Jlg G12-55A Operator Manual User Manual

Operation & SafetyManualOriginal InstructionsKeep this manual with machine at all times.An Oshkosh Corporation CompanyModelsG10-55AG12-55ABefore S

Table of Contentsiv 3126018Section 7 - Lubrication and Maintenance7.1 Introduction...

Section 5 - Attachments5-26 3126018Fork ExtensionUse Appropriate Carriage Attachment Capacity ChartTo determine maximum capacity, refer to “Telehandle

Section 5 - Attachments5-273126018Operation:• Heavy part of load must be against carriage backrest.• Do not allow load center of gravity to be in fron

Section 5 - Attachments5-28 3126018Mast CarriageUse Mast Carriage Capacity ChartTo determine maximum capacity, refer to “Telehandler/Attachment/Fork C

Section 5 - Attachments5-293126018Operation:• Always lower forks fully in mast before engaging load.• To drive with a load, lower forks fully in mast

Section 5 - Attachments5-30 3126018Mast Carriage w/Swing and Side Shift (Before S/N 0160037689)Use 6 ft Mast Carriage Capacity ChartTo determine maxim

Section 5 - Attachments5-313126018To Raise/Lower Mast:Press Forks Raise/Lower Switch (6) located on dash panel to activate Forks Raise/Lower function.

Section 5 - Attachments5-32 3126018Mast Carriage w/Side Tilt (S/N 0160037689 & After)Use Mast Carriage Capacity ChartTo determine maximum capacity

Section 5 - Attachments5-333126018Installation Procedure:• Refer to “Attachment Installation” on page 5-13.Operation:• Always lower forks fully in mas

Section 5 - Attachments5-34 3126018Fork Mounted HookUse Appropriate Carriage Attachment Capacity ChartTo determine maximum capacity, refer to “Telehan

Section 5 - Attachments5-353126018Operation:• Pallet or lumber forks of an appropriate load rating must be used. Do not use withcubing or block forks.

Section 1 - General Safety Practices1-13126018SECTION 1 - GENERAL SAFETY PRACTICES1.1 HAZARD CLASSIFICATION SYSTEMSafety Alert System and Safety Signa

Section 5 - Attachments5-36 3126018Truss BoomUse Appropriate Truss Boom Capacity ChartTo determine maximum capacity, refer to “Telehandler/Attachment/

Section 5 - Attachments5-373126018Operation:• Weight of rigging must be included as part of total load being lifted.WARNINGCRUSH HAZARD. Maintain a mi

Section 5 - Attachments5-38 3126018BucketUse Appropriate Bucket Capacity ChartTo determine maximum capacity, refer to “Telehandler/Attachment/Fork Cap

Section 5 - Attachments5-393126018Equipment Damage Precautions• Except for lifting or dumping a load, the boom must be fully retracted for allbucket o

Section 5 - Attachments5-40 3126018Grapple BucketUse Grapple Bucket Capacity ChartTo determine maximum capacity, refer to “Telehandler/Attachment/Fork

Section 5 - Attachments5-413126018Operation:• Raise or lower boom to appropriate height and open grapple for loading materialfrom stockpile.• Align te

Section 5 - Attachments5-42 3126018Personnel Work Platform - Quick Switch Mounted(Before S/N 0160037689)Use Personnel Work Platform - Quick Switch Mou

Section 5 - Attachments5-433126018Preparation and Setup:1. Ensure the telehandler is on a firm surface and is level.2. Engage the park brake. Blocking

Section 5 - Attachments5-44 3126018Personnel Work Platform - Fork MountedUse Appropriate Carriage Attachment Capacity ChartTo determine maximum capaci

Section 5 - Attachments5-453126018Preparation and Setup:1. Ensure the telehandler is on a firm surface and is level.2. Engage the park brake. Blocking

Section 1 - General Safety Practices1-2 31260181.3 OPERATION SAFETYElectrical Hazards• This machine is not insulated and does not provide protection f

