JLG Triple-L 248 Operation & Safety And Service Manual
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JLG Triple-L 248 Operation & Safety And Service Manual

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Operation & Safety and
Service Manual
Triple-L™ Trailers
3121224
December 21, 2010
ANSI
®

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Summary of Contents for JLG Triple-L 248

  • Page 1 Operation & Safety and Service Manual Triple-L™ Trailers 3121224 December 21, 2010 ANSI ®...
  • Page 3 Any alteration or modification of the trailer is strictly forbidden without writ- ten approval from JLG Industries, Inc. Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without prior notification. Contact JLG Industries, Inc. for updated information.
  • Page 4 FOREWORD SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS This is the Safety Alert Symbol. It is used to alert you to the potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death The Safety Alert Symbol will be used with the appropriate Safety Signal Word of “DANGER”...
  • Page 5 CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE. JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROPERTY OR THE JLG PRODUCT.
  • Page 6 FOREWORD TRAILER IDENTIFICATION TRAILER NUMBER MODEL NUMBER SERIAL NUMBER VIN NUMBER – Triple-L-Trailer – 3121224...

  • Page 7: New Product Warranty

    NEW PRODUCT WARRANTY NEW PRODUCT WARRANTY 1. WARRANTY. JLG Industries, Inc. (“Manufacturer”) or “special damages” as used herein includes but is warrants each new product made by it to be free not limited to costs of transportation, lost sales, lost...
  • Page 8 NEW PRODUCT WARRANTY REVISION LOG Original Issue - May 23, 2003 Revised - August 7, 2003 Revised - March 3, 2004 Revised September 30, 2004 (Edited to 0010598 Rev 7, 0010599 Rev 9, 0010600 Rev 6, 0010601Rev 9, 0010602 Rev 10) Revised - October 4, 2004 Revised - February 25, 2005 Revised - June 27, 2005...

  • Page 9: Table Of Contents

    Unsealed Bearings (Hubs) ............4-19 3121224 – JLG Lift –...
  • Page 10 Wheel Torque Chart ............4-19 – JLG Lift –...

  • Page 11: Section 1 - Safety Precautions

    Unsafe tires, lug nuts or wheels read another manual, and you do not have that manual, h. Overload call JLG to obtain a copy. i. Unsafe load distribution The safety information in this manual is denoted by the j. Shifting cargo safety alert symbols and signal words listed below: k.
  • Page 12 SECTION 1 - SAFETY PRECAUTIONS Incorrect Use of Breakaway Brake Anticipate the trailer “swaying.” Swaying is the trailer reac- tion to the air pressure wave caused by passing trucks and busses. Continued pulling of the trailer provides a sta- When equipped with brakes, a breakaway brake system bilizing force to correct swaying.

  • Page 13: Tire Information

    • Determine the combined weight of luggage and cargo being loaded on the vehicle. That weight may not safely exceed the available cargo and luggage load capacity. JLG Industries, Inc - M cConnellsburg, P A--USA Phone 877-JLG-LIFT M fd. By: DATE MODEL PNBV/GVWR (kg/lb) PNBE/GAWR (ea.axle)(kg/lb)

  • Page 14: Vin Label & Tire Information Label

    SECTION 1 - SAFETY PRECAUTIONS 1. VIN Label 2. Tire Information Label Figure 1-1. VIN Label & Tire Information Label Unsafe Load Distribution Uneven load distribution can cause tire, wheel, axle or DO NOT TRANSPORT PEOPLE ON OR INSIDE THE TRAILER. THE structural failure.

  • Page 15: Reporting Safety Defects

    Administrator trical, hydraulic or other systems on your trailer must be NHTSA approved by JLG and performed only by qualified techni- 1200 New Jersey Avenue S.E. cians who are familiar with the system as installed on your Washington, DC 20590 trailer.
  • Page 16 SECTION 1 - SAFETY PRECAUTIONS Figure 1-2. Decal Location – Triple-L-Trailer – 3121224...

