JLG 2505H Operation Manual Download Page 122

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Section 7 - Lubrication and Maintenance

7-2

31200743

7.2

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.

• After greasing telehandler, cycle all functions several times to distribute lubricants.

Perform this maintenance procedure without attachment installed.

• Apply a light coating of engine oil to all linkage pivot points.

• Intervals shown are for normal usage and conditions. Adjust intervals for abnormal

usage and conditions.

• Check all lubricant levels when lubricant is cool. For ease of filling hydraulic reservoir,

use a funnel with a hose or flexible tube for best results.

WARNING

CUT/CRUSH/BURN HAZARD.

Do not perform service or maintenance on the machine

with the engine running.

Summary of Contents for 2505H

Page 1: ...al Instructions Keep this manual with machine at all times An Oshkosh Corporation Company Models G5 18A 2505H SN 0160053000 to Present including 0160051045 0160051047 0160051049 0160051194 0160051359...

Page 2: ...lead compounds chemical known to the State of California to cause cancer and reproductive harm WASH HANDS AFTER HANDLING CALIFORNIA PROPOSITION 65 EXHAUSTWARNING Diesel Engine exhaust and some of its...

Page 3: ...evision Log REVISION LOG May 3 2013 A Original Issue of Manual June 22 2016 B Revised covers Section 1 and pages 2 4 thru 2 9 2 11 2 13 3 25 4 1 4 2 5 2 5 3 5 11 5 15 5 28 5 29 6 1 6 2 6 3 7 1 7 11 th...

Page 4: ...equires training per OSHA 1910 178 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 vis...

Page 5: ...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...

Page 6: ...ne Configuration Two configurations of each machine are included in this manual Determine if machine is equipped with Ultra Low Sulfur Fuel Decal 1 as indicated below If equipped with the Ultra Low Su...

Page 7: ...Falling Hazard 1 8 Lifting Personnel 1 9 Driving Hazards on Slopes 1 10 Pinch Points and Crush Hazards 1 11 Fall Hazard 1 13 Chemical Hazards 1 14 1 4 ClearSky if equipped 1 15 Federal Communications...

Page 8: ...18 Reversing Fan if equipped 3 19 3 3 Steer Modes 3 20 Steer Mode Change 3 20 3 4 Operator Seat 3 21 Operator Presence CE AUS 3 21 Adjustments 3 22 Seat Belt 3 23 3 5 Boom Angle and Extension Indicato...

Page 9: ...chments 5 2 5 4 Telehandler Attachment Fork Capacity 5 4 5 5 Use of the Capacity Chart 5 5 Capacity Indicator Locations 5 5 Sample Capacity Chart ANSI CE 5 6 Sample Capacity Chart AUS 5 7 Example 5 8...

Page 10: ...2 7 3 Service and Maintenance Schedule 7 3 10 1st 50 50 Hour Maintenance Schedule 7 3 1st 250 250 500 Hour Maintenance Schedule 7 4 1000 1500 Hour Maintenance Schedule 7 5 7 4 Lubrication Schedules 7...

Page 11: ...cifications 9 1 Product Specifications 9 1 Fluids 9 1 Capacities 9 4 Tires 9 5 Performance 9 6 Dimensions 9 7 Declaration of Vibration CE 9 8 Noise Emission Level CE 9 8 Machine Towing Capacity 9 8 In...

Page 12: ...Table of Contents vi 31200743...

Page 13: ...voided may result in minor or moderate injury 1 2 GENERAL PRECAUTIONS Hydraulic cylinders are subject to thermal expansion and contraction This may result in changes to the boom and or attachment posi...

Page 14: ...sulated parts according to the Minimum Approach Distance MAD Note This requirement shall apply except where employer local or governmental regulations are more stringent Allow for machine movement and...

Page 15: ...ached to the machine The minimum approach distance shall be reduced to a distance within the designed working dimensions of the insulating barrier This determination shall be made by a qualified perso...

