Operator & Safety Manual

Transcription

1 Operator & Safety Manual Keep this manual with machine at all times. Models 3507, , , , , Revised September 8, 2006

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3 Revision Log Revision Log REVISION LOG May 1, A - Original Issue of Manual May 15, B - Revised Manual November 18, C - Revised Manual September 8, D - Revised pages 2-2, 2-3, 2-15, 4-9, 4-10, 4-11, 4-13, 4-15, 8-2, 8-5 & a

4 Read This First Read This First This 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, and lessees with the precautions and operating procedures essential for the safe and proper machine operation for its intended purpose. 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. Operator Qualifications The operator of the machine must not operate the machine until this manual has been read, training is accomplished and operation of the machine has been completed under the supervision of an experienced and qualified operator. Operation within the U.S.A. requires training per OSHA Operators of this equipment must possess a valid, applicable driver s license, be in good physical and mental condition, have normal reflexes and reaction time, good vision and depth perception and normal hearing. Operator must not be using medication which could impair abilities nor be under the influence of alcohol or any other intoxicant during the work shift. In addition, the operator must read, understand and comply with instructions contained in the following material furnished with the telehandler: This Operator & Safety Manual Telehandler Safety Manual 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. b

5 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 safetyrelated 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. 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 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 Department JLG Industries, Inc. 1 JLG Drive McConnellsburg, PA USA or Your Local JLG Office (Addresses on back cover) In USA: Toll Free: 877-JLG-SAFE ( ) Outside USA: Phone: ProductSafety@JLG.com Other Publications Available Service Manual Illustrated Parts Manual c

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7 Table of Contents Table of Contents TABLE OF CONTENTS Revision Log Read This First Operator Qualifications...b Modifications...b Other Publications Available... c Table of Contents Section 1 - General Safety Practices 1.1 General Precautions Hazard Classification System Safety Alert System and Safety Signal Words Operation Safety Electrical Hazards Tip Over Hazard Travel Hazard Load Falling Hazard Lifting Personnel Driving Hazards on Slopes Pinch Points and Crush Hazards Fall Hazard Chemical Hazards Section 2 - Pre-Operation and Controls 2.1 Pre-Operation Checks and Inspection Walk-Around Inspection Safety Decals Operator Cab Controls Instrument Panel Display Screen Anti Theft Device Ignition Park Brake Parking Procedure Transmission Control Wiper, Lights and Turn Signal Control Lever Steering Column Adjuster Joystick Load Moment Indicator (LMI) Control and Indicator Console Heater and Air Conditioner (optional) Controls i

8 Table of Contents 2.5 Steer Modes Operator Seat Adjustments Seat Belt Mirrors and Windows Cab Door Window Rear Window Mirrors Hood Section 3 - Operation 3.1 Warm-Up and Operational Checks Engine Starting the Engine Battery Boosted Starting Normal Engine Operation Shut-Down Procedure Operating with a Load Lift Load Safely Before Picking Up a Load Transporting the Load Leveling Procedure Placing the Load Disengaging the Load Road Operation Loading and Securing for Transport Section 4 - Attachments and Hitch Options 4.1 Approved Attachments Unapproved Attachments Telehandler/Attachment/Fork Capacity Use of the Capacity Chart Capacity Indicator Locations Sample Capacity Chart Example Attachment Installation Mechanical Quick-Switch Device Hydraulic Quick-Switch Device Hydraulic Operated Attachment Adjusting/Moving Forks ii

9 Table of Contents 4.7 Attachment Operation Carriage w/forks Truss Boom Side Shift Carriage Bucket Fork Extension Fork Hook Adjustable Truss Boom Hitch Options Mechanical Hitch Hydraulic Hitch Section 5 - Emergency Procedures 5.1 Towing a Disabled Product Moving Short Distances Moving Longer Distances Emergency Lowering of Boom Electronic Control Unit Failure Engine Failure Cab Emergency Exit Section 6 - Lubrication and Maintenance 6.1 Introduction Clothing and Safety Gear General Maintenance Instructions Service and Maintenance Schedules & 1st 50 Hour Maintenance Schedule , 250 & 500 Hour Maintenance Schedule & 1500 Hour Maintenance Schedule Lubrication Schedules Hour Lubrication Schedule Hour Lubrication Schedule Operator Maintenance Instructions Fuel System Air Intake System Engine Oil Brake System Hydraulic Oil Tires Transmission Oil Engine Cooling System Battery iii

10 Table of Contents Section 7 - Additional Checks 7.1 Load Moment Indicator Test Section 8 - Specifications 8.1 Product Specifications Fluid and Lubrication Capacities Tires Performance Dimensions Noise Emission Level Telehandler Vibration Index iv

