Operation & Safety Manual Telehandlers/644E-42_944E-42...Sep 19, 2011 · Operation & Safety Manual Original Instructions Keep this manual with machine at all times. Models 644E-42

Operation & SafetyManual

Original InstructionsKeep this manual with machine at all times.

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Models644E-42

&944E-42

S/N 0160037794 & After

31200354

RevisedSeptember 19, 2011

CALIFORNIA PROPOSITION 65

BATTERY WARNINGBattery posts,

terminals and relatedaccessories contain

lead and lead compounds,chemical known to the

State of Californiato cause cancer andreproductive harm.

WASH HANDSAFTER HANDLING!

CALIFORNIA PROPOSITION 65

EXHAUST WARNINGDiesel Engine exhaust and some of its constituents are known to the State of

California to cause cancer, birth defects and other

reproductive harm.

Revision Log

Revision Log REVISION LOGMarch 18, 2009 - A - Original Issue of Manual

April 23, 2009 - B - Revised page 9-2.

December 21, 2010 - C - Revised pages 7-13, 9-2, 9-3 & 9-5.

September 19, 2011 - D - Revised covers and pages b, d, 1-5, 1-6, 1-9, 2-3, 2-6, 2-7, 2-8, 2-11, 2-13, 3-1, 3-4, 3-5, 3-6, 3-7, 4-3, 4-6, 4-9, 4-10, 5-2, 5-15, 5-16, 5-18,5-20, 5-21, 5-22, 5-24, 5-26, 5-28, 5-30, 5-32, 6-1, 7-3, 7-4, 7-5, 7-9, 7-10, 7-11,7-12, 7-13, 7-17, 7-18, 7-19, 7-20, 7-22, 7-23, 9-1 & 9-2.

a31200354

Read This First

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 changes without prior notification. Contact JLG Industries, Inc.for updated information.

Operator Qualifications

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

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

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

• This Operation & Safety Manual

• Telehandler Safety Manual (ANSI only)

• All instructional decals and plates

• Any optional equipment instructions furnished

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

Modifications

Any modification to this machine must be approved by JLG.

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Read This First

This product must comply with all safety related bulletins. Contact JLG Industries,Inc. or the local authorized JLG representative for information regarding safety-related bulletins which may have been issued for this product.

JLG Industries, Inc. sends safety related bulletins to the owner of record of thismachine. Contact JLG Industries, Inc. to ensure that the current owner records areupdated and accurate.

JLG Industries, Inc. must be notified immediately in all instances where JLGproducts have been involved in an accident involving bodily injury or death ofpersonnel or when damage has occurred to personal property or the JLG product.

FOR:

• Accident Reporting and Product Safety Publications

• Current Owner Updates

• Questions Regarding Product Applications and Safety

• Standards and Regulations Compliance Information

• Questions Regarding Product Modifications

CONTACT:

Product Safety and Reliability DepartmentJLG Industries, Inc.13224 Fountainhead PlazaHagerstown, MD 21742USA

or Your Local JLG Office(Addresses on back cover)

In USA:Toll Free: 1-877-JLG-SAFE (1-877-554-7233)

Outside USA:Phone: +1-717-485-6591

E-mail:[email protected]

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Read This First

Other Publications Available

Service ManualBefore S/N 0160041827 excluding 0160041630 ..................................8990461S/N 0160041827 & After including 0160041630..................................31200355

Illustrated Parts Manual...............................................................................8990462

Note: The following standards may be referenced in this manual:ANSI is compliant to ANSI/ITSDF B56.6AUS is compliant to AS 1418.19CE is compliant to EN1459Refer to the machine Serial Number Plate to identify the applicable compliance standard.

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Table of ContentsTable of Contents

TABLE OF CONTENTSRevision Log

Read This FirstOperator Qualifications ......................................................bModifications ......................................................................bOther Publications Available ..............................................d

Table of Contents

Section 1 - General Safety Practices1.1 Hazard Classification System ..............................................1-1

Safety Alert System and Safety Signal Words................1-11.2 General Precautions ............................................................1-11.3 Operation Safety ..................................................................1-2

Electrical Hazards ...........................................................1-2Tip Over Hazard..............................................................1-3Travel Hazard .................................................................1-6Load Falling Hazard........................................................1-7Lifting Personnel .............................................................1-8Driving Hazards on Slopes .............................................1-9Pinch Points and Crush Hazards ..................................1-10Fall Hazard....................................................................1-12Chemical Hazards.........................................................1-13

Section 2 - Pre-Operation and Inspection2.1 Pre-Operation Check and Inspection...................................2-12.2 Safety Decals.......................................................................2-3

Before S/N 0160041827 excluding 0160041630 ............2-3S/N 0160041827 & After including 0160041630.............2-6

2.3 Walk-Around Inspection.....................................................2-102.4 Warm-Up and Operational Checks....................................2-12

Warm-Up Check ...........................................................2-12Operational Check ........................................................2-12

2.5 Operator Cab .....................................................................2-132.6 Windows ............................................................................2-14

Cab Door Window (if equipped)....................................2-14

Section 3 - Controls and Indicators3.1 General ................................................................................3-13.2 Controls ...............................................................................3-2

Instrument Panel.............................................................3-4Dash Panel .....................................................................3-6Ignition ............................................................................3-8Park Brake ......................................................................3-9

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Table of Contents

Parking Procedure.......................................................... 3-9Transmission Control Lever.......................................... 3-10Front Joystick ............................................................... 3-12Middle Joystick ............................................................. 3-13Single Joystick (if equipped)......................................... 3-14Frame Level Joystick.................................................... 3-16Accessory Control Lever (if equipped) ......................... 3-17