Page 16: ...e the capacity charts located in cab DO NOT exceed rated lift capacity Be sure that the ground conditions are able to support the machine Be aware of wind conditions Wind may cause load swing and dang...

Page 17: ...ecifications for proper fill ratio and pressure requirements for tires equipped with ballast Always wear seat belt Keep head arms hands legs and all other body parts inside operator s cab at all times...

Page 18: ...oad DO NOT attempt to use telehandler frame leveling to compensate for load swing Keep heavy part of load closest to attachment Never drag the load lift vertically When driving with a suspended load S...

Page 19: ...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...

Page 20: ...31200743 Load Falling Hazard 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...

Page 21: ...ices 1 9 31200743 Lifting Personnel When lifting personnel USE ONLY an approved personnel work platform with proper capacity chart displayed in the cab DO NOT drive machine from cab when personnel are...

Page 22: ...to the appropriate capacity chart To avoid overspeeding the engine and drivetrain when driving down slopes downshift to a lower gear and use the service brake as necessary to maintain a slow speed DO...

Page 23: ...inch Points and Crush Hazards Stay clear of pinch points and rotating parts on the telehandler Stay clear of moving parts while engine is running Keep clear of steering tires and frame or other object...

Page 24: ...fety Practices 1 12 31200743 Keep clear of boom holes Keep arms and hands clear of attachment tilt cylinder Keep hands and fingers clear of carriage and forks Keep others away while operating OW0240 O...

Page 25: ...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 pa...

Page 26: ...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 DO NOT attempt to repair or tighten any hydraul...

Page 27: ...ipment does cause harmful interference to radio or television reception which can be determined by turning the equipment off and on the user is encouraged to try to correct the interference by one or...

Page 28: ...ion with any other antenna or transmitter in order to satisfy FCC RF exposure requirements for mobile transmitting devices Important To comply with the FCC RF exposure limits and to satisfy the catego...

Page 29: ...ety Manuals Operation Safety Manual and AEM Safety Manual ANSI only are located in cab manual holder 5 Walk Around Inspection See page 2 10 for details 6 Fluid Levels Check fluids including fuel brake...

Page 30: ...see page 2 12 of all systems in an area free of overhead and ground level obstructions See Section 3 Controls and Indicators for more specific operating instructions WARNING If telehandler does not op...

Page 31: ...Section 2 Pre Operation and Inspection 2 3 31200743 This Page Intentionally Left Blank...

Page 32: ...NSI G5 18A if equipped OAH2232 1701500 1701500 1702300 1702300 4100181 4100181 1706301A 1706301 ENGLISH 1001163222 ENGLISH FRENCH ENGINE COMPARTMENT 1001139578 ENGLISH 1001163323 ENGLISH FRENCH 170630...

Page 33: ...1702300 91563220 91563220 REV A 1701500 1701500 1001125387 ENGLISH 1001163355 ENGLISH FRENCH ULTRA LOW SULFUR DIESEL FUEL ONLY S 15 mg kg 1001125387 A 1706302 ENGLISH 1001163223 ENGLISH FRENCH 170630...

Page 34: ...ENGLISH 1001163285 ENGLISH FRENCH 1706851A 1706851 ENGLISH 1001163321 ENGLISH FRENCH 1706304A RUN OVER HAZARD could cause death or serious injury 1706304 ENGLISH 1001163276 ENGLISH FRENCH Axle Trunnio...

Page 35: ...Kg Kg PERMISSIBLE TOWABLE MASS MASSA RIMORCHIABILE AMMISSIBILE TECHNISCH ZULAESSIGE ANHAENGELAST UNBRAKED TOWABLE MASS MASSA RIMORCHIABILE NON FRENATA UNGEBREMSTE ANHAENGELAST INDEPENDENTLY BRAKED TO...

Page 36: ...8006038 AUS 8006038 B C D E A 1001099783 10 0 10 20 30 40 5 0 6 0 70 80 4105262 1702300 1702300 1701500 1701500 B A 91563220 91563220 REV A 1001092878 3700016 20 2603207 30 1001081158 GERMANY 20 TBD L...