Section 5 - Attachments5-46 3126018Boom Head-Mounted Winch (Before S/N 0160037689)Use Carriage Attachment Capacity ChartTo determine maximum capacity,

Section 6 - Emergency Procedures6-13126018SECTION 6 - EMERGENCY PROCEDURES6.1 TOWING A DISABLED PRODUCTThe following information assumes the telehandl

Section 6 - Emergency Procedures6-2 31260186.2 EMERGENCY LOWERING OF BOOMIn the event of total loss of engine power or hydraulic pump failure with an

Section 7 - Lubrication and Maintenance7-13126018SECTION 7 - LUBRICATION AND MAINTENANCE7.1 INTRODUCTIONService the product in accordance with the mai

Section 7 - Lubrication and Maintenance7-2 31260187.2 GENERAL MAINTENANCE INSTRUCTIONSPrior to performing any service or maintenance on the telehandle

Section 7 - Lubrication and Maintenance7-331260187.3 SERVICE AND MAINTENANCE SCHEDULE10 & 1st 50 and 50 Hour Maintenance ScheduleOW0764CheckTransm

Section 7 - Lubrication and Maintenance7-4 31260181st 250, 250 & 500 Hour Maintenance ScheduleNote: Engine oil and filter service interval may be

Section 7 - Lubrication and Maintenance7-531260181000 & 1500 Hour Maintenance ScheduleOAL22911500EVERYChangeEngine CoolantChangeHydraulicFluid &am

Section 7 - Lubrication and Maintenance7-6 31260187.4 LUBRICATION SCHEDULES50 Hour Lubrication ScheduleOAL045050EVERY

Section 7 - Lubrication and Maintenance7-73126018250 Hour Lubrication ScheduleOW1211EVERY250

Section 1 - General Safety Practices1-33126018Tip Over HazardGeneral• For additional load requirements, refer to the appropriate capacity chart.• Neve

Section 7 - Lubrication and Maintenance7-8 31260181000 Hour Lubrication ScheduleOY2080EVERY1000

Section 7 - Lubrication and Maintenance7-93126018This Page Intentionally Left Blank

Section 7 - Lubrication and Maintenance7-10 31260187.5 OPERATOR MAINTENANCE INSTRUCTIONSFuel SystemA. Fuel Level Check1. Check fuel gauge (1) located

Section 7 - Lubrication and Maintenance7-113126018B. Drain Fuel/Water Separator1. Perform “Shut-Down Procedure” on page 4-5.2. Open the engine cover.3

Section 7 - Lubrication and Maintenance7-12 3126018Air Intake SystemA. Air Filter Restriction Indicator Check1. Perform “Shut-Down Procedure” on page

Section 7 - Lubrication and Maintenance7-133126018B. Element Change (as restriction indicator indicates)1. Perform “Shut-Down Procedure” on page 4-5.2

Section 7 - Lubrication and Maintenance7-14 3126018Engine OilA. Engine Oil Level Check1. Perform “Shut-Down Procedure” on page 4-5.2. Open the engine

Section 7 - Lubrication and Maintenance7-153126018Hydraulic OilA. Hydraulic Oil Level Check1. Be sure all cylinders are fully retracted and machine is

Section 7 - Lubrication and Maintenance7-16 3126018TiresA. Tire Air Pressure Check1. Perform “Shut-Down Procedure” on page 4-5.2. Remove valve stem ca

Section 7 - Lubrication and Maintenance7-173126018C. Tire and Wheel ReplacementIt is recommended that a replacement tire to be the same size, ply and

Section 1 - General Safety Practices1-4 3126018• MAINTAIN proper tire pressure at all times. If proper tire pressures are notmaintained, this machine

Section 7 - Lubrication and Maintenance7-18 3126018E. Wheel InstallationTorque lug nuts after first 50 hours and after each wheel installation.Note:

Section 7 - Lubrication and Maintenance7-193126018Transmission OilA. Transmission Oil Level Check1. Apply park brake, shift transmission to "Neut