3.3 Steer Modes ...................................................................... 3-18Steer Mode Change ..................................................... 3-18

3.4 Stabil-Trak™ System ...................................................... 3-193.5 Operator Seat.................................................................... 3-20

Adjustments.................................................................. 3-20Seat Belt ....................................................................... 3-21

3.6 Indicators........................................................................... 3-22Boom Angle and Extension .......................................... 3-22Transfer Carriage Extension......................................... 3-22

Section 4 - Operation4.1 Engine ................................................................................. 4-1

Starting the Engine ......................................................... 4-1Cold Weather Starting Aids ............................................ 4-2Battery Boosted Starting................................................. 4-3Normal Engine Operation ............................................... 4-4Shut-Down Procedure .................................................... 4-4

4.2 Operating with a Non-Suspended Load .............................. 4-5Lift Load Safely............................................................... 4-5Picking Up a Load .......................................................... 4-5Transporting a Load ....................................................... 4-6Leveling Procedure......................................................... 4-6Placing a Load................................................................ 4-7Disengaging a Load........................................................ 4-7

4.3 Operating with a Suspended Load ...................................... 4-8Lift Load Safely............................................................... 4-8Picking Up a Suspended Load ....................................... 4-8Transporting a Suspended Load .................................... 4-9Leveling Procedure......................................................... 4-9Placing a Suspended Load........................................... 4-10Disengaging a Suspended Load .................................. 4-10

4.4 Loading and Securing for Transport.................................. 4-11Tiedown........................................................................ 4-11Lifting............................................................................ 4-12

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Table of Contents

Section 5 - Attachments5.1 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

Capacity Indicator Locations...........................................5-5Sample Capacity Chart ...................................................5-6Example ..........................................................................5-8

5.6 Attachment Installation ......................................................5-10Hydraulic Operated Attachment....................................5-12

5.7 Adjusting/Moving Forks......................................................5-135.8 Attachment Operation........................................................5-14

Carriage w/Forks...........................................................5-15Side Tilt Carriage ..........................................................5-16Swing Carriage .............................................................5-18Dual Fork Positioning Carriage .....................................5-20Mast Carriage ...............................................................5-22Fork Mounted Hook ......................................................5-24Truss Boom...................................................................5-26Bucket ...........................................................................5-28Grapple Bucket .............................................................5-30Personnel Work Platform ..............................................5-32

Section 6 - Emergency Procedures6.1 Towing a Disabled Product ..................................................6-1

Moving Short Distances ..................................................6-1Moving Longer Distances ...............................................6-1

6.2 Emergency Lowering of Boom.............................................6-26.3 Emergency Exit from Enclosed Cab ....................................6-2

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 Schedule ....................................7-3

10 & 50 Hour Maintenance Schedule .............................7-31st 100, 250 & 1st 500 Hour Maintenance Schedule......7-4500, 1000 & 2000 Hour Maintenance Schedule .............7-5

7.4 Lubrication Schedules .........................................................7-650 Hour Lubrication Schedule.........................................7-6

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Table of Contents

7.5 Operator Maintenance Instructions ..................................... 7-8Fuel System.................................................................... 7-8Engine Oil ..................................................................... 7-10Hydraulic Oil ................................................................. 7-11Engine Cooling System ................................................ 7-12Tires.............................................................................. 7-14Transmission Oil........................................................... 7-17Battery .......................................................................... 7-18Air Intake System ......................................................... 7-20

Section 8 - Additional Checks8.1 Stabil-Trak™ ....................................................................... 8-1

Section 9 - Specifications9.1 Product Specifications......................................................... 9-1

Capacities....................................................................... 9-1Tires................................................................................ 9-3Performance................................................................... 9-4Dimensions..................................................................... 9-5

Index

Inspection, Maintenance and Repair Log

iv 31200354

Section 1 - General Safety Practices

SECTION 1 - GENERAL SAFETY PRACTICES

1.1 HAZARD CLASSIFICATION SYSTEM

Safety Alert System and Safety Signal Words

DANGER indicates an imminently hazardous situation which, if not avoided, willresult in death or serious injury.

WARNING indicates a potentially hazardous situation which, if not avoided, couldresult in death or serious injury.

CAUTION indicates a potentiality hazardous situation which, if not avoided, mayresult in minor or moderate injury.

1.2 GENERAL PRECAUTIONS

WARNINGBefore operation, read and understand this manual. Failure to comply with thesafety precautions listed in this manual could result in machine damage, propertydamage, personal injury or death.

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1.3 OPERATION SAFETY

Electrical Hazards

• This machine is not insulated and does not provide protection from contact orbeing near electrical current.

• NEVER operate the telehandler in an area where overhead power lines,overhead or underground cables, or other power sources may exist withoutensuring the appropriate power or utility company de-energizes the lines.

• Always check for power lines before raising the boom.

• Follow employer, local and governmental regulations for clearance frompowerlines.

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Tip Over Hazard

General

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

• Never use an attachment without the appropriate JLG approved capacity chartinstalled on the telehandler.

• Understand how to properly use the capacity charts located in cab.

• DO NOT exceed rated lift capacity.

• Be sure that the ground conditions are able to support the machine.

• DO NOT raise boom unless frame is level (0 degrees), unless otherwise noted oncapacity chart.

• DO NOT level machine with boom/attachment above 4 ft (1,2 m).(AUS - DO NOT level machine with load more than 11.8 in (300 mm) aboveground surface.)