11 Section 1 - General Safety Practices SECTION 1 - GENERAL SAFETY PRACTICES 1.1 GENERAL PRECAUTIONS WARNING Before operation, read & understand this manual. Failure to comply with the safety precautions listed in this manual could result in machine damage, property damage, personal injury or death. 1.2 HAZARD CLASSIFICATION SYSTEM Safety Alert System and Safety Signal Words DANGER OW0010 DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING OW0020 WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION OW0030 CAUTION indicates a potentiality hazardous situation which, if not avoided, may result in minor or moderate injury

12 Section 1 - General Safety Practices 1.3 OPERATION SAFETY Electrical Hazards 10 FT (3 M) OW0040 This machine is not insulated and does not provide protection from contact or being near electrical current. NEVER operate the telehandler in an area where overhead power lines, overhead or underground cables, or other power sources may exist without ensuring the appropriate power or utility company de-energizes the lines. Always check for power lines before raising the boom

13 Tip Over Hazard Section 1 - General Safety Practices OW0050 Never use an attachment without the appropriate JLG supplied capacity chart installed on the telehandler. DO NOT exceed rated lift capacity. Be sure that the ground conditions are able to support the machine. OW0060 DO NOT drive with boom raised. When driving in high speed, use only front wheel steer (if steering modes are selectable). OW0080 DO NOT raise boom unless frame is level (0 degrees)

14 Section 1 - General Safety Practices 4 FT (1,2 M) OW0100 DO NOT level machine with boom/attachment above 1,2 m (4 ft). OW0150 Carry load as low as possible. Tether suspended loads to restrict movement. Understand how to properly use the capacity charts located in cab (see page 4-3). Weight of all rigging (slings, etc.) must be included as part of load. Start, travel, turn and stop slowly to prevent load from swinging. Beware of wind. Wind can cause a suspended load to swing and cause dangerous 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

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 Always wear the seat belt. Keep head, arms, hands, legs and all other body parts inside operator s cab at all times. OH2221 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 Trying to escape from a tipping machine could result in death or serious injury

16 Section 1 - General Safety Practices Travel Hazard 4-Wheel Steer Pivot Steer OW0120 Steering characteristics differ between 4-Wheel Steer & Pivot Steer telehandlers as shown above. Identify the telehandler you are operating & others on the jobsite. Ensure that adequate clearance is provided between both rear tail swing and front fork swing. Unlike a conventional 4-wheel steer telehandler the rear wheels of a pivot steer telehandler turn a wider circle than the front wheels. Look out for and avoid other personnel, machinery and vehicles in the area. Use a 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 while maintaining visibility of mirrors and maximum visibility of path of travel. Always look in the direction of travel. Always check boom clearances carefully before driving underneath overhead obstructions. Position attachment/load to clear obstacles

17 Load Falling Hazard Section 1 - General Safety Practices OW0130 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

18 Section 1 - General Safety Practices Lifting Personnel OW0170 When lifting personnel, USE ONLY a JLG manufactured personnel work platform, with proper capacity chart displayed in the cab. OW0190 DO NOT drive machine from cab when personnel are in platform. DO NOT use the personnel work platform until you study & understand the capacity chart. If your telehandler does not have the correct personnel work platform capacity chart, ask your supervisor to get one before using the attachment

19 Preparation and Setup 1. Ensure the telehandler is on a firm surface and is level. Section 1 - General Safety Practices 2. Engage the park brake. Blocking the wheels is also recommended. 3. Level the platform, both side to side (frame sway) and front to back (attachment tilt). 4. Keep area under the platform free from personnel. 5. DO NOT lift or carry persons in the bucket or on forks. Never tilt the platform forward, rearward, or sway the machine when the platform is occupied. Serious injury or death could result

20 Section 1 - General Safety Practices Driving Hazards on Slopes OW0200 To maintain sufficient traction and braking capabilities, travel on slopes as follows: 1. When unloaded, the rear of the machine is the heavy end. Drive with forks pointed downhill. 2. When loaded, the front of the machine is the heavy end. Drive with the forks pointed uphill. To avoid overspeeding the engine and drivetrain when driving down slopes, downshift to a lower gear and use the service brake as necessary to maintain a slow speed. DO NOT shift into neutral and coast downhill. Avoid excessively steep slopes or unstable surfaces. To avoid tip over DO NOT drive across excessively steep slopes under any circumstances. Avoid turning on a slope. Never engage inching or shift to Neutral when going downhill. DO NOT park on a slope

21 Pinch Points and Crush Hazards Section 1 - General Safety Practices 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 Keep clear from under boom

22 Section 1 - General Safety Practices OW0240 Keep clear of boom holes. 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

23 Fall Hazard Section 1 - General Safety Practices 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 3-4 has been performed. OW0290 DO NOT carry riders. Riders could fall off machine causing death or serious injury

