JLG Skytrak 3013 Operation & Safety Manual
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JLG Skytrak 3013 Operation & Safety Manual

JLG Skytrak 3013 Operation & Safety Manual

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Operation & Safety
Manual
Original Instructions
Keep this manual with machine at all times.
Model
3013
PVC 1911
31211476
March 27, 2020 - Rev A
An Oshkosh Corporation Company

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Summary of Contents for JLG Skytrak 3013

  • Page 1 Operation & Safety Manual Original Instructions Keep this manual with machine at all times. Model 3013 PVC 1911 31211476 March 27, 2020 - Rev A An Oshkosh Corporation Company...
  • Page 2 WARNING Operating, servicing and maintaining this vehicle or equipment can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. To minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your vehicle or equipment in a well-ventilated area and wear gloves or wash your hands frequently when servicing.
  • Page 3 Revision Log REVISION LOG Re v is ion L og March 27, 2020 - A - Original Issue of Manual. 31211476...

  • Page 4: Read This First

    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 5 JLG representative for information regarding safety-related bulletins which may have been issued for this product. JLG Industries, Inc. sends safety related bulletins to the owner of record of this machine. Contact JLG Industries, Inc. to ensure that the current owner records are updated and accurate.

  • Page 6: Other Publications Available

    Read This First Other Publications Available Service Manual..........................31211477 Parts Manual ..........................31211478 Note: The following standards may be referenced in this manual: ANSI is compliant to ANSI/ITSDF B56.6 AUS is compliant to AS 1418.19 CE is compliant to EN1459 Refer to the machine Serial Number Plate to identify the applicable compliance standard. 31211476...

  • Page 7: Table Of Contents

    Table of Contents Table of Contents TABLE OF CONTENTS Revision Log Read This First Operator Qualifications ................b Modifications....................b Other Publications Available ..............d Table of Contents Section 1 - General Safety Practices 1.1 Hazard Classification System ..............1-1 Safety Alert System and Safety Signal Words.......1-1 1.2 General Precautions ..................1-1 1.3 Operation Safety....................1-2 Electrical Hazards..................1-2...
  • Page 8 Disengaging a Suspended Load ............ 4-10 4.4 Loading and Securing for Transport ........... 4-11 Tiedown ....................4-11 Lifting....................... 4-12 Section 5 - Attachments and Hitches 5.1 Approved Attachments ................5-1 Coupler Mounted Attachments ............5-1 JLG Supplied Fork Mounted Attachments ........5-1 31211476...
  • Page 9 Non-OEM Attachments.................5-4 5.4 Equivalent Load .....................5-5 Load Centers Beyond 24 Inches ............5-5 Fork Mounted Attachments Equivalent Load ......5-6 5.5 JLG Supplied Attachments.................5-7 5.6 Telehandler/Attachment/Fork Capacity ..........5-8 5.7 Use of the Capacity Chart ................5-9 Capacity Indicator Locations ..............5-9 Sample Capacity Chart............... 5-10 Example....................
  • Page 10 Table of Contents Every 400 Hours ..................7-5 Every 600 Hours ..................7-5 Every 1000 Hours..................7-6 Every 1500 Hours..................7-6 7.4 Lubrication Schedules.................7-7 50 Hour Lubrication Schedule ............7-7 7.5 Operator Maintenance Instructions ............7-8 Fuel System....................7-8 Engine Oil ....................7-10 Hydraulic Oil ..................7-11 Tires ......................

  • Page 11: Section 1 - General Safety Practices

    Section 1- General Safety Practices SECTION 1 - GENERAL SAFETY PRACTICES HAZARD CLASSIFICATION SYSTEM Safety Alert System and Safety Signal Words DANGER DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

  • Page 12: Operation Safety

    Section 1- General Safety Practices OPERATION SAFETY Note: The manufacturer has no direct control over machine application and operation. Therefore, safety issues listed in this manual are non-exhaustive. The user and operator are responsible for conforming with good safety practices. Electrical Hazards 10 ft (3m)
  • Page 13 Section 1- General Safety Practices • The minimum approach distance may be reduced if insulating barriers are installed to prevent contact, and the barriers are rated for the voltage of the line being guarded. These barriers shall not be part of (or attached to) the machine. The minimum approach distance shall be reduced to a distance within the designed working dimensions of the insulating barrier.

  • Page 14: Tip Over Hazard

    Section 1- General Safety Practices Tip Over Hazard General • For additional load requirements, refer to the appropriate capacity chart. OW0050 • Never use an attachment without the appropriate original equipment manufacturer (OEM) approved capacity chart installed on the telehandler. •...
  • Page 15 Section 1- General Safety Practices OH2291 • MAINTAIN proper tire pressure at all times. If proper tire pressures are not maintained, this machine could tip over. • Refer to manufacturer’s specifications for proper fill ratio and pressure requirements for tires equipped with ballast. OH20911 •...
  • Page 16 Section 1- General Safety Practices Non-Suspended Load O 0901 • DO NOT drive with boom raised. Suspended Load OW0150 • Tether suspended loads to restrict movement. • Weight of all rigging (slings, etc.) must be included as part of load. •...