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• MAINTAIN proper tire pressure at all times. If proper tire pressures are notmaintained, this machine could tip over.

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

• Always wear the seat belt.

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

If the telehandler starts to tip over:

• DO NOT JUMP

• BRACE YOURSELF and STAY WITH THE MACHINE

• KEEP YOUR SEAT BELT FASTENED

• HOLD ON FIRMLY

• LEAN AWAY FROM THE POINT OF IMPACT

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Non-Suspended Load

• DO NOT drive with boom raised.

Suspended Load

• Tether suspended loads to restrict movement.

• Weight of all rigging (slings, etc.) must be included as part of load.

• Beware of wind. Wind can cause a suspended load to swing and causedangerous side loads - even with tag lines.

• DO NOT attempt to use telehandler frame-leveling to compensate for load swing.

• Keep heavy part of load closest to attachment.

• Never drag the load; lift vertically.

When driving with a suspended load:

• Start, travel, turn and stop slowly to prevent load from swinging.

• DO NOT extend boom.

• DO NOT raise the load more than 11.8 in (300 mm) above ground surface orthe boom more than 45°.

• DO NOT exceed walking speed.

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1-531200354


Travel Hazard

• Steering characteristics differ between steer modes. Identify the steer modesettings of the telehandler being operated.

• DO NOT change steer modes while traveling. Steer modes must be changedwhile telehandler is stationary.

• Visually verify proper wheel alignment after each steer mode change.

• Ensure that adequate clearance is provided for both rear tail swing and front forkswing.

• Look out for and avoid other personnel, machinery and vehicles in the area. Usea spotter if you DO NOT have a clear view.

• Before moving be sure of a clear path and sound horn.

• When driving, retract boom and keep boom/attachment as low as possible whilemaintaining 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 overheadobstructions. Position attachment/load to clear obstacles.

• When driving in high speed, use only front wheel steer (if steering modes areselectable).

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

1-6 31200354


Load Falling Hazard

• Never suspend load from forks or other parts of carriage.

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

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

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1-731200354


Lifting Personnel

• When lifting personnel, USE ONLY a JLG approved personnel work platform,with proper capacity chart displayed in the cab.

• DO NOT drive machine from cab when personnel are in platform.

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1-8 31200354


Driving Hazards on Slopes

To maintain sufficient traction and braking capabilities, travel on slopes as follows:

• When unloaded, drive with forks pointed downhill.

• When loaded, drive with the forks pointed uphill.

• For additional travel requirements, refer to the appropriate capacity chart.

• To avoid overspeeding the engine and drivetrain when driving down slopes,downshift to a lower gear and use the service brake as necessary to maintain aslow speed. DO NOT shift into neutral and coast downhill.

• Avoid excessively steep slopes or unstable surfaces. To avoid tip over DO NOTdrive across excessively steep slopes under any circumstances.

• Avoid turning on a slope. Never engage “inching” or shift to “Neutral” when goingdownhill.

• DO NOT park on a slope.

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1-931200354


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.

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• 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.

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Fall Hazard

• Enter using the proper hand holds and steps provided. Always maintain 3-pointcontact when mounting or dismounting. Never grab control levers or steeringwheel when mounting or dismounting the machine.

• DO NOT get off the machine until the shutdown procedure on page 4-5 has beenperformed.

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

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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 forthat purpose by JLG and site owner. Sparks from the electrical system and theengine exhaust can cause an explosion.

• If spark arrestors are required, ensure they are in place and in good workingorder.

Flammable Fuel

• DO NOT fill the fuel tank or service the fuel system near an open flame, sparksor smoking materials. Engine fuel is flammable and can cause a fire and/orexplosion.

Hydraulic Fluid

• DO NOT attempt to repair or tighten any hydraulic hoses or fittings while theengine is running or when the hydraulic system is under pressure.

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

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

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This Page Intentionally Left Blank

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Section 2 - Pre-Operation and Inspection

SECTION 2 - PRE-OPERATION AND INSPECTION

2.1 PRE-OPERATION CHECK AND INSPECTION

Note: Complete all required maintenance before operating unit.

The pre-operation check and inspection, performed at beginning of each work shiftor at each change of operator, should include the following:

1. Cleanliness - Check all surfaces for leakage (oil, fuel or battery fluid) or foreign objects. Report any leakage to the proper maintenance personnel.

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

3. Safety Decals - Ensure all safety decals are legible and in place. Clean or replace as required. See page 2-3 for details.

4. Operation and Safety Manuals - Operation & Safety Manual and AEM Safety Manual (ANSI only) are located in cab manual holder.

5. Walk-Around Inspection - See page 2-10 for details.

6. Fluid Levels - Check fluids, including fuel, hydraulic oil, engine oil, transmission fluid and coolant. When adding fluids, refer to Section 7 - Lubrication and Maintenance and Section 9 - Specifications to determine proper type and intervals. Before removing filler caps or fill plugs, wipe all dirt and grease away from the ports. If dirt enters these ports, it can severely reduce component life.

7. Attachments/Accessories - Ensure correct capacity charts are installed on the telehandler. If provided, reference the Operation & Safety Manual of each attachment or accessory installed for specific inspection, operation and maintenance instructions.

WARNINGFALL HAZARD. Use extreme caution when checking items beyond your normalreach. Use an approved ladder.

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PARENT METAL CRACK WELD CRACK

2-131200354


8. Operational Check - Once the walk-around inspection is complete, perform a warm-up and operational check (see page 2-12) of all systems in an area free of overhead and ground level obstructions. See Section 3 - Controls and Indicators for more specific operating instructions.

