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Manual
Keep this manual with machine at all times.
Models
534D-9
&
534D-10
S/N 0160003966 & After
31200169
Revised
January 14, 2009
CALIFORNIA PROPOSITION 65
BATTERY WARNING
Battery posts,
terminals and related
accessories contain
lead and lead 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 constituents
are known to the State of
California to cause cancer,
birth defects and other
reproductive harm.
Revision Log
Revision Log
REVISION LOG
31200169
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 1910.178.
Operators of this equipment must possess a valid, applicable drivers 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 Operation & Safety Manual
Telehandler Safety Manual (as required)
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.
31200169
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.
13224 Fountainhead Plaza
Hagerstown, MD 21742
USA
or Your Local JLG Office
(Addresses on back cover)
In USA
Toll Free: 1-877-JLG-SAFE (1-877-554-7233)
Outside USA
Phone:
+1-717-485-6591
E-mail
ProductSafety@JLG.com
31200169
31200169
Table of Contents
Table of Contents
TABLE OF CONTENTS
Revision Log
Read This First
Operator Qualifications ...................................................... b
Modifications ...................................................................... b
Other Publications Available .............................................. d
Table of Contents
Section 1 - General Safety Practices
1.1 Hazard Classification System ..............................................1-1
Safety Alert System and Safety Signal Words ................1-1
1.2 General Precautions ............................................................1-1
1.3 Operation Safety ..................................................................1-2
Electrical Hazards ...........................................................1-2
Tip Over Hazard..............................................................1-3
Travel Hazard .................................................................1-6
Load Falling Hazard........................................................1-7
Lifting Personnel .............................................................1-8
Driving Hazards on Slopes .............................................1-9
Pinch Points and Crush Hazards ..................................1-10
Fall Hazard....................................................................1-12
Chemical Hazards.........................................................1-13
Table of Contents
Outrigger Levers (534D-10).......................................... 3-10
Left Hand Lever (if equipped) ....................................... 3-11
Heater (if equipped)...................................................... 3-12
3.3 Operator Seat.................................................................... 3-13
Adjustments.................................................................. 3-13
Seat Belt ....................................................................... 3-15
3.4 Boom Angle and Extension Indicators .............................. 3-16
Section 4 - Operation
4.1 Engine ................................................................................. 4-1
Starting the Engine ......................................................... 4-1
Cold Weather Starting Aids ............................................ 4-2
Battery Boosted Starting................................................. 4-3
Normal Engine Operation ............................................... 4-4
Shut-Down Procedure .................................................... 4-4
4.2 Operating with a Non-Suspended Load .............................. 4-5
Lift Load Safely............................................................... 4-5
Picking Up a Load .......................................................... 4-5
Transporting a Load ....................................................... 4-6
Leveling Procedure......................................................... 4-6
Placing a Load................................................................ 4-7
Disengaging a Load........................................................ 4-7
4.3 Operating with a Suspended Load ...................................... 4-8
Lift Load Safely............................................................... 4-8
Picking Up a Suspended Load ....................................... 4-8
Transporting a Suspended Load .................................... 4-9
Leveling Procedure......................................................... 4-9
Placing a Suspended Load........................................... 4-10
Disengaging a Suspended Load .................................. 4-10
4.4 Loading and Securing for Transport.................................. 4-11
Tiedown ........................................................................ 4-11
Lifting ............................................................................ 4-12
Section 5 - Attachments
5.1
5.2
5.3
5.4
31200169
Table of Contents
5.7 Attachment Operation ........................................................5-16
Carriage w/Forks...........................................................5-18
Side Tilt Carriage ..........................................................5-20
Swing Carriage .............................................................5-22
Mast Carriage ...............................................................5-24
Mast Carriage w/Swing and Side Shift
(Before S/N 0160037689) .............................................5-26
Mast Carriage w/Side Tilt (S/N 0160037689 & After) ...5-28
Fork Mounted Hook (Before S/N 0160037689) ............5-30
Fork Mounted Hook (S/N 0160037689 & After) ............5-32
Truss Boom...................................................................5-34
Bucket ...........................................................................5-36
Grapple Bucket (S/N 0160037689 & After) ...................5-38
Boom Head-Mounted Winch
(Before S/N 0160037689) .............................................5-40
Personnel Work Platform (Before S/N 0160037689) ....5-41
Personnel Work Platform (S/N 0160037689 & After)....5-42
iii
Table of Contents
Section 8 - Additional Checks
Section 9 - Specifications
9.1 Product Specifications......................................................... 9-1
Fluid and Lubrication Capacities .................................... 9-1
Tires................................................................................ 9-2
Performance ................................................................... 9-3
Dimensions..................................................................... 9-4
Index
Inspection, Maintenance and Repair Log
iv
31200169
DANGER
OW0010
WARNING
OW0021
CAUTION
OW0031
1.2
GENERAL PRECAUTIONS
WARNING
Before operation, read and 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.
31200169
1-1
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.
Follow employer, local and governmental regulations for clearance from
powerlines.
1-2
31200169
OW0050
Never use an attachment without the appropriate JLG approved capacity chart
installed on the telehandler.
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.
OW0080
DO NOT raise boom unless frame is level (0 degrees), unless otherwise noted on
capacity chart.
4 FT
(1,2 M)
OW0100
31200169
1-3
OH2291
MAINTAIN proper tire pressure at all times. If proper tire pressures are not
maintained, this machine could tip over.
Refer to manufacturers specifications for proper fill ratio and pressure
requirements for tires equipped with ballast.
OH20911
OH2221
1-4
31200169
OW0060
Suspended Load
OW0150
31200169
1-5
OX0650
Steering characteristics differ between steer modes. Identify the steer mode
settings of the telehandler being operated.
Ensure that adequate clearance is provided between both rear tail swing and
front fork swing.
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.
When driving in high speed, use only front wheel steer (if steering modes are
selectable).
1-6
31200169
OW0130
31200169
1-7
OW0170
When lifting personnel, USE ONLY a JLG approved personnel work platform,
with proper capacity chart displayed in the cab.
OW0190
1-8
31200169
OW0200
31200169
1-9
OW0210
OW0220
OW0230
1-10
31200169
OW0240
OW0250
OW0260
OW0960
31200169
1-11
OW0280
Enter using the proper hand holds and steps provided. Always maintain 3-point
contact when mounting or dismounting. Never grab control levers or steering
wheel when mounting or dismounting the machine.
DO NOT get off the machine until the shutdown procedure on page 4-4 has been
performed.
OW0290
DO NOT carry riders. Riders could fall off machine causing death or serious
injury.
1-12
31200169
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.
31200169
1-13
1-14
31200169
WARNING
FALL HAZARD. Use extreme caution when checking items beyond your normal
reach. Use an approved ladder.
The pre-operation check and inspection, performed at beginning of each work shift
or at each change of operator, should include the following:
1. Cleanliness - Check all surfaces for leakage (oil, fuel or battery fluid) or foreign
objects. Report any leakage to the proper maintenance personnel.
2. Structure - Inspect the machine structure for dents, damage, weld or parent
metal cracks or other discrepancies.
OAH1000
WELD CRACK
3. Safety Decals - Ensure all safety decals are legible and in place. Clean or
replace as required. See page 2-3 for details.
4. Operation and Safety Manuals - Operation & Safety Manual and AEM Safety
Manual (as required) are located in cab manual holder.
5. Walk-Around Inspection - See page 2-6 for details.
6. Fluid Levels - Check fluids, including fuel, hydraulic oil, engine oil and coolant.
When adding fluids, refer to Section 7 - Lubrication and Maintenance and
Section 9 - Specifications to determine proper type and intervals. 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.
7. Attachments/Accessories - Ensure correct capacity charts are installed on
the telehandler. If provided, reference the Operation & Safety Manual of each
attachment or accessory installed for specific inspection, operation and
maintenance instructions.
31200169
2-1
WARNING
If telehandler does not operate properly, immediately bring machine to a stop,
lower boom and attachment to ground and stop the engine. Determine cause and
correct before continued use.
2-2
31200169
SAFETY DECALS
Ensure all DANGER, WARNING, CAUTION and instructional decals and proper
capacity charts are legible and in place. Clean and replace as required.
2-FRONT
UB
T OR Q
UE
Model
Year of Manufacture
Serial Number
Refer to load capacity chart for truck with attachment, and individual load ratings stamped
on forks, if equipped. Use lowest capacity of all rattings.
As released from factory this truck meets design specifications in ASME B56.6-2002 Part III
One or more of the following patents may apply to this truck: U.S. Nos. 4,954,041
5,639,119 5,813,697 5,230,399 5,052,532. Other patents pending.
6,349,969
1705882
Manufactured by
JLG Industries Inc.