  • Page 17: Travel Hazard

    Section 1- General Safety Practices Travel Hazard 2-WHEEL REAR STEER O 0121 • Look out for and avoid other personnel, machinery and vehicles in the area. Use a spotter if you DO NOT have a clear view. • Ensure that adequate clearance is provided between both rear tailswing and front fork swing.

  • Page 18: Load Falling Hazard

    Section 1- General Safety Practices Load Falling Hazard OW0130 • Never suspend load from forks or other parts of carriage weldment. Use only approved lift points. • DO NOT burn or drill holes in fork(s). • Forks must be centered under load and spaced apart as far as possible. 31211476...

  • Page 19: Lifting Personnel

    Section 1- General Safety Practices Lifting Personnel O 0171 • When lifting personnel, USE ONLY an approved personnel work platform, with proper capacity chart displayed in the cab. O 0921 • DO NOT drive machine from cab when personnel are in platform. 31211476...

  • Page 20: Driving Hazards On Slopes

    Section 1- General Safety Practices Driving Hazards on Slopes OW0200 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. •...

  • Page 21: Pinch Points And Crush Hazards

    Section 1- General Safety Practices Pinch Points and Crush Hazards Stay clear of pinch points and rotating parts on the telehandler. OW0210 • Stay clear of moving parts while engine is running. OW0220 • Keep clear of steering tires and frame or other objects. OW0230 •...
  • Page 22 Section 1- General Safety Practices OW0250 • Keep arms and hands clear of attachment tilt cylinder. OW0260 • Keep hands and fingers clear of carriage and forks. OW0960 • Keep others away while operating. 1-12 31211476...

  • Page 23: Fall Hazard

    Section 1- General Safety Practices Fall Hazard OW0280 • Enter using the proper hand holds and steps provided. Always maintain 3-point contact when mounting or dismounting. Never grab control levers or steering wheel when mounting or dismounting the machine. • DO NOT get off the machine until the shutdown procedure on page 4-4 has been performed.

  • Page 24: Chemical Hazards

    • 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 and site owner. Sparks from the electrical system and the engine exhaust can cause an explosion.

  • Page 25: Clearsky (If Equipped)

    Section 1- General Safety Practices CLEARSKY (IF EQUIPPED) Federal Communications Commission (FCC) Information for Users FCC Statement Regarding Interference This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation.
  • Page 26 Section 1- General Safety Practices Notice Regarding Radio Frequency Radiation Exposure Do not operate your unit when a person is within eight inches (20 centimeters) of the antenna. A person or object within eight inches (20 centimeters) of the antenna could impair call quality and may cause the unit to operate at a higher power level than necessary, as well as expose that person to RF energy in excess of that established by the FCC RF Exposure Guidelines.

  • Page 27: Section 2 - Pre-Operation And Inspection

    Section 2 - Pre-Operation and Inspection SECTION 2 - PRE-OPERATION AND INSPECTION PREPARATION, INSPECTION AND MAINTENANCE The following table covers the periodic machine inspections and maintenance required. Consult local regulations for further requirements for telehandlers. The frequency of inspections and maintenance must be increased as necessary when the machine is used in a harsh or hostile environment, if the machine is used with increased frequency, or if the machine is used in a severe manner.

  • Page 28: Pre-Operation Check And Inspection

    Section 2 - Pre-Operation and Inspection PRE-OPERATION CHECK AND INSPECTION Note: Complete all required maintenance before operating unit. WARNING FALL HAZARD. Use extreme caution when checking items beyond your normal reach. Use an approved ladder. The pre-operation check & inspection, performed at beginning of each work shift or at each change of operator, should include the following: 1.
  • Page 29 Section 2 - Pre-Operation and Inspection 8. Operational Check - Once the walk-around inspection is complete, perform a warm-up and operational check (see page 2-10) of all systems in an area free of overhead and ground level obstructions. See Section 3 - Controls and Indicators for more specific operating instructions.

  • Page 30: Safety Decals

    Section 2 - Pre-Operation and Inspection SAFETY DECALS Ensure all DANGER, WARNING, CAUTION and instructional decals and proper capacity charts are legible and in place. Clean and replace as required. ANSI (if equipped) CAPACITY CHARTS 1001200101 Universal Quick Coupling (UQC) Pin-type fork carriage Pin-type forks 48”...
  • Page 31 Section 2 - Pre-Operation and Inspection 1001263406 1001263406 1001125387 1001189017 SERIAL NUMBER PLATE Model Serial Number Product Identification Number Maximum Weight Without Attachments (lbs / kg) 4108302 Maximum Capacity (lbs / kg)* Year of manufacture * Refer to load capacity chart for truck with attachment, and individual load ratings stamped on forks, if equipped. Use lowest capacity of all ratings.
  • Page 32 Section 2 - Pre-Operation and Inspection 1001260780 (1 inside and 1 outside) IMPORTANT EMERGENCY EXIT 1001260780A 1001263408 3” 35.12110.00 1001263396 35.12111.00 1001263397 ON0060 31211476...
  • Page 33 Section 2 - Pre-Operation and Inspection 1001263410 1001263411 35.12025.00 35.12026.00 1001260291 VIEW A-A 1706299-ENGLISH 1001260880 1001260776-ENGLISH 1001260879 1001260776A ON0070 31211476...