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

2-2 31200354


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

Before S/N 0160041827 excluding 0160041630

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VIEW OF ENGINE COMPARTMENT

UNDERSIDE VIEW OF ENGINE COVER

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S/N 0160041827 & After including 0160041630

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VIEW INSIDE CAB

DUAL JOYSTICK CONFIGURATION

SINGLE JOYSTICK CONFIGURATION

CAPACITY CHARTS

VIEW OF DECALS LOCATED INSIDE CAB ON RIGHT HAND WALL

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2-931200354


2.3 WALK-AROUND INSPECTION

Begin your walk-around inspection at item 1, as noted below. Continue to your right(counterclockwise when viewed from top) checking each item in sequence.

INSPECTION NOTE: On all components, make sure there are no loose or missingparts, that they are securely fastened and no visible leaks or excessive wear existsin addition to any other criteria mentioned. Inspect all structural members includingattachment for cracks, excessive corrosion and other damage.

1. Boom Sections and Lift, Tilt, Extend/Retract, Compensating (Slave) Cylinders -

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

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

2. Front Axle - Steer cylinders undamaged, not leaking; pivot pins secure; hydraulic hoses undamaged, not leaking.

3. Wheel/Tire Assembly - Properly inflated and secured; no loose or missing lug nuts. Inspect for worn tread, cuts, tears or other discrepancies.

4. Mirrors - Clean and undamaged.

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5. Cab and Electrical -

• General appearance; no visible damage.

• Frame level indicator and window glass undamaged and clean.

• Gauges, switches, joysticks, foot controls and horn operational.

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

6. Main Control Valve (under cab floor) - See Inspection Note.


8. Stabil-Trak Cylinder - Pins secure; hydraulic hoses undamaged, not leaking.

9. Rear Axle - Steer cylinders undamaged, not leaking; pivot pins secure; hydraulic hoses undamaged, not leaking.


11. Transfer Carriage - See inspection note. Transfer carriage cylinder pins secure; hydraulic hoses undamaged, not leaking.

12. Engine Compartment -

• Drive belts, check condition and replace as required.

• Engine mounts - See inspection note.

• (Before S/N 0160041827 including 0160041630) Battery cables tight, novisible damage or corrosion.

• Engine cover closed and properly secured.


14. Frame Level Cylinder - Pins secure; hydraulic hoses undamaged, not leaking.

15. Attachment - Properly installed, see “Attachment Installation” on page 5-10.

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2.4 WARM-UP AND OPERATIONAL CHECKS

Warm-Up Check

During warm-up period, check:

1. Heater, defroster and windshield wiper (if equipped).

2. Check all lighting systems (if equipped) for proper operation.

3. Adjust mirror(s) for maximum visibility.

Operational Check

When engine warms, perform an operational check:

1. Service brake and parking brake operation.

2. Forward and reverse travel.

3. Each gear.

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

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

6. All joystick functions - operate smoothly and correctly.

7. Perform any additional checks described in Section 8.

WARNINGCUT/CRUSH/BURN HAZARD. Keep engine cover closed while engine isrunning except when checking transmission oil level.

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

WARNINGNever operate telehandler unless the overhead guard, cab structure and rightside glass or screen are in good condition. Any modification to this machine mustbe approved by JLG to assure compliance with ROPS/FOPS certification for thiscab/machine configuration. If the overhead guard or cab structure is damaged,the CAB CANNOT BE REPAIRED. It must be REPLACED.

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2.6 WINDOWSKeep all windows and mirrors clean and unobstructed.

Cab Door Window (if equipped)

• Cab door (1) must be closed during operation.

• During operation the cab door window (2) must either be latched open or closed.

• Open the cab door window with the latch handle (3) and secure in place onoutside of cab.

• Turn either inside or outside knob (4) to unlatch the window.

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Section 3 - Controls and Indicators

SECTION 3 - CONTROLS AND INDICATORS

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

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

NOTICEEQUIPMENT DAMAGE. When a red indicator illuminates (except park brake andengine air-intake heater), immediately bring machine to a stop, lower boom andattachment to ground and stop the engine. Determine cause and correct beforecontinued use.

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3.2 CONTROLS

1. Accelerator Pedal: Pressing down the pedal increases engine and hydraulic speed.

2. Ignition Switch: Key activated. See page 3-8.

3. Service Brake Pedal: The further the pedal is depressed, the slower the travel speed.With service brake pedal depressed and boom angles above 40°, the locked mode of the Stabil-Trak system is activated. See page 3-19.

4. Transmission Control Lever: See page 3-10.

5. Dash Panel: See page 3-6.

6. Instrument Panel: See page 3-4.

7. 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 3-18.

8. Frame Level Indicator: Enables operator to determine the left to right level condition of the telehandler.

9. Horn: Depress button to sound horn.

10. Accessory Control Lever (if equipped): See page 3-17.

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11. Front Joystick: See page 3-12.

12. Middle Joystick: See page 3-13.

13. Frame Level Joystick: See page 3-16.

14. Single Joystick (if equipped): See page 3-14.

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Instrument Panel

1. Fuel Gauge: Indicates amount of fuel in fuel tank.

2. Engine Air-Intake Heater Indicator: Illuminates with ignition key in the “RUN” position. Indicator goes out when start temperature is reached. At temperatures below 40° F (4° C), do not start until indicator turns off.

Note: Indicator may illuminate when engine is running and ambient temperatures are below 40° F (4° C).