McConnellsburg, PA
17233-9533 USA
9114-3283
1705881
1705882
(S/N 0160003966 (S/N 0160034838
& After)
thru 0160034816)
91143283
91143282
91303047
9130-3047
90553028
000850
91164094
2-FRONT
90553027
80603022
9055-3027 REV. A
91343073
JLG HANDLER
SERVICE INSTRUCTIONS
FOR: 534D-9, 534D-10
8060-3022
SERVICE INTERVALS
DAILY
OR
10 HRS
WEEKLY
OR
50 HRS
EVERY
5WKS OR
250 HRS
3 MO.
OR
500 HRS
6 MO.
OR
1000 HRS
ANNUALLY
OR
1500 HRS
DIESEL ENGINE
AIR CLEANER ELEMENTS- - - - - - - - - - - - - - - * * - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - FUEL FILTERS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - CHANGE - - - - - - - - - - - OIL FILTER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - CHANGE - - - - - - - - - - - - - - - - - - OIL (12 QT.) - - - - - - - - - - - - - - - - - - - - - - CHECK - - - - - - CHANGE - - - - - - - - - - - - - - - - - - DIESEL FUEL (38 GAL.) - - - - - - - - - - - - - - - FILL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - HYDRAULIC SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - OIL (47 GAL.) - - - - - - - - - - - - - - - - - - - - - CHECK - - - - - - - - - - - - INSPECT - - - - - - CHANGE
FILTERS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - CHANGE
HYD.TANK BREATHER/FILTER CAP - - - - - - - - - - - - - - - - - - -
TYPE OR
EQUIVALENT
CHECK - - - - - - CHANGE - - - - - -
FRONT AXLE
(5 GAL) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - CHECK - - - - - - - - - - - - - - - - - - -
MOBIL 424
MOBIL 424
WHEEL NUT TORQUE-350/400 FT-LBS - - - - - - - - - - - - - - - - - - - - - - - - TORQUE - - - - - - - - - - - BATTERY & TERMINALS - - - - - - - - - - - - - - - - - - - - CHECK - - - - - - - - - - - - - - - - - - - - - - - - RADIATOR
3 GAL. WATER
3 GAL ANTI-FREEZE - - - - - - - - - - - - - - - - - - - - - - - CHECK - - - - - - - - - - - - - - - - - - - - - - - - TIRES: 13.00x24(12 PLY) 65 PSI- - - - - - - - - - - - - - - - CHECK - - - - - - - - - - - - - - - - - - - - - - - - TIRES: 14.00x24(12 PLY) 65 PSI- - - - - - - - - - - - - - - - CHECK - - - - - - - - - - - - - - - - - - - - - - - - TIRES: RADIAL 70 PSI - - - - - - - - - - - - - - - - - - - - CHECK - - - - - - - - - - - - - - - - - - - - - - - - CYLINDER FITTINGS EACH END - - - - - - - - - - - - - - - GREASE - - - - - - - - - - - - - - - - - - - - - - - - -
ETHYLENE GLYCOL
ANTI-FREEZE
MYSTIK TETRIMOLY
REAR AXLE (12) FITTINGS - - - - - - - - - - - - - - - - - - - GREASE - - - - - - - - - - - - - - - - - - - - - - - - FRONT AXLE PIVOT (2) FITTINGS - - - - - - - - - - - - - - GREASE - - - - - - - - - - - - - - - - - - - - - - - - ALL BEARINGS PADS - - - - - - - - - - - - - - - - - - - - - - - - - - - - GREASE - - - - - - - - - - - - - - - - - - -
MYSTIK TETRIMOLY
FRONT BOTTOM BEARING PADS - - - - - - - - - - - - - - GREASE CHECK - - - - - - - - - - - - - - - - - - BOOM PIVOT (2) FITTINGS- - - - - - - - - - - - - - - - - - - GREASE - - - - - - - - - - - - - - - - - - - - - - - - HEAD PIN (2) FITTINGS - - - - - - - - - - - - - - - - - - - - - GREASE - - - - - - - - - - - - - - - - - - - - - - - - BOOM SHEAVES (3) FITTINGS - - - - - - - - - - - - - - - - GREASE - - - - - - - - - - - - - - - - - - - - - - - - QUICK SWITCH (1) FITTING - - - - - - - - - - - - - - - - - - GREASE - - - - - - - - - - - - - - - - - - - - - - - - RETRACT & EXTEND CABLE- - - - - - - - - - - - - - - - - - - - - - - - CHECK - - - - - - - - - - - - - - - - - - SEE OPERATOR & MAINTENANCE MANUAL
MYSTIK TETRIMOLY
MYSTIK TETRIMOLY
MYSTIK TETRIMOLY
MYSTIK TETRIMOLY
MYSTIK TETRIMOLY
MYSTIK TETRIMOLY
MYSTIK TETRIMOLY
OX0113
THIS CHART MUST BE USED IN CONJUNCTION WITH SERVICE MANUAL AND RECOMMENDED PROCEDURE.
*
**
9134-3073 REV -
VIEW A-A
31200169
2-3
91163130
HYDRAULIC
OIL LEVEL
91143282
91143281
FULL
91143285
(BEFORE
91143284 S/N 0160035983)
JUMP STARTING INSTRUCTIONS
ADD
STAY CLEAR OF PINCH POINT AREA
ANYTIME ENGINE IS RUNNING.
BEING IN PINCH POINT AREA COULD
CAUSE SERIOUS INJURY OR DEATH.
9114-3282
9114-3280
9114-3283
9114-3285
9116-3130
91143280
(BEFORE
S/N 0160027138)
EXHAUST SYSTEMS CAN BE HOT.
KEEP AWAY FROM EXHAUST SYSTEM WHEN HOT.
HOT EXHAUST COMPONENTS CAN CAUSE
SEVERE BURNS.
9114-3280
4-LEFT
UB
T OR Q
UE
91143288
(BEFORE
S/N 0160035983)
91083492
(BEFORE
S/N 0160035983)
91143286
Genuine Parts
91143282
STAY CLEAR OF PINCH POINT AREA
ANYTIME ENGINE IS RUNNING.
BEING IN PINCH POINT AREA COULD
CAUSE SERIOUS INJURY OR DEATH.
HYDRAULIC SYSTEM
9114-3282
91143162
TEST PORTS
IMPLEMENT
PRESSURE
IMPLEMENT
PRESSURE
5-TOP
5-TOP
9114-3162
COOLING SYSTEM
IS PRESSURIZED.
REMOVE CAP SLOWLY.
HOT FLUID CAN
CAUSE BURNS.
8060-3026
80603026
1706300
(S/N 0160035983
& AFTER)
91143182
9114-3182
91323030
FUEL
TEMP
80
OIL
240
16
100
10
VOLTS
-
ON
OFF
QUARTZ
DRIVE
4X4
ON
0 0 0 0 0 0
9134-3016
OFF
ALT
4X2
91343016
9116-3184
9103-3089
91163028
2-4
SWITCH LOCATED
ON FLOOR. SWITCH
HYDRAULICALLY
LOCKS FRONT AND
REAR WHEELS
TOGETHER FOR
INCREASED TRACTION.
DO NOT ENGAGE
WHEN WHEELS ARE
IN MOTION OR
ON IMPROVED
SURFACES. MACHINE
MUST BE IN 4
WHEEL DRIVE.
9108-3314
ACC
OFF
CAPACITY
CHARTS
RUN
START
MACHINE MUST BE
IN NEUTRAL AND
PARK BRAKE ON TO START
91083314
91143120
(BEFORE
S/N 0160035983)
9103-3089
91033089
OX0582
31200169
80603037
50 60
70 80
4105262
40
20
-10 0 10 30
9114-3282
PINCH POINT
KEEP OUT
8060-3037-A
8060-3037-A
50
60
70
80
80603037
PINCH POINT
KEEP OUT
40
-10
10
20
30
91143290
A
80603037
91553072
PINCH POINT
KEEP OUT
REACHING INTO BOOM
HOLES AND OTHER PINCH
POINTS CAN CAUSE
SERIOUS INJURY
OR DEATH.
8060-3037-A
80603037
80603037
PINCH POINT
KEEP OUT
PINCH POINT
KEEP OUT
8060-3037-A
8060-3037-A
90553026
READ AND UNDERSTAND THE FOLLOWING PRIOR TO LIFTING PERSONNEL.
WHEN LIFTING PERSONNEL USE ONLY A GRADALL MANUFACTURED
PERSONNEL WORK PLATFORM.
ALL PERSONNEL IN PLATFORM MUST WEAR A FULL BODY HARNESS WITH
LANYARD ATTACHED TO A DESIGNATED ANCHORAGE POINT.
READ AND UNDERSTAND PERSONNEL WORK PLATFORM USER'S MANUAL
BEFORE OCCUPYING PERSONNEL WORK PLATFORM.
FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY OR DEATH.
9055-3026 REV. A
80603037
PINCH POINT
KEEP OUT
REACHING INTO BOOM
HOLES AND OTHER PINCH
POINTS CAN CAUSE
SERIOUS INJURY
OR DEATH.
8060-3037-A
VIEW B-B
OX0590
VIEW A-A
31200169
2-5
WALK-AROUND INSPECTION
18
17
3
16
15
14
13
5
6
12
11
8
9
10
OX0123
Begin your walk-around inspection at item 1, as noted below. Continue to your right
(counterclockwise when viewed from top) checking each item in sequence.
INSPECTION NOTE: On all components, make sure there are no loose or missing
parts, that they are securely fastened and no visible leaks or excessive wear exists
in addition to any other criteria mentioned. Inspect all structural members including
attachment for cracks, excessive corrosion and other damage.
1. Boom Sections and Lift, Tilt, Extend/Retract, Compensating (Slave) Cylinders Check front, top, side and rear wear pads for presence of grease.
Pivot pins secure; hydraulic hoses undamaged, not leaking.
2. Left Outrigger (534D-10) - Pins secure; hydraulic hoses and cylinder
undamaged, not leaking.
3. Front Axle - Pivot pins secure; hydraulic hoses undamaged, not leaking.
2-6
31200169
31200169
2-7
Warm-Up Check
During warm-up period, check:
1. Heater, defroster and windshield wiper (if equipped).
2. Check all lighting systems (if equipped) for proper operation.
3. Voltmeter should show 13.5 to 14 volts.
4. Adjust mirror(s) for maximum visibility.
WARNING
CUT/CRUSH/BURN HAZARD. Keep engine cover closed while engine is running
except when checking hydraulic filter condition indicator.
Operational Check
When engine 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.
4. Horn and back-up alarm. Must be audible from inside operators cab with engine
running.
5. All joystick functions - operate smoothly and correctly.
6. Perform any additional checks described in Section 8.
7. Hydraulic filter condition indicator.
2-8
31200169
OPERATOR 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.