  • Page 17: Decal Location

    SECTION 1 - SAFETY PRECAUTIONS Table 1-1. Decal Location Legend Item Number/Model Decal Number 1705809 1705782 Model UT610 1705761 Model UT612 1705762 Model UT614 1705763 Model EC-10 1705764 Model EC-12 1705765 Model EC-14 1705766 Model 248 1705767 Model UT28 1705768 Model 449 1705769 Model UT49...
  • Page 18 SECTION 1 - SAFETY PRECAUTIONS NOTES: – Triple-L-Trailer – 3121224...

  • Page 19: Section 2 - Trailer Operation

    SECTION 2 - TRAILER OPERATION SECTION 2. TRAILER OPERATION 2.1 TRAILER MODELS Triple-L™ Trailers employ a unique trailer deck design to make loading and unloading easier. The trailer deck can be lowered to the ground while remaining level, allowing equipment to be rolled or driven directly onto the trailer deck. Table 2-1.

  • Page 20: Production Option And Accessory Weights

    SECTION 2 - TRAILER OPERATION Production Option and Accessory Weights Any time a trailer is equipped with a production option or accessory or one of these components is added to a trailer, the weights listed in the following table must be subtracted from the rated vehicle capacity weight. NOTE: The specified options and accessories must be considered part of cargo weight.

  • Page 21: Trailer Features

    SECTION 2 - TRAILER OPERATION Shown with cover open on this side Figure 2-1. Trailer Features 3121224 – Triple-L-Trailer –...

  • Page 22: Trailer Features

    SECTION 2 - TRAILER OPERATION 2.2 TRAILER FEATURES 15. Serial Number - This is a 17 digit number, also referred to as the Vehicle Identification Number (VIN), that can be found on the identification plate 1. Rails (Not Shown) - These surround the front and and stamped on the frame of the trailer.

  • Page 23: General

    Identification Plate on your trailer. The trailer is equipped with a ball hitch coupler that is suit- JLG Industries, Inc - M cConnellsburg, P A--USA Phone 877-JLG-LIFT M fd. By: able for the size and weight of the trailer. Your trailer may be equipped with a 2"...

  • Page 24: Battery (Option)

    SECTION 2 - TRAILER OPERATION 2.6 BATTERY (OPTION) Battery The battery is carried on the trailer and is used for power- ing the motor running the hydraulic pump. If the trailer has electric brakes, this same battery is used for power to the break-away switch.

  • Page 25: Tow Vehicle And Hitch Information

    SECTION 2 - TRAILER OPERATION 2.8 TOW VEHICLE AND HITCH Coupler Height Adjustment INFORMATION Remove the bolts securing the couper to the mounting bracket. Move the coupler up of down to desired height. Follow all of the safety precautions and instructions in this Secure with the bolts.

  • Page 26: Coupling And Uncoupling The Trailer

    SECTION 2 - TRAILER OPERATION Automatic Transmission Oil Cooler The automatic transmission of a towing vehicle handles more power when a trailer is being towed. Inadequate cooling will shorten transmission life, and may result in sudden transmission failure. Ask the tow vehicle dealer if it is necessary to install a separate oil cooler for the auto- matic transmission.
  • Page 27 If you do not have these instructions, call NOTE: If the coupler cannot be secured to the hitch ball, do JLG to obtain a copy. not tow the trailer. The breakaway brake system may be fitted with a charg- 9.
  • Page 28 SECTION 2 - TRAILER OPERATION Connect the Electrical Cables Connect the trailer lights to the tow vehicle's electrical sys- TO AVOID POSSIBLE INJURY DO NOT TOW THE TRAILER WITH tem using the electrical connectors. THE PULLPIN REMOVED AND THE BREAKAWAY BRAKE SYSTEM ON BECAUSE THE BRAKES WILL OVERHEAT WHICH CAN Check all lights for proper operation: RESULT IN PERMANENT BRAKE FAILURE.