3. Stabil-Trak Indicator - Slow Pivot Mode: Illuminates when Stabil-Trak system is in slow pivot mode. See page 3-19.

4. Engine Speed: Indicates engine speed in revolutions per minute (rpm).

5. High Beam Indicator (if equipped): Illuminates when high beam lights are on.

6. Stabil-Trak Indicator - Locked Mode: Illuminates when Stabil-Trak system is in locked mode. See page 3-19.

7. Turn Signal Indicator (if equipped): Illuminates and flashes when turn signals or hazard lights are activated.

8. Engine Temperature Gauge: Indicates engine operating temperature.(Before S/N 0160041827 excluding 0160041630) If temperature is above 212° F (100° C) bring machine to a stop, lower boom and attachment to ground and idle engine. Shut-down engine. Determine cause and correct before continued use.(S/N 0160041827 & After including 0160041630) If temperature is above 224° F (107° C) bring machine to a stop, lower boom and attachment to ground and idle engine. Shut-down engine. Determine cause and correct before continued use.

9. Hydraulic Oil Filter Restriction Indicator: Illuminates when hydraulic oil filter requires maintenance.

10. Low Brake Pressure Indicator: Illuminates and buzzer sounds when hydraulic brake pressure is too low.

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11. Air Filter Restriction Indicator: Illuminates when air filter(s) require maintenance.

12. Hydraulic Oil Temperature Indicator: Illuminates when hydraulic oil temperature is too high.

13. Hourmeter: Records and indicates engine operating hours.

14. Transmission Oil Temperature Indicator: Illuminates and buzzer sounds when transmission oil temperature is too high.

15. Park Brake Indicator: Illuminates when park brake is applied. See page 3-9.

16. Battery Charge Indicator: Illuminates when battery is at low charge or charging system is not functioning properly.

17. Engine Oil Pressure Indicator: Illuminates and buzzer sounds when engine oil pressure is too low.

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Dash Panel

1. Steer Mode Selector: Three positions: 4-wheel circle steer, 4-wheel crab steer and 2-wheel steer. See page 3-18.

2. Transmission Disconnect Switch: Depress bottom of switch to activate transmission disconnect function and have transmission disconnect while depressing service brake. Indicator illuminates to indicate transmission has disconnected. Depress top of switch to deactivate transmission disconnect function and keep transmission engaged while depressing service brake.

3. Park Brake Switch: See page 3-9.

4. Engine Fault Indicators: Indicators illuminate when an engine fault occurs during operation.

a. If red indicator illuminates during operation, stop the engine immediately anddiagnose the fault using the ECM diagnostic system. See Service Manualfor details.

b. If amber indicator illuminates during operation, the diagnostic system hasdetected a fault. Stop the engine and diagnose the fault using the ECMdiagnostic system. See Service Manual for details.

Note: Indicators also flash fault codes. See Service Manual for details.

5. Beacon or Strobe Light Switch (if equipped): On/Off switch.

6. Hazard Lights Switch (if equipped): On/Off switch.

WARNINGUNEXPECTED MOVEMENT HAZARD. Always apply park brake or servicebrake and return engine to idle before deactivating transmission disconnectfunction. Deactivating transmission disconnect with engine above idle couldcause the machine to move abruptly.

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7. Work Lights Switch (if equipped): Three position switch. Move switch to middle position to turn on front work lights. Push bottom of switch to turn on all work lights. Push top of switch to turn all work lights off.

8. Roof Wiper/Washer Switch (if equipped): Three position switch. Move switch to middle position to turn on wiper. Push and hold bottom of switch to activate washer. Push top of switch to turn off wiper.

9. Front Washer Switch (if equipped): Push and hold bottom of switch to activate washer.

10. Front Wiper Switch (if equipped): Three position switch. Move switch to middle position to operate at low speed. Push bottom of switch to operate at high speed. Push top of switch to turn off wiper.

Heater and Air Conditioning Controls (if equipped)

11. Temperature Control Switch: Adjustable rotary switch.

12. Air Conditioning Switch: On/Off switch.

13. Fan Speed Switch: Four position rotary switch.

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Ignition

• In the "RUN" position, voltage is available for all electrical functions.

• Full clockwise rotation to "START" engages starter motor.

• Counter-clockwise rotation to "OFF" stops engine and removes voltage from allelectrical functions.

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Park Brake

Park brake switch controls the application and release of the park brake. Indicator onswitch illuminates to indicate brake is applied.

• With the engine running and the park brake switch in "OFF" position (1), parkbrakes are disengaged.

• With switch in "ON" position (2), park brake is engaged and transmission will notengage forward or reverse.

• With switch in “ON” position and boom angles greater than 40°, locked mode ofStabil-Trak system is activated. See page 3-19.

Parking Procedure

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

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

WARNINGMACHINE ROLL-AWAY HAZARD. Always move park brake switch to "ON"position, lower boom to ground and stop engine before leaving cab.

WARNINGCRUSH HAZARD. Turning engine off applies the park brake. Applying park brakeor turning engine off while traveling will cause unit to stop abruptly and couldcause load loss. Either may be used in an emergency situation.

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Transmission Control Lever

Direction of Travel Selection

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

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

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

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

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

• If transmission disconnect function is not active (see page 3-6), do not increaseengine speed with the transmission in forward or reverse and the service brakedepressed in an attempt to get quicker hydraulic performances. This could causeunexpected machine movement.

WARNINGTIP OVER/CRUSH HAZARD. Bring telehandler to a complete stop beforeshifting transmission control lever. A sudden change in direction of travel couldreduce stability and/or cause load to shift or fall.

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Gear Selection

Gear selection is located on the twist grip handle (2) of transmission control lever.

• Twist hand grip to select gear.

