Page 1
Operation & Safety Manual Original Instructions Keep this manual with machine at all times. Models G10-55A G12-55A S/N 0160045636 & After including 0160045082, 0160045094, 0160045209, 0160045295, 0160045296, 0160045449 31200745 Revised October 3, 2014 An Oshkosh Corporation Company...
Page 2
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,...
Page 3
Revision Log 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, 8-2, 9-1, 9-3, 9-5, 9-6 &...
Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without prior notification. Contact JLG Industries, Inc.
Page 5
Inc. or the local authorized JLG representative for information regarding safety- related bulletins which may have been issued for this product. JLG Industries, Inc. sends safety related bulletins to the owner of record of this machine. Contact JLG Industries, Inc. to ensure that the current owner records are updated and accurate.
Read This First Other Publications Available Service Manual..................31200795 Illustrated Parts Manual................31200728 Note: The following standards may be referenced in this manual: ANSI is compliant to ANSI/ITSDF B56.6 AUS is compliant to AS 1418.19 CE is compliant to EN1459 Refer to the machine Serial Number Plate to identify the applicable compliance standard.
Table of Contents Table of Contents TABLE OF CONTENTS Revision Log Read This First Operator Qualifications ............b Modifications ..............b Other Publications Available ..........d Machine Configuration ............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...
Page 8
Table of Contents Ignition ................3-6 Park Brake..............3-7 Parking Procedure............3-7 Transmission Control Lever..........3-8 Boom Joystick .............. 3-10 Frame Level Joystick............ 3-11 Auxiliary Hydraulic Joystick .......... 3-12 Outrigger Joysticks ............3-13 Right Hand Panel ............3-14 Accessory Control Lever (if equipped) ......3-15 3.3 Steer Modes ..............
Page 9
Table of Contents Section 5 - Attachments 5.1 Approved Attachments ............5-1 5.2 Unapproved Attachments ............5-1 5.3 JLG Supplied Attachments ..........5-2 5.4 Telehandler/Attachment/Fork Capacity........5-4 5.5 Use of the Capacity Chart............5-5 Capacity Indicator Locations ...........5-5 Sample Capacity Chart ...........5-6 Example ................5-8 5.6 Attachment Installation ............5-9 Mechanical Quick Switch ..........5-10...
Page 10
Table of Contents Section 7 - Lubrication and Maintenance 7.1 Introduction................7-1 Clothing and Safety Gear ..........7-1 7.2 General Maintenance Instructions........7-2 7.3 Service and Maintenance Schedule........7-3 10 & 1st 50 and 50 Hour Maintenance Schedule ... 7-3 1st 250 &...
Section 1 - General Safety Practices SECTION 1 - GENERAL SAFETY PRACTICES HAZARD CLASSIFICATION SYSTEM Safety Alert System and Safety Signal Words DANGER OW0010 DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING OW0021 WARNING indicates a potentially hazardous situation which, if not avoided, could...
Section 1 - General Safety Practices 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.
• For additional load requirements, refer to the appropriate capacity chart. 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.
Page 14
Section 1 - General Safety Practices OH2291 • MAINTAIN proper tire pressure at all times. If proper tire pressures are not maintained, this machine could tip over. • Refer to manufacturer’s specifications for proper fill ratio and pressure requirements for tires equipped with ballast. OH20911 •...
Page 15
Section 1 - General Safety Practices Non-Suspended Load OW0060 • DO NOT drive with boom raised. Suspended Load OW0150 • Tether suspended loads to restrict movement. • Weight of all rigging (slings, etc.) must be included as part of load. •...
• Telehandlers equipped with solid tires should not be used in applications requiring excessive roading or driving extended distances. In the event an application requires excessive roading or driving expanded distances, JLG recommends the use of telehandlers not equipped with solid tires.
OW0130 • 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 and spaced apart as far as possible.
Section 1 - General Safety Practices Lifting Personnel OW0170 • When lifting personnel, USE ONLY an approved personnel work platform, with proper capacity chart displayed in the cab. OW0190 • DO NOT drive machine from cab when personnel are in platform. 31200745...