  • Page 34: Walk-Around Inspection

    Section 2 - Pre-Operation and Inspection WALK-AROUND INSPECTION ON0080 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 missing parts, that they are securely fastened and no visible leaks or excessive wear exists in addition to any other criteria mentioned.
  • Page 35 Section 2 - Pre-Operation and Inspection 1. Boom Sections and Lift, Tilt, Extend/Retract, Compensating Cylinders - • Check front, top, side and rear wear pads for presence of grease. • Pivot pins secure; hydraulic hoses undamaged, not leaking. 2. Front Axle - Not leaking; axle mount bolts secure. 3.

  • Page 36: Warm-Up And Operational Checks

    Section 2 - Pre-Operation and Inspection 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. WARNING CUT/CRUSH/BURN HAZARD.

  • Page 37: Operator Cab

    Never operate telehandler unless the overhead guard, cab structure and right side glass or screen are in good condition. Any modification to this machine must be approved by JLG to assure compliance with ROPS/FOPS certification for this cab/ machine configuration. If the overhead guard or cab structure is damaged, the CAB CANNOT BE REPAIRED.

  • Page 38: Windows

    Section 2 - Pre-Operation and Inspection WINDOWS Keep all windows and mirrors clean and unobstructed. Cab Door Window (if equipped) ON0090 • Cab door (1) must be closed during operation. • Open the cab door sliding window using pull (2). •...

  • Page 39: Rear Window

    Section 2 - Pre-Operation and Inspection Rear Window ON0100 • Lift levers (3) and push to open rear window (4). • Lift levers and pull to close. 31211476 2-13...
  • Page 40 Section 2 - Pre-Operation and Inspection This Page Intentionally Left Blank 2-14 31211476...

  • Page 41: Section 3 - Controls And Indicators

    Section 3 - Controls and Indicators SECTION 3 - CONTROLS AND INDICATORS GENERAL This section provides the necessary information needed to understand control functions. 31211476...

  • Page 42: Controls

    Section 3 - Controls and Indicators CONTROLS ON0110 1. Accelerator Pedal: Pressing down the pedal increases engine and hydraulic speed. 2. Service Brake Pedal: The further the pedal is depressed, the slower the travel speed. 3. Transmission Control Lever: See page 3-6. 4.
  • Page 43 Section 3 - Controls and Indicators 11. LSI Indicator: See page 3-7. 12. Right Hand Console: See page 3-13. 13. Quick Attach Button (if equipped): Used in conjunction with the joystick to hydraulically lock or unlock an attachment. 14. Continuous Auxiliary Hydraulics Switch (if equipped): See page 3-13. 15.

  • Page 44: Park Brake

    Section 3 - Controls and Indicators Park Brake Park Brake Switch ON0120 Park brake switch (1) controls the application and release of the park brake. Indicator light in switch illuminates to indicate brake is applied. • Depress switch to engage park brake. With park brake applied, transmission will not engage forward or reverse.

  • Page 45: Ignition

    Section 3 - Controls and Indicators Ignition ON0130 • Position P: Not active, reserved for future use. • Position 0: Engine off. • Position 1: Voltage available for all electrical functions. Wait to start engine until preheat indicator on instrument panel goes out. Prohibits rotating switch to position 2 in the event the engine does not start.

  • Page 46: Transmission Control Lever

    Section 3 - Controls and Indicators Transmission Control Lever ON0140 Transmission control lever (1) engages forward or reverse travel. • Lift and push lever forward for forward travel; lift and pull lever rearward for reverse travel. Move lever to centered position for ‘Neutral’ . •...

  • Page 47: Load Stability Indicator - Lsi

    Section 3 - Controls and Indicators Load Stability Indicator - LSI WARNING TIP OVER HAZARD. The LSI considers only longitudinal stability limitations, observe all operating parameters. Failure to follow operating parameters of the telehandler could damage the equipment and/or cause tip over. ON0150 The LSI (9) provides visual and audible indication of forward stability limitations when machine is static on firm, level surface.
  • Page 48 Section 3 - Controls and Indicators • Travel in accordance with the requirements set forth in Section 1- General Safety Practices. • Test LSI at the beginning of each work shift. See Section 8 - Additional Checks. • When placing a load, ensure the rear axle is not fully steered in either direction. WARNING TIP OVER HAZARD.

  • Page 49: Lsi Override Switch

    Section 3 - Controls and Indicators LSI Override Switch ON0160 The LSI override switch (1) momentarily disables the automatic function cut-out. • Sliding the locking actuator down, depress and hold the switch up to 60 seconds while operating joystick to momentarily disable the automatic function cut-out. When the LSI override switch (1) is depressed, the warning buzzer also sounds intermittently.

  • Page 50: Instrument Panel

    Section 3 - Controls and Indicators Instrument Panel ON0170 NOTICE EQUIPMENT DAMAGE. When a red indicator illuminates (except park brake), immediately bring machine to a stop, lower boom and attachment to ground and stop the engine. Determine cause and correct before continued use. 1.
  • Page 51 Section 3 - Controls and Indicators Display and Switches 8. Beacon Light Switch: On/Off switch. 9. Not used. Reserved for future use. 10. Heater Fan Speed Switch (if equipped): Three position switch. Press to middle position of switch for slow speed; bottom of switch for fast speed; top of switch to turn off.