  • Page 29: Loading The Trailer

    SECTION 2 - TRAILER OPERATION 2.10 LOADING THE TRAILER For a ball hitch trailer the tongue weight should be between 10% and 15% of the total trailer weight, including the cargo. For example, a trailer, with a loaded weight of Improper trailer loading causes many accidents and 4,000 pounds, should have 10-15% of 4,000 pounds on deaths.
  • Page 30 SECTION 2 - TRAILER OPERATION DO NOT TRANSPORT FLAMMABLE, EXPLOSIVE, POISONOUS OR DO NOT TRANSPORT PEOPLE ON OR INSIDE THE TRAILER. THE OTHER DANGEROUS MATERIALS IN YOUR TRAILER. EXCEP- TRANSPORT OF PEOPLE PUTS THEIR LIVES AT RISK AND MAY TIONS ARE: FUEL IN THE TANKS OF EQUIPMENT BEING BE ILLEGAL.

  • Page 31: Lift Tie Down

    SECTION 2 - TRAILER OPERATION NOTE: Be sure that the deck is lowered to seat the weight of the deck on the latch and not the cylinder. BEFORE TOWING THE TRAILER, ENSURE THAT THE TRAVEL LATCH HAS PROPERLY LATCHED INTO PLACE. TIE DOWN ALL LOADS WITH PROPER SIZED FASTENERS, ROPES, STRAPS, ETC.

  • Page 32: Lift Tie Down Procedure

    SECTION 2 - TRAILER OPERATION 2.11 LIFT TIE DOWN PROCEDURE 2.12 TOWING OPERATIONS The tie downs at the front of the trailer are a fixed length Trailer Maneuvering and remain attached to the D-rings in the front corners of the deck. Driving a vehicle with a trailer in tow is vastly different from 1.
  • Page 33 SECTION 2 - TRAILER OPERATION Safe Trailer Towing Guidelines • Allow plenty of room for passing. A rule of thumb is that the passing distance with a trailer is 4 times the pass- • Recheck the load tie downs to make sure the load will ing distance without a trailer.

  • Page 34: Pre-Tow Inspection

    SECTION 2 - TRAILER OPERATION 2.13 PRE-TOW INSPECTION 10. Trailer Battery - Charged and capable of raising trailer deck. Prior to each tow, a Pre-Tow Inspection must be per- 11. Hydraulic Pump - Free of Leaks. Reservoir level full. formed. Check each item as specified in the checklist Proper operation.

  • Page 35: Breaking-In A New Trailer

    If you do not have these Adjust Brake Shoes at First 200 Miles instructions, call your dealer or JLG to obtain a copy. A hard stop is used to: Brake shoes and drums experience a rapid initial wear.
  • Page 36 SECTION 2 - TRAILER OPERATION NOTES: 2-18 – Triple-L-Trailer – 3121224...

  • Page 37: Section 3 - Accessories

    You must read and follow these instructions Off @ 12.9 V DC ±0.1V DC before using the accessory. If you are uncertain whether you have all of the instructions, call JLG before operating • Indication: LED indicates charge mode the accessory.
  • Page 38 SECTION 3 - ACCESSORIES Electric Winch Spare Tire Bracket This bolt on bracket attaches directly to the chassis frame. The spare tire is carried neatly over the frame. • 12 Volt • Freespooling clutch • Power In & Out • 12 ft. Remote Control •...

  • Page 39: Scissor Lift Chocks (If Equipped)

    JLG Industries, Inc. (JLG). The Model UT49 THE SCISSOR LIFT CHOCKS ARE INTENDED FOR USE ONLY or Model 449 are designed to haul a JLG Model 1932E2 FOR SPECIFIED SCISSOR LIFTS THAT ARE MANUFACTURED BY Scissor LIft.

  • Page 40: Chock Location

    The chocks must be properly positioned to achieve the THE ORIGINAL FASTENERS CANNOT BE REUSED. required tongue weight (10-15% of load) for the JLG scis- sor lift. NOTE: Purchase new fasteners as referenced in the table below.