Section 1 - General Safety Practices Driving Hazards on Slopes OW0200 To maintain sufficient traction and braking capabilities, travel on slopes as follows: • When unloaded, drive with forks pointed downhill. • When loaded, drive with the forks pointed uphill. •...
Section 1 - General Safety Practices Pinch Points and Crush Hazards Stay clear of pinch points and rotating parts on the telehandler. OW0210 • Stay clear of moving parts while engine is running. OW0220 • Keep clear of steering tires and frame or other objects. OW0230 •...
Page 21
Section 1 - General Safety Practices OW0240 • Keep clear of boom holes. OW0250 • Keep arms and hands clear of attachment tilt cylinder. OW0260 • Keep hands and fingers clear of carriage and forks. OW0960 • Keep others away while operating. 31200745 1-11...
Section 1 - General Safety Practices Fall Hazard OW0280 • Enter using the proper hand holds and steps provided. Always maintain 3-point contact when mounting or dismounting. Never grab control levers or steering wheel when mounting or dismounting the machine. •...
• DO NOT operate machine in an enclosed area without proper ventilation. • DO NOT operate the machine in hazardous environments unless approved for that purpose by JLG and site owner. Sparks from the electrical system and the engine exhaust can cause an explosion.
Section 1 - General Safety Practices CLEARSKY (IF EQUIPPED) Federal Communications Commission (FCC) Information for Users FCC Statement Regarding Interference This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation.
Page 25
Section 1 - General Safety Practices Antenna Installation A minimum separation distance of eight inches (20 centimeters) must be maintained between the antenna and all persons. The combined 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 in order to comply with the EIRP limit of 24.232 (b).
Page 26
Section 1 - General Safety Practices This Page Intentionally Left Blank 1-16 31200745...
Section 2 - Pre-Operation and Inspection SECTION 2 - PRE-OPERATION AND INSPECTION PRE-OPERATION CHECK AND INSPECTION Note: Complete all required maintenance before operating unit. WARNING FALL HAZARD. Use extreme caution when checking items beyond your normal reach. Use an approved ladder. The pre-operation check and inspection, performed at beginning of each work shift or at each change of operator, should include the following: 1.
Page 28
Section 2 - Pre-Operation and Inspection 8. Operational Check - Once the walk-around inspection is complete, perform a warm-up and operational check (see page 2-12) of all systems in an area free of overhead and ground level obstructions. See Section 3 - Controls and Indicators for more specific operating instructions.
Section 2 - Pre-Operation and Inspection SAFETY DECALS Ensure all DANGER, WARNING, CAUTION and instructional decals and proper capacity charts are legible and in place. Clean and replace as required. ANSI (If Equipped) 1706768-ENGLISH 1001163300-ENGLISH/FRENCH (ENCLOSED CAB) 1001154575 1701640 1701640 9150-3112 REV - 91503112 1706768-ENGLISH...
Page 30
Section 2 - Pre-Operation and Inspection 1706303-ENGLISH 1001150157 1001145498 1001131745 1001163273-ENGLISH/FRENCH Operator must be trained and Fasten must read and understand seat all capacity charts, operator belt. and safety manuals. 1706767-ENGLISH 1706851-ENGLISH 1001163291- 1001163321- ENGLISH/FRENCH ENGLISH/FRENCH CAPACITY CHARTS 1001131745A RUN-OVER HAZARD could cause 1706851A...
Section 2 - Pre-Operation and Inspection WALK-AROUND INSPECTION OY3600 Begin your walk-around inspection at item 1, as noted below. Continue to your right (counterclockwise when viewed from top) checking each item in sequence. INSPECTION NOTE: On all components, make sure there are no loose or missing parts, that they are securely fastened and no visible leaks or excessive wear exists in addition to any other criteria mentioned.
Page 37
Section 2 - Pre-Operation and Inspection 4. Wheel/Tire Assembly - Properly inflated and secured; no loose or missing lug nuts. Inspect for worn tread, cuts, tears or other discrepancies. 5. Mirrors - Clean and undamaged. 6. Cab and Electrical - •...