31200169
2-9
WINDOWS
3
4
2
1
OAL0011
2-10
31200169
GENERAL
NOTICE
EQUIPMENT DAMAGE. When a red light illuminates, immediately bring machine
to a stop, lower boom and attachment to ground and stop the engine. Determine
cause and correct before continued use.
31200169
3-1
CONTROLS
3
2
VIEW A-A
A
A
FUEL
F
E
TEMP
100
12
80 OIL
0
16
240
10
VOLTS
-
QUARTZ
0 0 0 0 0 0
UP
9136-30
8
7 13 6
10
11
OX0362
3-2
31200169
4 6
AUXILIARY ELECTRICS
CONTROL
SIDE SHIFT
SWING
MAST
ONLY ONE FUNCTION CAN
BE ACTIVE AT A TIME
F
FUEL
80
OIL
E
240
TEMP
0
16
VOLTS
-
100
10
HEATER
ON
QUARTZ
OFF
SHUTDWN
OVERRIDE
ON
OFF
PARK
BRAKE
DRIVE
4X4
ON
0 0 0 0 0 0
OFF
ALT
4X2
7 1 11 10 9
OX0034
31200169
3-3
19
16 13 14
FUEL
E
240
TEMP
100
15 23 17
100
OIL
0
16
VOLTS
10
HEATER
DIAG.LIGHT
WAIT-TO-START
LIGHT
ON
OFF
PARK
BRAKE
ON
ENG.
SHUTDOWN
LIGHT
DRIVE
4X4
1/10
OFF
ALT
4X2
18 12 22 21 20
OX0621
3-4
31200169
FUEL
TEMP
80
E
0
240 16
100
10
OIL
VOLTS
+
QUARTZ
ACC
OFF
0 0 0 0 0 0
RUN
START
OX0072
31200169
3-5
FUEL
TEMP
80
E
0
240 16
100
10
OIL
VOLTS
-
PARK
BRAKE
ON
QUARTZ
DRIVE
4X4
PARK
BRAKE
ON
OFF
0 0 0 0 0 0
OFF
4X2
PARK
BRAKE
ON
OFF
OX0043
Park brake switch controls the application and release of the park brake. Indicator
light (3) illuminates to indicate brake is applied.
With the engine running and the park brake switch in "OFF" position (1), park
brakes are disengaged.
With switch in "ON" position (2), park brake is engaged and transmission will not
engage forward or reverse.
WARNING
MACHINE ROLL-AWAY HAZARD. Always move park brake switch to "ON"
position, lower boom to ground and stop engine before leaving cab.
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. 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 4-4.
3-6
31200169
4
F
OX0083
2-FRONT
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.
31200169
3-7
IF EQUIPPED
OX0060
The boom joystick (1) controls the boom and attachment tilt (if equipped) 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.
Attachment Tilt (if equipped)
Tilt control is actuated by the switch (2).
Depress the rear of the switch to tilt up; depress the front of switch to tilt down.
WARNING
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.
3-8
31200169
ATTACHMENT
TILT
3
4
FRAME
LEVEL
AUXILIARY
HYDRAULICS
OX0660
The right hand levers control attachment tilt, frame level or auxiliary hydraulics.
Attachment Tilt (if equipped)
The attachment tilt lever (3) controls attachment tilt.
Move lever forward to tilt down; move lever back to tilt up.
Frame Level (if equipped)
The frame level lever (4) controls the left to right frame level.
Move lever forward to rotate frame left, move lever back 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 boom as low as possible while allowing for
best visibility of right hand mirror before leveling frame. Attempting to level
machine with boom raised could cause it to tip over.
31200169
3-9
2
1
OX0492
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. Always ensure surface can support telehandler and load.
3-10
31200169
AUXILIARY
HYDRAULICS
FUEL
F
E
TEMP
80 OIL
0
16
240
100
10
VOLTS
-
QUARTZ
DRIVE
4X4
PARK
BRAKE
ON
0 0 0 0 0 0
OFF
FRAME
LEVEL
ALT
4X2
9136-30
3
ATTACHMENT
TILT
OX0222
The left hand lever (3) controls auxiliary hydraulics, frame level, or attachment tilt.
Auxiliary Hydraulics (if equipped)
Controls function of attachments that require hydraulic supply for operation. See
Section 5 - Attachments for approved attachments and control instructions.
Frame Level (if equipped)
Move lever left to rotate frame left, move lever right to rotate frame right.
A level indicator is located in the upper front window frame to permit operator to
determine whether the telehandler frame is level.
WARNING
TIP OVER HAZARD. Always move boom as low as possible while allowing for
best visibility of right hand mirror before leveling frame. Attempting to level
machine with boom raised could cause it to tip over.
31200169
3-11
2
F
FUEL
80
OIL
E
240
TEMP
0
16
VOLTS
-
100
10
HEATER
ON
QUARTZ
OFF
PARK
BRAKE
DRIVE
4X4
ON
0 0 0 0 0 0
OFF
ALT
4X2
OX0234
1. Defroster Fan: Two speed fan. Press fan switch down for slow speed; press
switch up for fast speed. Return switch to middle position to turn off.
2. Heater Fan Switch: On/Off switch.
3-12
31200169
OPERATOR SEAT
Adjustments
Prior to starting engine adjust seat for position and comfort.
Before S/N 0160016100
1
OX0013
31200169
3-13
3
4
1
2
OW0480
3-14
31200169
OH20912
31200169
3-15
40
20
-10 10 30
OW1220
The boom angle indicator (1) is located on the left side of the boom. Use this
indicator to determine the boom angle when using the capacity chart (see Use
of the Capacity Chart on page 5-4).
Boom extension indicators (2) are located on the left side of the boom. Use these
indicators to determine boom extension when using the capacity chart (see Use
of the Capacity Chart on page 5-4).
3-16
31200169
Section 4 - Operation
SECTION 4 - OPERATION
4.1
ENGINE
Note: Engine will not start unless transmission control lever is in Neutral and park
brake switch 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.
31200169
4-1
Section 4 - Operation
Cold Weather Starting Aids
John Deere Engine
JLG approved starting aids employ ether. If your telehandler is equipped with an
ether starting aid, the following applies:
Injection of ether is triggered by temperature sensor located on engine.
At start-up, temperature sensor on engine will detect if ether is needed. Follow
normal start-up procedure.
Ether will be automatically injected if needed, to keep engine running.
A second battery is added for additional cold-cranking capacity.
WARNING
ENGINE EXPLOSION. If your telehandler is equipped with a cold start aid, do
not spray additional ether into air cleaner. If machine is not equipped with cold
start aid, follow instructions listed in the engine manual supplied with the
telehandler.
Cummins Engine
Cummins engines are equipped with preheat for cold weather starting. Refer to
Starting the Engine on page 4-1 for cold weather starting procedure.
WARNING
ENGINE EXPLOSION. Do not use ether for cold weather starting.
4-2
31200169
Section 4 - Operation
Battery Boosted Starting
OW0530
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.
31200169
4-3
Section 4 - Operation
Normal Engine Operation
Observe instrument panel 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. Block wheels (if necessary).
4-4
31200169
Section 4 - Operation
4.2
WARNING
TIP OVER HAZARD. Exceeding lift capacity of the telehandler could damage the
equipment and/or cause tip over.
Know the rated load capacities (see Section 5) of the telehandler to determine
the operating range in which you can safely lift, transport and place a load.
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 5-15.
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 cab for the telehandler/attachment combination you are using.
31200169
4-5
Section 4 - Operation
Transporting a Load
OW0540
After engaging the load and resting it against the backrest, tilt the load back to
position it for travel. Travel in accordance with the requirements set forth in Section
1 - General Safety Practices and Section 5 - Attachments.
Leveling Procedure
1. Position machine in best location to lift or place load.
2. Apply parking brake and move transmission control lever to NEUTRAL.
3. Move boom/attachment to 4 ft (1,2 m) off ground.
(AUS - Move boom so forks are no more than 11.8 in (300 mm) above ground
surface.)
4. Observe level indicator to determine whether machine must be leveled prior to
lifting load. Level machine with frame level joystick (see page 3-9 or page 3-11)
or if equipped, outrigger joysticks (see page 3-10).
4-6
31200169
Section 4 - Operation
Placing a Load
Before placing any load be sure that:
The landing point can safely support the weight of the load.
The landing point is level; front to back and side to side.
Use the capacity chart to determine safe boom extension range. See Use of the
Capacity Chart on page 5-4.
Align forks at the level load is to be placed, 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 been placed safely at the landing point, proceed as follows:
1. With the forks free from the weight of the load, the boom can be retracted
and/or the telehandler can be backed away from under the load if surface will
not change level condition of telehandler.
2. Lower the carriage.
3. The telehandler can now be driven from the landing location to continue work.
31200169
4-7
Section 4 - Operation
4.3
WARNING
TIP OVER HAZARD. Exceeding lift capacity of the telehandler could damage the
equipment and/or cause tip over.
Know the rated load capacities (refer to Section 5) of the telehandler to
determine the operating range in which you can safely lift, transport and place a
load.
4-8
31200169
Section 4 - Operation
Transporting a Suspended Load
OZ3160
OW0130
Leveling Procedure
1. Position machine in best location to lift or place load.
2. Apply parking brake and move transmission control lever to NEUTRAL.
3. Move boom so load is no more than 11.8 in (300 mm) above ground surface
and boom/or boom is raised no more than 45.
4. Observe level indicator to determine whether machine must be leveled prior to
lifting load. Level machine with frame level joystick (see page 3-9 or page 3-11)
or if equipped, outrigger joysticks (see page 3-10).
The telehandler is designed to permit leveling the main frame 8 to left or right to
compensate for uneven ground conditions.
31200169
4-9
Section 4 - Operation
Placing a Suspended Load
Before placing any load be sure that:
The landing point can safely support the weight of the load.
The landing point is level; front to back and side to side.
Use the capacity chart to determine safe boom extension range. See Use of the
Capacity Chart on page 5-4.