  • Page 52: Joystick

    Section 3 - Controls and Indicators Joystick Joystick Pattern ON0180 The joystick (1) controls the boom, attachment tilt and auxiliary hydraulic functions. Boom Functions • Move the joystick back to lift boom; move joystick forward to lower boom; move joystick right to extend boom; move joystick left to retract boom. •...

  • Page 53: Right Hand Console

    Section 3 - Controls and Indicators Right Hand Console ON0190 1. Quick Attach Button: Used in conjunction with joystick to hydraulically lock or unlock an attachment. See page 5-15 for details. 2. Continuous Auxiliary Hydraulics Switch (if equipped): Provides continuous operation of hydraulic powered attachments.

  • Page 54: Accessory Control Lever (If Equipped)

    Section 3 - Controls and Indicators Accessory Control Lever (if equipped) The accessory control lever (1) enables the skylight and front windshield wiper. ON0200 Skylight and Front Windshield Wiper OD0210 • Rotate hand grip (2) to activate skylight and front windshield wiper. O - Off, I - Continuous or II - Fast.

  • Page 55: Operator Seat

    Section 3 - Controls and Indicators OPERATOR SEAT Adjustments Prior to starting engine adjust seat for position and comfort. ON0210 1. Suspension: Use knob to adjust suspension to the appropriate setting. Turn clockwise to increase stiffness. Turn counterclockwise to reduce stiffness. 2.

  • Page 56: Operator Presence

    Section 3 - Controls and Indicators Operator Presence Note: Operator Presence works in conjunction with the seat belt sensor. See “Seat Belt Fastened” on page 3-18. ON0740 The operator seat (1) is equipped with an operator presence system. Transmission is disabled and joystick (4) movements are locked if operator is not present.

  • Page 57: Seat Belt

    Section 3 - Controls and Indicators Seat Belt OH20912 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.

  • Page 58: Seat Belt Fastened

    Section 3 - Controls and Indicators Seat Belt Fastened Note: Seat Belt Fastened works in conjunction with the Operator Presence. See “Operator Presence” on page 3-16. ON0750 The seat belt receptacle (buckle) (1) is equipped with a seat belt fastened system. Transmission is disabled and joystick (4) movements are locked if seat belt is unfastened.

  • Page 59: Boom Angle And Extension Indicators

    Section 3 - Controls and Indicators BOOM ANGLE AND EXTENSION INDICATORS ON0220 • The boom angle indicator (1) is located on the left side of the boom. Use this indicator to determine the boom angle when using the capacity chart (see “Use of the Capacity Chart”...
  • Page 60 Section 3 - Controls and Indicators This Page Intentionally Left Blank 3-20 31211476...

  • Page 61: Section 4 - Operation

    Starting the Engine This machine can be operated under normal conditions in temperatures of 6°F to 114°F (-14°C to 45°C). Consult JLG for operation outside this range or under abnormal conditions. If equipped for cold weather, -20°F to 86°F (-30°C to 30°C), see page 4-2 for hydraulic warm-up procedure.

  • Page 62: Cold Weather Starting

    Section 4 - Operation Cold Weather Starting If equipped with cold weather engine components, the machine can be operated in temperatures down to -20°F (-30°C). 1. Follow start-up procedure on page 4-1 and allow engine to idle 10 minutes. 2. Operate each boom function a minimum of ten complete cycles. 3.

  • Page 63: Battery Boosted Starting

    Section 4 - Operation Battery Boosted Starting OW0530 If battery-boost starting (jump-start) is necessary, proceed as follows: • Never allow vehicles to touch. • Ensure booster vehicle engine is running. • Connect the positive (+) jumper cable to positive (+) post of discharged battery. •...

  • Page 64: Normal Engine Operation

    • When operating a machine at high altitudes, a decrease in machine performance may occur due to a decrease in air density. When operating a machine at high temperatures, a decrease in machine performance and an increase in engine coolant temperature may occur. Contact JLG for operation under abnormal conditions. Shut-Down Procedure ON0230 When parking the telehandler, park in a safe location on flat level ground and away from other equipment and/or traffic lanes.

  • Page 65: Operating With A Non-Suspended Load

    Section 4 - Operation 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 not sure of the weight and load center, check with your supervisor or with the supplier of the material.

  • Page 66: Transporting A Load

    Section 4 - Operation Transporting a Load OW0540 • After engaging the load and resting it against the backrest, tilt the load back to position it for travel. Travel in accordance with the requirements set forth in Section 1- General Safety Practices and Section 5 - Attachments and Hitches. •...

  • Page 67: Placing A Load

    Section 4 - Operation 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 extension range. See “Use of the Capacity Chart”...

  • Page 68: Operating With A Suspended Load

    Section 4 - Operation OPERATING WITH A SUSPENDED LOAD Lift Load Safely • You must know the weight and load center of every load you lift. If you are not sure of the weight and load center, check with your supervisor or with the supplier of the material.