Section 2 - Pre-Operation and Inspection WARM-UP AND OPERATIONAL CHECKS Warm-Up Check During warm-up period, check: 1. Heater, defroster and windshield wiper (if equipped). 2. Check all lighting systems (if equipped) for proper operation. 3. Voltmeter should show 13.5 to 14 volts. 4.
Never operate telehandler unless the overhead guard, cab structure and right side glass or screen are in good condition. Any modification to this machine must be approved by JLG to assure compliance with ROPS/FOPS certification for this cab/machine configuration. If the overhead guard or cab structure is damaged, the CAB CANNOT BE REPAIRED.
Section 2 - Pre-Operation and Inspection WINDOWS Keep all windows and mirrors clean and unobstructed. Cab Door Window (if equipped) OAL0011 • Cab door (1) must be closed during operation. • During operation the cab door window (2) must either be latched open or closed. •...
Section 3 - Controls and Indicators SECTION 3 - CONTROLS AND INDICATORS 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 and operator are responsible for conforming with good safety practices.
Section 3 - Controls and Indicators CONTROLS OY2810 1. Transmission Control Lever: See page 3-8. 2. Instrument Panel: See page 3-4. 3. Steering Wheel: Turning the steering wheel to the left or right steers the machine in the corresponding direction. Three steering modes are available. See “Steer Modes”...
Page 43
Section 3 - Controls and Indicators 10. Outrigger Joysticks: See page 3-13. 11. Decompression 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 pedal is depressed, the slower the travel speed.
Section 3 - Controls and Indicators Dash Controls and Indicators OY3190 1. Transmission Temperature Indicator: Illuminates red when transmission temperature is too high. Immediately bring machine to a stop, retract and lower boom and stop the engine. Determine cause and correct before continued use. 2.
Page 45
Section 3 - Controls and Indicators This Page Intentionally Left Blank 31200745...
Section 3 - Controls and Indicators Ignition START OY2760 • 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 from all electrical functions.
Section 3 - Controls and Indicators Park Brake OY2770 Park brake switch controls the application and release of the park brake. Indicator light on switch illuminates to indicate brake is applied. • With the engine running and the park brake switch in "OFF" position (1), park brakes are disengaged.
Section 3 - Controls and Indicators Transmission Control Lever Direction of Travel Selection OY2780 Transmission control lever (1) engages forward or reverse travel. • Lift and push lever forward for forward travel; lift and pull lever rearward for reverse travel. Move lever to centered position for neutral. •...
Page 49
Section 3 - Controls and Indicators Gear Selection OY2790 Gear selection is located on the twist grip handle (2) of transmission control lever. • Twist hand grip to select gear. • Select the appropriate gear for the task being performed. Use a lower gear when transporting a load.
Section 3 - Controls and Indicators Boom Joystick OY2800 The boom joystick (1) controls the boom and attachment tilt 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. •...
Section 3 - Controls and Indicators Frame Level Joystick OY2820 The frame level joystick (4) controls the left to right frame level. • Move joystick left to rotate frame left, move joystick 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.
Section 3 - Controls and Indicators Auxiliary Hydraulic Joystick OY2830 The auxiliary hydraulic joystick (1) controls function of attachments that require hydraulic supply for operation. See Section 5 - Attachments for approved attachments and control instructions. 3-12 31200745...
Section 3 - Controls and Indicators Outrigger Joysticks OY2840 The rear joysticks (2) control the outriggers. • Left joystick controls left outrigger and right joystick controls right outrigger. • Push joysticks forward to lower outriggers; push joysticks back to raise outriggers. •...
Section 3 - Controls and Indicators Right Hand Panel OAL0543 Heater and Air Conditioning Controls (if equipped) 1. Air Vent: Two individually adjustable round vents. 2. Air Louver: Three individually adjustable air louvers. 3. Defroster Fan: Two speed fan. Press fan switch down for slow speed; press switch up for fast speed.
Section 3 - Controls and Indicators Accessory Control Lever (if equipped) The accessory control lever (1) operates turn signals, parking lights and headlights. OY1350 Turn Signals • Push the lever forward (2) to activate the left turn signal. • Pull the lever back (3) to activate the right turn signal. •...