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 men and operator remain in constant communication
(verbal or hand) when placing the load.
4-10
31200169
Section 4 - Operation
4.4
OX0670
Tiedown
1. Level the telehandler prior to loading.
2. Using a spotter, load the telehandler with boom as low as possible.
3. Once loaded, apply parking brake and lower boom until boom or attachment is
resting on deck. Move all controls to Neutral, stop engine and remove ignition
key.
4. Secure machine to deck by passing chains through the designated tie down
points as shown in the figure.
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 the weight of the vehicle being transported and that all manufacturers
instructions and warnings, regulations and safety rules of their employer, the
Department of Transportation and/or any other local, state or federal/provincial laws
are followed.
WARNING
TELEHANDLER SLIDE HAZARD. Before loading telehandler for transport,
make sure deck, ramps and telehandler wheels are free of mud, snow and ice.
Failure to do so could cause telehandler to slide.
31200169
4-11
Section 4 - Operation
Lifting
When lifting machine, it is very important that the lifting device and equipment is
attached only to designated lifting points. If machine is not equipped with lifting
lugs contact JLG Product Safety for information.
Make adjustments to the lifting device 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 suitable for
the intended purpose. See Section 9 - Specifications for machine weight.
Remove all loose items from machine prior to lifting.
Lift machine with smooth, even motion. Set machine down gently. Avoid quick or
sudden motions that could cause shock loads to machine and/or lifting devices.
4-12
31200169
Section 5 - Attachments
SECTION 5 - ATTACHMENTS
5.1
APPROVED ATTACHMENTS
To determine if an attachment is approved for use on the specific telehandler you are
using, perform the following prior to installation.
Before S/N 0160037689
The attachment model/option number on the attachment identification plate must
match the attachment number on a capacity chart located in the operator cab.
The model on the capacity chart must match the model telehandler being used.
The load center of the fork (if equipped) must match the load center as indicated
on the capacity chart.
Hydraulically powered attachments must only be used on machines equipped
with auxiliary hydraulics.
Hydraulically powered attachments that require auxiliary electrics must only be
used on machines equipped with auxiliary hydraulics and electrics.
S/N 0160037689 & After
The attachment type, weight, dimensions and load center must be equal to or
less than the data shown on a capacity chart located in the operator cab.
The model on the capacity chart must match the model telehandler being used.
Hydraulically powered attachments must only be used on machines equipped
with auxiliary hydraulics.
Hydraulically powered attachments that require auxiliary electrics must only be
used on machines equipped with auxiliary hydraulics and 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 telehandler being used. Contact JLG or a local
distributor for further information.
31200169
5-1
Section 5 - Attachments
5.2
UNAPPROVED ATTACHMENTS
WARNING
Use only approved attachments. Attachments which have not been approved for
use with your telehandler could cause machine damage or an accident.
5-2
31200169
Section 5 - Attachments
5.3
TELEHANDLER/ATTACHMENT/FORK CAPACITY
1
3
2
OW0550
Prior to installing the attachment verify it is approved and the telehandler is equipped
with the proper capacity chart. See Approved Attachments on page 5-1.
To determine the maximum capacity of the telehandler and attachment, use the
smallest of the following capacities:
Capacity stamped on the attachment identification plate (1).
Fork capacities and load centers are stamped on the side of each fork (2)
(if equipped). This rating specifies the maximum load capacity that the individual
fork can safely carry at the maximum load center (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. See Approved
Attachments on page 5-1.
When the load rating of the telehandler differs from the capacity of the forks or
attachment, the lower value becomes the overall load capacity.
Use the proper capacity chart to determine maximum capacity at various machine
configurations. Lifting and placing a load may require use of more than one capacity
chart based on machine configuration.
Other than block forks, all forks should be used in matched pairs, block forks used in
matched sets.
WARNING
Never use an attachment without the appropriate JLG approved capacity chart
installed on the telehandler.
31200169
5-3
Section 5 - Attachments
5.4
To properly use the capacity chart (see page 5-6), the operator must first determine
and/or have the following:
1. An approved attachment. See Approved Attachments on page 5-1.
2. The proper Capacity Chart(s).
3. Weight of the load being lifted.
4. Load placement information:
a. HEIGHT where the load is to be placed.
b. DISTANCE from the front tires of the telehandler 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
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 the load
to be lifted. Determine the limits of the load zone on the capacity chart and keep
within these limits.
BOOM ANGLE
INDICATOR
50
60
70
80
ATTACHMENT
IDENTIFICATION
PLATE
40
-10
10
20
30
FORK
WEIGHT
STAMP
OX0190
5-4
31200169
Section 5 - Attachments
31200169
5-5
Section 5 - Attachments
Sample Capacity Chart
Before S/N 0160037689
This Capacity Chart may be
used with this model ONLY.
The model of your
telehandler is indicated on
the boom or chassis.
Model XXXXX is used for
demonstration purposes only.
MODEL
XXXXX
69
40'
5
50
36'
12'
10
8'
3000 LBS
20
16'
11 0 0 L B S
20'
2000 LBS
30
4000 LBS
24'
9000 LB
S
40
7000 LB
S
32'
28'
Boom Angle
60
5000 LBS
6000 LBS
Boom Extension
Indicator (arc)
2
1
4'
0
0'
-6
-4'
-8'
36'
32'
28'
24'
20'
16'
12'
USE WITH:
1234-5678 48" CARRIAGE
8765-4321 72" CARRIAGE
8'
4'
0'
OWO650
Note: This is a sample capacity chart only! DO NOT use this chart, use the one
located in your operator cab.
WARNING
TIP OVER HAZARD. All loads shown on rated capacity chart are based on
machine being on firm ground with frame level (see page 4-6); the forks being
positioned evenly on carriage; the load being centered on forks; proper size tires
being properly inflated; and the telehandler being in good operating condition.
5-6
31200169
Section 5 - Attachments
To identify the proper capacity chart on telehandlers equipped with outriggers, refer
to the following icons which may be located on the capacity chart.
31200169
5-7
Section 5 - Attachments
S/N 0160037689 & After
This Capacity Chart may be used with this model ONLY.
The telehandler model is indicated on the boom or chassis.
Model XXXX is used for demonstration purposes only.
XXXXXX
< = XX
+
XXXX XX MAX
=XXXX XX MAX
Attachment type,
weight and
dimensions must
be equal to or less
than the data
shown.
XX
71
XX
XX
10
60
XX
XX
40
XX
Boom Extension
Indicator (arc)
3
30
LBS
LB
BS
XX
XX
LB
XX
XX
L
XX
XX
10
XX
XX
XX
XXXX LBS
20
XX
XX
LBS
XX
XX
XX
XX
5
4
XX
XX
7
6
XX
Boom Angle
50
XX
XX
XX
OY1520
0
-4
XX
XX XX XX XX XX XX XX XX XX XX XX XX XX
ANSI/ITSDF B56.6-2005
XXXXXXXXXX X
Note: This is a sample capacity chart only! DO NOT use this chart, use the one
located in your operator cab.
WARNING
TIP OVER HAZARD. All loads shown on rated capacity chart are based on
machine being on firm ground with frame level (see page 4-6); the forks being
positioned evenly on carriage; the load being centered on forks; proper size tires
being properly inflated; and the telehandler being in good operating condition.
5-8
31200169
Section 5 - Attachments
To identify the proper load chart on telehandlers equipped with outriggers, refer to
the following icons which may be located on the load chart.
31200169
5-9
Section 5 - Attachments
Example
A contractor owns a model xxxxx telehandler with a fork carriage. He knows this
attachment may be used with his model since:
Before S/N 0160037689
The attachment model/option number matches the attachment number on the
capacity chart.
The capacity chart is clearly marked for model xxxxx and corresponds with
machine configuration being used.
S/N 0160037689 & After
The attachment style, weight, dimensions and load center match the attachment
data on the capacity chart.
The capacity chart is clearly marked for model xxxxx and corresponds with
machine configuration being used.
Below are examples with various conditions the contractor may encounter and
whether or not the load may be lifted.
Load Weight
Distance
Height
OK to Lift
18 ft (5,5 m)
12 ft (3,7 m)
Yes
30 ft (9,1 m)
26 ft (7,9 m)
NO
8 ft (2,4 m)
24 ft (7,3 m)
Yes
12 ft (3,7 m)
44 ft (13,4 m)
NO
60'
71
56'
52'
10
60
48'
44'
40
36'
0 L
BS
100
0
0 L
B
800
LB
0 L
B
00
50
400
0 L
BS
10
8'
3000 LBS
20
16'
Example 3
600
24'
Example 1
30
28'
12'
5
4
32'
20'
7
6
40'
Example 2
Example 4
8
50
4'
0'
-4'
0
-4
48 44' 40' 36' 32' 28' 24' 20' 16' 12'
XX
8'
4'
0'
OY1710
Note: This is a sample capacity chart only! DO NOT use this chart, use the one
located in your operator cab.
5-10
31200169
Section 5 - Attachments
5.5
ATTACHMENT INSTALLATION
BEFORE S/N 0160037689
1
2
OX0680
3
4
5
6
2
3
5
4
1. Attachment
2. Attachment Pin Recess
3. Attachment Pin
4. Lock Pin
5. Retaining Pin
6. Quick Switch (attachment tilt control in cab, see page 3-8)
WARNING
CRUSH HAZARD. Always be certain that carriage or attachment is properly
positioned on boom and is secured by lock pin and retainer pin. Failure to ensure
proper installation could permit carriage/attachment/load to disengage.
31200169
5-11
Section 5 - Attachments
Before S/N 0160037689
This installation procedure is designed for one-person operation. Prior to exiting cab,
perform Shut-Down Procedure on page 4-4.
OX0710
OY0601
5-12
31200169
Section 5 - Attachments
S/N 0160037689 & After
This installation procedure is designed for one-person operation. Prior to exiting cab,
perform Shut-Down Procedure on page 4-4.