24 Section 1 - General Safety Practices Chemical Hazards Exhaust Fumes DO NOT operate machine in an enclosed area without proper ventilation. DO NOT operate the machine in hazardous environments unless approved for that purpose by JLG and site owner. Sparks from the electrical system and the engine exhaust can cause an explosion. Flammable Fuel OW0300 DO NOT fill the fuel tank or service the fuel system near an open flame, sparks or smoking materials. Engine fuel is flammable and can cause a fire and/or explosion. Hydraulic Fluid OW0950 DO NOT attempt to repair or tighten any hydraulic hoses or fittings while the engine is running or when the hydraulic system is under pressure. Stop engine and relieve trapped pressure. Fluid in the hydraulic system is under enough pressure that it can penetrate the skin. DO NOT use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks. Wear gloves to protect hands from spraying fluid

25 Section 2 - Pre-Operation and Controls SECTION 2 - PRE-OPERATION AND CONTROLS 2.1 PRE-OPERATION CHECKS 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. Failure to comply could result in death or serious injury. Walk around inspection must be performed at beginning of each work shift or at each change of operator. Ensure all Safety decals are legible and in place. Clean or replace as required. See Safety Decals on page 2-4. 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. If spark arrestors are required, be sure they are in place and in good working order. When adding fluids, refer to lubrication section of this manual to determine proper type and intervals

26 Section 2 - Pre-Operation and Controls Walk-Around Inspection Begin your walk-around inspection at item 1. 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. Inspect all structural members including attachment for cracks, excessive corrosion and other damage. 1. Boom Sections & Lift, Tilt, Extend/Retract, Compensating (Slave) Cylinders - Check front, top, side & rear slider pads for adequate grease. Pivot pins secure; hydraulic hoses undamaged, not leaking. 2. Left Outrigger (12 & 13M)- Pins secure; hydraulic hoses & cylinder undamaged, not leaking. 3. Front Work Lights - Clean, undamaged and work properly

27 Section 2 - Pre-Operation and Controls 4. Front Axle - Steer cylinders undamaged, not leaking; pivot pins secure; hydraulic hoses undamaged, not leaking. 5. Wheel/Tire Assembly - No loose or missing lug nuts; proper inflation. 6. Cab & Electrical - General appearance; no visible damage; proper load charts and applicable Operator & Safety manual located in cab. Window glass undamaged and clean. Gauges, switches, joystick, foot controls, park brake & horn operational. Check seat belt for damage, replace belt if frayed or cut webbing, damaged buckles or loose mounting hardware. Check brake fluid level, refill as required. 7. Hydraulic Reservoir - Recommended fluid level on sight gauge (lubricant must be cool); filler/breather cap secure and working. 8. Wheel/Tire Assembly - No loose or missing lug nuts; proper inflation. 9. Rear Axle - Steer cylinders undamaged, not leaking; pivot pins secure; hydraulic hoses undamaged, not leaking. 10. Rear Work Lights- Clean, undamaged and work properly. 11. Fuel Tank - Check fluid level, refill as required; filler cap is securely fastened. 12. Wheel/Tire Assembly - No loose or missing lug nuts; proper inflation. 13. Engine Compartment - Engine Crankcase and Radiator, check levels & refill as required. Drive belts, check condition & replace as required. Air cleaner element condition indicator, check for clogged condition. Replace element as required. Check and clean pre-cleaner as required. Main control valve, see inspection note. Battery cables tight, no visible damage or corrosion. Engine cover properly secured and latched. 14. Mirrors - Clean, undamaged and work properly. 15. Wheel/Tire Assembly - No loose or missing lug nuts; proper inflation. 16. Sway Cylinder - Pins secure; hydraulic hoses undamaged, not leaking. 17. Right Outrigger (12 & 13M)- Pins secure; hydraulic hoses & cylinder undamaged, not leaking. 18. Attachment - Properly installed, see Attachment Installation on page

28 Section 2 - Pre-Operation and Controls 2.2 SAFETY DECALS Ensure all DANGER, WARNING, CAUTION and instructional decals and proper capacity charts are legible and in place. Clean and replace as required A A Optional (40) (35) (25) (20) (22) (12) (S/N & After) (Before S/N ) (EXCEPT WITH HYDRAULIC HITCH ASSEMBLY KIT OPTION) 35 Optional (40) (35) (25) (20) (22) (12) VIEW A-A OZ

29 Section 2 - Pre-Operation and Controls B B C C 35 Optional (40) (35) (25) (20) (22) (12) VIEW C-C VIEW B-B OZ

30 P/N P/N P/N P/N m m G 70 G F E F D E C P/N P/N P/N P/N D B C A B A A 2 15 A A A A A A A A 12V A A A A ESX A A S A A A A A A A A A/C A A A Fusecard _C Section 2 - Pre-Operation and Controls (Optional) (12 & 13M) LOAD CHARTS kg 4017 EN 1459 B (1998) B EN 1459 B (1998) 500kg 1.000kg 1.500kg 2.000kg 2.500kg 3.000kg 3.500kg 4.000kg 400kg 750kg 1.300kg 1.500kg 2.000kg 2.500kg 3.000kg 3.500kg 4.000kg OIL ATF Dexron D dB L WA L WA 106dB E R (ALTERNATE LOCATION WITH HYDRAULIC HITCH ASSEMBLY KIT) h 100% Load Moment Indicator VIEW OF REAR WINDOW TEST VIEW OF LOAD MOMENT INDICATOR 8h OZ