Section 3 - Controls and Indicators STEER MODES Three steer modes are available for operator use. 2-Wheel Front Steer 4-Wheel Circle Steer 4-Wheel Crab Steer OAL2030 Note: 2-Wheel Front Steer mode is required for travel on public roads. Steer Mode Change OY1491 1.
Section 3 - Controls and Indicators OPERATOR SEAT Adjustments Prior to starting engine adjust seat for position and comfort. OW0480 1. Suspension: Use knob to adjust suspension to the appropriate setting. Turn clockwise to increase stiffness. Turn counterclockwise to reduce stiffness. 2.
Section 3 - Controls and Indicators Seat Belt OH20912 Fasten seat belt as follows: 1. Grasp both free ends of the belt making certain that belt webbing is not twisted or entangled. 2. With back straight in the seat, couple the retractable end (male end) of the belt into the receptacle (buckle) end of the belt.
Section 3 - Controls and Indicators REVERSE SENSOR SYSTEM (IF EQUIPPED) Reverse Sensor System provides audible indication of objects to rear of unit while in reverse gear. • Alarm sounds signaling machine is placed in reverse gear. Note: Reverse Sensing System detects objects larger than 36 square inches (232.25 square centimeters) area and is functional when machine is moving in reverse direction.
Section 3 - Controls and Indicators BOOM ANGLE AND EXTENSION INDICATORS 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”...
Starting the Engine This machine can be operated under normal conditions in temperatures of 0°F to 104°F (-20°C to 40°C). Consult JLG for operation outside this range or under abnormal conditions. If equipped for extreme cold weather, -40°F to 0°F (-40°C to -20°C), see page 4-2 for starting procedure.
Section 4 - Operation Extreme Cold Weather Starting (if equipped) If equipped with extreme cold weather components, machine can be operated in temperatures of -40°F to 0°F (-40° C to -20° C). 1. Machine must be equipped with heating components and extreme cold weather fluids.
Section 4 - Operation Battery Boosted Starting OW0530 If battery-boost starting (jump-start) is necessary, proceed as follows: • Never allow vehicles to touch. • Ensure boosting vehicle engine is running. • Connect the positive (+) jumper cable to positive (+) post of discharged battery. •...
Section 4 - Operation Normal Engine Operation • Observe instrument panel frequently to be sure all 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. Report condition to your supervisor or maintenance personnel.
Section 4 - Operation OPERATING WITH A NON-SUSPENDED LOAD Lift Load Safely • You must know the weight and load center of every load you lift. If you are not sure of the weight and load center, check with your supervisor or with the supplier of the material.
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.
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”...
Section 4 - Operation OPERATING WITH A SUSPENDED LOAD Lift Load Safely • You must know the weight and load center of every load you lift. If you are not sure of the weight and load center, check with your supervisor or with the supplier of the material.
Section 4 - Operation Transporting a Suspended Load OZ3160 OW0130 • Travel in accordance with the requirements set forth in Section 1 - General Safety Practices and Section 5 - Attachments. • For additional requirements, refer to the appropriate capacity chart in the operator cab.
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. •...
Section 4 - Operation LOADING AND SECURING FOR TRANSPORT OAL0591 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.
• 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.
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.
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. 31200745...
Section 5 - Attachments USE OF THE CAPACITY CHART 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.
Section 5 - Attachments Sample Capacity Chart 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. Attachment type, XXXXXX weight and <...
Page 79
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. • Use when lifting a load with outriggers up. OAL1090 • Use when lifting a load with outriggers down. OAL1100 31200745...
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: • The attachment style, weight, dimensions and load center match the attachment data on the capacity chart. •...
Section 5 - Attachments ATTACHMENT INSTALLATION OY2851 1. Attachment 2. Attachment Pin Recess 3. Attachment Pin 4. Lock Pin 5. Retaining Pin (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 by lock pin and retainer pin.
Section 5 - Attachments Mechanical Quick Switch This installation procedure is designed for one-person operation. Prior to exiting cab, perform “Shut-Down Procedure” on page 4-4. 1. Tilt quick switch back to provide clearance. Check to be sure lock pin is removed. OY1550 2.