OY1550
OY1560
OY1570
31200169
5-13
Section 5 - Attachments
Hydraulic Operated Attachment
1. Install attachment (see page 5-11).
2. Lower attachment to ground and perform Shut-Down Procedure on page 4-4.
BEFORE S/N 0160037689
2
2
OX0740
OY1720
5-14
31200169
Section 5 - Attachments
5.6
ADJUSTING/MOVING FORKS
Carriages may have different locations where forks can be positioned. Two different
methods can be used for repositioning, depending upon the carriage structure.
Note: Apply a light coating of appropriate lubricant to ease sliding of forks or fork
bar.
To slide forks:
1. Ensure attachment is properly installed. See Attachment Installation on
page 5-11.
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 the center of the carriage,
push the fork near the fork eye. To slide fork toward the edge of the carriage,
pull the fork near the fork eye. To avoid pinching, do not place fingers or thumb
between the fork and carriage structure.
If removing fork bar is necessary:
1. Rest forks on ground.
2. Remove fork bar.
3. Reposition forks.
4. Reinstall the fork bar and fork bar retaining mechanism(s).
31200169
5-15
Section 5 - Attachments
5.7
ATTACHMENT OPERATION
Capacities and range limits for the telehandler change depending on the
attachment in use.
Separate attachment instructions must be kept in manual holder in cab with this
Operation & Safety Manual. An additional copy must be kept with the attachment
if it is equipped with a manual holder.
Operations described within this section reference right hand attachment tilt and
left hand auxiliary hydraulics controls. Refer to pages 3-9 or 3-11 if equipped with
a different configuration.
NOTICE
EQUIPMENT DAMAGE. Some attachments may contact the front tires or
machine structure when the boom is retracted and the attachment is rotated.
Improper use of attachment may result in attachment or machine structural
damage.
NOTICE
EQUIPMENT DAMAGE. Avoid contact with any structure or object when lifting a
load. Maintain clearance around boom structure and load. Failure to maintain
clearance may result in attachment or machine structural damage.
5-16
31200169
Section 5 - Attachments
31200169
5-17
Section 5 - Attachments
Carriage w/Forks
OY0690
Description
P/N
Carriage, 48 in (Before S/N 0160037689) .................... 90455051
Carriage, 66 in (Before S/N 0160037689) .................... 90455052
Carriage, 72 in (Before S/N 0160037689) .................... 90555008
Fork, Block 2x2x48 in (Before S/N 0160037689).......... 90600390
Fork, Pallet 1.75x6x48 in (Before S/N 0160037689) .... 90601819
Fork, Pallet 2x4x48 in (Before S/N 0160037689) ......... 90453002
Fork, Pallet 2.25x4x48 in (Before S/N 0160037689) .... 90453048
Fork, Pallet 2x6x48 in (Before S/N 0160037689) ......... 90553005
Fork, Pallet 2x6x60 in (Before S/N 0160037689) ......... 90601015
Fork, Pallet 2x6x60 in (Before S/N 0160037689) ......... 91163269
Fork, Pallet 2x6x72 in (Before S/N 0160037689) ......... 90553018
Fork, Pallet 2x6x72 in (Before S/N 0160037689) ......... 91123132
Carriage, 50 in (Before S/N 0160037689) ...................... 1170020
Carriage, 50 in (S/N 0160037689 & After)...................... 1170021
Carriage, 60 in (Before S/N 0160037689) ...................... 1170023
Carriage, 60 in (S/N 0160037689 & After)...................... 1170024
Carriage, 72 in (Before S/N 0160037689) ...................... 1170026
Carriage, 72 in (S/N 0160037689 & After)...................... 1170027
Fork, Block 2x2x48 in ..................................................... 2340037
Fork, Pallet 2.36x4x48 in ................................................ 2340045
Fork, Pallet 2.36x5x48 in ................................................ 2340038
Fork, Dual Taper 1.75x7x60 in........................................ 2340046
Fork, Dual Taper 2.36x6x60 in........................................ 2340039
Fork, Dual Taper 2x6x72 in....................................... 1001092391
1
2
2-FRONT
5-18
OX0241
31200169
Section 5 - Attachments
The joystick (1) controls lift/lower and extend/retract movement of the boom.
The tilt lever (2) controls the carriage tilt.
Move lever back to tilt up.
Move lever forward to tilt down.
Installation Procedure:
Refer to Attachment Installation on page 5-11.
31200169
5-19
Section 5 - Attachments
Side Tilt Carriage
OAL1550
Description
P/N
Side Tilt Carriage, 48 in (Before S/N 0160037689) ...... 91085058
Side Tilt Carriage, 50 in (S/N 0160037689 & After)........ 1170054
Side Tilt Carriage, 60 in (S/N 0160037689 & After).. 1001101956
Side Tilt Carriage, 66 in (Before S/N 0160037689) ...... 91305016
Side Tilt Carriage, 72 in (S/N 0160037689 & After)........ 1170057
Fork, Block 2x2x48 in (Before S/N 0160037689).......... 90600390
Fork, Block 2x2x48 in (S/N 0160037689 & After) ........... 2340037
Fork, Pallet 1.75x6x48 in (Before S/N 0160037689) .... 90601819
Fork, Pallet 2.36x4x48 in (S/N 0160037689 & After) ...... 2340045
Fork, Pallet 2x4x48 in (Before S/N 0160037689) ......... 90453002
Fork, Pallet 2.25x4x48 in (Before S/N 0160037689) .... 90453048
Fork, Pallet 2.36x5x48 in (S/N 0160037689 & After) ...... 2340038
Fork, Pallet 2x6x48 in (Before S/N 0160037689) ......... 90553005
Fork, Dual Taper 1.75x7x60 in
(S/N 0160037689 & After) .............................................. 2340046
Fork, Pallet 2x6x60 in (Before S/N 0160037689) ......... 90601015
Fork, Pallet 2x6x60 in (Before S/N 0160037689) ......... 91163269
Fork, Dual Taper 2.36x6x60 in
(S/N 0160037689 & After) .............................................. 2340039
Fork, Pallet 2x6x72 in (Before S/N 0160037689) ......... 90553018
Fork, Pallet 2x6x72 in (Before S/N 0160037689) ......... 91123132
Fork, Dual Taper 2x6x72 in
(S/N 0160037689 & After) ........................................ 1001092391
1
2
OX0311
5-20
2-FRONT
31200169
Section 5 - Attachments
The joystick (1) controls lift/lower and extend/retract movement of the boom.
The tilt lever (2) controls the carriage tilt.
Move lever back to tilt up.
Move lever forward to tilt down.
To Side Tilt:
The auxiliary hydraulic lever (3) controls the carriage side tilt.
Move lever up to (side) tilt left.
Move lever down to (side) tilt right.
Installation Procedure:
Refer to Attachment Installation on page 5-11.
WARNING
CRUSH HAZARD. Do not use side tilt to push or pull objects or load. Failure to
comply could cause object or load to fall.
Operation:
Approach load with forks centered on load and stop telehandler.
Level telehandler before side tilting carriage to engage load.
Side tilt carriage to left or right to align forks with load and engage load.
Raise load slightly and level carriage side to side.
Travel in accordance with the requirements set forth in Section 1 - General
Safety Practices.
31200169
5-21
Section 5 - Attachments
Swing Carriage
OU2150
Description
P/N
90 Swing Carriage (S/N 0160037689 & After) ........ 1001095418
100 Swing Carriage (Before S/N 0160037689) .......... 90455044
180 Swing Carriage (534D-10)
(Before S/N 0160037689) .............................................91553076
180 Swing Carriage (S/N 0160037689 & After) ...... 1001104992
Fork, Block 2x2x48 in (Before S/N 0160037689).......... 90600390
Fork, Block 2x2x48 in (S/N 0160037689 & After) ........... 2340037
Fork, Pallet 1.75x6x48 in (Before S/N 0160037689) .... 90601819
Fork, Pallet 2.36x4x48 in (S/N 0160037689 & After) ...... 2340045
Fork, Pallet 2x4x48 in (Before S/N 0160037689) ......... 90453002
Fork, Pallet 2.25x4x48 in (Before S/N 0160037689) .... 90453048
Fork, Pallet 2.36x5x48 in (S/N 0160037689 & After) ...... 2340038
Fork, Pallet 2x6x48 in (Before S/N 0160037689) ......... 90553005
Fork, Dual Taper 1.75x7x60 in
(S/N 0160037689 & After) .............................................. 2340046
Fork, Pallet 2x6x60 in (Before S/N 0160037689) ......... 90601015
Fork, Pallet 2x6x60 in (Before S/N 0160037689) ......... 91163269
Fork, Dual Taper 2.36x6x60 in
(S/N 0160037689 & After) .............................................. 2340039
Fork, Pallet 2x6x72 in (Before S/N 0160037689) ......... 90553018
Fork, Pallet 2x6x72 in (Before S/N 0160037689) ......... 91123132
Fork, Dual Taper 2x6x72 in
(S/N 0160037689 & After) ........................................ 1001092391
1
2
OX0301
5-22
2-FRONT
31200169
Section 5 - Attachments
The joystick (1) controls lift/lower and extend/retract movement of the boom.
The tilt lever (2) controls the carriage tilt.
Move lever back to tilt up.
Move lever forward to tilt down.
To Swing:
The auxiliary hydraulic lever (3) controls the carriage swing.
Move lever up to swing left.
Move lever down to swing right.
Installation Procedure:
Refer to Attachment Installation on page 5-11.
WARNING
CRUSH HAZARD. Always level forks (horizontally) and telehandler frame before
swinging load to side. Swinging unlevel forks could cause load to slide off forks.
WARNING
CRUSH HAZARD. Do not use swing carriage to push or pull objects or load.