  • Page 69: Transporting A Suspended Load

    Section 4 - Operation Transporting a Suspended Load OZ3160 OW0130 • Travel in accordance with the requirements set forth in Section 1- General Safety Practices and Section 5 - Attachments and Hitches. • For additional requirements, refer to the appropriate capacity chart in the operator cab.

  • Page 70: Placing A Suspended Load

    Section 4 - Operation 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. •...

  • Page 71: Loading And Securing For Transport

    Section 4 - Operation LOADING AND SECURING FOR TRANSPORT ON0240 Tiedown 1. Using a spotter, load the telehandler with boom as low as possible. 2. 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. 3.

  • Page 72: Lifting

    Section 4 - Operation Lifting • When lifting machine, it is very important that the lifting device and equipment is attached only to designated lifting points. • Make adjustments to the lifting device and equipment to ensure the machine will be level when elevated.

  • Page 73: Section 5 - Attachments And Hitches

    If any of the above conditions are not met, do not use attachment. Telehandler may not be equipped with proper capacity chart or attachment may not be approved for the model telehandler being used. Contact JLG or a local distributor for further information. JLG Supplied Fork Mounted Attachments To determine if an attachment is approved for use on specific telehandler you are using, perform following prior to installation.

  • Page 74: Unapproved Attachments

    Section 5 - Attachments and Hitches UNAPPROVED ATTACHMENTS Do not use unapproved attachments for the following reasons: • Range and capacity limitations for “will fit,” homemade, altered, or other non-approved attachments cannot be established. • An overextended or overloaded telehandler can tip over with little or no warning and cause serious injury or death to the operator and/or those working nearby.

  • Page 75: Fork Mounted Attachments

    Section 5 - Attachments and Hitches FORK MOUNTED ATTACHMENTS General Requirements • Certain fork mounted attachments have a dedicated capacity chart. The attachment type, weight and dimensions must be equal to or less than the data shown on a capacity chart located in the operator cab. If it does not have a dedicated capacity chart, utilize the applicable carriage capacity chart on which the fork mounted attachment is attached.

  • Page 76: Non-Oem Attachments

    Section 5 - Attachments and Hitches Non-OEM Attachments User of non-OEM attachments is responsible for: • Design • Fabrication • Workmanship • Structural Integrity • Maximum Capacity • Fit and Function • Overall Quality • Any operation and safety instructions specific to the attachment •...

  • Page 77: Equivalent Load

    Equivalent Load must be calculated to use with the carriage capacity chart. Utilizing Equivalent Load Calculation is applicable for all carriage and fork arrangements. The forks of the JLG carriage must support 2/3 of the load length for any load applied. Equivalent Load Calculation The Equivalent Load is determined with the calculation below.

  • Page 78: Fork Mounted Attachments Equivalent Load

    Section 5 - Attachments and Hitches Fork Mounted Attachments Equivalent Load Equivalent Load Calculation The Equivalent Load is determined with the calculation below. The Equivalent Load is the value applied to the respective carriage capacity chart to determine the appropriate use zone(s).

  • Page 79: Jlg Supplied Attachments

    Section 5 - Attachments and Hitches JLG SUPPLIED ATTACHMENTS Quick Coupler Attachment Part Number 1001261158 Carriage, 41 in (1050 mm) 1001263389 Fork, Pallet 1.4x4x48 in (35x100x1200 mm) 1001262108 1001263392 Bucket, Light Material 0.45 yd (0,34 m 1001263394 31211476...

  • Page 80: Telehandler/Attachment/Fork Capacity

    (if equipped), up to the maximum capacity of the attachment. • Maximum capacity as indicated on the proper capacity chart. See “JLG Supplied Attachments” on page 5-7. • When the load rating of the telehandler differs from the capacity of the forks or attachment, the lower value becomes the overall load capacity.

  • Page 81: Use Of The Capacity Chart

    To properly use the capacity chart (see page 5-10), the operator must first determine and/ or have the following: 1. An approved attachment. See “JLG Supplied Attachments” on page 5-7. 2. The proper Capacity Chart(s). 3. Weight of the load being lifted.

  • Page 82: Sample Capacity Chart

    Section 5 - Attachments and Hitches Sample Capacity Chart Quick Attach Type This Capacity Chart may be used with this model ONLY. The telehandler model is indicated on the boom or chassis. Model Forks Carriage Type XXXX is used for demonstration purposes only. Forks Type XXXXXXXXXXXXXXXXXXXXXXXXX XXXX...

  • Page 83: Example

    Section 5 - Attachments and Hitches Example A contractor owns a model xxxxx telehandler with a fork carriage. He knows this attachment may be used with his model since: • The attachment style, weight, dimensions and load center match the attachment data on the capacity chart.

  • Page 84: Attachment Installation

    Section 5 - Attachments and Hitches ATTACHMENT INSTALLATION Mechanical Standard Quick Attach ON0290 1. Attachment 2. Attachment Pin Recess 3. Attachment Pin 4. Lock Pin 5. Retainer Pin (mechanical quick attach) 6. Quick Attach (attachment tilt control in cab, see page 3-12) WARNING CRUSH HAZARD.
  • Page 85 Section 5 - Attachments and Hitches 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 forward to provide clearance. Check to be sure lock pin and retainer pin are out. ON0300 2.