Section 5 - Attachments Hydraulic Quick Switch This installation procedure is designed for one-person operation. 1. Tilt quick switch back to provide clearance. OY3250 2. Align attachment pin with recess in attachment. Raise boom slightly to engage attachment pin in recess. OY3260 3.
Section 5 - Attachments DISENGAGED 5. Raise boom to eye level and visually check that the lock pins protrude through the holes on both sides of the quick switch. If the lock pins do not protrude through the holes, place the attachment on the ground and return to step 2.
Section 5 - Attachments 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.
Page 86
Section 5 - Attachments This Page Intentionally Left Blank 5-14 31200745...
Section 5 - Attachments 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.
Section 5 - Attachments Carriage w/Forks Use Carriage Attachment Capacity Chart determine maximum capacity, refer “Telehandler/ Attachment/Fork Capacity” on page 5-4. OY0690 Suspend loads in accordance with requirements set forth in Section 1 - General Safety Practices. OY2860 The joystick (1) controls lift/lower and extend/retract movement of the boom. The tilt switch (2) controls fork tilt.
Section 5 - Attachments Side Shift Carriage Use Side Shift Carriage Capacity Chart determine maximum capacity, refer “Telehandler/ Attachment/Fork Capacity” on page 5-4. OAL1540 OY3560 The joystick (1) controls lift/lower and extend/retract movement of the boom. The tilt roller switch (2) controls fork tilt. •...
Page 90
Section 5 - Attachments WARNING CRUSH HAZARD. Do not use side shift to push or pull objects or load. Failure to comply could cause object or load to fall. Equipment Damage Precautions: • Do not use forks as a lever to pry material. Excessive prying forces could damage forks or machine structure.
Section 5 - Attachments Side Tilt Carriage Use Side Tilt Carriage Capacity Chart determine maximum capacity, refer “Telehandler/ Attachment/Fork Capacity” on page 5-4. OAL1550 OY2870 The joystick (1) controls lift/lower and extend/retract movement of the boom. The tilt switch (2) controls fork tilt. •...
Page 92
Section 5 - Attachments 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. •...
Section 5 - Attachments Swing Carriage Use Swing Carriage Capacity Chart determine maximum capacity, refer “Telehandler/ Attachment/Fork Capacity” on page 5-4. OU2150 OY2880 The joystick (1) controls lift/lower and extend/retract movement of the boom. The tilt switch (2) controls fork tilt. •...
Page 94
Section 5 - Attachments 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.
Section 5 - Attachments Dual Fork Positioning Carriage Use Carriage Load Chart determine maximum capacity, refer “Telehandler/ Attachment/Fork Capacity” on page 5-4. OZ3670 OY2890 The joystick (1) controls lift/lower and extend/retract movement of the boom. The tilt switch (2) controls fork tilt. •...
Page 96
Section 5 - Attachments WARNING CRUSH HAZARD. Do not use fork positioning to push or pull objects or load. Failure to comply could cause object or load to fall. Operation: • Travel in accordance with the requirements set forth in Section 1 - General Safety Practices.
5-4. The maximum capacity of the carriage when equipped with fork extensions may be reduced to the capacity indicated on the fork extensions. If the load exceeds the capacity of the fork extension contact JLG to obtain forks and/or fork extensions of the proper load rating and length.
Page 98
Section 5 - Attachments 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 tip of fork extensions. 5-26 31200745...
Section 5 - Attachments Mast Carriage Use Mast Carriage Capacity Chart determine maximum capacity, refer “Telehandler/ Attachment/Fork Capacity” on page 5-4. OY0580 OY2900 The joystick (1) controls lift/lower and extend/retract movement of the boom. The tilt switch (2) controls mast tilt. •...
Page 100
Section 5 - Attachments 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.
Section 5 - Attachments Mast Carriage w/Side Tilt Use Mast Carriage Capacity Chart determine maximum capacity, refer “Telehandler/ Attachment/Fork Capacity” on page 5-4. OY0590 OY2910 The joystick (1) controls lift/lower and extend/retract movement of the boom. The tilt switch (2) controls mast tilt. •...
