JLG G10-55A Operation & Safety Manual Download Page 1

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Operation & Safety

Manual

Original Instructions

Keep this manual with machine at all times.

An Oshkosh Corporation Company

Models

G10-55A
G12-55A

S/N 0160045636 & After including

0160045082, 0160045094,
0160045209, 0160045295,

0160045296, 0160045449

31200745

Revised

October 3, 2014

Summary of Contents for G10-55A

Page 1: ...tructions Keep this manual with machine at all times An Oshkosh Corporation Company Models G10 55A G12 55A S N 0160045636 After including 0160045082 0160045094 0160045209 0160045295 0160045296 0160045...

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

Page 3: ...Revision Log REVISION LOG April 27 2012 A Original Issue of Manual October 3 2014 B Revised pages 1 6 1 7 1 13 1 14 1 15 2 3 thru 2 7 3 19 4 10 5 2 5 9 5 11 5 12 5 16 5 17 5 18 6 2 7 4 thru 7 9 8 1 8...

Page 4: ...requires 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 v...

Page 5: ...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 Re...

Page 6: ...guration 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 Sulfur dec...

Page 7: ...sonnel 1 8 Driving Hazards on Slopes 1 9 Pinch Points and Crush Hazards 1 10 Fall Hazard 1 12 Chemical Hazards 1 13 1 4 ClearSky if equipped 1 14 Federal Communications Commission FCC Information for...

Page 8: ...tors 3 20 Section 4 Operation 4 1 Engine 4 1 Starting the Engine 4 1 Extreme Cold Weather Starting if equipped 4 2 Battery Boosted Starting 4 3 Normal Engine Operation 4 4 Shut Down Procedure 4 4 4 2...

Page 9: ...Adjusting Moving Forks 5 13 5 8 Attachment Operation 5 15 Carriage w Forks 5 16 Side Shift Carriage 5 17 Side Tilt Carriage 5 19 Swing Carriage 5 21 Dual Fork Positioning Carriage 5 23 Fork Extension...

Page 10: ...edules 7 8 50 Hour Lubrication Schedule 7 8 250 Hour Lubrication Schedule 7 10 1000 Hour Lubrication Schedule 7 11 7 5 Operator Maintenance Instructions 7 12 Fuel System 7 12 Air Intake System 7 14 En...

Page 11: ...dicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION indicates a potentiality hazardous situation which if not avoided may result in minor or...

Page 12: ...ctrical 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 co...

Page 13: ...lehandler Understand how to properly use the capacity charts located in cab DO NOT exceed rated lift capacity Be sure that the ground conditions are able to support the machine DO NOT raise boom unles...

Page 14: ...ications for proper fill ratio and pressure requirements for tires equipped with ballast Always wear the seat belt Keep head arms hands legs and all other body parts inside operator s cab at all times...

Page 15: ...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 loa...

Page 16: ...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 dire...

Page 17: ...200745 Load Falling Hazard Never suspend load from forks or other parts of carriage weldment Use only JLG approved lift points DO NOT burn or drill holes in fork s Forks must be centered under load an...

Page 18: ...ctices 1 8 31200745 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 a...

Page 19: ...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 20: ...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 21: ...fety Practices 1 11 31200745 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 22: ...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 23: ...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 24: ...echnician for help This device complies with Part 15 of the FCC Rules Operation is subject to the following two conditions 1 this device may not cause harmful interference and 2 this device must accep...

Page 25: ...ed cable loss and antenna gain must not exceed 7 5 dBi 850 band The combined cable loss and antenna gain must not exceed 2 5 dBi and total system output must not exceed 2 0W EIRP in the PCS 1900 band...

Page 26: ...Section 1 General Safety Practices 1 16 31200745 This Page Intentionally Left Blank...

Page 27: ...ty 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 hydrau...

Page 28: ...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 29: ...NGLISH 1001163210 ENGLISH FRENCH DO NOT use Ether or other high energy starting aids Engine equipped with Pre heating system ENGINE EXPLOSION could result in death or serious injury 1706300C ULTRA LOW...

Page 30: ...5498 CAPACITY CHARTS 91163028 REV B F N R 91163028 1706851 ENGLISH 1001163321 ENGLISH FRENCH 1706767 ENGLISH 1001163291 ENGLISH FRENCH 1706304 ENGLISH 1001163276 ENGLISH FRENCH 1001139578 ENGLISH 1001...