Page 37: ...ons Axle Kingpins Both Axles Boom Pivot Tilt Cylinder Carriage Pivot 1001100107 1001150347 D 50 10 50 D 250 1 2 3 4 5 XXXXX XXX 8005671 8005671 1706287 1706289 1706283 1706293 1706288 XXXXX XXXXX XXXX...

Page 38: ...astened 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...

Page 39: ...ulic hoses undamaged not leaking 8 Wheel Chock if equipped See inspection note 9 Main Control Valve See inspection note 10 Boom Prop 2505H if equipped See inspection note 11 LSI Sensor 2505H See inspe...

Page 40: ...ne warms perform an operational check 1 Service brake and parking brake operation 2 Forward and reverse travel 3 Steering in both directions with engine at low idle steering lock to lock will not be r...

Page 41: ...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 CAN...

Page 42: ...structed Cab Door Window if equipped Cab door 1 must be closed during operation During operation the cab door window 2 must either be latched open or closed Open the cab door window using lever 3 and...

Page 43: ...Section 2 Pre Operation and Inspection 2 15 31200743 Rear Window Lift lever 5 and push to open rear window 6 Lift lever and pull to close 5 6 OAM2110...

Page 44: ...Section 2 Pre Operation and Inspection 2 16 31200743 This Page Intentionally Left Blank...

Page 45: ...Section 3 Controls and Indicators 3 1 31200743 SECTION 3 CONTROLS AND INDICATORS 3 1 GENERAL This section provides the necessary information needed to understand control functions...

Page 46: ...al The further the pedal is depressed the slower the travel speed 5 Tilt Steering Column if equipped See page 3 11 6 Quick Attach Switch if equipped Used in conjunction with the joystick to hydraulica...

Page 47: ...n Depress button to sound horn 12 Frame Level Indicator Enables operator to determine the left to right level condition of the telehandler 13 Accessory Control Lever if equipped See page 3 18 14 LSI I...

Page 48: ...ransmission will not engage forward or reverse Depress bottom of switch to disengage park brake WARNING MACHINE ROLL AWAY HAZARD Always move park brake switch to ON position lower boom to ground and s...

Page 49: ...wn to disengage park brake Parking Procedure 1 Using service brake stop telehandler in an appropriate parking area 2 Follow Shut Down Procedure on page 4 4 WARNING MACHINE ROLL AWAY HAZARD Always move...

Page 50: ...e available for all electrical functions Hold in position until engine preheat indicator on instrument panel goes out Prohibits rotating switch to position 2 in the event the engine does not start Rot...

Page 51: ...p 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 at...

Page 52: ...ates the automatic function cut out is activated All boom functions are disabled except for boom retract CE AUS and boom lift CE Retract boom to re enable functions In some instances the LSI system ma...

Page 53: ...rovided and the automatic function cut out and or slow down feature is disabled Travel in accordance with the requirements set forth in Section 1 General Safety Practices Test LSI 14 at the beginning...

Page 54: ...ic function cut out Depress and hold top of switch up to 30 seconds while operating joystick to momentarily disable the automatic function cut out Release switch to re enable the automatic function cu...

Page 55: ...Procedure on page 4 4 Turn lever counterclockwise to unlock Place steering column in the desired position Turn lever clockwise to lock steering wheel WARNING TIP OVER CRUSH HAZARD Bring telehandler t...

Page 56: ...continued use 7 Engine Pre Heat Indicator Illuminates with ignition key in position P Light goes out when start temperature has been reached 8 Steer Mode Indicators Illuminates active steering mode 9...

Page 57: ...ormally shown Displays engine coolant temperature b Fault Codes Replaces the engine coolant temperature Displays fault codes of engine and machine systems 13 Engine Speed Battery Voltage and Operating...

Page 58: ...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 Atta...

Page 59: ...peed 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 up simultaneously Attachment Fu...