Section 7 - Lubrication and Maintenance7-20 3126018Hydraulic Return Filter (Before S/N 0160039451 excluding 0160039394 & 0160039397)A. Hydraulic R

Section 7 - Lubrication and Maintenance7-213126018Engine Cooling SystemA. Engine Coolant Level Check1. Perform “Shut-Down Procedure” on page 4-5.2. Op

Section 7 - Lubrication and Maintenance7-22 3126018BatteryA. Battery Check1. Perform “Shut-Down Procedure” on page 4-5.2. Open the engine cover.3. Wea

Section 7 - Lubrication and Maintenance7-233126018Windshield Washer System (if equipped)A. Windshield Washer Fluid Level Check1. Perform “Shut-Down Pr

Section 7 - Lubrication and Maintenance7-24 3126018This Page Intentionally Left Blank

Section 8 - Additional Checks8-13126018SECTION 8 - ADDITIONAL CHECKS8.1 AUTO-FRAME LEVEL SYSTEM (BEFORE S/N 0160038592)A. Auto-Frame Level Function Ch

Section 8 - Additional Checks8-2 3126018This Page Intentionally Left Blank

Section 9 - Specifications9-13126018SECTION 9 - SPECIFICATIONS9.1 PRODUCT SPECIFICATIONSCapacitiesEngine Crankcase OilCapacity with Filter ChangeJohn

Section 1 - General Safety Practices1-53126018Non-Suspended Load• DO NOT drive with boom raised.Suspended Load• Tether suspended loads to restrict mov

Section 9 - Specifications9-2 3126018Hydraulic SystemSystem CapacityG10-55A ...

Section 9 - Specifications9-33126018Tires14.00 x 24, G-2/L-2 Bias-Ply Traction - 12 Ply (G10-55A only)Pneumatic...

Section 9 - Specifications9-4 3126018PerformanceNote: Values shown are per machine as originally manufactured. Reference capacity charts in operator

Section 9 - Specifications9-53126018DimensionsOverall Height...101 in (

Section 9 - Specifications9-6 3126018Maximum Ground Bearing PressureG10-55ABefore S/N 0160039451 excluding 0160039394 & 016003939714.00 x 24Air Fi

Index13126018AAccessory Control Lever ... 3-15Additional Checks... 8-1Adjusting/Moving Forks ...

Index2 3126018Hydraulic Oil Level... 7-15Hydraulic Operated Attachment ... 5-16IIgnition...

Index33126018TransportLifting ... 4-13Tiedown ... 4-12Transporting a Load ...

Index4 3126018

Inspection, Maintenance and Repair LogSerial Number ______________________________Date CommentsInspection, Maintenance and Repair Log

Section 1 - General Safety Practices1-6 3126018Travel Hazard• Steering characteristics differ between steer modes. Identify the steer modesettings of

Inspection, Maintenance and Repair LogDate Comments

TRANSFER OF OWNERSHIPTo Product Owner:If you now own but ARE NOT the original purchaser of the product covered by this manual, we would like to know w

- When signals for auxiliary equipment functions or conditions not covered are required, they shall be agreed upon in advance by the operator and sig

JLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USAPhone: +1-717-485-5161Customer Support Toll Free: 1-877-554-5438Fax: +1-717-485-6417JLG

Section 1 - General Safety Practices1-73126018Load Falling Hazard• Never suspend load from forks or other parts of carriage.• DO NOT burn or drill hol

Section 1 - General Safety Practices1-8 3126018Lifting Personnel• When lifting personnel, USE ONLY a JLG approved personnel work platform,with proper

Section 1 - General Safety Practices1-93126018Driving Hazards on SlopesTo maintain sufficient traction and braking capabilities, travel on slopes as f

CALIFORNIA PROPOSITION 65BATTERY WARNINGBattery posts,terminals and relatedaccessories containlead and lead compounds,chemical known to theState of Ca

Section 1 - General Safety Practices1-10 3126018Pinch Points and Crush HazardsStay clear of pinch points and rotating parts on the telehandler.• Stay