Page 31: ...3 ENGLISH FRENCH 1706302 ENGLISH 1001163223 ENGLISH FRENCH 1706302 ENGLISH 1001163223 ENGLISH FRENCH 1706302 ENGLISH 1001163223 ENGLISH FRENCH OY2661 1706302 ENGLISH 1001163223 ENGLISH FRENCH 4105262...

Page 32: ...1706288 1706284 1001092877 1706098 1706098 B 91503112 9150 3112 REV 1701640 1701640 1001092878 ENCLOSED CAB 1001092878 OPEN CAB 1001154575 D 1001139654 A S 15 mg kg 1001139654 IF EQUIPPED FOR LS 1001...

Page 33: ...91413061 1001131745A 1001131745 1001109053 1001139942 1001150157 1702300 1702300 1001145498 CAPACITY CHARTS 2 5 GPM 9 5 lpm MAX 1001109053 REV A 1001139069 4100181 4100181 1001130323 1001130323 REV A...

Page 34: ...Section 2 Pre Operation and Inspection 2 8 31200745 91553072 1706292 1706292 1706292 1706292 1706292 1706292 1706282 1706292 1706292 4105262 VIEW E E E VIEW F F E F F...

Page 35: ...Section 2 Pre Operation and Inspection 2 9 31200745 This Page Intentionally Left Blank...

Page 36: ...aks 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 and Lift Ti...

Page 37: ...loose or missing lug nuts Inspect for worn tread cuts tears or other discrepancies 10 Stabilizer Cylinder Pins secure hydraulic hoses undamaged not leaking 11 Rear Axle Steer cylinders undamaged not l...

Page 38: ...nal check 1 Service brake and parking brake operation 2 Forward and reverse travel 3 Each gear 4 Steering in both directions with engine at low idle steering lock to lock will not be reached Check in...

Page 39: ...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...

Page 40: ...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 and secure it in the latch...

Page 41: ...NDICATORS 3 1 GENERAL This section provides the necessary information needed to understand control functions Note The manufacturer has no direct control over machine application and operation The user...

Page 42: ...sponding direction Three steering modes are available See Steer Modes on page 3 16 4 Frame Level Indicator Enables the operator to determine the left to right level condition of the telehandler 5 Acce...

Page 43: ...ression Valve Depress button to relieve pressure in auxiliary hydraulic circuit 12 Accelerator Pedal Pressing down the pedal increases engine and hydraulic speed 13 Service Brake Pedal The further the...

Page 44: ...of attachments that require auxiliary electrics See Section 5 Attachments for approved attachments and control instructions 7 Quick Switch Switch if equipped Use in conjunction with the auxiliary hydr...

Page 45: ...Section 3 Controls and Indicators 3 5 31200745 This Page Intentionally Left Blank...

Page 46: ...on In ACC or RUN position voltage is available for all electrical functions Full clockwise rotation to START engages starter motor Counter clockwise rotation to OFF stops engine and removes voltage fr...

Page 47: ...transmission will not engage forward or reverse 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 A...

Page 48: ...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 re...

Page 49: ...smission 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 fo...

Page 50: ...eous boom functions move the joystick between quadrants For example moving the joystick forward and to the left will lower and retract boom simultaneously Attachment Function Tilt control is actuated...

Page 51: ...oystick right to rotate frame right A level indicator is located above the front cab window to permit operator to determine whether the telehandler frame is level WARNING TIP OVER HAZARD Always move b...

Page 52: ...2 31200745 Auxiliary Hydraulic Joystick The auxiliary hydraulic joystick 1 controls function of attachments that require hydraulic supply for operation See Section 5 Attachments for approved attachmen...

Page 53: ...sticks back to raise outriggers Use outriggers to increase stability and or load capacity and in leveling the telehandler Study capacity charts to determine maximum load capacities with and without ou...

Page 54: ...itch 5 Fan Speed Four position rotary switch 6 Air Conditioning Switch On Off switch 7 Air Louver Two individually adjustable air louvers 8 Recirculation Vent Open louvers when operating heat Close lo...

Page 55: ...ver must be manually returned to the center position to deactivate either turn signal The lever will not cancel automatically after a turn Parking Lights and Headlights Turn the twist grip 4 of the le...

Page 56: ...ice 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...