Page 60: ...ight Switch if equipped On Off switch 5 Rear Work Light Switch if equipped On Off switch Note Accessory control lever if equipped must be on to enable work light switches 6 Front Wiper Switch if equip...

Page 61: ...enable rear auxiliary hydraulics 13 Hazard Light Switch if equipped On Off switch 14 Lift Loader Joystick Pattern Switch Depress left side of switch to activate lift joystick pattern Depress right sid...

Page 62: ...e manually returned to the center position to deactivate either turn signal The lever will not cancel automatically after a turn Parking Lights Headlights and Work Lights Turn the twist grip 4 of the...

Page 63: ...speed 1 Timed Depress right side of switch 1 to activate Fan will reverse automatically every 20 minutes for a duration of 5 seconds Depress left side of switch to deactivate 2 Manual With switch 1 al...

Page 64: ...ce brake while either circle steer mode 1 or crab steer mode 3 is selected 2 Turn the steering wheel until the left rear wheel 4 is aligned with the side of the machine 3 Select front steer mode 2 4 T...

Page 65: ...rake 2 disengaged and the transmission in neutral 3 Horn sounds continuously Upon returning to seated position horn will cease 2 With the park brake 2 disengaged and transmission in forward or reverse...

Page 66: ...t 1 Suspension Use knob to adjust suspension to the appropriate setting Turn clockwise to increase stiffness Turn counterclockwise to reduce stiffness 2 Fore Aft Pull up on handle to move seat fore an...

Page 67: ...ngled 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...

Page 68: ...de of the boom Use this indicator to determine the boom angle when using the capacity chart see Use of the Capacity Chart on page 5 5 Boom extension indicators 2 are located on the left side of the bo...

Page 69: ...ing alarm sounds when an object is in range of Reverse Sensing System Alarm increases in frequency as object becomes closer If alarm sounds at a frequency of eight pulses per second 8 Hz an object is...

Page 70: ...Section 3 Controls and Indicators 3 26 31200743 This Page Intentionally Left Blank...

Page 71: ...ting motor Release key immediately when engine starts If engine fails to start within 20 seconds release key and allow starting motor to cool for two minutes before trying again 4 After engine starts...

Page 72: ...idle 10 minutes 2 Operate each boom function a minimum of ten complete cycles 3 While in 4 wheel circle steer mode turn steering wheel completely left and right a minimum of ten complete cycles 4 Dis...

Page 73: ...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 st...

Page 74: ...onnel 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...

Page 75: ...ns 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 the...

Page 76: ...ace load 2 Apply parking brake and move transmission control lever to NEUTRAL 3 Observe level indicator to determine whether machine must be leveled prior to lifting load 4 Move boom attachment to 4 f...

Page 77: ...then extend boom slowly until load is just above area where it is to be placed Lower the boom until the load rests in position and the forks are free to retract Disengaging a Load Once the load has be...

Page 78: ...ions warrant Avoid lifting double tiered loads Make sure load is clear of any adjacent obstacles NEVER operate telehandler without a proper and legible capacity chart in the operator cab for the teleh...

Page 79: ...cause the telehandler to tip over The guide persons and operator must remain in constant communication verbal or hand and be in visual contact with the operator at all times Never place the guide per...

Page 80: ...5 Align load at the level load is to be placed then position boom slowly until load is just above area where it is to be placed Ensure that the guide persons and operator remain in constant communicat...

Page 81: ...2 Lower boom Lowest part of attachment should be approximately 12 in 30 cm above the ground 3 Fully tilt attachment back 4 Place protective shield over front bucket edge remove or reposition carriage...

Page 82: ...of boom Note User assumes all responsibility for choosing proper method of transportation and tie down devices making sure equipment used is capable of supporting weight of vehicle being transported...

Page 83: ...equipment to ensure the machine will be level when elevated The machine must remain level at all times while being lifted Ensure that the lifting device and equipment is adequately rated and suitable...

Page 84: ...Section 4 Operation 4 14 31200743 This Page Intentionally Left Blank...