31 2.3 OPERATOR CAB Section 2 - Pre-Operation and Controls The telehandler is equipped with an enclosed ROPS/FOPS cab. WARNING Never operate telehandler unless the overhead guard and cab structure 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 damaged, the CAB CANNOT BE REPAIRED. It must be REPLACED

32 Section 2 - Pre-Operation and Controls 2.4 CONTROLS 1. Parking Brake: See page 2-17 for details. 2. Accelerator Pedal: Pressing down the pedal increase engine and hydraulic speed. 3. Service Brake Pedal: The further the pedal is depressed, the slower the travel speed. 4. Steering Column Adjuster: See page 2-21 for details. 5. Wipers, Lights, Turn Signal Lever: See page 2-20 for details. 6. Transmission Control Lever: See page 2-18 for details

33 Section 2 - Pre-Operation and Controls 7. Round Air Vents: Three individually adjustable round vents. 8. Brake Fluid Reservoir: The brake fluid level should be between the MIN and MAX marks. The sight gauge is on the left side of the reservoir. 9. Air Louvers: Four individually adjustable air louvers. 10. Instrument Panel: Controls and indicates some machine functions and displays the output of the machine. See page 2-10 for details. 11. Level Indicator: Enables the operator to determine the left to right level condition of the telehandler. 12. Fuel Gauge: Gauge for the diesel fuel tank. 13. Load Moment Indicator: See page 2-26 for details. 14. Engine Temperature Gauge: At high working load do not exceed the critical coolant temperature of 102 C (221 F). Stop immediately and allow the engine to run at idle in order to cool. (See engine manual.) 15. Control & Indicator Console: See page 2-27 for details. 16. Hazard Flashers: Press button to activate, press button to deactivate. 17. Ignition: Key activated. See page 2-16 for details. 18. Joystick: See page 2-22 for details. 19. Continuous Hydraulic Powered Attachment Operation Button: Press button for continuous operation of hydraulic powered attachment. See Section 4 - Attachments and Hitch Options for approved attachments and control instructions. 20. Auxiliary Hydraulic Circuit/Hydraulic Quick-Switch Button: Press button to select the desired auxiliary hydraulic circuit. See Section 4 - Attachments and Hitch Options for approved attachments and control instructions V Receptacle: Supplies power for service laptop, light, etc. 22. Heater and Air Conditioner Controls: See page 2-28 for details

34 Section 2 - Pre-Operation and Controls Instrument Panel C OK ! OZ Steer Mode Selection LED lit while activated. Blinks during change to another steer mode. See page 2-29 for details. 2. C Key Returns user interface one level during navigation and deletes user inputs. 3. Up/Down Arrows Scroll up and down in the user interface. 4. OK Key Confirms user interface inputs. 5. Overload Protection Override When the button is activated the LED lights and the buzzer sounds. The automatic overload protection function (see page 2-26) is disabled. Push button or cycle ignition switch to re-enable function. WARNING TIP OVER HAZARD. Exceeding lift capacity of the telehandler could damage the equipment and/or cause tip over resulting in death or serious injury. 6. Declutch Shutoff With the LED not lit, the transmission is in neutral and all power is routed to the hydraulic system when the service brake is depressed. Function is deactivated when LED is lit

35 Section 2 - Pre-Operation and Controls 7. Road Use Operation LED lit while activated: The outrigger, boom, sway and auxiliary hydraulic systems are disengaged. No functions can be operated with the joystick. The Declutch Shutoff is not lit and Front-Wheel Steer Mode must be active to proceed to Road Use Operation. Note: Activate this function before traveling on public roads. See Road Operation on page Warning Indicator The RED LED illuminates for high priority problems. Engine Oil Pressure Engine Temperature Transmission Temperature Air Filter Hydraulic Oil Filter CAN Bus Engine Speed Sensor Hydraulic Pump Pressure Short Circuit Main Control Valve Boom Angle Sensor CAUTION EQUIPMENT DAMAGE. When the red LED illuminates and a warning tone is heard, immediately bring machine to a stop, lower boom and attachment to ground and stop the engine. Determine cause before continued use. 9. Auxiliary Hydraulic Indicator Attachment hydraulic system in continuous operating mode when LED is lit. (e.g. street sweeper) 10. Display Screen Displays Operating Status, Fault Codes and Service Codes. See page 2-12 for details. 11. Anti Theft Device Indicator LED lit while actived: Enter the anti theft code. Refer to page 2-15 for details. 12. Service Indicator Indicates a maintenance interval when LED is lit. Service is required