Section 1 - General Safety Practices1-113126018• Keep clear of boom holes.• Keep arms and hands clear of attachment tilt cylinder.• Keep hands and fin

Section 1 - General Safety Practices1-12 3126018Fall Hazard• Enter using the proper hand holds and steps provided. Always maintain 3-pointcontact when

Section 1 - General Safety Practices1-133126018Chemical HazardsExhaust Fumes• DO NOT operate machine in an enclosed area without proper ventilation.•

Section 1 - General Safety Practices1-14 3126018This Page Intentionally Left Blank

Section 2 - Pre-Operation and Inspection2-13126018SECTION 2 - PRE-OPERATION AND INSPECTION2.1 PRE-OPERATION CHECK AND INSPECTIONNote: Complete all re

Section 2 - Pre-Operation and Inspection2-2 31260188. Operational Check - Once the walk-around inspection is complete, perform a warm-up and operation

Section 2 - Pre-Operation and Inspection2-331260182.2 SAFETY DECALSEnsure all DANGER, WARNING, CAUTION and instructional decals and propercapacity c

Section 2 - Pre-Operation and Inspection2-4 3126018OY20119150-3097 REV. -MOVING PARTS cancut or entangle. Keepclear while engine isrunning.91503097Die

Section 2 - Pre-Operation and Inspection2-53126018OW035391513210MOVING PARTS could cut or crush causingdeath or serious injury. Keep clear ofmoving pa

Revision Loga3126018Revision LogREVISION LOGJuly 9, 2004 - A - Original Issue of ManualAugust 8, 2007 - B - Revised manual and added Tier III informat

Section 2 - Pre-Operation and Inspection2-6 3126018S/N 0160040120 & After, If EquippedOY26401706850ACRUSHING HAZARDKeep othersaway whileoperating.

Section 2 - Pre-Operation and Inspection2-73126018OY2650410980141098014109801410980117062961706304ARUN-OVERHAZARDcould causedeath orseriousinjury.1706

Section 2 - Pre-Operation and Inspection2-8 3126018OY26601706302170630217063021706298A17062981706302-10°-10°0°10°10°20°20°30°30°40°40°50°50°60°60°70°7

Section 2 - Pre-Operation and Inspection2-93126018ISO (S/N 0160040120 & After, If Equipped)OY2670170628817062841001092877915031129150-3112 REV -1

Section 2 - Pre-Operation and Inspection2-10 3126018OY2680410980141098014109801410980191163028REV.BFNR9116302810011211261001092897A10D50LB-FT(Nm)50100

Section 2 - Pre-Operation and Inspection2-113126018OY269017062821706292 1706292915530721706292170629217062921706292-10°-10°0°10°10°20°20°30°30°40°40°5

Section 2 - Pre-Operation and Inspection2-12 31260182.3 WALK-AROUND INSPECTIONBegin your walk-around inspection at item 1, as noted below. Continue to

Section 2 - Pre-Operation and Inspection2-1331260184. Wheel/Tire Assembly - Properly inflated and secured; no loose or missing lug nuts. Inspect for w

Section 2 - Pre-Operation and Inspection2-14 31260182.4 WARM-UP AND OPERATIONAL CHECKSWarm-Up CheckDuring warm-up period, check:1. Heater, defroster a

Section 2 - Pre-Operation and Inspection2-1531260182.5 OPERATOR CABThe telehandler is equipped with an open or enclosed ROPS/FOPS cab.WARNINGNever ope

Read This Firstb 3126018Read This FirstThis manual is a very important tool! Keep it with the machine at all times.The purpose of this manual is to pr

Section 2 - Pre-Operation and Inspection2-16 31260182.6 WINDOWSKeep all windows and mirrors clean and unobstructed.Cab Door Window (if equipped)• Cab

Section 3 - Controls and Indicators3-13126018SECTION 3 - CONTROLS AND INDICATORS3.1 GENERALThis section provides the necessary information needed to u