  • Page 86: Hydraulic Universal Quick Attach (Uqc)

    Section 5 - Attachments and Hitches Hydraulic Universal Quick Attach (UQC) ON0340 1. Attachment 2. Attachment Recess 3. Engaging Edge 4. Lock Pin 5. Universal Quick Attach (attachment tilt control in cab, see page 3-12) 6. Latch Pin WARNING CRUSH HAZARD. Always be certain that carriage or attachment is properly positioned on boom and is secured by lock pin.
  • Page 87 Section 5 - Attachments and Hitches This installation procedure is designed for one-person operation. 1. Tilt quick attach forward to provide clearance. ON0350 2. Align engaging edge with recess in attachment. Raise boom slightly to engage edge in recess. ON0360 3.

  • Page 88: Hydraulic Operated Attachment

    Section 5 - Attachments and Hitches HYDRAULIC OPERATED ATTACHMENT ON0400 ON0390 1. Install attachment (see page 5-12). 2. Perform “Shut-Down Procedure” on page 4-4. 3. Turn the ignition switch to position 1. See “Ignition” on page 3-5. 4. Press and hold button (1), button (2) and button (3), at the same time move the joystick right and then left to relieve pressure at auxiliary fittings (4).

  • Page 89: 5.10 Adjusting/Moving Forks

    Section 5 - Attachments and Hitches 5.10 ADJUSTING/MOVING FORKS Carriages may have different locations where forks can be positioned. Two different methods 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.

  • Page 90: 5.11 Attachment Operation

    Section 5 - Attachments and Hitches 5.11 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 attachment if it is equipped with a manual holder.

  • Page 91: Carriage With Forks

    Section 5 - Attachments and Hitches Carriage with Forks Use Carriage Attachment Capacity Chart To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-8. ON0410 ON0420 The joystick (1) controls lift/lower and the extend/retract movement of the boom. The tilt button (2) enables fork tilt.

  • Page 92: Side Shift Carriage

    Section 5 - Attachments and Hitches Side Shift Carriage Use Side Shift Carriage Attachment Capacity Chart To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-8. ON0430 ON0420 The joystick (1) controls lift/lower and the extend/retract movement of the boom. The tilt button (2) enables fork tilt.
  • Page 93 Section 5 - Attachments and Hitches WARNING CRUSH HAZARD. Do not use side shift to push or pull objects or load. Failure to comply could cause object or load to fall. Equipment Damage Precautions: • Do not use forks as a lever to pry material. Excessive prying forces could damage forks or machine structure.

  • Page 94: Bucket

    Section 5 - Attachments and Hitches Bucket Use Appropriate Bucket Capacity Chart To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-8. ON0450 ON0460 The joystick (1) controls lift/lower and the extend/retract movement of the boom. The tilt button (2) enables bucket tilt. •...
  • Page 95 Section 5 - Attachments and Hitches Equipment Damage Precautions: • Except for lifting or dumping a load, the boom must be fully retracted for all bucket operations. • Do not corner-load bucket. Distribute material evenly within the bucket. Bucket capacity charts are for evenly distributed loads only. •...

  • Page 96: 5.12 Hitches

    Section 5 - Attachments and Hitches 5.12 HITCHES Machines may be equipped with various types of hitches. If not previously installed, secure hitch to machine with hardware supplied with installation. Maximum towing capacity shall be the smallest of the telehandler and hitch capacities. Refer to page 9-6 for details.

  • Page 97: Ball Hitch - 2" (50 Mm)

    Section 5 - Attachments and Hitches Ball Hitch - 2" (50 mm) Hitch Capacities Maximum combined weight of trailer and load ......not available at publication Maximum vertical load at hitch interface......... not available at publication Note: Verify that the trailer ball and hitch sizes match. ON0500 31211476 5-25...
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  • Page 99: Section 6 - Emergency Procedures

    Section 6 - Emergency Procedures SECTION 6 - EMERGENCY PROCEDURES TOWING A DISABLED PRODUCT The following information assumes the telehandler cannot be moved under its own power. • Before moving the telehandler, read all of the following information to understand options available.

  • Page 100: Emergency Lowering Of Boom

    In the event of total loss of engine power or hydraulic pump failure with an elevated load, the situation must be properly evaluated and dealt with on an individual basis. Contact JLG Industries or the local Authorized Distributor for specific instructions. Secure the telehandler using the following procedures: 1.

  • Page 101: Emergency Exit From Enclosed Cab

    Section 6 - Emergency Procedures EMERGENCY EXIT FROM ENCLOSED CAB Inside Cab ON0510 In an emergency the rear window can be used to exit the telehandler. • Remove latch pins (1). The window is then free to swing open. Outside Cab (if equipped) ON0520 •...
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  • Page 103: Section 7 - Lubrication And Maintenance

    Section 7- Lubrication and Maintenance SECTION 7 - LUBRICATION AND MAINTENANCE INTRODUCTION This section is intended as information to assist the operator to perform maintenance tasks only. Service the product in accordance with the maintenance schedule on the following pages. 50 h 50 h 200 h...