Page 85: ...nd electrics If any of the above conditions are not met do not use the attachment The telehandler may not be equipped with the proper capacity chart or the attachment may not be approved for the model...

Page 86: ...1099613 X X X 1001102331 X X X Fork Pallet2x4x48in 50x100x1220mm 1001099458 X X X X Fork Lumber1 5x6x60in 38x150x1525mm 1001099457 X X X X Fork Block2x2x48in 50x50x1220mm 2340037 X X X X Fork Pallet45...

Page 87: ...1200743 ForkMountedHook 91565094 X X X 1001097205 X X X 2700118 X X X CouplerMountedHook 1170058 X X UniversalQuickCouplerAdapter 1001102332 X X X X Attachment Part Number Applicable Standard Quick Co...

Page 88: ...city is multiplied by the number of forks on the attachment if equipped up to the maximum capacity of the attachment Maximum capacity as indicated on the proper capacity chart See Approved Attachments...

Page 89: ...where the load is to be placed 5 On the capacity chart find the line for the height and follow it over to the distance 6 The number in the load zone where the two cross is the maximum capacity for th...

Page 90: ...rating condition OAL1771 XX XX XX XX XX XX XX XX XX XX X XX XX XX XX XX XX XX XX XXXX XXXX 0 10 20 30 40 50 60 70 B D A C E 1 XX XXX XX MAX XXXX XX XX XX XX XX XX XX XX XX X X X X X X X X X X X X XXX...

Page 91: ...PICK CARRY REQUIRES FIRM SURFACE WITH LOAD ON FORKS MAX TRAVEL SPEED XXKM H BOOM FULLY RETRACTED LIFTING STATIONARY REQUIRES FIRM SURFACE WITH LOAD ON FORKS SPECIFICATIONS FOR SAFE USE 1 TIRE SIZES XX...

Page 92: ...th various conditions the contractor may encounter and whether or not the load may be lifted Note This is a sample capacity chart only DO NOT use this chart use the one located in your operator cab Lo...

Page 93: ...Pin mechanical quick attach 6 Quick Attach attachment tilt control in cab see page 3 14 or 3 15 WARNING CRUSH HAZARD Always be certain that carriage or attachment is properly positioned on boom and is...

Page 94: ...forward to provide clearance Check to be sure lock pin and retainer pin are out 2 Align attachment pin with recess in attachment Raise boom slightly to engage attachment pin in recess 3 Tilt quick att...

Page 95: ...uick attach back to engage attachment 4 Press and hold switch 1 and button 2 at the same time move the joystick right to engage or left to disengage the quick attach 5 Raise boom to eye level and visu...

Page 96: ...in 5 Lock Pin Handle 6 Universal Quick Attach attachment tilt control in cab see page 3 14 or 3 15 WARNING CRUSH HAZARD Always be certain that carriage or attachment is properly positioned on boom and...

Page 97: ...to provide clearance Check to be sure lock pin handles and pins are pulled up 2 Align engaging edge with recess in attachment Raise boom slightly to engage edge in recess 3 Tilt quick attach back to e...

Page 98: ...Install attachment see page 5 9 or 5 12 2 Press and hold auxiliary hydraulic pressure relief switch 1 for two seconds to relieve pressure at both auxiliary fittings 2 3 Perform Shut Down Procedure on...

Page 99: ...rk locking bolt 3 Elevate attachment to approximately 5 ft 1 5 m and tilt carriage forward until fork heel is free from attachment 4 Stand at the side of the carriage To slide fork toward the center o...

Page 100: ...ons described within this section reference the Lift joystick pattern Refer to page 3 15 if using Loader joystick pattern NOTICE EQUIPMENT DAMAGE Some attachments may contact the front tires or machin...

Page 101: ...Section 5 Attachments and Hitches 5 17 31200743 This Page Intentionally Left Blank...

Page 102: ...om The tilt button 2 enables fork tilt While pressing and holding button move joystick left to tilt up While pressing and holding button move joystick right to tilt down Installation Procedure Refer t...