Failure to comply could cause object or load to fall.
WARNING
CRUSH HAZARD. Use retaining pin (if equipped) for locking swing frame to fixed
frame when carrying loads greater than 5000 lb. Failure to comply could cause
object or load to fall.
Operation:
To drive with a load, keep forks pointed forward and travel in accordance with the
requirements set forth in Section 1 - General Safety Practices.
31200169
5-23
Section 5 - Attachments
Mast Carriage
OY0580
Description
P/N
6 ft Mast Carriage, 48 in (Before S/N 0160037689) .....90455035
6 ft Mast Carriage, 66 in (Before S/N 0160037689) .....90455037
8 ft Mast Carriage, 50 in (S/N 0160037689 & After) .1001108668
Fork, Block 2x2x48 in (Before S/N 0160037689).......... 90600390
Fork, Block 2x2x48 in (S/N 0160037689 & After) ........... 2340037
Fork, Pallet 1.75x6x48 in (Before S/N 0160037689) .... 90601819
Fork, Pallet 2.36x4x48 in (S/N 0160037689 & After) ...... 2340045
Fork, Pallet 2x4x48 in (Before S/N 0160037689) ......... 90453002
Fork, Pallet 2.25x4x48 in (Before S/N 0160037689) .... 90453048
Fork, Pallet 2.36x5x48 in (S/N 0160037689 & After) ...... 2340038
Fork, Pallet 2x6x48 in (Before S/N 0160037689) ......... 90553005
Fork, Dual Taper 1.75x7x60 in
(S/N 0160037689 & After) .............................................. 2340046
Fork, Pallet 2x6x60 in (Before S/N 0160037689) ......... 90601015
Fork, Pallet 2x6x60 in (Before S/N 0160037689) ......... 91163269
Fork, Dual Taper 2.36x6x60 in
(S/N 0160037689 & After) .............................................. 2340039
Fork, Pallet 2x6x72 in (Before S/N 0160037689) ......... 90553018
Fork, Pallet 2x6x72 in (Before S/N 0160037689) ......... 91123132
Fork, Dual Taper 2x6x72 in
(S/N 0160037689 & After) ........................................ 1001092391
1
2
OX0291
5-24
2-FRONT
31200169
Section 5 - Attachments
The joystick (1) controls lift/lower and extend/retract movement of the boom.
The tilt lever (2) controls the mast tilt.
Move lever back to tilt up.
Move lever forward to tilt down.
To Raise/Lower Mast:
The auxiliary hydraulic lever (3) controls the raise/lower movement of the mast.
Move lever up to lower.
Move lever down to raise.
Installation Procedure:
Refer to Attachment Installation on page 5-11.
WARNING
CRUSH HAZARD. Do not use mast to push or pull objects or load. Failure to
comply could cause object or load to fall.
Operation:
Always lower forks fully in mast before engaging load.
To drive with a load, lower forks 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 of load if necessary.
31200169
5-25
Section 5 - Attachments
Mast Carriage w/Swing and Side Shift (Before S/N 0160037689)
GNINRAW
OY0590
Description
P/N
6 ft Mast Carriage, 100 Swing, 48 in Fork................... 90455047
Fork, Pallet 1.75x4x48 in .............................................. 90553008
6 ft Mast Carriage, 100 Swing, 60 in Fork................... 90455054
Fork, Pallet 2x6x60 in ................................................... 90453045
VIEW A-A
AUXILIARY ELECTRICS
CONTROL
SIDE SHIFT
SIDE SHIFT
SWING
MAST
SWING
MAST
AUXILIARY
HYDRAULICS
LEFT/DOWN
AUXILI
HYDRA
9136-30
5
SIDE SHIFT
SWING
MAST
+
A
7
SIDE SHIFT
SWING
1
2
MAST
OX0321
The joystick (1) controls lift/lower and extend/retract movement of the boom.
The tilt lever (2) controls the mast tilt.
Move lever back to tilt up.
Move lever forward to tilt down.
To Swing:
Pull Swing Switch (5) located on dash panel (4) to activate Swing function.
The auxiliary hydraulic lever (3) controls the carriage swing.
Move lever up to swing left.
Move lever down to swing right.
5-26
31200169
Section 5 - Attachments
To Raise/Lower Mast:
Pull Mast Raise/Lower Switch (6) located on dash panel to activate Mast Raise/
Lower function.
The auxiliary hydraulic lever controls the mast raise/lower function.
Move lever up to lower.
Move lever down to raise.
To Side Shift:
Push Side Shift Switch (7) located on dash panel to activate Side Shift function.
The auxiliary hydraulic lever controls the carriage side shift.
Move lever up to shift left.
Move lever down to shift right.
Installation Procedure:
Refer to Attachment Installation on page 5-11.
WARNING
CRUSH HAZARD. Always level forks (horizontally) and telehandler frame before
swinging load to side. Swinging unlevel forks could cause load to slide off forks.
WARNING
CRUSH HAZARD. Do not use mast to push or pull objects or load. Failure to
comply could cause object or load to fall.
Operation:
Always lower forks fully in mast and position forks straight ahead before
engaging load.
To drive with a load, lower forks fully in mast, keep forks pointed forward 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.
31200169
5-27
Section 5 - Attachments
Mast Carriage w/Side Tilt (S/N 0160037689 & After)
GNINRAW
OY0590
Description
P/N
8 ft Mast Carriage with Side Tilt................................ 1001108669
Fork, Block 2x2x48 in ..................................................... 2340037
Fork, Pallet 2.36x4x48 in ................................................ 2340045
Fork, Pallet 2.36x5x48 in ................................................ 2340038
Fork, Dual Taper 1.75x7x60 in........................................ 2340046
Fork, Dual Taper 2.36x6x60 in........................................ 2340039
Fork, Dual Taper 2x6x72 in....................................... 1001092391
AUXILIARY
HYDRAULICS
LEFT/DOWN
AUXILI
HYDRA
9136-30
+
6
1
2
OX0750
The joystick (1) controls lift/lower and extend/retract movement of the boom.
The tilt lever (2) controls the mast tilt.
Move lever back to tilt up.
Move lever forward to tilt down.
To Side Tilt:
Press Side Tilt Switch (5) located on dash panel (4) to activate Side Tilt function.
The auxiliary hydraulic lever (3) controls the carriage side tilt.
Move lever up to (side) tilt left.
Move lever down to (side) tilt right.
5-28
31200169
Section 5 - Attachments
To Raise/Lower Mast:
Press Mast Raise/Lower Switch (6) located on dash panel to activate Mast Raise/
Lower function.
The auxiliary hydraulic lever controls the mast raise/lower function.
Move joystick up to lower.
Move joystick down to raise.
Installation Procedure:
Refer to Attachment Installation on page 5-11.
WARNING
CRUSH HAZARD. Do not use mast to push or pull objects or load. Failure to
comply could cause object or load to fall.
WARNING
CRUSH HAZARD. Do not use side tilt to push or pull objects or load. Failure to
comply could cause object or load to fall.
Operation:
Always lower forks fully in mast before engaging load.
To drive with a load, lower forks 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.
31200169
5-29
Section 5 - Attachments
Fork Mounted Hook (Before S/N 0160037689)
Description
P/N
Fork Mounted Hook ...................................................... 90553036
Fork Mounted Hook ...................................................... 91565094
OY0640
1
2
2-FRONT
OX0261
The joystick (1) controls lift/lower and extend/retract movement of the boom.
The tilt lever (2) controls the fork mounted hook tilt.
Move lever back to tilt up.
Move lever forward to tilt down.
Installation Procedure:
Refer to Attachment Installation on page 5-11.
Secure the fork mounted hook to the forks by sliding the fork mounted hook onto
the parent forks and install the retaining pin behind the vertical shank of the fork.
5-30
31200169
Section 5 - Attachments
Operation:
Pallet or lumber forks of an appropriate load rating must be used. 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 fork mounted hook with attachments capable of rotating (i.e. side tilt
and swing carriages) without disabling the rotation feature(s).
31200169
5-31
Section 5 - Attachments
Fork Mounted Hook (S/N 0160037689 & After)
Description
P/N
Fork Mounted Hook ...................................................... 91565094
OY0640
1
2
2-FRONT
OX0261
The joystick (1) controls lift/lower and extend/retract movement of the boom.
The tilt lever (2) controls the fork mounted hook tilt.
Move lever back to tilt up.
Move lever forward to tilt down.
Installation Procedure:
Refer to Attachment Installation on page 5-11.
Secure the fork mounted hook to the forks by sliding the fork mounted hook onto
the parent forks and install the retaining pin behind the vertical shank of the fork.
5-32
31200169
Section 5 - Attachments
Operation:
Pallet or lumber forks of an appropriate load rating must be used. Do not use with
cubing or block forks.
Weight of rigging must be included as part of total load being lifted.
Do not use fork mounted hook with attachments capable of rotating (i.e. side tilt
and swing carriages) without disabling the rotation feature(s).
31200169
5-33
Section 5 - Attachments
Truss Boom
OY0570
Description
P/N
Truss Boom, 10 ft (Before S/N 0160037689)................90455011
Truss Boom, 10 ft w/winch (Before S/N 0160037689) ..90455012
Truss Boom, 10 ft w/winch reeving
(Before S/N 0160037689) .............................................90555018
Truss Boom, 12 ft (S/N 0160037689 & After) ...........1001099902
Truss Boom, 12 ft w/winch
(S/N 0160037689 & After) ........................................1001099351
Truss Boom, 15 ft (S/N 0160037689 & After) ...........1001099901
1
2
2-FRONT
OX0271
The joystick (1) controls lift/lower and extend/retract movement of the boom.
The tilt lever (2) controls truss boom tilt.
Move lever back to tilt up.
Move lever forward to tilt down.
5-34
31200169
Section 5 - Attachments
Installation Procedure:
Refer to Attachment Installation on page 5-11.