  • Page 41: Section 4. Service And Maintenance

    SECTION 4 - SERVICE AND MAINTENANCE SECTION 4. SERVICE AND MAINTENANCE INTRODUCTION 4.2 INSPECTIONS, SERVICE & MAINTENANCE This section of the manual provides additional neces- sary information to the operator for proper operation NOTE: In addition to this manual, also check the relevant and maintenance of the trailer.

  • Page 42: Inspection And Service Instructions

    SECTION 4 - SERVICE AND MAINTENANCE 4.3 INSPECTION AND SERVICE To perform many of the inspection and maintenance activ- ities, you must jack up the trailer. Figure 4-1., Jacking INSTRUCTIONS Points indicates the general areas where jacks and jack stands may be applied. Axle Bolts, Frame, Suspension, &...

  • Page 43: Hydraulic Cylinder

    Using a power washer and a detergent solution, wash the floor and walls of the trailer. Rinse the trailer floor and walls. DO NOT REPAIR CRACKED OR BROKEN WELDS, CONTACT JLG. Fasteners and Frame Members Hydraulic Cylinder Inspect all of the fasteners and structural frame members The cylinder is a single acting cylinder designed to bleed for bending and other damage, cracks, or failure.
  • Page 44 SECTION 4 - SERVICE AND MAINTENANCE 1. Cylinder Barrel 2. Cylinder Rod 3. Cylinder Head 4. Piston 5. Nut, Grade 8 6. Breather 7. Seal 8. Seal 9. Rod Wiper 10. O-Ring 11. O-Ting 12. Back-up Ring 13. Back-up Ring 14.

  • Page 45: Hydraulic Schematic

    SECTION 4 - SERVICE AND MAINTENANCE TO CYLINDER PORT BATTERY (ROD END) DOWN Figure 4-3. Hydraulic Schematic Hydraulic Pump/Motor Specifications: Motor - 12 Volts This unitized motor/pump package should be inspected Tank Capacity - 3 Quarts periodically for any fluid leaks and tank level. Pressure Relief Setting - 1900 psi Displacement - 0.138 in^3/rev Full Tank Level - 1"...

  • Page 46: Volt Motor/Pump Parts

    SECTION 4 - SERVICE AND MAINTENANCE RESERVOIR MOTOR SWITCH RETURN TUBE ADJUSTABLE RELIEF VALVE FILTER BRACKET SUCTION TUBE DRAIN HOLE REF Figure 4-4. 12 Volt Motor/Pump Parts Relief Valve Adjustment: 1. Loosen Jam Nut 2. Adjust Pressure a. Turn screw clockwise to increase pressure. b.
  • Page 47 SECTION 4 - SERVICE AND MAINTENANCE Brake Shoes and Drums Properly functioning brake shoes and drums are essential to ensure safety. You must have your dealer inspect these components at least once per year, or each 12,000 miles. The brakes should be adjusted (1) after the first 200 miles of operation when the brake shoes and drums have "seated,"...

  • Page 48: Electric Brakes With Parking Brake Feature

    SECTION 4 - SERVICE AND MAINTENANCE Brake Controller - A tow vehicle brake controller is The electric brakes that operate in conjunction with the required. These controllers have gain control to vary the tow vehicle brakes must be “synchronized” so that brak- amount of current to the brakes, and a level control which ing is properly distributed to the tow vehicle brakes and sets the controller's inertia sensor to sense deceleration.
  • Page 49 SECTION 4 - SERVICE AND MAINTENANCE Brake Cleaning and Inspection - Your trailer brakes must Shoes and Linings - A simple visual inspection of your be inspected and serviced at yearly or 12,000 miles inter- brake linings will tell if they are usable. Replacement is vals or more often as use and performance requires.

  • Page 50: Bleeding Surge Brakes

    SECTION 4 - SERVICE AND MAINTENANCE Hydraulic (Surge) Brakes (Option) • Drums - Check drums for scoring, cracking, or uneven wear. Turn drum smooth only if under maximum diame- If your trailer has hydraulically-operated brakes, they func- ter. Replace as necessary. tion the same way the hydraulic brakes do on your tow Brake Actuator (Surge Tongue Actuator) vehicle.