  • Page 104: General Maintenance Instructions

    Section 7- Lubrication and Maintenance GENERAL MAINTENANCE INSTRUCTIONS Prior to performing any service or maintenance on the telehandler, follow the shut- down procedure on page 4-4 unless otherwise instructed. Ensure telehandler is level, for proper fluid readings. • Clean lubrication fittings before lubricating. •...

  • Page 105: Maintenance Schedules

    Section 7- Lubrication and Maintenance MAINTENANCE SCHEDULES Every 8 Hours O 0910 O 0920 O 0970 ON0540 Check Engine Check Engine Oil Check Hydraulic Check Fuel Level Coolant Level Level Oil Level O 0950 O 0890 Check Air Filter Check Tire Condition and Pressure First 50 Hours...

  • Page 106: Every 50 Hours

    Section 7- Lubrication and Maintenance Every 50 Hours O 1010 O 0900 O 1020 ON0550 Lubrication Check Wheel Lug Check Brake Fluid Check Washer Schedule Nut Torque Level Fluid Level (if equipped) O 0980 Additional Checks (see Section 8) Every 200 Hours O 1140 O 1110 O 1160...

  • Page 107: Every 400 Hours

    Section 7- Lubrication and Maintenance Every 400 Hours OY4030 O 1220 OY4020 OF0650 Change Air Filter Change Fuel Filter Check LSI Check Hydraulic Elements Calibration Tank Cap Every 600 Hours ON0570 O 1150 Check Battery Change Fan Belt 31211476...

  • Page 108: Every 1000 Hours

    Section 7- Lubrication and Maintenance Every 1000 Hours O 1230 O 1040 OY4040 ON0580 Change Axle Change Hydraulic Change Change Hydraulic Differential Oil Fluid and Filters Transmission Filter Tank Breather ON0600 ON0590 Check Park Brake Engine Valve Lash Adjustment Every 1500 Hours O 1240 Change Engine Coolant...

  • Page 109: Lubrication Schedules

    Section 7- Lubrication and Maintenance LUBRICATION SCHEDULES 50 Hour Lubrication Schedule ON0610 ON0620 31211476...

  • Page 110: Operator Maintenance Instructions

    Section 7- Lubrication and Maintenance OPERATOR MAINTENANCE INSTRUCTIONS Fuel System A. Fuel Level Check ON0630 OW0990 ON0640 1. Check fuel gauge (1) located in cab. 2. If fuel is low, proceed to fuel source and perform “Shut-Down Procedure” on page 4-4. 3.
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  • Page 112: Engine Oil

    Section 7- Lubrication and Maintenance Engine Oil A. Engine Oil Level Check ON0630 OW1020 ON0650 1. Perform “Shut-Down Procedure” on page 4-4. 2. Open the engine cover. 3. Remove dipstick (1) and check oil mark. The oil should be between the full (2) and add (3) marks within the crosshatched area of the dipstick.

  • Page 113: Hydraulic Oil

    Section 7- Lubrication and Maintenance Hydraulic Oil A. Hydraulic Oil Level Check ON0630 OW1030 ON0660 1. Perform “Shut-Down Procedure” on page 4-4. 2. Check level of hydraulic oil at the sight gauge (5) on the hydraulic oil tank. The oil level should be visible in the gauge window.

  • Page 114: Tires

    Section 7- Lubrication and Maintenance Tires A. Tire Air Pressure Check ON0630 OW1040 1. Perform “Shut-Down Procedure” on page 4-4. 2. Remove valve stem cap. 3. Check tire pressure. 4. Add air if required. See page 9-3 for tire pressures. 5.
  • Page 115 Section 7- Lubrication and Maintenance The rims installed have been designed for stability requirements which consist of track width, tire pressure and load capacity. Size changes such as rim width, center piece location, larger or smaller diameter, etc., without written factory recommendations, may result in unsafe condition regarding stability.

  • Page 116: Air Intake System

    Section 7- Lubrication and Maintenance Air Intake System A. Air Filter Check and Element Cleaning ON0630 OW1010 ON0680 1. Perform “Shut-Down Procedure” on page 4-4. 2. Open the engine cover. 3. Locate air cleaner (1). 4. Unlock air cleaner cover (2) and remove from air cleaner. 5.
  • Page 117 Section 7- Lubrication and Maintenance B. Element Change 1. Perform “Shut-Down Procedure” on page 4-4. 2. Open engine cover. 3. Unlock air cleaner cover (2) and remove from air cleaner. 4. Remove element (3). Inspect element for damage then discard. 5.

  • Page 118: Engine Cooling System

    Section 7- Lubrication and Maintenance Engine Cooling System A. Engine Coolant Level Check OW0980 OW1070 ON0690 1. Perform “Shut-Down Procedure” on page 4-4. 2. Open the engine cover. 3. Check coolant level in surge tank (1). When coolant is hot, the tank should be 1/2 to 3/4 full.

  • Page 119: Battery

    Section 7- Lubrication and Maintenance Battery A. Battery Check OW0980 OW1080 ON0700 1. Perform “Shut-Down Procedure” on page 4-4. 2. Open the engine cover. 3. Wearing eye protection, visually inspect the battery (3). Check terminals for corrosion. Replace battery if it has a cracked, melted or damaged case. 4.