WARNING
CRUSH HAZARD. Maintain a minimum of three wraps of wire rope on the cable
drum at all times. Failure to comply could cause object or load to fall.
31200169
5-35
Section 5 - Attachments
Bucket
OZ0730
Description
P/N
Bucket, 60 in - 0.75 yd3 (Before S/N 0160037689)....... 90455049
Bucket, 72 in - 1.0 yd3 (S/N 0160037689 & After) .... 1001100822
Bucket, 74 in - 1.25 yd3 (Before S/N 0160037689)....... 90555020
Bucket, 74 in - 2.0 yd3 (Before S/N 0160037689)......... 90453039
Bucket, 96 in - 1.5 yd3 (S/N 0160037689 & After) .... 1001100823
Bucket, 102 in - 2.0 yd3 (S/N 0160037689 & After) .. 1001100824
Concrete Hopper - 0.75 yd3
(Before S/N 0160037689) ............................................. 91123115
1
2
2-FRONT
OX0251
The joystick (1) controls lift/lower and extend/retract movement of the boom.
The tilt lever (2) controls bucket tilt.
Move lever back to tilt up.
Move lever forward to tilt down.
Installation Procedure:
Refer to Attachment Installation on page 5-11.
5-36
31200169
Section 5 - Attachments
Operation:
Raise or lower boom to appropriate height for loading material from stockpile.
Align telehandler with face of stockpile and drive slowly and smoothly into pile to
load bucket.
Tilt bucket up far enough to retain load and back away from pile.
Travel in accordance with requirements set forth in Section 1 - General Safety
Practices.
Tilt bucket down to dump load.
31200169
5-37
Section 5 - Attachments
Grapple Bucket (S/N 0160037689 & After)
Description
P/N
Bucket, Grapple, 96 in - 1.75 yd3 .................................... 0930020
OZ1450
1
2
OX0760
2-FRONT
The joystick (1) controls lift/lower and extend/retract movement of the boom.
The tilt lever (2) controls grapple bucket tilt.
Move lever back to tilt up.
Move lever forward to tilt down.
To open/close grapple:
The auxiliary hydraulic lever (3) controls the open/close movement of the grapple.
Move lever up to close grapple.
Move lever down to open grapple.
Installation Procedure:
Refer to Attachment Installation on page 5-11.
5-38
31200169
Section 5 - Attachments
Operation:
Raise or lower boom to appropriate height and open grapple for loading material
from stockpile.
Align telehandler with face of stockpile and drive slowly and smoothly into pile to
load bucket.
Tilt bucket up far enough to retain load, close grapple and back away from pile.
Travel in accordance with requirements set forth in Section 1 - General Safety
Practices.
Open grapple and tilt bucket down to dump load.
31200169
5-39
Section 5 - Attachments
Boom Head-Mounted Winch (Before S/N 0160037689)
Description
P/N
Winch (Before S/N 0160027771) ..................................91355004
Winch (S/N 0160027771 thru 0160037689) .................91535026
OY0650
1
3
2-FRONT
OX0281
The joystick (1) controls lift/lower and extend/retract movement of the boom.
The auxiliary hydraulic lever (3) controls the winch.
Move lever up to lower cable.
Move lever down to raise cable.
WARNING
CRUSH HAZARD. Maintain a minimum of three wraps of wire rope on the cable
drum at all times. Failure to comply could cause object or load to fall.
5-40
31200169
Section 5 - Attachments
Personnel Work Platform (Before S/N 0160037689)
The operator and personnel in platform must read and understand the
separate personnel work platform manual prior to installing and using a
platform.
WARNING
FALL HAZARD. Never tilt the platform forward, rearward, or level the machine
when the platform is occupied.
31200169
5-41
Section 5 - Attachments
Personnel Work Platform (S/N 0160037689 & After)
Description
P/N
Personnel Work Platform, ANSI................................ 1001103637
Personnel Work Platform, ANSI (French) ................. 1001103736
Personnel Work Platform, ISO.................................. 1001103730
OY1610
1
2
2-FRONT
OX0770
The joystick (1) controls lift/lower and extend/retract movement of the boom.
The tilt lever (2) controls platform tilt.
Move lever back to tilt up.
Move lever forward to tilt down.
Installation Procedure:
Refer to Attachment Installation on page 5-11.
Check to ensure the personnel platform is securely attached to the forks and/or
carriage.
5-42
31200169
Section 5 - Attachments
Preparation and Setup:
1. Ensure the telehandler is on a firm surface and is level.
2. Engage the park brake. Blocking the wheels is also recommended.
3. Level the platform, 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
personnel in direct line of sight.
6. DO NOT lift or carry persons in a bucket or on forks.
WARNING
FALL HAZARD. Never tilt the platform forward, rearward, or level the machine
when the platform is occupied.
31200169
5-43
Section 5 - Attachments
5-44
31200169
The following information assumes the telehandler cannot be moved under its
own power.
Before moving the telehandler, read all of the following information to understand
options available. Then select the appropriate method.
Machine mounted retrieval devices provide suitable means to attach a tow rope,
chain or tow bar only in the event the telehandler becomes stuck or disabled.
Retrieval devices 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 NOT attempt to tow a telehandler that is loaded or the boom/attachment is
raised above 4 ft (1,2 m).
31200169
6-1
In the event of total loss of engine power or hydraulic pump failure with an elevated
load, the situation must be properly evaluated and dealt with on an individual basis.
Contact a local Authorized Distributor for specific instructions.
Secure the telehandler using the following procedures:
1. Clear the area around 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 restrict any
personnel from entering this area.
6.3
EMERGENCY
EXIT
PULL PINS AND PUSH
WINDOW OUT TO EXIT
D21080
OX0500
In an emergency, pull pins at bottom of front window and push window out to exit.
6-2
31200169
INTRODUCTION
Service the product in accordance with the maintenance schedule on the following
pages.
A
A
1
VIEW A-A
OX0371
The Lubrication and Maintenance Decal (1) contains 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
instructions.
31200169
7-1
WARNING
CUT/CRUSH/BURN HAZARD. Do not perform service or maintenance on the
machine with the engine running, with the exception of the hydraulic return filter
indicator checks.
7-2
31200169
EVERY
10
Air Filter
Restriction
Indicator
Check Fuel
Level
Check Engine
Oil Level
Check Hydraulic
Oil Level
Check Tire
Condition &
Pressure
Check Hydraulic
Return Filter
Indicator
1st
50
LB/F
T (N
m)
Change Front
Axle Oil
Change
Engine Filter
Change
Hydraulic Filter
Check Wheel
Lug Nut
Torque
Check Boom
Cable & Tension
OX0202
31200169
7-3
EVERY
50
Drain Fuel/
Water
Separator
Check Engine
Coolant Level
Check
Battery
Check Washer
Fluid Level
(if equipped)
Lubrication
Schedule
Check
Fan Belt
EVERY
250
Change Engine
Oil and
Filter*
Check
Front Axle
Oil Level
Air Filter
Vacuator
Valve
Check Boom
Cable & Tension
Check Boom
Wear Pads
Lubrication
Schedule
EVERY
500
LB/F
T (N
m)
Change Fuel
Filter & Strainer
Check Wheel
Lug Nut
Torque
OX0531
Note: Engine oil and filter service interval can be extended, see page 7-12 for
details.
7-4
31200169
EVERY
1000
Change Front
Axle Oil
Change
Hydraulic Tank
Breather
EVERY
1500
Change
Engine Coolant
Change
Hydraulic
Fluid & Filters
OY1042
31200169
7-5
LUBRICATION SCHEDULES
EVERY
250
OX0342
7-6
31200169
EVERY
250
OX0352
31200169
7-7
Fuel System
10
OW0970
F
FUEL
E
240
TEMP
80
OIL
0
16
VOLTS
-
100
OW0990
10
F
FUEL
80
OIL
E
240
TEMP
0
16
VOLTS
-
100
QUARTZ
10
PARK
BRAKE
DRIVE
4X4
ON
0 0 0 0 0 0
OFF
ALT
4X2
VIEW OF DASH
2
3
OX0212
NOTICE
EQUIPMENT DAMAGE. Do not allow machine to run out of fuel during operation.
See Engine Operation & Maintenance Manual for details prior to servicing.
7-8
31200169
50
OW0980
OW1000
5-FRONT
OX0130
CUMMINS ENGINE
OX0630
4
1. Perform Shut-Down Procedure on page 4-4.
2. Open the engine cover.
3. Loosen drain cock (4) on underside of fuel filter (5) and allow all water to drain
into a glass until clear fuel is visible.
4. Tighten drain cock.
5. Close and secure the engine cover.
31200169
7-9
10
OW0970
OW1010
4
1
6
3
OX0331
Note: Only remove canister cover to service the elements as restriction indicator
indicates. Excessive access to check an element can lead to premature element
failure.
7-10
31200169
Note: An inner safety element should never be washed or reused. Always install a
new element.
31200169
7-11
10
OW0970
OW1020
AD
2
3
OX0140
CUMMINS ENGINE
1
2
AD
OX0610
7-12
31200169
10
OW0970
OW1030
5
6
2-FRONT
OX0180
31200169
7-13
10
OW0970
OW1040
B. Tire Damage
For pneumatic tires, when any cut, rip or tear is discovered that exposes sidewall or
tread area cords in the tire, measures be taken to remove the product from service
immediately. Arrangements must be made 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.
Arrangements must be made for replacement of the tire or tire assembly.
a smooth even cut through the cord piles which exceeds 3 in (7,5 cm) in total
length.
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, the tire must be inspected
daily to ensure the damage has not propagated beyond the allowable criteria.
7-14
31200169
31200169
7-15
10
9
8
2
6
4
OY1220
WARNING
TIP OVER HAZARD. Lug nuts must be installed and maintained at the proper
torque to prevent loose wheels, broken studs and possible separation of wheel
from the axle.