36 Section 2 - Pre-Operation and Controls Display Screen 1 2 0km/h P min OZ The display screen consists of five sections: 1. Speed Indicator (km/h) 2. Symbol Display 3. Engine Speed Indicator (rpm) 4. Operating Hours Indicator (Bh) 5. Boom Angle, Aux Hydraulic and Common Message Display Symbol Display (Section 2) a. Parking Brake Displayed permanently when parking brake is applied (see page 2-17). Parking brake must be applied to start engine. Symbol will flash when parking brake is not applied and attempting to start engine. b. Glow Indicator Displayed when ignition key is in position-1; engine preheat. Symbol is shown until start temperature is reached. After the symbol disappears, the engine can be started, do not start before. c. Diagnostic Startup Displayed after system start, while startup diagnostic is in progress. Symbol is shown until startup diagnostics has been successfully completed. If the symbol does not disappear, a failure has been detected within the diagnosis. Stop engine immediately. d. Engine Oil Pressure Symbol displayed and buzzer sounds when low oil pressure exists. Stop engine immediately. P OH2480 OU0040 OZ1150 OT

37 Section 2 - Pre-Operation and Controls e. Engine Temperature Symbol displayed and buzzer sounds when engine oil temperature is too high. Stop engine immediately. f. Transmission Temperature Symbol displayed and buzzer sounds when transmission temperature is too high. Stop engine immediately. g. Air Filter Symbol displayed and buzzer sounds when air filter is clogged. Stop engine immediately. h. Hydraulic Oil Filter Symbol displayed when the hydraulic oil filter requires cleaning. Stop engine immediately. i. CAN Bus Symbol displayed when there is a component failure. Stop engine immediately. j. Engine Speed Sensor Symbol displays when engine speed is too low (faulty engine speed signal). Stop engine immediately. k. Main Hydraulic Pump Pressure Symbol displayed when there is low hydraulic oil pressure. Only emergency steering is available. Stop engine immediately. l. Short Circuit Main Control Valve Symbol displayed and buzzer sounds when voltage to the main control valve is out of range. Stop engine immediately. m. Boom Angle Sensor Symbol displayed and buzzer sounds when the boom angle is lower or higher than the allowed value. Retract and lower boom immediately. OZ0250 OT0990 OZ0260 OT1030 OZ0270 OZ0250 OZ0290 OZ0310 OZ

38 Section 2 - Pre-Operation and Controls Boom Angle, Auxiliary Hydraulic & Message Window (Section 5) a. Boom Angle Indicator Displays the boom angle in degrees. (0 degrees indicates horizontal) OZ0330 b. Auxiliary Hydraulics When the permanent auxiliary hydraulic function is active, the display shows the percentage value (-100% to +100%) of the auxiliary hydraulic for 30 seconds. Also displays for 30 seconds at each change. See Section 4 - Attachments and Hitch Options for details. c. Message Window Code Entry - Anti Theft Device: Driver must enter four-digit code after system start. See page 2-15 for details. Hardware-exchange: After a hardware exchange has occurred, the hardware-display will appear for 30 seconds. Pressing the OK button within those 30 seconds will access the hardware exchange menu. Service: Service messages will be displayed after start-up for 30 seconds when a given service time interval elapses. Pressing the OK button within those 30 seconds will allow the driver to verify if the service has been completed. User Interface - Level 1 To access the menu hold the OK key down for 2 seconds. Language Anti Theft Device Operating Modes Diagnostics Fault Memory Service Display Vehicle Data Note: Access authorization (a numeric code) is required to view Levels 2 and

39 Anti Theft Device Section 2 - Pre-Operation and Controls Machines equipped with an anti theft device require entering a numeric code for operation to prevent unauthorized use. Use the arrow buttons in conjunction with the OK button to enter the code at startup. 2 1 C OK! OZ2100 Activating/Deactivating the Anti Theft Code The anti theft device is set to a numeric code of 0000 when delivered from the factory. To prevent unauthorized access change the code upon first use. 1. Turn on the ignition key and wait for the power up checks to complete. 2. Press the OK button (1) for 2 seconds to access the user interface. 3. Using the arrow buttons (2), move to and select the Anti Theft Device menu item. Select modify code. 4. Enter the old code. (e.g. 0000). Use the arrow buttons to select the first digit. When selected, press the OK button to move to the next digit. Continue until the code is completed. Within 30 seconds enter the new code (e.g. 7777). Confirm with the OK button. Note: Memorize the new code. If the anti theft feature is active and the current access code is not known, it may be viewed by the machine owner in level 2 of Diagnostics (password required). To deactivate the anti theft device, go to the Anti Theft Device menu. Select modify code. Enter the current code (e.g. 7777). Within 30 seconds, enter the code

40 Section 2 - Pre-Operation and Controls Ignition OZ0050 Position 0 - Engine off Position 1- Engine preheat at temperature below 0 C. Wait until icon on display screen goes out. Position 2 - Prohibits rotating key switch to position 3 in the event the engine does not start. Rotate the key to position 0 then back to position 3 to re-engage the starter. Position 3- Engine start