Page 102
Section 5 - Attachments To Raise/Lower Mast: Press Forks Raise/Lower Switch (6) located on dash panel to activate Forks Raise/ Lower function. The auxiliary hydraulic joystick controls the mast raise/lower function. • Move joystick left to lower. • Move joystick right to raise. Installation Procedure: •...
Section 5 - Attachments Fork Mounted Hook Use Appropriate Carriage Attachment Capacity Chart determine maximum capacity, refer “Telehandler/ Attachment/Fork Capacity” on page 5-4. OY0640 Suspend loads in accordance with requirements set forth in Section 1 - General Safety Practices. OY2920 The joystick (1) controls lift/lower and extend/retract movement of the boom.
Page 104
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.
Section 5 - Attachments Truss Boom Use Appropriate Truss Boom Capacity Chart determine maximum capacity, refer “Telehandler/ Attachment/Fork Capacity” on page 5-4. OY0570 Suspend loads in accordance with requirements set forth in Section 1 - General Safety Practices. OY2930 The joystick (1) controls lift/lower and extend/retract movement of the boom. The tilt switch (2) controls truss boom tilt.
Page 106
Section 5 - Attachments 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. Operation: • Weight of rigging must be included as part of total load being lifted. 5-34 31200745...
Section 5 - Attachments Bucket Use Appropriate Bucket Capacity Chart determine maximum capacity, refer “Telehandler/ Attachment/Fork Capacity” on page 5-4. OZ0730 OY2940 The joystick (1) controls lift/lower and extend/retract movement of the boom. The tilt switch (2) controls bucket tilt. •...
Page 108
Section 5 - Attachments Equipment Damage Precautions • Except for lifting or dumping a load, the boom must be fully retracted for all bucket operations. • Do not corner-load bucket. Distribute material evenly within the bucket. Bucket capacity charts are for evenly distributed loads only. •...
Section 5 - Attachments Grapple Bucket Use Grapple Bucket Capacity Chart determine maximum capacity, refer “Telehandler/ Attachment/Fork Capacity” on page 5-4. OZ1450 OY2950 The joystick (1) controls lift/lower and extend/retract movement of the boom. The tilt switch (2) controls grapple bucket tilt. •...
Page 110
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. •...
Section 5 - Attachments Personnel Work Platform - Fork Mounted Use Appropriate Carriage Attachment Capacity Chart determine maximum capacity, refer “Telehandler/ Attachment/Fork Capacity” on page 5-4. OY1610 The operator and personnel in platform must read and understand the separate personnel work platform manual prior to installing and using a platform.
Page 112
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).
Section 6 - Emergency Procedures SECTION 6 - EMERGENCY PROCEDURES TOWING A DISABLED PRODUCT The following information assumes the telehandler cannot be moved under its own power. • Before moving the telehandler, read all of the following information to understand options available.
Section 6 - Emergency Procedures EMERGENCY LOWERING OF BOOM In the event of total loss of engine power or hydraulic pump failure with an elevated load, the situation must be properly evaluated and dealt with on an individual basis. Contact a local Authorized Distributor for specific instructions. Secure the telehandler using the following procedures: 1.
Section 7 - Lubrication and Maintenance SECTION 7 - LUBRICATION AND MAINTENANCE INTRODUCTION Service the product in accordance with the maintenance schedule on the following pages. OY2970 The lubrication and maintenance charts (1) 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 instructions.
Section 7 - Lubrication and Maintenance GENERAL MAINTENANCE INSTRUCTIONS Prior to performing any service or maintenance on the telehandler, follow the shut-down procedure on page 4-4 unless otherwise instructed. Ensure telehandler is level, for proper fluid readings. • Clean lubrication fittings before lubricating. •...
Section 7 - Lubrication and Maintenance OPERATOR MAINTENANCE INSTRUCTIONS Fuel System A. Fuel Level Check OW0970 OW0990 OY2990 1. Check fuel gauge (1) located on instrument panel in cab. 2. If fuel is low, proceed to fuel source and perform “Shut-Down Procedure” on page 4-4.