• Select the appropriate gear for the task being performed. Use a lower gearwhen transporting a load. Use a higher gear only when driving unloaded forlonger distances.

• Slow down prior to downshifting. Do not downshift more than one gear at atime.

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Front Joystick

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

Attachment Tilt Function

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

Transfer Carriage Function

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

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

Auxiliary Hydraulic Function

• For attachments that require hydraulic supply for operation, press button (2) toactivate auxiliary hydraulics control. The button must be held down while movingthe joystick left or right. See Section 5 - Attachments for approved attachmentsand 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.

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Middle Joystick

The middle joystick (3) controls boom functions.

Boom Functions

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

• The speed of boom functions depends upon the amount of joystick travel incorresponding direction. Increasing engine speed will also increase functionspeed.

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


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Single Joystick (if equipped)

The single joystick (1) controls boom, attachment tilt, transfer carriage and auxiliaryhydraulic functions.

Boom Functions

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

• The speed of functions depends upon the amount of joystick travel incorresponding direction. Increasing engine speed will also increase functionspeed.

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

Transfer Carriage and Auxiliary Hydraulics

Transfer carriage and auxiliary hydraulic functions are enabled by the button (2).

Note: The button must be held during operation of the transfer carriage or auxiliary hydraulics. Releasing the button will immediately change the controls back to boom functions.

• While depressing button, move the joystick forward to extend transfer carriage;move joystick back to retract transfer carriage.

• For attachments that require hydraulic supply for operation, the button must beheld down while moving the joystick left or right. See Section 5 - Attachments forapproved attachments and control instructions.

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• The speed of functions depends upon the amount of joystick travel incorresponding direction. Increasing engine speed will also increase functionspeed.

• For two simultaneous functions, move the joystick between quadrants. Forexample; moving the joystick forward and to the left will extend transfer carriageand activate auxiliary hydraulics simultaneously.

Attachment Tilt

• Slide the thumb control (3) forward to tilt down, slide the thumb control back to tiltup.


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Frame Level Joystick

The frame level joystick (1) controls the left to right frame level.

• Lift detent ring (2) and move the joystick left to rotate frame left; lift detent ringand move the joystick right to rotate frame right.

• A level indicator is located above the front cab window to permit the operator todetermine whether the telehandler frame is level.

WARNINGTIP OVER HAZARD. Always move boom as low as possible while allowing forbest visibility of right hand mirror before leveling frame. Attempting to levelmachine with boom raised could cause it to tip over.

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Accessory Control Lever (if equipped)

The accessory control lever (3) operates the turn signals, parking lights andheadlights.

Turn Signals

• Push lever forward (4) to activate the left turn signal.

• Pull lever back (5) to activate the right turn signal.

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

Parking Lights and Headlights

• Turn the twist grip (6) of the lever counterclockwise to the first position (7) to turnon the parking lights.

• Turn the twist grip to the second position (8) to turn on the headlights.

• Raise/lower the lever to switch between low and high beam.

• Turn the twist grip clockwise to the OFF position (9) to turn all lights off.

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3.3 STEER MODESThree steer modes are available for operator use.

Note: 2-Wheel Front Steer mode is required for travel on public roads.

Steer Mode Change

1. Bring machine to a stop using service brake while either circle steer mode (1) or crab steer mode (3) is selected.

2. Turn the steering wheel until the left rear wheel (4) is aligned with the side of the machine.

3. Select front steer mode (2).

4. Turn the steering wheel until the left front wheel (5) is aligned with the side of the machine.

5. Wheels are now aligned. Select desired steer mode.

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3.4 STABIL-TRAK™ SYSTEM

Free Pivot Mode

With boom below 40° (1), the Stabil-Trak system is in free pivot mode.

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

• The Stabil-Trak slow pivot (3) and lock (4) indicators will not illuminate.

Slow Pivot Mode

With boom above 40° (2), the Stabil-Trak system is in slow pivot mode if the servicebrake is not depressed and the transmission is in gear.

• The rear axle will respond slowly to changes in terrain and frame level functionsnormally.

• The Stabil-Trak slow pivot indicator (3) will illuminate.

Locked Mode

With boom above 40° (2) and the park brake engaged, transmission control lever inneutral or service brake depressed, the system is in locked mode.

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

• The Stabil-Trak lock indicator (4) will illuminate.

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3.5 OPERATOR SEAT

Adjustments

Prior to starting engine adjust seat for position and comfort.

1. Suspension: Use knob to adjust suspension to the appropriate setting. Turn clockwise to increase stiffness. Turn counterclockwise to reduce stiffness.

2. Fore/Aft: Pull up on handle to move seat fore and aft.

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

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Seat Belt

Fasten seat belt as follows:

1. Grasp both free ends of the belt making certain that belt webbing is not twisted or entangled.

2. With back straight in the seat, couple the retractable end (male end) of the belt into the receptacle (buckle) end of the belt.

3. With belt buckle positioned as low on the body as possible, pull the retractable end of the belt away from the buckle until it is tight across the lap.

4. To release belt latch, depress red button on the buckle and pull free end from buckle.

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3.6 INDICATORS

Boom Angle and Extension

• The boom angle indicator (1) is located on the left side of the boom. Use thisindicator to determine the boom angle when using the capacity chart (see “Useof the Capacity Chart” on page 5-5).

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

Transfer Carriage Extension

• The transfer carriage extension indicator (3) is located on the right main framerail. Use this indicator to determine transfer carriage extension when using thecapacity chart (see “Use of the Capacity Chart” on page 5-5).