41 Park Brake Section 2 - Pre-Operation and Controls The Park Brake Lever (1) controls the application and release of the park brake. Pull back to activate. Push forward to deactivate. WARNING MACHINE ROLL-AWAY HAZARD. Always move park brake lever to "ON" position, lower boom to ground and stop engine before leaving cab. Machine roll-away could cause death or serious injury. WARNING CRUSH HAZARD. Turning engine off applies the park brake. Applying park brake or turning engine off while traveling will cause unit to stop abruptly and could cause load loss, resulting in death or serious injury. Either may be used in an emergency situation. Parking Procedure 1. Using service brake, stop telehandler in an appropriate parking area. 2. Follow Shut-Down Procedure on page

42 Section 2 - Pre-Operation and Controls Transmission Control Direction of Travel Selection OZ0060 This lever (1) engages forward or reverse travel. Push lever forward (2) for forward travel; pull lever rearward (3) for reverse travel. Move lever 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. Do not increase engine speed with the transmission in forward or reverse and the service brake depressed in an attempt to get quicker hydraulic performances. This could cause unexpected machine movement. WARNING TIP OVER/CRUSH HAZARD. Bring telehandler to a complete stop before shifting transmission control lever. A sudden change in direction of travel could reduce stability and/or cause load to shift or fall. Failure to comply could result in death or serious injury

43 Gear Selection Section 2 - Pre-Operation and Controls 4 OZ0070 Gear selection is located on the twist grip handle (4) of transmission control lever. Twist hand grip to select gear. Select the appropriate gear for the task being performed. Use a lower gear when transporting a load. Use a higher gear only when driving unloaded for longer distances. Slow down prior to downshifting. Do not downshift more than one gear at a time. Neutral Lock Lever OZ0080 To lock the transmission control lever in the neutral position, place the transmission control lever in the neutral position and move the neutral lock lever (5) the N position (6). To unlock, move the neutral lock lever to the D position (7)

44 Section 2 - Pre-Operation and Controls Wiper, Lights and Turn Signal Control Lever 1. Flash-to-Pass: Pull the lever back completely. The high beam indicator will light. 2. High/Low Beam: With the lights on, pull the lever to switch to high or low beam. The high beam indicator will light when the high beam lights are on. 3. Left Turn Signal: Push the lever forward. 4. Right Turn Signal: Pull the lever backward. 5. Horn: Push the button. 6. Windshield Washer: Slide the sleeve toward the steering column. 7. Windshield Wiper: Rotate the sleeve to the desired setting, O -Off, J -Interval or I -Continuous

45 Steering Column Adjuster Section 2 - Pre-Operation and Controls Follow Shut-Down Procedure on page 3-4. Loosen the knob (8). Place the steering column in the desired position. Retighten the knob. WARNING TIP OVER/CRUSH HAZARD. Bring telehandler to a complete stop and shutdown engine before adjusting steering column. A sudden change in direction of travel could reduce stability and/or cause load to shift or fall. Failure to comply could result in death or serious injury

46 Section 2 - Pre-Operation and Controls Joystick Standard Controls 12 & 13M ONLY The joystick (1) controls the boom, attachment and outrigger 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. The speed of boom functions depends upon the amount of joystick travel in corresponding direction. Increasing engine speed will also increase function speed. For two simultaneous boom functions, move the joystick between quadrants. For example; moving the joystick forward and to the left will lower and retract boom simultaneously. WARNING OZ2020 TIP 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 fall or could cause the machine to tip over. Failure to comply could result in death or serious injury

47 Attachment Functions Section 2 - Pre-Operation and Controls Attachment tilt is control by the rocker switch (2). Push the rocker switch up to tilt attachment forward (down); push the rocker switch down to tilt attachment back (up). Auxiliary Hydraulics (optional) button (6) controls function of attachments that require hydraulic supply for operation. See Section 4 - Attachments and Hitch Options for approved attachments and control instructions. Outrigger Functions (12 & 13M) Button (3) controls the left outrigger. Press and hold the button; move the joystick forward to lower the outrigger; move the joystick back to raise the outrigger. Button (5) controls the right outrigger. Press and hold the button; move the joystick forward to lower the outrigger; move the joystick back to raise the outrigger. Button (4) controls both outriggers simultaneously. Press and hold the button; move the joystick forward to lower the outriggers; move the joystick back to raise the outriggers. WARNING TIP OVER HAZARD. Outriggers increase stability and load capacity only if they are used properly. Using outriggers on soft surfaces could cause telehandler to tip over and result in death or serious injury. Always ensure surface can support telehandler and load