Page 103: ...ressing and holding button move joystick right to tilt down Installation Procedure Ensure carriage is properly installed Refer to Attachment Installation on page 5 9 Secure the fork mounted hook to th...

Page 104: ...f the boom The tilt button 2 enables fork tilt While pressing and holding button move joystick left to tilt up While pressing and holding button move joystick right to tilt down To Side Tilt The auxil...

Page 105: ...s a lever to pry material Excessive prying forces could damage forks or machine structure Do not attempt to lift loads that are attached or connected to another object WARNING CRUSH HAZARD Do not use...

Page 106: ...the boom The tilt button 2 enables fork tilt While pressing and holding button move joystick left to tilt up While pressing and holding button move joystick right to tilt down To Side Shift The auxil...

Page 107: ...s a lever to pry material Excessive prying forces could damage forks or machine structure Do not attempt to lift loads that are attached or connected to another object WARNING CRUSH HAZARD Do not use...

Page 108: ...tick left to tilt up While pressing and holding button move joystick right to tilt down Installation Procedure Refer to Attachment Installation on page 5 9 Operation Raise or lower boom to appropriate...

Page 109: ...aterial evenly within the bucket Bucket capacity charts are for evenly distributed loads only Do not use bucket as a lever to pry material Excessive prying forces could damage bucket or machine struct...

Page 110: ...utton 2 enables bucket tilt While pressing and holding button move joystick left to tilt up While pressing and holding button move joystick right to tilt down To open close grapple The auxiliary hydra...

Page 111: ...n grapple and tilt bucket down to dump load 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 Distr...

Page 112: ...ontrols lift lower and the extend retract movement of the boom The tilt button 2 enables coupler mounted hook tilt While pressing and holding button move joystick left to tilt up While pressing and ho...

Page 113: ...f the telehandler and hitch capacities Refer to page 9 8 for details Note Ensure hitch is in lowest position when towing trailer Speed and or load may need reduced if traveling on ground which is not...

Page 114: ...n 2 fully retracts 2 Align hitch mouth 3 and tow eye of trailer 3 Reverse machine toward trailer 4 After the tow eye contacts trigger 4 the pin and lever will be released 5 If equipped connect trailer...

Page 115: ...aximum combined weight of trailer and load 13 225 lb 6000 kg Maximum vertical load at hitch interface 3305 lb 1500 kg Connecting trailer for towing 1 Remove safety pin 1 and pull pin 2 from hitch 3 2...

Page 116: ...Maximum combined weight of trailer and load 26 450 lb 12 000 kg Maximum vertical load at hitch interface 5500 lb 2500 kg Connecting trailer for towing 1 Remove safety pin 1 and pull pin 2 from hitch 3...

Page 117: ...stem permits manual steering if engine or power assist feature fails however steering will be slow and will require much greater force DO NOT attempt to tow a telehandler that is loaded or the boom at...

Page 118: ...vidual basis Contact JLG Industries or the local Authorized Distributor for specific instructions Secure the telehandler using the following procedures 1 Clear the area around telehandler of all perso...

Page 119: ...M ENCLOSED CAB Inside Cab In an emergency the rear window can be used to exit the telehandler Remove the latch pin 1 The window is then free to swing open Outside Cab if equipped Remove the knob 2 sec...

Page 120: ...Section 6 Emergency Procedures 6 4 31200743 This Page Intentionally Left Blank...

Page 121: ...Lubrication 1 and Maintenance 2 Charts contain instructions that must be followed to keep this product in good operating condition The Operation Safety Manual and Service Manual contain more detailed...

Page 122: ...er cycle all functions several times to distribute lubricants Perform this maintenance procedure without attachment installed Apply a light coating of engine oil to all linkage pivot points Intervals...

Page 123: ...1 Check Wheel Lug Nut Torque LB FT Nm 50 1st Check Fuel Level 10 EVERY Additional Checks Section 8 Check Engine Oil Level Check Hydraulic Oil Level Check Tire Condition Pressure 50 EVERY Drain Fuel Wa...