Page 57: ...nob to adjust suspension to the appropriate setting Turn clockwise to increase stiffness Turn counterclockwise to reduce stiffness 2 Fore Aft Pull up on handle to move seat fore and aft 3 Arm Rest Arm...

Page 58: ...tangled 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 th...

Page 59: ...s area and is functional when machine is moving in reverse direction No alarm when detection zone is clear of objects Pulsing alarm sounds when an object is in range of Reverse Sensing System Alarm in...

Page 60: ...m Use this indicator to determine the boom angle when using the capacity chart see Use of the Capacity Chart on page 5 5 The boom extension indicators 2 are located on the left side of the boom Use th...

Page 61: ...cool for two minutes before trying again Note If equipped for ULS Engine is equipped with starter lockout feature and may prevent starter engagement under certain conditions Fault code will appear on...

Page 62: ...es with a minimum rating of 15 Amps each 4 Allow heating components to operate a minimum of 12 hours prior to machine operation 5 Locate recirculation hoses stored behind seat in cab 6 Connect recircu...

Page 63: ...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 s...

Page 64: ...isor 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...

Page 65: ...f 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 en...

Page 66: ...3 Observe level indicator to determine whether machine must be leveled prior to lifting load Level machine with frame level joystick see page 3 11 or outrigger joysticks see page 3 13 4 Move boom atta...

Page 67: ...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 68: ...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 telehandl...

Page 69: ...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 persons between the suspended load and the telehandler...

Page 70: ...Chart on page 5 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 con...

Page 71: ...5 Do not tie down front of boom Note The user assumes all responsibility for choosing the proper method of transportation and tie down devices making sure the equipment used is capable of supporting...

Page 72: ...evice and 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...

Page 73: ...s 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 telehandle...

Page 74: ...in 1270 mm 1001108669 X X Fork Pallet 2 36x4x48 in 60x100x1220 mm 2340045 X X Fork Pallet 2 36x5x48 in 60x127x1220 mm 2340038 X X Fork Dual Taper 1 75x7x60 in 44x178x1524 mm 2340046 X X Fork Dual Tape...

Page 75: ...Section 5 Attachments 5 3 31200745 This Page Intentionally Left Blank...

Page 76: ...3 Total attachment capacity 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...

Page 77: ...two cross is the maximum capacity for this lift If the two cross at a division between zones the smaller number must be used The number in the load zone must be equal to or greater than the weight of...

Page 78: ...XXXXXX 30 50 XXXXXXXXXX X ANSI ITSDF B56 6 2005 X X X X L B S X X X X L B S L X X X X B S L X X X X B S X X X X B L S XXXX S LB 4 0 10 20 40 60 71 1 2 3 4 5 6 7 8 9 10 XXXX XX MAX XX XX XXXX XX MAX XX...

Page 79: ...y the proper capacity chart on telehandlers equipped with outriggers refer to the following icons which may be located on the capacity chart Use when lifting a load with outriggers up Use when lifting...

Page 80: ...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 Load Weight Distance Height OK to Lift 1 60...

Page 81: ...n mechanical quick switch 6 Quick Switch attachment tilt control in cab see page 3 10 WARNING CRUSH HAZARD Always be certain that carriage or attachment is properly positioned on boom and is secured b...

Page 82: ...s removed 2 Align attachment pin with recess in attachment Raise boom slightly to engage attachment pin in recess 3 Tilt quick switch forward to engage attachment 4 Lift retainer pin and insert lock p...

Page 83: ...nt pin with recess in attachment Raise boom slightly to engage attachment pin in recess 3 Check to be sure lock pin is disengaged Tilt quick switch forward to engage attachment 4 Press and hold quick...

Page 84: ...and return to step 2 6 If attachment is equipped connect auxiliary hydraulic hoses See Hydraulic Operated Attachment on page 5 12 Hydraulic Operated Attachment 1 Install attachment see page 5 9 2 Lowe...

Page 85: ...ent Installation on page 5 9 2 Elevate attachment to approximately 5 ft 1 5 m and tilt carriage forward until fork heel is free from attachment 3 Stand at the side of the carriage To slide fork toward...

Page 86: ...Section 5 Attachments 5 14 31200745 This Page Intentionally Left Blank...

Page 87: ...ttachment if it is equipped with a manual holder NOTICE EQUIPMENT DAMAGE Some attachments may contact the front tires or machine structure when the boom is retracted and the attachment is rotated Impr...

