bar5-15

properly installed. Refer to Attachment Installation

o approximately 1,5 m (5 ft) and tilt carriage forward until attachment.

he carriage. To slide fork toward the center of the carriage, e fork eye. To slide fork toward the edge of the carriage, fork eye. To avoid pinching, do not place fingers or thumb carriage structure.ecessary:.

and fork bar retaining mechanism(s).


5-16

5.8 ATTACHMENT OPERATION Capacities and range limits for the telehandler change depending on the

attachment in use. Separate attachment instructions must be kept in Manual Holder in cab with this

Operation & Safety Manual. An additional copy must be kept with the attachmentif it is equipped with a

Note: Operations describRefer to page 3-20 if utiliz

EQUIPMENT DAMAGmachine structure wheImproper use of attachdamage.

EQUIPMENT DAMAGEload. Maintain clearancclearance may result in 31200537

manual holder.

ed within this section reference the Lift joystick pattern. in

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