Page 124: ...Box Oil Check Enclosed Cab Air Filter if equipped 250 EVERY Check Boom Wear Pads Lubrication Schedule Check Fan Belt Check Wheel End Oil Levels Check Axle Differential Oil Level Check Front Axle Drop...

Page 125: ...enance Schedule OAH2220 1000 EVERY Change Axle Differential Oil Change Wheel End Oil Change Transmission Filter Change Hydraulic Fluid Filters Check Hydraulic Tank Cap Change Front Axle Drop Box Oil C...

Page 126: ...Section 7 Lubrication and Maintenance 7 6 31200743 7 4 LUBRICATION SCHEDULES 250 Hour Lubrication Schedule OAL1980 250 EVERY...

Page 127: ...Section 7 Lubrication and Maintenance 7 7 31200743 This Page Intentionally Left Blank...

Page 128: ...Down Procedure on page 4 4 3 Turn fuel tank cap 2 and remove from filler neck 4 Add diesel fuel as needed 5 Replace fuel tank cap Note Replenish diesel fuel at end of each work shift to minimize cond...

Page 129: ...ator 1 Perform Shut Down Procedure on page 4 4 2 Open the engine cover 3 Loosen drain cock 3 on underside of fuel filter 4 and allow all water to drain into a glass until clear fuel is visible Tighten...

Page 130: ...ove 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 4 Replace dipstick 5 If oil is low remove oil fill cap 4 and add mot...

Page 131: ...frame The oil level should be visible in the gauge window 3 If hydraulic oil is low remove oil fill cap 6 from filler neck Add hydraulic fluid to bring oil up to the upper mark on the sight gauge 4 R...

Page 132: ...Any tears or rips ragged edges in the cord plies which exceeds 1 in 2 5 cm in any direction Any punctures which exceed 1 in 2 5 cm in diameter If a tire is damaged but within the above noted criteria...

Page 133: ...ours and after each wheel installation Note If machine is equipped with directional tire assemblies wheel and tire assemblies must be installed with directional tread pattern arrows facing in directio...

Page 134: ...m precleaner bowl 4 Replace precleaner bowl and secure cover 5 Open the engine cover 6 Locate air cleaner 2 and remove dust from vacuator valve 3 by squeezing bottom of valve to allow loose particles...

Page 135: ...nge or if primary element was found to be damaged If replacing inner safety element at this time carefully slide element out and replace with new element 7 Slide new primary element over inner safety...

Page 136: ...he engine cover 3 Check coolant level in surge tank 1 When coolant is hot the tank should be 1 2 to 3 4 full When coolant is cool bottle should be 1 4 to 1 2 full 4 If coolant is low allow fluid to co...

Page 137: ...Perform Shut Down Procedure on page 4 4 2 Remove the battery cover 3 Wearing eye protection visually inspect the battery 3 Check terminals for corrosion Replace battery if it has a cracked melted or...

Page 138: ...evel Check 1 Perform Shut Down Procedure on page 4 4 2 The brake fluid level should be visible in the reservoir 1 3 If brake fluid level is low add hydraulic fluid as needed Note All other work on the...

Page 139: ...hield Washer System if equipped A Windshield Washer Fluid Level Check 1 Perform Shut Down Procedure on page 4 4 2 The windshield washer fluid should be visible in the reservoir 2 3 If washer fluid lev...

Page 140: ...Section 7 Lubrication and Maintenance 7 20 31200743 This Page Intentionally Left Blank...

Page 141: ...505H A Load Stability Indicator System Test The Load Stability Indicator LSI is intended to continuously monitor the forward stability of the telehandler To check this feature perform the following 1...

Page 142: ...object must be used to test the Reverse Sensing System 4 Verify operation with no objects in detection zone No audible alarm 5 Verify operation when object is in range of approximately 9 to 15 ft 2 7...