Page 127
Section 7 - Lubrication and Maintenance B. Drain Fuel/Water Separator OW0980 OW1000 IF EQUIPPED FOR ULS OY3080 IF EQUIPPED FOR LS OY3050 1. Perform “Shut-Down 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.
Section 7 - Lubrication and Maintenance Air Intake System If Equipped for ULS A. Air Filter Restriction Indicator Check OW0970 OW1010 OY3000 1. Perform “Shut-Down Procedure” on page 4-4. 2. Locate air cleaner (1) and check restriction indicator (2). If red band is visible, filter(s) must be replaced.
Page 129
Section 7 - Lubrication and Maintenance B. Element Change (as restriction indicator indicates) 1. Perform “Shut-Down Procedure” on page 4-4. 2. Unlock air cleaner cover (4) and remove from air cleaner canister. 3. Lightly remove any loose dirt from cover and precleaner (5). 4.
Page 130
Section 7 - Lubrication and Maintenance If Equipped for LS A. Air Filter Restriction Indicator Check OW0970 OW1010 OY3010 1. Perform “Shut-Down Procedure” on page 4-4. 2. Locate air cleaner (1) and check restriction indicator (2). If red band is visible, filter(s) must be replaced.
Page 131
Section 7 - Lubrication and Maintenance B. Element Change (as restriction indicator indicates) 1. Perform “Shut-Down Procedure” on page 4-4. 2. Unlock air cleaner cover (4) and remove from air cleaner canister. 3. Remove outer primary element (5) and inspect for damage. Damaged elements should not be reused.
Section 7 - Lubrication and Maintenance Engine Oil A. Engine Oil Level Check OW0970 OW1020 OY3070 1. Perform “Shut-Down Procedure” on page 4-4. 2. Open the engine cover. 3. Remove dipstick (1) and check oil mark. The oil should be between the full (2) and add (3) marks within the crosshatched area of the dipstick.
Section 7 - Lubrication and Maintenance Hydraulic Oil A. Hydraulic Oil Level Check OW0970 OW1030 OY3020 1. Be sure all cylinders are fully retracted and machine is level. 2. Perform “Shut-Down Procedure” on page 4-4. 3. Open the engine cover. 4.
Section 7 - Lubrication and Maintenance Tires A. Tire Air Pressure Check OW0970 OW1040 1. Perform “Shut-Down Procedure” on page 4-4. 2. Remove valve stem cap. 3. Check tire pressure. 4. Add air if required. See page 9-5 for tire pressures. 5.
Page 135
• 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 filled or ballast filled tire assembly with a pneumatic tire. Due to size variations between tire brands, when selecting and installing a replacement tire ensure both tires on the axle are the same.
Page 136
Section 7 - Lubrication and Maintenance E. Wheel Installation Torque lug nuts after first 50 hours and after each wheel installation. Note: If machine is equipped with directional tire assemblies, the wheel and tire assemblies must be installed with the directional tread pattern “arrows” facing in the direction of forward travel.
Section 7 - Lubrication and Maintenance Transmission Oil A. Transmission Oil Level Check OW0970 OW1050 OY3060 1. Apply park brake, shift transmission to "Neutral" and lower forks or attachment to the ground. 2. Check transmission oil level with engine at idle and oil at normal operating temperature.
Section 7 - Lubrication and Maintenance Engine Cooling System A. Engine Coolant Level Check OW0980 OW1070 OY3030 1. Perform “Shut-Down Procedure” on page 4-4. 2. Open the engine cover. 3. Check coolant level in surge tank (1). When coolant is hot, bottle should be 1/2 to 3/4 full.
Section 7 - Lubrication and Maintenance Battery A. Battery Check OW0980 OW1080 OY3040 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 damaged case. 4.
Section 7 - Lubrication and Maintenance Windshield Washer System (if equipped) A. Windshield Washer Fluid Level Check OW0980 OAL2040 OAL2300 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 level is low, add fluid as needed. 7-26 31200745...
Section 8 - Additional Checks SECTION 8 - ADDITIONAL CHECKS GENERAL If any of the following test results cannot be achieved, the system is not functioning properly and the machine must be removed from service and repaired before continued operation. REVERSE SENSOR SYSTEM (IF EQUIPPED) A.