48 Section 2 - Pre-Operation and Controls Optional Controls 12 & 13M ONLY The joystick (1) controls the boom, attachment and outrigger functions. Boom Functions Move the joystick back to lift boom; move joystick forward to lower boom. Boom extend/retract is controlled by the rocker switch (2). Push the rocker switch up to extend boom; push the rocker switch down to retract boom. The speed of boom functions depends upon the amount of joystick travel in corresponding direction. Increasing engine speed will also increase function speed. For two simultaneous boom functions, move the joystick between quadrants. For example; moving the joystick forward and to the left will lower boom and tilt attachment back (up) simultaneously. WARNING OZ2010 TIP 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 fall or could cause the machine to tip over. Failure to comply could result in death or serious injury

49 Attachment Functions Section 2 - Pre-Operation and Controls Move the joystick right to tilt attachment forward (down); move joystick left to tilt attachment back (up). Auxiliary Hydraulics (optional) button (6) controls function of attachments that require hydraulic supply for operation. See Section 4 - Attachments and Hitch Options for approved attachments and control instructions. Outrigger Functions (12 & 13M) Button (3) controls the left outrigger. Press and hold the button; move the joystick forward to lower the outrigger; move the joystick back to raise the outrigger. Button (5) controls the right outrigger. Press and hold the button; move the joystick forward to lower the outrigger; move the joystick back to raise the outrigger. Button (4) controls both outriggers simultaneously. Press and hold the button; move the joystick forward to lower the outriggers; move the joystick back to raise the outriggers. WARNING TIP OVER HAZARD. Outriggers increase stability and load capacity only if they are used properly. Using outriggers on soft surfaces could cause telehandler to tip over and result in death or serious injury. Always ensure surface can support telehandler and load

50 Section 2 - Pre-Operation and Controls Load Moment Indicator (LMI) The Load Moment Indicator (1) provides a visual indication for forward stability limitations. All five LEDs (2) will progressively light (three green, then yellow & then red). The warning buzzer sounds and the red LED is illuminated as the telehandler reaches its forward stability limitations. Overload Protection Function. When the red LED is illuminated the automatic overload protection function is activated. Boom extension and lower functions are disabled. Test the Load Moment Indicator (3) at the beginning of each work shift. See Section 7 - Additional Checks

51 Control and Indicator Console Section 2 - Pre-Operation and Controls Controls and indicates the electrical accessories of the telehandler. 4. High Beam Indicator: Illuminates when high beam lights are on. 5. Battery Charge Indicator: Illuminates when battery is at low charge. 6. Telehandler Turn Signal Indicator 7. Trailer Turn Signal Indicator (optional) 8. Rear Work Light Switch 9. Boom Work Light Switch 10. Rear Wiper Switch: Press and hold for 2 seconds or more to turn on. Remains on until the key is released. 11. Rotating Beacon Switch (optional): Place the magnetic base of the rotating beacon on the cab roof. Power is supplied by a 12V receptacle at the left rear part of the cab roof. 12. Frame Sway (optional): Controls the left to right frame sway. Press left side of switch to sway frame left; press right side of switch to sway frame right. Note: Frame Sway is inoperable with boom angle greater than 20 degrees. 13. Front Work Light Switch (optional) 14. Driving Lights Switch

52 Section 2 - Pre-Operation and Controls Heater and Air Conditioner (optional) Controls 1. Fan Speed: 3-position rotary switch for heater and air conditioner. 2. Temperature Control: Adjustable rotary switch. 3. Air Conditioner (optional): On/Off switch. 4. Recirculate (optional): On/Off switch used for optimum air conditioner performance. In this mode no outside air is drawn into the cab. 5. Round Vent 6. Air Louver Heater Turn the temperature control to the desired temperature and set the fan speed. Adjust the air flow through the air louvers and round vents. Air Conditioner (optional) Turn on the air conditioner and set the fan speed. Activate the recirculation control to cool the cab more quickly. Adjust the air flow through the air louvers and round vents. Note: When the windows are misted over, run the air conditioner and heater at the same time. Defrosting Direct the flow of air through the louvers and the left front round vent toward the windshield. Close the other two round vents

53 2.5 STEER MODES Section 2 - Pre-Operation and Controls Stop the telehandler before changing steering modes. An LED will indicate the steering mode selected. All-Wheel Steer C OZ0180 Front-Wheel Steer Note: This mode is required for travel on public roads. C OZ0190 Crab Steer C OZ

54 Section 2 - Pre-Operation and Controls 2.6 OPERATOR SEAT Adjustments OZ0830 Prior to starting the engine adjust seat for position and comfort as follows: Fore/Aft Use the handle (1) to move seat fore and aft. Height Use the knob (2) to adjust the height of the seat. Suspension Use the knob (3) to adjust the suspension to the appropriate weight setting (4). Backrest Use knob (5) to adjust backrest angle. Seat Belt Always fasten seat belt (6) during operation

55 Seat Belt Section 2 - Pre-Operation and Controls 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. 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