Page 143: ...SAE 20W 50 24 122 5 50 Axle Differential and Wheel End Mobilfluid 424 10W 30 4 115 20 46 Mobilfluid LT 75W 80 40 0 40 20 API GL4 with LS Additives or API GL5 with LS Additives SAE90 SAE90LS 32 115 0 4...

Page 144: ...tra Low Sulfur S 15 mg kg Standard B5 Biodiesel Blend of 1 diesel and 2 diesel fuels winterized 2 Cold Weather B5 Biodiesel with Winter Conditioner Air Conditioning Refrigerant R 134 a Tetrafluoroetha...

Page 145: ...W 80 40 0 40 20 API GL4 with LS Additives or API GL5 with LS Additives SAE90 SAE90LS 32 115 0 46 80W 90 4 115 20 46 75W 90 40 115 40 46 75W 40 50 40 10 Hydraulic System Mobilfluid 424 10W 30 6 115 15...

Page 146: ...806 to Present including 0160076010 0160076011 0160076012 27 gal 103 L Reservoir Capacity to Full Mark Prior to SN 0160076806 excluding 0160076010 0160076011 0160076012 16 gal 61 L SN 0160076806 to Pr...

Page 147: ...s 12 00 x 16 5 Bias 12 Ply Pneumatic 80 psi 5 5 bar Foam Approx 220 lb 100 kg 14 00 x 17 5 Bias 10 Ply Pneumatic 70 psi 4 8 bar Foam Approx 220 lb 100 kg 10 50 x 18 0 Bias 16 Ply Pneumatic 87 psi 6 0...

Page 148: ...91 lb Maximum Forward Reach 11 ft 3 4 m Capacity at Maximum Forward Reach G5 18A Standard Quick Attach 1850 lb 839 kg Universal Quick Attach 1700 lb 771 kg 2505H CE Standard Quick Attach 800 kg 1764 l...

Page 149: ...achment G5 18A 12 500 lb 5670 kg 2505H CE 5670 kg 12 500 lb AUS 5738 kg 12 650 lb Distribution of Operating Weight no attachment boom level and fully retracted Front Axle G5 18A 5270 lb 2390 kg 2505H...

Page 150: ...se emission after maintenance and repair work all panels and other sound absorbing materials must be replaced in their original condition Do not modify the machine in such a manner as to increase nois...

Page 151: ...ions 5 5 Carriage w Forks 5 18 Chemical Hazards 1 14 Cooling System 9 4 Coupler Mounted Hook 5 28 D Decals ANSI 2 4 ISO 2 7 Dimensions 9 7 Disengaging a Load 4 7 Disengaging a Suspended Load 4 10 Driv...

Page 152: ...at 3 21 P Park Brake 3 4 Parking Procedure 3 5 Performance 9 6 Picking Up a Suspended Load 4 8 Pin Hitch CUNA C Italy 5 31 EEC Manual 5 32 Pinch Points and Crush Hazards 1 11 Placing a Load 4 7 Placin...

Page 153: ...6 1 Capacity 9 8 Transmission Control Lever 3 7 Transport Lifting 4 13 Tiedown 4 12 Transporting a Load 4 6 Transporting a Suspended Load 4 9 Travel Hazard 1 7 V Vibration 9 8 W Walk Around Inspection...

Page 154: ...Index 4 31200743...

Page 155: ...Inspection Maintenance and Repair Log Serial Number___________________________________ Date Comments Inspection Maintenance and Repair Log...

Page 156: ...Inspection Maintenance and Repair Log Date Comments...

Page 157: ...r rented units should not be included on this form Mfg Model ______________________________________________________________ Serial Number ___________________________________________________________ Pr...

Page 158: ......

Page 159: ...osed point thumb upward LOWER BOOM With either arm extended horizontally fingers closed point thumb downward MOVE SLOWLY Place one hand motionless in front of hand giving motion signal Raise load slow...

Page 160: ...rmany 49 0 421 69350 0 49 0 421 69350 45 Email german parts jlg com JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong 852 2639 5783 852 2639 5797 JLG Indus...

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