Page 88: ...ment of the boom The tilt switch 2 controls fork tilt Press left side of switch to tilt up Press right side of switch to tilt down Installation Procedure Refer to Attachment Installation on page 5 9 O...

Page 89: ...ls lift lower and extend retract movement of the boom The tilt roller switch 2 controls fork tilt Press roller switch down to tilt up Press roller switch up to tilt down To Side Shift The auxiliary hy...

Page 90: ...ver 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 side s...

Page 91: ...ft lower and extend retract movement of the boom The tilt switch 2 controls fork tilt Press left side of switch to tilt up Press right side of switch to tilt down To Side Tilt The auxiliary hydraulic...

Page 92: ...y and level carriage side to side Travel in accordance with the requirements set forth in Section 1 General Safety Practices Equipment Damage Precautions Do not use forks as a lever to pry material Ex...

Page 93: ...s lift lower and extend retract movement of the boom The tilt switch 2 controls fork tilt Press left side of switch to tilt up Press right side of switch to tilt down To Swing The auxiliary hydraulic...

Page 94: ...to lift loads that are attached or connected to another object WARNING CRUSH HAZARD Always level forks horizontally and telehandler frame before swinging load to side Swinging unlevel forks could caus...

Page 95: ...lift lower and extend retract movement of the boom The tilt switch 2 controls fork tilt Press left side of switch to tilt up Press right side of switch to tilt down To Fork Position The auxiliary hydr...

Page 96: ...ent Damage Precautions Do not use forks as 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 anothe...

Page 97: ...er load rating and length The joystick 1 controls lift lower and extend retract movement of the boom The tilt switch 2 controls fork tilt Press left side of switch to tilt up Press right side of switc...

Page 98: ...26 31200745 Operation Heavy part of load must be against carriage backrest Do not allow load center of gravity to be in front of tip of the supporting fork Do not pick up a load or pry materials with...

Page 99: ...er and extend retract movement of the boom The tilt switch 2 controls mast tilt Press left side of switch to tilt up Press right side of switch to tilt down To Raise Lower Mast The auxiliary hydraulic...

Page 100: ...al Safety Practices Use a signal person to assist in positioning of load if necessary Equipment Damage Precautions Do not use forks as a lever to pry material Excessive prying forces could damage fork...

Page 101: ...ract movement of the boom The tilt switch 2 controls mast tilt Press left side of switch to tilt up Press right side of switch to tilt down To Side Tilt Press Side Tilt Switch 5 located on dash panel...

Page 102: ...rks fully in mast and travel in accordance with the requirements set forth in Section 1 General Safety Practices Use a signal person to assist in positioning load if necessary Equipment Damage Precaut...

Page 103: ...ices The joystick 1 controls lift lower and extend retract movement of the boom The tilt switch 2 controls fork tilt Press left side of switch to tilt up Press right side of switch to tilt down Instal...

Page 104: ...Do not use with cubing or block forks Weight of fork mounted hook and rigging must be included as part of total load being lifted Do not use with mast carriage attachment Do not use fork mounted hook...

Page 105: ...Practices The joystick 1 controls lift lower and extend retract movement of the boom The tilt switch 2 controls truss boom tilt Press left side of switch to tilt up Press right side of switch to tilt...

Page 106: ...5 Operation Weight of rigging must be included as part of total load being lifted WARNING CRUSH HAZARD Maintain a minimum of three wraps of wire rope on the cable drum at all times Failure to comply c...

Page 107: ...ch to tilt up Press right side of switch to tilt down Installation Procedure Refer to Attachment Installation on page 5 9 Operation Raise or lower boom to appropriate height for loading material from...

Page 108: ...n 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 structure Do not attempt t...

Page 109: ...retract movement of the boom The tilt switch 2 controls grapple bucket tilt Press left side of switch to tilt up Press right side of switch to tilt down To Open Close Grapple The auxiliary hydraulic...

Page 110: ...ucket 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 Distribute material evenl...

Page 111: ...to installing and using a platform The joystick 1 controls lift lower and extend retract movement of the boom The tilt switch 2 controls platform tilt Press left side of switch to tilt up Press right...

Page 112: ...atform both side to side frame level and front to back attachment tilt 4 Keep area under platform free from personnel 5 When personnel are on platform the operator must remain seated in cab with perso...