Page 142
Section 8 - Additional Checks 4. Verify operation with no objects in detection zone. No audible alarm. 5. Verify operation when object is in range of approximately 9 to 15 ft (2.7 to 4.5 m). Produces pulsing audible alarm at a frequency of one per second (1 Hz). 6.
Section 9 - Specifications SECTION 9 - SPECIFICATIONS PRODUCT SPECIFICATIONS Fluids If Equipped for ULS Ambient Temperature Range Compartment Type and Viscosities or System Classification °F °C Min Max Min Max SAE 15W-40 Engine API CJ-4 Plus Crankcase SAE 0W-40 Transmission Mobilfluid 424 10W-30...
Page 144
Section 9 - Specifications Ambient Temperature Range Compartment Type and Viscosities or System Classification °F °C Min Max Min Max #2 Diesel Standard B5 Biodiesel Blend of #1 diesel and Ultra Low Sulfur Fuel #2 diesel fuels (S ≤ 15 mg/kg) ("winterized"...
Page 145
Section 9 - Specifications If Equipped for LS Ambient Temperature Range Compartment Type and Viscosities or System Classification °F °C Min Max Min Max SAE 15W-40 Engine API CI-4 Multigrade Crankcase SAE 0W-40 Transmission Mobilfluid 424 10W-30 and Transfer Mobilfluid LT 75W-80 Case Mobilfluid 424*...
Section 9 - Specifications Capacities Engine Crankcase Oil Capacity with Filter Change..............14.0 qt (13,3 L) Fuel Tank Capacity....................38 gal (144 L) Cooling System System Capacity................. 20.0 qt (18,9 L) Hydraulic System System Capacity.................60.5 gal (229 L) Reservoir Capacity to Middle of Sight Gauge........33 gal (125 L) Auxiliary Hydraulic Circuit Max Flow ..........10 gpm (37,9 lpm) Transmission Capacity with Filter Change..............
Note: Values shown are per machine as originally manufactured. Reference capacity charts in operator cab for specific model and attachment configuration values. Maximum Lift Capacity G10-55A .................10,000 lb (4536 kg) G12-55A .................12,000 lb (5443 kg) Maximum Lift Height................55 ft (16,8 m) Capacity at Maximum Height Outriggers Engaged..............5,000 lb (2268 kg)
Page 152
Index Hazard Classification System... 1-1 Park Brake ........3-7 Headlights........3-15 Parking Lights .........3-15 Heater Controls ......3-14 Parking Procedure ......3-7 Hydraulic Oil Level......7-19 Performance........9-6 Hydraulic Operated Attachment ..5-12 Personnel Work Platform Fork Mounted......5-39 Picking Up a Load ......4-5 Ignition ..........
Page 153
Index Tip Over Hazard ....... 1-3 Tires ........7-20, 9-5 Air Pressure ......7-20 Damage ........7-20 Replacement......7-21 Towing..........6-1 Transmission Control Lever Direction of Travel....... 3-8 Gear Selection ......3-9 Transport Lifting ........4-12 Tiedown ........4-11 Transporting a Load ......4-6 Transporting a Suspended Load ..
Inspection, Maintenance and Repair Log Inspection, Maintenance and Repair Log Serial Number ______________________________ Date Comments...
Page 156
Inspection, Maintenance and Repair Log Date Comments...
Page 157
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.
Page 159
Hand Signals OY1090 OY1100 OY1110 EMERGENCY STOP - With both STOP - With either arm extended STOP ENGINE - Draw thumb or arms extended laterally, hands laterally, hand open downward, forefinger across throat. open downward, move arms back move arm back and forth. and forth.
Page 160
McConnellsburg PA. 17233-9533 Phone: +1-717-485-5161 Customer Support Toll Free: 1-877-554-5438 Fax: +1-717-485-6417 JLG Worldwide Locations JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) Ltd P.O. Box 5119 Rua Antonia Martins Luiz, 580 Bentley House 11 Bolwarra Road Distrito Industrial João Narezzi...
Need help?
Do you have a question about the G10-55A and is the answer not in the manual?
Questions and answers