  • Page 51: Trailer Connection To Tow Vehicle

    If you do not have this using the same type of grease. A light weight oil must be manual, contact a JLG representative at 1-877-JLG-SAFE applied to the handle unit at both sides of the tube.

  • Page 52: Lights And Signals

    SECTION 4 - SERVICE AND MAINTENANCE 4.7 LIGHTS AND SIGNALS 4.8 TRAILER CONNECTIONS Before each tow, check the trailer taillights, stoplights, turn Before each tow, verify that the proper trailer connections signals and any clearance lights for proper operation. have been made. IMPROPER OPERATING TAILLIGHTS, STOPLIGHTS AND TURN SIGNALS CAN CAUSE COLLISIONS.

  • Page 53: Trailer Wiring Diagram

    SECTION 4 - SERVICE AND MAINTENANCE 1870165 D Figure 4-8. Trailer Wiring Diagram Disconnect the accessory battery when you do not plan to NOTE: The blue and orn/brn breakaway switch wires and be using the trailer for an extended period, such as sea- the white and black wires are used only with trailers sonal storage.

  • Page 54: Wheel Alignment

    SECTION 4 - SERVICE AND MAINTENANCE 4.9 WHEEL ALIGNMENT Figure 4-10. Flex Ride Suspension Model 248 Torsion To check wheel alignment, position a straight edge at the center line of the wheels and see that all sidewalls are in Model 4610 Spring alignment.

  • Page 55: Deck Bearing Replacement

    SECTION 4 - SERVICE AND MAINTENANCE 4.11 DECK BEARING REPLACEMENT 1. In a clear flat area, lower the deck completely to the ground. 5. Using a fork lift or hoist, slowly lift the chassis up to allow the bearings to lift out of the bearing channels. If you do not have extended forks to reach the full width of the trailer, chain the far side of the trailer to the fork lift mask so as to hold the chassis level while...

  • Page 56: Tire And Wheel Maintenance

    SECTION 4 - SERVICE AND MAINTENANCE 4.12 TIRE AND WHEEL MAINTENANCE Checking Tire Pressure It is important to check your vehicle's tire pressure at least Glossary of Tire and Loading Terminology once a month for the following reasons: 1. Cold Inflation Pressure - The pressure in the tire •...

  • Page 57: Tire Wear

    SECTION 4 - SERVICE AND MAINTENANCE Tire Wear A bubble, cut or bulge in a sidewall can result in a tire blowout. Inspect both sidewalls of each tire for any bub- Replace the tire before towing the trailer, if the tire treads ble, cut or bulge;...
  • Page 58 SECTION 4 - SERVICE AND MAINTENANCE Information on Trailer Tires 1. Tire Application - This letter identifies the tire by 6. Maximum Load Rating - This number indicates the application. maximum load in kilograms and pounds that can be carried by the tire. •...

  • Page 59: Unsealed Bearings (Hubs)

    SECTION 4 - SERVICE AND MAINTENANCE Lug Nuts 4. Wheel nuts should be torqued before first road use and after each wheel removal. Check and torque after the first 10 miles, 25 miles, and again at 50 It is extremely important to apply and maintain proper miles.
  • Page 60 SECTION 4 - SERVICE AND MAINTENANCE Wheel Bearings Wheel Bearing Disassembly A loose, worn or damaged wheel bearing is the most com- 1. After removing the grease cap, cotter pin, spindle mon cause of brakes that grab. nut and spindle washer, remove the hub and drum to inspect the bearings for wear and damage.
  • Page 61 CALIFORNIAN PROPOSITION 65 BATTERY WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemical known to the State of Califormia to cause cancer and reproductive harm. WASH HANDS AFTER HANDLING!
  • Page 62 JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) Ltd JLG France SAS P.O. Box 5119 Rua Eng. Carlos Stevenson, Bentley House Z.I. de Baulieu...

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