Page 113: ...are not intended for trailer towing devices The steering system permits manual steering if engine or power assist feature fails however steering will be slow and will require much greater force DO NO...

Page 114: ...d telehandler of all personnel 2 Engage the parking brake Place the transmission control lever in NEUTRAL 3 Block all four wheels 4 Section off a large area under the boom with string or tape to restr...

Page 115: ...contain instructions that must be followed to keep this product in good operating condition The Operation Safety Manual and Service Manual contain more detailed service information with specific instr...

Page 116: ...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 in...

Page 117: ...Section 7 Lubrication and Maintenance 7 3 31200745 7 3 SERVICE AND MAINTENANCE SCHEDULE 10 1st 50 and 50 Hour Maintenance Schedule OAL2651...

Page 118: ...Section 7 Lubrication and Maintenance 7 4 31200745 1st 250 250 Hour Maintenance Schedule Check Spring Tension OY3570 Check Boom Extend Chains...

Page 119: ...Section 7 Lubrication and Maintenance 7 5 31200745 1st 500 500 1000 Hour Maintenance Schedule OY3580 Check Spring Tension Check Boom Retract Chains...

Page 120: ...Section 7 Lubrication and Maintenance 7 6 31200745 1500 2000 5000 Hour Maintenance Schedule OY3590 Change Hydraulic Fluid Filters...

Page 121: ...Section 7 Lubrication and Maintenance 7 7 31200745 This Page Intentionally Left Blank...

Page 122: ...Section 7 Lubrication and Maintenance 7 8 31200745 7 4 LUBRICATION SCHEDULES 50 Hour Lubrication Schedule Before S N 0160050017 OAL0450 50 EVERY...

Page 123: ...Section 7 Lubrication and Maintenance 7 9 31200745 S N 0160050017 After OAL3890...

Page 124: ...Section 7 Lubrication and Maintenance 7 10 31200745 250 Hour Lubrication Schedule OW1211 EVERY 250...

Page 125: ...Section 7 Lubrication and Maintenance 7 11 31200745 1000 Hour Lubrication Schedule OY2080 EVERY 1000...

Page 126: ...and perform Shut 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 and secure fuel tank cap Note Replenish diesel fuel at end of each...

Page 127: ...Procedure on page 4 4 2 Open the engine cover 3 Loosen drain cock 5 on underside of fuel filter 6 and allow all water to drain into a glass until clear fuel is visible 4 Tighten drain cock 5 Close and...

Page 128: ...r 1 and check restriction indicator 2 If red band is visible filter s must be replaced 3 Remove dust from vacuator valve 3 by squeezing bottom of valve to allow loose particles to fall out Note Only r...

Page 129: ...lean the interior of the air cleaner canister and vacuator valve 6 Replace inner safety element 7 after every third primary element change If replacing the inner safety element at this time carefully...

Page 130: ...check restriction indicator 2 If red band is visible filter s must be replaced 3 Remove dust from vacuator valve 3 by squeezing bottom of valve to allow loose particles to fall out Note Only remove ca...

Page 131: ...leaner canister and vacuator valve 5 Replace inner safety element 6 after every third primary element change If replacing the inner safety element at this time carefully slide the element out and repl...

Page 132: ...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 4 If oil is low remove oil fill cap 4 and add oil to bring oil...

Page 133: ...dure on page 4 4 3 Open the engine cover 4 Check level of hydraulic oil at the sight gauge 6 on the hydraulic tank 5 The oil level should be visible in the sight gauge 5 If hydraulic oil is low remove...

Page 134: ...de for replacement of the tire or tire assembly For polyurethane foam filled tires when any of the following are discovered measures must be taken to remove the product from service immediately Arrang...

Page 135: ...imensions equal to the original Approved for the application by the tire manufacturer including inflation pressure and maximum tire load Unless specifically approved by JLG do not replace a foam fille...

Page 136: ...tional tread pattern arrows facing in the direction of forward travel 1 Start all nuts by hand to prevent cross threading DO NOT use a lubricant on threads or nuts 2 Tighten lug nuts in an alternating...

Page 137: ...2 Check transmission oil level with engine at idle and oil at normal operating temperature 3 Open the engine cover 4 Remove the transmission dipstick 1 and check oil level The oil level should be with...