  • Page 120: Brake System

    Section 7- Lubrication and Maintenance Brake System A. Brake Fluid Level Check OW0980 OD1380 ON0710 1. Perform “Shut-Down Procedure” on page 4-4. 2. Remove inspection cap (1). 3. The brake fluid level should be visible in the reservoir (2). 4. If brake fluid level is low, add mineral fluid as needed. 5.

  • Page 121: Windshield Washer System (If Equipped)

    Section 7- Lubrication and Maintenance Windshield Washer System (if equipped) A. Windshield Washer Fluid Level Check OW0980 OAL2040 ON0720 1. Perform “Shut-Down Procedure” on page 4-4. 2. Open the engine cover. 3. The windshield washer fluid should be visible in the reservoir (3). 4.
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  • Page 123: Section 8 - Additional Checks

    Section 8 - Additional Checks SECTION 8 - ADDITIONAL CHECKS GENERAL If any of the following test results cannot be achieved, the system is not functioning properly and the machine must be removed from service and repaired before continued operation. LOAD STABILITY INDICATOR SYSTEM A.
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  • Page 125: Section 9 - Specifications

    Section 9 - Specifications SECTION 9 - SPECIFICATIONS PRODUCT SPECIFICATIONS Fluids Ambient Temperature Range Compartment Type and Viscosities or System Classification °F °C Min Max Min Max Repsol MID SAPS SAE 10W-40 Engine Crankcase Shell Rotella T6 SAE 5W-40 Mobil DEVLAC 1 ESP SAE 5W-40 75W-90 Axle Differential...

  • Page 126: Capacities

    Section 9 - Specifications Capacities Engine Crankcase Oil Capacity with Filter Change ....................5.4 qt (5,1 L) Fuel Tank Capacity .............................14.5 gal (55 L) Cooling System System Capacity ..........................5.3 qt (5 L) Hydraulic System System Capacity ........................14.5 gal (55 L) Reservoir Capacity to Full Mark...................

  • Page 127: Tires

    Section 9 - Specifications Tires Multi-Purpose Ag Tires 11.00/65, Bias - 8 Ply Pneumatic ..........................57 psi (4 bar) Foam............................. 112 lb (51 kg) Non-Marking Tires (if equipped) 27 x 10, Bias - 14 Ply Pneumatic ..........................72 psi (5 bar) Foam............................. 117 lb (53 kg) Turf Tires (if equipped) 26 x 12.00, Bias - 14 Ply Pneumatic ........................

  • Page 128: Performance

    Section 9 - Specifications Performance Maximum Lift Capacity Standard Quick Attach................... 2700 lb (1225 kg) Universal Quick Attach ..................2360 lb (1070 kg) Maximum Lift Height......................13.1 ft (3,9 m) Capacity at Maximum Height Standard Quick Attach....................1555 lb (705 kg) Universal Quick Attach .....................1355 lb (615 kg) Maximum Forward Reach ......................7.1 ft (2,1 m) Capacity at Maximum Forward Reach...

  • Page 129: Dimensions

    Section 9 - Specifications Dimensions Overall Height......................... 78.7 in (2000 mm) Overall Width ........................55.3 in (1405 mm) Track Width ........................44.5 in (1132 mm) Wheelbase........................66.9 in (1700 mm) Length at Front Wheels ....................96.6 in (2455 mm) Overall Length (less Attachment) ................105.7 in (2685 mm) Ground Clearance.......................

  • Page 130: Machine Towing Capacity

    Section 9 - Specifications Machine Towing Capacity Note: Refer to machine specific documents and/or plates for local governmental requirements and/or restrictions. Off-Road ......................not available at publication On-Road.............................0 lb (0 kg) 31211476...

  • Page 131: Index

    Mechanical Quick Attach....5-12 Starting ............4-1 Attachment Operation ......5-18 Engine Coolant Level ......... 7-16 Attachments Engine Oil Level ........... 7-10 JLG Supplied ..........5-7 Fall Hazard ............. 1-13 Battery ............. 7-17 Fluids..............9-1 Boom Angle and Extension Indicators 3-19 Fuel Level ............7-8 Brake Fluid Level..........
  • Page 132 Index Side Shift Carriage........5-20 Specifications ..........9-1 Maintenance Schedule Every 1000 Hours ........7-6 Every 1500 Hours ........7-6 Every 400 Hours........7-5 This installation procedure is designed for Every 50 Hours ......... 7-4 one-person operation ........5-15 Every 600 Hours........7-5 Tip Over Hazard ..........

  • Page 133: Inspection, Maintenance And Repair Log

    Inspection, Maintenance and Repair Log Inspection, Maintenance and Repair Log Serial Number ___________________________________ Date Comments...
  • Page 134 Inspection, Maintenance and Repair Log Date Comments...
  • Page 135 Hand Signals OY1090 OY1100 OY1110 EMERGENCY STOP - With both STOP - With either arm extended STOP ENGINE - Draw thumb or arms extended laterally, hands laterally, hand open downward, forefinger across throat. open downward, move arms back move arm back and forth. and forth.
  • Page 136 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg, PA 17233-9533 USA (717) 485-5161 (Corporate) (877) 554-5438 (Customer Support) (717) 485-6417 Visit our website for JLG Worldwide Locations. www.jlg.com...

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