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Section 4 - Operation

SECTION 4 - OPERATION

4.1 ENGINE

Starting the Engine

This machine can be operated under normal conditions in temperatures of 0°F to104°F (-20°C to 40°C). Consult JLG for operation outside this range or underabnormal conditions.

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

2. If equipped with engine air-intake heater and temperature is below 40° F (4° C), turn the ignition switch to “RUN” position and wait for engine air-intake heater indicator on instrument panel to turn off.

3. Turn ignition switch to “START” to engage starting motor. Release key immediately when engine starts. If engine fails to start within 20 seconds, release key and allow starting motor to cool for a few minutes before trying again.

4. After engine starts, observe engine oil pressure gauge. If gauge remains on zero for more than five seconds, stop engine and determine cause before restarting engine.

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

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

WARNINGUNEXPECTED MOVEMENT HAZARD. Always ensure that transmission controllever is in neutral and the service brake is applied before releasing park brake.Releasing park brake in either forward or reverse could cause the machine tomove abruptly, causing an accident.

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Cold Weather Starting Aids

If the telehandler is equipped with an engine air-intake heater, the following applies:

• Air-intake heater is triggered by a temperature sensor on the engine.

• At start-up, temperature sensor will detect if air-intake heater is needed.

• A second battery is added for additional cold-cranking capacity.

WARNINGENGINE EXPLOSION. If your telehandler is equipped with a cold start aid, donot spray additional ether into air cleaner. If machine is not equipped with coldstart aid, follow instructions listed in the engine manual supplied with thetelehandler.

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Battery Boosted Starting

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

• Never allow vehicles to touch.

• Ensure boosting vehicle engine is running.

• (Before S/N 0160041827 excluding 0160041630) Connect the positive (+)jumper cable to positive (+) post of discharged battery.(S/N 0160041827 & After including 0160041630) Connect the positive (+) jumpercable to positive (+) jumper post of discharged machine.

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

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

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

• Follow standard starting procedures.

• Remove cables in reverse order after machine has started.

WARNINGBATTERY EXPLOSION HAZARD. Never jump start or charge a frozen batteryas it could explode. Keep sparks, flames and lighted smoking materials awayfrom the battery. Lead acid batteries generate explosive gases when charging.Wear safety glasses.

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Normal Engine Operation

• Observe gauges and indicators frequently to be sure all engine 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 supervisor or maintenance personnel.

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

Shut-Down Procedure

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

1. Apply the park brake.

2. Shift the transmission to “Neutral.”

3. Lower forks or attachment to the ground.

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

5. Shut off engine and remove ignition key.

6. Exit telehandler properly.

7. Block wheels (if necessary).

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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 material.

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

Picking Up a Load

• Note the conditions of the terrain. Adjust travel speed and reduce amount of loadif 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. NEVERattempt to lift a load with just one fork.

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

WARNINGTIP OVER HAZARD. Exceeding lift capacity of the telehandler could damage theequipment and/or cause tip over.

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Transporting a Load

After engaging the load and resting it against the backrest, tilt the load back toposition it for travel and fully retract transfer carriage. Travel in accordance with therequirements set forth in Section 1 - General Safety Practices and Section5 - Attachments.

Leveling Procedure

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

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

3. Observe level indicator to determine whether machine must be leveled prior to lifting load. Level machine with frame level joystick (see page 3-16).

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 the boom/attachment more than 4 ft (1,2 m) above ground unlesstelehandler is level.(AUS - Never raise the forks more than 11.8 in (300 mm) above ground surfaceunless telehandler is level.)

• The combination of frame leveling and load could cause the telehandler to tipover.

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Placing a Load

Before placing any load be sure that:

• The landing point can safely support the weight of the load.

• The landing point is level; front to back and side to side.

• Use the capacity chart to determine safe boom and transfer carriage extensionrange. See “Use of the Capacity Chart” on page 5-5.

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

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

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

Disengaging a Load

Once the load has been placed safely at the landing point, proceed as follows:

1. With the forks free from the weight of the load, the boom or transfer carriage can be retracted.

2. Lower the carriage.

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

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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 material.

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

Picking Up a Suspended Load

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

• Avoid lifting double-tiered loads.

• Make sure load is clear of any adjacent obstacles.

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

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

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

• Ensure to always properly tether loads to restrict movement.

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

WARNINGTIP OVER HAZARD. Exceeding lift capacity of the telehandler could damage theequipment and/or cause tip over.

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Transporting a Suspended Load

• Travel in accordance with the requirements set forth in Section 1 - GeneralSafety Practices and Section 5 - Attachments.

• For additional requirements, refer to the appropriate capacity chart in theoperator cab.

Important things to remember:

• Ensure the boom and transfer carriage is fully retracted.

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

• The combination of frame leveling and load could cause the telehandler to tipover.

• The guide persons and operator must remain in constant communication (verbalor hand) and be in visual contact with the operator at all times.

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

• Only transport the load at walking speed, 0.9 mph (0.4 m/s), or less.

Leveling Procedure

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

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

3. Observe level indicator to determine whether machine must be leveled prior to lifting load. Level machine with frame level joystick (see page 3-16).

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

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Placing a Suspended Load

Before placing any load be sure that:

• The landing point can safely support the weight of the load.

• The landing point is level; front to back and side to side.

• Use the capacity chart to determine safe boom and transfer carriage extensionrange. See “Use of the Capacity Chart” on page 5-5.

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

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

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

Disengaging a Suspended Load

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

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

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4.4 LOADING AND SECURING FOR TRANSPORT

Tiedown

1. Level the telehandler prior to loading.

2. Using a spotter, load the telehandler with boom as low as possible.

3. Once loaded, apply parking brake and lower boom until boom or attachment is resting on deck. Move all controls to “Neutral,” stop engine and remove ignition key.