Page 138: ...tank 1 When coolant is hot bottle 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 cool 5 Remove surge tank cap 2 and add coolant as r...

Page 139: ...1 Perform Shut Down Procedure on page 4 4 2 Open the engine cover 3 Wearing eye protection visually inspect the batteries 1 Check terminals for corrosion Replace battery if it has a cracked melted or...

Page 140: ...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 141: ...to rear of unit while in reverse gear 1 Clear all people and or obstacles behind machine before performing Reverse Sensing System check 2 Start machine and depress and hold brake Place machine in rev...

Page 142: ...operation when object is in range of approximately 7 to 9 ft 2 1 to 2 7 m Produces pulsing audible alarm Produces pulsing audible alarm at a frequency of two per second 2 Hz 7 Verify operation when ob...

Page 143: ...Wheel End Mobilfluid 424 10W 30 0 104 20 40 Mobilfluid LT 75W 80 40 0 40 20 API GL4 with LS Additives or API GL5 with LS Additives SAE140 50 122 10 50 80W 140 85W 140 14 122 10 50 SAE90 SAE90LS 32 10...

Page 144: ...xle differential Fuel 2 Diesel Ultra 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 Compartment or Syst...

Page 145: ...0 API GL4 with LS Additives or API GL5 with LS Additives SAE140 50 122 10 50 80W 140 85W 140 14 122 10 50 SAE90 SAE90LS 32 104 0 40 80W 90 85W 90 4 104 20 40 75W 90 40 104 40 40 75W 40 50 40 10 Hydrau...

Page 146: ...gal 125 L Auxiliary Hydraulic Circuit Max Flow 10 gpm 37 9 lpm Transmission Capacity with Filter Change 22 0 qt 20 8L Transfer Case Capacity 1 8 qt 1 7 L Axles Differential Housing Capacity Front Axle...

Page 147: ...12 Ply G10 55A only Pneumatic 65 psi 4 5 bar Foam Approx 720 lb 327 kg 17 50 x 25 G 2 L 2 Bias Ply Traction 12 Ply Pneumatic 65 psi 4 0 bar Foam Approx 785 lb 356 kg 400 75 28 16 Ply Pneumatic 76 psi...

Page 148: ...ht 55 ft 16 8 m Capacity at Maximum Height Outriggers Engaged 5 000 lb 2268 kg Outriggers Not Engaged 4 000 lb 1814 kg Maximum Forward Reach 42 ft 12 8 m Capacity at Maximum Forward Reach Outriggers E...

Page 149: ...mm Overall Length less Forks 254 in 6452 mm Ground Clearance G10 55A 18 in 457 mm G12 55A 19 in 482 mm Turning Radius Over Tires 174 in 4420 mm Turning Radius at Forks 48 inch forks 24 inch on center...

Page 150: ...d 204 lb in 14 3 kg cm 17 50 x 25 Air Filled 161 lb in 11 3 kg cm Foam Filled 207 lb in 14 6 kg cm 400 75 28 Air Filled 123 lb in 8 6 kg cm Foam Filled 157 lb in 11 0 kg cm G12 55A 17 50 x 25 Air Fill...

Page 151: ...ity 5 4 Capacity Chart Example 5 8 Sample 5 6 Capacity Indicator Locations 5 5 Carriage w Forks 5 16 Chemical Hazards 1 13 Controls 3 2 D Dash Controls and Indicators 3 4 Decals 2 3 ANSI 2 3 ISO 2 6 D...

Page 152: ...Instructions 7 12 Operator Seat 3 17 Outrigger Joysticks 3 13 P Park Brake 3 7 Parking Lights 3 15 Parking Procedure 3 7 Performance 9 6 Personnel Work Platform Fork Mounted 5 39 Picking Up a Load 4 5...

Page 153: ...ion of Travel 3 8 Gear Selection 3 9 Transport Lifting 4 12 Tiedown 4 11 Transporting a Load 4 6 Transporting a Suspended Load 4 9 Travel Hazard 1 6 Truss Boom 5 33 Turn Signals 3 15 W Walk Around Ins...

Page 154: ...Index 4 31200745...

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: ...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: ...88 31 79 JLG Deutschland GmbH Max Planck Str 21 D 27721 Ritterhude lhlpohl Germany Phone 49 0 421 69 350 20 Fax 49 0 421 69 350 45 JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue...

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