56 Section 2 - Pre-Operation and Controls 2.7 MIRRORS AND WINDOWS Keep all windows and mirrors clean and unobstructed. Cab Door Window 1 2 OZ0210 During operation the window must either be latched open or closed. Open the cab door window (1) and secure it in the latch. Press the release button (2) inside the cab to unlatch the window. Rear Window 4 3 OZ0220 Lift lever (3) and push to open the rear window (4). Lift lever and pull to close

57 Mirrors Section 2 - Pre-Operation and Controls 5 OZ1680 Adjust mirrors (5) as required for maximum visibility, before and during operation

58 Section 2 - Pre-Operation and Controls 2.8 HOOD To close the hood, slide the gas cylinder lock (1) to one side. Close and secure the hood

59 SECTION 3 - OPERATION 3.1 WARM-UP AND OPERATIONAL CHECKS Section 3 - Operation This section outlines the checks to be performed at the beginning of each work shift or at each change of operator. During warm-up period, check: 1. Heater, defroster and windshield wiper (if equipped). 2. Check all lighting systems (if equipped) for proper operation. WARNING CUT/CRUSH/BURN HAZARD. Keep engine cover closed while engine is running except when checking transmission oil level and hydraulic filter condition indicator (if equipped). Failure to comply could result in death or serious injury. When engine warms, check: 1. Transmission fluid level. 2. Service brake and parking brake operation. 3. Forward and reverse travel. 4. Each gear. 5. Steering in both directions with engine at low idle (steering lock to lock will not be reached). Check in each steering mode. 6. Horn and back-up alarm. Must be audible from inside operators cab with engine running. 7. All boom and attachment functions - operate smoothly and correctly. 8. Perform any additional checks described in Section

60 Section 3 - Operation 3.2 ENGINE Starting the Engine This machine can be operated in temperatures of -20 C to 40 C (0 F to 104 F). Consult JLG for operation outside this range. 1. If equipped, turn on the battery disconnect switch located in engine compartment. 2. Make sure all controls are in Neutral and all electrical components (lights, heater, defroster, etc.) are turned off. Set parking brake. 3. Turn ignition switch to preheat position. Enter anti theft code if anti theft device is activated. Wait for preheat symbol on display to disappear. 4. Turn ignition switch to position 3 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. 5. After engine starts, if engine oil pressure does not rise for more than ten seconds, the engine oil pressure symbol will show on display screen and buzzer will sound. Stop engine and determine cause before restarting engine. Reference engine manual for minimum pressure at operating temperature. 6. Warm up engine at approximately 1/2 throttle. Note: Engine will not start unless transmission control lever is in Neutral and park brake is applied. WARNING UNEXPECTED MOVEMENT HAZARD. Always ensure that transmission control lever 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 to move abruptly, causing an accident resulting in death or serious injury. CAUTION ENGINE EXPLOSION. Do not spray ether into air intake for cold weather starting. Failure to comply could result in death or serious injury

61 Battery Boosted Starting Section 3 - Operation OW0530 If battery-boost starting (jump-start) is necessary, proceed as follows: Never allow vehicles to touch. Connect the positive (+) jumper cable to positive (+) post of discharged battery. Connect the opposite end of positive (+) jumper cable to positive (+) post of booster battery. Connect the negative (-) jumper cable to negative (-) post on booster battery. Connect opposite end of negative (-) jumper cable to ground point on machine away from discharged battery. Follow standard starting procedures. Remove cables in reverse order after machine has started. WARNING BATTERY EXPLOSION HAZARD. Never jump start or charge a frozen battery as it could explode. Keep sparks, flames and lighted smoking materials away from the battery. Lead acid batteries generate explosive gases when charging. Wear safety glasses. Failure to comply could result in death or serious injury

62 Section 3 - Operation Normal Engine Operation Observe gauges and display screen frequently to be sure all engine systems are functioning properly. Be alert for unusual noises or vibration. When an unusual condition is noticed, park machine in safe position and perform shut-down procedure. See Shut-Down Procedure. Report condition 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 away from 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. Turn off electrical master switch in engine compartment (if equipped). 8. Block wheels (if necessary)

63 Section 3 - Operation 3.3 OPERATING WITH A 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. WARNING TIP OVER HAZARD. Exceeding lift capacity of the telehandler could damage the equipment and/or cause tip over resulting in death or serious injury. Know the rated load capacities (refer to Section 4) of the telehandler to determine the operating range in which you can safely lift, transport and place a load. Before Picking Up a Load Note the conditions of the terrain. Adjust travel speed and reduce amount of load if conditions warrant. Avoid lifting double-tiered loads. Make sure load is clear of any adjacent obstacles. Adjust spacing of forks so they engage the pallet or load at maximum width. See Adjusting/Moving Forks on page Approach load slowly and squarely with fork tips straight and level. NEVER attempt to lift a load with just one fork. NEVER operate telehandler without a proper and legible Capacity Chart in the operator s cab for the telehandler/attachment combination you are using