4. Secure machine to deck by passing chains through the designated tie down points as shown in the figure.

5. Do not tie down front of boom.

Note: The user assumes all responsibility for choosing the proper method of transportation and tie-down devices, making sure the equipment used is capable of supporting the weight of the vehicle being transported and that all manufacturer’s instructions and warnings, regulations and safety rules of their employer, the Department of Transportation and/or any other local, state or federal/provincial laws are followed.

WARNINGTELEHANDLER SLIDE HAZARD. Before loading telehandler for transport,make sure deck, ramps and telehandler wheels are free of mud, snow and ice.Failure to do so could cause telehandler to slide.

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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 elevated. The machine must remain level at all times while beinglifted.

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

• Remove all loose items from machine prior to lifting.

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

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Section 5 - Attachments

SECTION 5 - ATTACHMENTS

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

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

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

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

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

5.2 UNAPPROVED ATTACHMENTSDo not use unapproved attachments for the following reasons:

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

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

• The ability of a non-approved attachment to perform its intended function safelycannot be assured.

WARNINGUse only approved attachments. Attachments which have not been approved foruse with your telehandler could cause machine damage or an accident.

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5.3 JLG SUPPLIED ATTACHMENTS

Attachment Part NumberApplicable Model

644E-42 944E-42

Carriage, 50 in (1270 mm) 1170021 X X

Carriage, 60 in (1524 mm) 1170024 X X

Carriage, 72 in (1829 mm) 1170027 X X

Side Tilt Carriage, 50 in (1270 mm) 1170054 X X



90° Swing Carriage, 72 in (1829 mm) 1001095418 X X

180° Swing Carriage, 72 in (1829 mm) 1001104992 X X

Dual Fork Positioning Carriage, 50 in (1270 mm) 7301295 X X

8 ft Mast Carriage, 50 in (1270 mm) 1001108668 X X

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

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

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

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

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

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

Bucket, 72 in - 1.0 yd3 1001100822 X X

Bucket, 96 in - 1.5 yd3 1001100823 X X

Bucket, 102 in - 2.0 yd3 1001100824 X X

Grapple Bucket, 96 in - 1.75 yd3 0930020 X X

Hook, Fork Mounted 91565094 X X

Truss Boom, 12 ft (3658 mm) 1001099902 X X

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

Truss Boom, 15 ft (4572 mm) 1001099901 X X

Platform, Fork Mounted (ASME)1001092280 X X

1001103637 X X

Platform, Fork Mounted (ASME - French)1001097072 X X

1001103736 X X

Platform, Fork Mounted (ISO)1001096306 X X

1001103730 X X

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5.4 TELEHANDLER/ATTACHMENT/FORK CAPACITY

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

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

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

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

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

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

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

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

WARNINGNever use an attachment without the appropriate JLG approved capacity chartinstalled on the telehandler.

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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 Capacity Chart(s).

3. Weight of the load being lifted.

4. Load placement information:

a. HEIGHT where the load is to be placed.

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

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

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

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

Capacity Indicator Locations

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TRANSFER CARRIAGEEXTENSION INDICATOR

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Sample Capacity Chart

Note: This is a sample capacity chart only! DO NOT use this chart, use the one located in your operator cab.

WARNINGTIP OVER HAZARD. All loads shown on rated capacity chart are based onmachine being on firm ground with frame level (see page 4-6); the forks beingpositioned evenly on carriage; the load being centered on forks; proper size tiresbeing properly inflated; and the telehandler being in good operating condition.

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

Model XXXXX is used for demonstration purposes only.

Boom Extension Indicator (arc)

Boom Angle

Load zones indicate the maximum weight that may be safely lifted.

Load centermust be equal to

or less thanvalue shown.

Attachment type, weight and dimensions must be equal to or

less than the data shown.

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

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

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

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Example

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

• The attachment style, weight, dimensions and load center match the attachmentdata on the capacity chart.

• The capacity chart is clearly marked for model xxxxx and corresponds withmachine configuration being used.

Below are examples with various conditions the contractor may encounter andwhether 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 6000 lb (2722 kg) 18 ft (5,5 m) 12 ft (3,7 m) Yes

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

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

4 5750 lb (2608 kg) 12 ft (3,7 m) 44 ft (13,4 m) NO

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5.6 ATTACHMENT INSTALLATION

1. Attachment

2. Attachment Pin Recess

3. Attachment Pin

4. Lock Pin

5. Lock Lever

6. Quick Attach (attachment tilt control in cab, see page 3-12)

WARNINGCRUSH HAZARD. Always be certain that carriage or attachment is properlypositioned on boom and is secured by lock pin and lock lever. Failure to ensureproper installation could permit carriage/attachment/load to disengage.

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

1. Tilt quick attach back to provide clearance. Check to be sure lock pin is removed.

2. Align attachment pin with recess in attachment. Raise boom slightly to engage attachment pin in recess.

3. Tilt quick attach forward to engage attachment.

4. Lift lock lever and insert lock pin completely through quick attach. Release lock lever and ensure lock pin is secured.

5. If equipped, connect auxiliary hydraulic hoses. See “Hydraulic Operated Attachment” on page 5-12.

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Hydraulic Operated Attachment

1. Install attachment (see page 5-10).

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

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

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Documents

Operation & Safety Manual Telehandlers/644E-42_944E-42...Sep 19, 2011 · Operation & Safety Manual Original Instructions Keep this manual with machine at all times. Models 644E-42