Section 3 - Controls and Indicators3-2 31260183.2 CONTROLS1. Transmission Control Lever: See page 3-8.2. Instrument Panel: See page 3-4.3. Steering Wh

Section 3 - Controls and Indicators3-3312601811. Decompression Valve: Depress button to relieve pressure in auxiliary hydraulic circuit.12. Accelerato

Section 3 - Controls and Indicators3-4 3126018Dash Controls and Indicators1. Hourmeter: Indicates total time of engine operation in hours and tenths o

Section 3 - Controls and Indicators3-531260187. Warning and Check Engine Lights (Perkins and Cummins Only): Any combination of illumination indicates

Section 3 - Controls and Indicators3-6 3126018Ignition• In "ACC" or "RUN" position, voltage is available for all electrical functi

Section 3 - Controls and Indicators3-73126018Park BrakePark brake switch controls the application and release of the park brake. Indicatorlight on swi

Section 3 - Controls and Indicators3-8 3126018Transmission Control LeverDirection of Travel SelectionTransmission control lever (1) engages forward or

Section 3 - Controls and Indicators3-93126018Gear SelectionGear selection is located on the twist grip handle (2) of transmission control lever.• Twis

Read This Firstc3126018This product must comply with all safety related bulletins. Contact JLG Industries,Inc. or the local authorized JLG representat

Section 3 - Controls and Indicators3-10 3126018Boom JoystickThe boom joystick (1) controls the boom and attachment tilt functions.Boom Functions• Move

Section 3 - Controls and Indicators3-113126018Frame Level JoystickThe frame level joystick (4) controls the left to right frame level.• Move the joyst

Section 3 - Controls and Indicators3-12 3126018Auxiliary Hydraulic Joystick (if equipped)The auxiliary hydraulic joystick (1) controls function of att

Section 3 - Controls and Indicators3-133126018Outrigger JoysticksThe rear joysticks (2) control the outriggers.• The left joystick controls the left o

Section 3 - Controls and Indicators3-14 3126018Right Hand PanelHeater and Air Conditioning Controls (if equipped)1. Air Vent: Two individually adjusta

Section 3 - Controls and Indicators3-153126018Accessory Control Lever (if equipped)The accessory control lever (1) operates the turn signals, parking

Section 3 - Controls and Indicators3-16 31260183.3 STEER MODESThree steer modes are available for operator use.Note: 2-Wheel Front Steer mode is requ

Section 3 - Controls and Indicators3-1731260183.4 OPERATOR SEATAdjustmentsPrior to starting engine adjust seat for position and comfort.1. Suspension:

Section 3 - Controls and Indicators3-18 3126018Seat BeltFasten seat belt as follows:1. Grasp both free ends of the belt making certain that belt webbi

Section 3 - Controls and Indicators3-1931260183.5 BOOM ANGLE AND EXTENSION INDICATORS• The boom angle indicator (1) is located on the left side of the

Read This Firstd 3126018Other Publications AvailableService Manual...

Section 3 - Controls and Indicators3-20 3126018This Page Intentionally Left Blank

Section 4 - Operation4-13126018SECTION 4 - OPERATION4.1 ENGINEStarting the EngineThis machine can be operated under normal conditions in temperatures

Section 4 - Operation4-2 3126018Cold Weather Starting AidsJohn Deere EngineJLG approved starting aids employ ether. If your telehandler is equipped wi

Section 4 - Operation4-33126018Extreme Cold Weather Starting (if equipped)If equipped with extreme cold weather components, machine can be operated in

Section 4 - Operation4-4 3126018Battery Boosted StartingIf battery-boost starting (jump-start) is necessary, proceed as follows:• Never allow vehicles

Section 4 - Operation4-53126018Normal Engine Operation• Observe instrument panel frequently to be sure all systems are functioningproperly.• Be alert

Section 4 - Operation4-6 31260184.2 OPERATING WITH A NON-SUSPENDED LOADLift Load Safely• You must know the weight and load center of every load you li