7-16
31200169
10
OW0970
OW1060
OX0170
1. Apply park brake, shift transmission to "Neutral" and lower forks or attachment
to horizontal position.
2. Check hydraulic return filter indicator with engine at normal operating
temperature.
3. Have an assistant open the tank cover.
4. With the engine at full throttle and the assistant observing the indicator (2)
located on the hydraulic return filter (1), extend and retract the boom 10 to 12 ft
(3,0 to 3,7 m). The bar gauge should be within the green area.
5. Replace filter before the gauge reaches the red area on the indicator. If it
reaches the red area, the filter is too dirty and hydraulic oil is bypassing the
filter.
6. Close and secure the tank cover.
31200169
7-17
50
OW0980
OW1070
CUMMINS ENGINE
OX0160
OX0641
7-18
31200169
50
A. Battery Check
OW0980
CUMMINS ENGINE
OW1080
3
+
2-FRONT
OX0151
OX0601
31200169
7-19
7-20
31200169
31200169
8-1
8-2
31200169
Section 9 - Specifications
SECTION 9 - SPECIFICATIONS
9.1
PRODUCT SPECIFICATIONS
31200169
9-1
Section 9 - Specifications
Tires
534D-9
13.00 x 24, G-2/L-2 Bias-Ply Traction - 12 Ply
Pneumatic ................................................................................65 psi (4,5 bar)
Foam ........................................................................... Approx 542 lb (246 kg)
13.00 x 24, G-2/L-2 Radial - 1 Star
Pneumatic ................................................................................70 psi (4,8 bar)
Foam ........................................................................... Approx 542 lb (246 kg)
13.00 x 24, G-3/L-3 Bias Ply Rock - 12 Ply
Pneumatic ................................................................................65 psi (4,5 bar)
Foam ........................................................................... Approx 542 lb (246 kg)
534D-10
14.00 x 24, G-2/L-2 Bias-Ply Traction - 12 Ply
Pneumatic ................................................................................65 psi (4,5 bar)
Foam ........................................................................... Approx 720 lb (327 kg)
14.00 x 24, G-2/L-2 Radial - 1 Star
Pneumatic ................................................................................70 psi (4,8 bar)
Foam ........................................................................... Approx 720 lb (327 kg)
14.00 x 24, G-3/L-3 Bias Ply Rock - 12 Ply
Pneumatic ................................................................................65 psi (4,5 bar)
Foam ........................................................................... Approx 720 lb (327 kg)
Wheel Lug Nut
Torque.............................................................................. 350-400 lb-ft (475-543 Nm)
9-2
31200169
Section 9 - Specifications
Performance
Maximum Lift Capacity
534D-9...................................................................................... 9,000 lb (4082 kg)
534D-10.................................................................................. 10,000 lb (4536 kg)
Maximum Lift Height...............................................................................45 ft (13,7 m)
Capacity at Maximum Height ......................................................... 7,000 lb (3175 kg)
Maximum Forward Reach .....................................................................31.6 ft (9,6 m)
Capacity at Maximum Forward Reach
534D-9
Before S/N 0160037689 ....................................................... 1,600 lb (726 kg)
S/N 0160037689 & After....................................................... 1,500 lb (680 kg)
534D-10
Outriggers Not Engaged ....................................................... 1,000 lb (454 kg)
Outriggers Engaged
Before S/N 0160037689................................................ 3,000 lb (1360 kg)
S/N 0160037689 & After ............................................... 2,900 lb (1315 kg)
Reach at Maximum Height ......................................................................4.3 ft (1,3 m)
Maximum Travel Speed
534D-9...................................................................................18 mph (28.9 kmph)
534D-10.................................................................................19 mph (30.6 kmph)
Towing Capacity
534D-9...................................................................................... 9,000 lb (4082 kg)
534D-10.................................................................................. 10,000 lb (4536 kg)
Frame Leveling ............................................................................................ 8 degrees
Maximum Travel Grade
Gradeability ....................................................................................................45%
Side Slope ...................................................................................................8.75%
31200169
9-3
Section 9 - Specifications
Dimensions
Overall Height
534D-9 .........................................................................................96 in (2438 mm)
534D-10 .......................................................................................97 in (2464 mm)
Overall Width
534D-9 .........................................................................................97 in (2464 mm)
534D-10 ....................................................................................98.8 in (2510 mm)
Cab Width.........................................................................................32.7 in (831 mm)
Track Width........................................................................................83 in (2108 mm)
Wheelbase.......................................................................................135 in (3429 mm)
Length at Front Wheels
534D-9 ....................................................................................188.1 in (4778 mm)
534D-10 ..................................................................................189.6 in (4816 mm)
Overall Length (less Forks)...........................................................242.5 in (6160 mm)
Ground Clearance
534D-9 ...........................................................................................19 in (483 mm)
534D-10 ......................................................................................19.4 in (493 mm)
Outside Turning Radius
534D-9 .......................................................................................174 in (4420 mm)
534D-10 ..................................................................................176.4 in (4481 mm)
Maximum Gross Vehicle Weight (no attachment)
534D-9 .................................................................................27,166 lb (12.322 kg)
534D-10 ...............................................................................29,324 lb (13.301 kg)
Maximum Front Axle Weight (no attachment)
(boom level and fully retracted)
534D-9 ....................................................................................12,225 lb (5545 kg)
534D-10 ..................................................................................14,369 lb (6518 kg)
Maximum Rear Axle Weight (no attachment)
(boom level and fully retracted)
534D-9 ....................................................................................14,941 lb (6777 kg)
534D-10 ..................................................................................14,955 lb (6783 kg)
Maximum Ground Bearing Pressure
534D-9 - 13.00 x 24
Air Filled ......................................................................147 lb/in (10,3 kg/cm)
Foam Filled .................................................................175 lb/in (12,3 kg/cm)
534D-10 - 14.00 x 24
Air Filled ........................................................................139 lb/in (9,8 kg/cm)
Foam Filled .................................................................164 lb/in (11,5 kg/cm)
9-4
31200169
Index
Index
A
Engine
Normal Operation ........................4-4
Starting ........................................4-1
C
Capacities......................................... 9-1
Capacity ........................................... 5-3
Capacity Chart
Example .................................... 5-10
Sample........................................ 5-6
Fall Hazard......................................1-12
Fork Mounted Hook ...............5-30, 5-32
Frame Level .............................3-9, 3-11
Fuel Level .........................................7-8
Fuel Tank ..........................................9-1
Fuel/Water Separator........................7-9
G
General Maintenance........................7-2
Grapple Bucket ...............................5-38
Heater .............................................3-12
I
D
Ignition ..............................................3-5
31200169
Index
Lubrication and Maintenance ........... 7-1
Lubrication Schedule
250 Hour ..................................... 7-7
50 Hour ....................................... 7-6
Seat Belt..........................................3-15
O
Operating with a Non-Suspended
Load.................................................. 4-5
Operating with a Suspended Load ... 4-8
Operation.......................................... 4-1
Operational Check............................ 2-8
Operator Cab.................................... 2-9
Shut-Down Procedure.......................4-4
Side Tilt Carriage ............................5-20
Specifications ....................................9-1
Swing Carriage................................5-22
Towing...............................................6-1
Transport
Lifting .........................................4-12
Tiedown .....................................4-11
R
Restriction Indicator........................ 7-10
Return Filter Indicator ..................... 7-17
W
Walk-Around Inspection ....................2-6
Warm-Up Check................................2-8
Wheel Installation............................7-16
Wheel Lug Nut ..................................9-2
Wheel Replacement........................7-15
Windows..........................................2-10
31200169
Date
Comments
Comments
TRANSFER OF OWNERSHIP
An Oshkosh Corporation Company
To Product Owner:
If you now own but ARE NOT the original purchaser of the product covered by this
manual, we would like to know who you are. For the purpose of receiving safety-related
bulletins, it is very important to keep JLG Industries, Inc. updated with the current
ownership of all JLG products. JLG maintains owner information for each JLG product
and uses this information in cases where owner notification is necessary.
Please use this form to provide JLG with updated information with regard to the
current ownership of JLG products. Please return completed form to the JLG Product
Safety & Reliability Department via facsimile or mail to address as specified below.
Thank You,
Product Safety & Reliability Department
JLG Industries, Inc.
13224 Fountainhead Plaza
Hagerstown, MD 21742
USA
Telephone: +1-717-485-6591
Fax: +1-301-745-3713
NOTE: Leased or rented units should not be included on this form.
Mfg. Model: _______________________________________________________________
Serial Number: ____________________________________________________________
Previous Owner: ___________________________________________________________
Address: _________________________________________________________________
_________________________________________________________________________
Country: _________________________ Telephone: (_______) ____________________
Date of Transfer: _________________________________
Current Owner: ____________________________________________________________
Address: _________________________________________________________________
_________________________________________________________________________
Country: _________________________ Telephone: (_______) ____________________
Hand Signals
OY1090
OY1120
OY1150
OY1180
OY1100
OY1130
OY1160
OY1110
OY1140
OY1170
OY1190
Special Signals - When signals for auxiliary equipment functions or conditions not
covered are required, they shall be agreed upon in advance by the operator and
signalman.
JLG Polska
UI. Krolewska
00-060 Warsawa
Poland
Phone: +48 (0)914 320 245
Fax: +48 (0)914 358 200
Plataformas Elevadoras
JLG Iberica, S.L.
Trapadella, 2
P.I. Castellbisbal Sur
08755Castellbisbal, Barcelona
Spain
Phone: +34 93 772 4 700
Fax: +34 93 771 1762
JLG Sverige AB
Enkopingsvagen 150
Box 704
SE - 176 27 Jarfalla
Sweden
Phone: +46 (0)850 659 500
Fax: +46 (0)850 659 534