Section 4 - Operation4-73126018Transporting a LoadAfter engaging the load and resting it against the backrest, tilt the load back toposition it for tr

Section 4 - Operation4-8 3126018Placing a LoadBefore placing any load be sure that:• The landing point can safely support the weight of the load.• The

Section 4 - Operation4-931260184.3 OPERATING WITH A SUSPENDED LOADLift Load Safely• You must know the weight and load center of every load you lift. I

Table of Contentsi3126018TABLE OF CONTENTSRevision LogRead This FirstOperator Qualifications ... bM

Section 4 - Operation4-10 3126018Transporting a Suspended Load• Travel in accordance with the requirements set forth in Section 1 - GeneralSafety Prac

Section 4 - Operation4-113126018Placing a Suspended LoadBefore placing any load be sure that:• The landing point can safely support the weight of the

Section 4 - Operation4-12 31260184.4 LOADING AND SECURING FOR TRANSPORTTiedown1. Level the telehandler prior to loading.2. Using a spotter, load the t

Section 4 - Operation4-133126018Lifting• When lifting machine, it is very important that the lifting device and equipment isattached only to designate

Section 4 - Operation4-14 3126018This Page Intentionally Left Blank

Section 5 - Attachments5-13126018SECTION 5 - ATTACHMENTS5.1 APPROVED ATTACHMENTSTo determine if an attachment is approved for use on the specific tele

Section 5 - Attachments5-2 31260185.2 UNAPPROVED ATTACHMENTSDo not use unapproved attachments for the following reasons:• Range and capacity limitatio

Section 5 - Attachments5-331260185.3 JLG SUPPLIED ATTACHMENTSBefore S/N 0160037689Attachment Part NumberApplicable ModelG10-55A G12-55ACarriage, 48 in

Section 5 - Attachments5-4 3126018Grapple Bucket, 96 in -1.75 yd30930021 X XHook, Fork Mounted 90553036 X XHook, Fork Mounted 91565094 X XTruss Boom,

Section 5 - Attachments5-53126018S/N 0160037689 & AfterAttachment Part NumberApplicable ModelG10-55A G12-55ACarriage, 50 in (1270 mm) 1170021 X XC

Table of Contentsii 3126018Transmission Control Lever... 3-8Boom Joystick ...

Section 5 - Attachments5-6 31260185.4 TELEHANDLER/ATTACHMENT/FORK CAPACITYPrior to installing the attachment verify it is approved and the telehandler

Section 5 - Attachments5-731260185.5 USE OF THE CAPACITY CHARTTo properly use the capacity chart (see page 5-8), the operator must first determineand/

Section 5 - Attachments5-8 3126018Sample Capacity ChartBefore S/N 0160037689Note: This is a sample capacity chart only! DO NOT use this chart, use th

Section 5 - Attachments5-93126018To identify the proper capacity chart on telehandlers equipped with outriggers, referto the following icons which may

Section 5 - Attachments5-10 3126018S/N 0160037689 & AfterNote: This is a sample capacity chart only! DO NOT use this chart, use the one located i

Section 5 - Attachments5-113126018To identify the proper load chart on telehandlers equipped with outriggers, refer tothe following icons which may be

Section 5 - Attachments5-12 3126018ExampleA contractor owns a model xxxxx telehandler with a fork carriage. He knows thisattachment may be used with h

Section 5 - Attachments5-1331260185.6 ATTACHMENT INSTALLATION1. Attachment 2. Attachment Pin Recess 3. Attachment Pin 4. Lock Pin 5. Retaining Pin 6.

Section 5 - Attachments5-14 3126018Before S/N 0160037689This installation procedure is designed for one-person operation. Prior to exiting cab,perform

Section 5 - Attachments5-153126018S/N 0160037689 & AfterThis installation procedure is designed for one-person operation. Prior to exiting cab,per

Table of Contentsiii3126018Section 5 - Attachments5.1 Approved Attachments ...5-15.2 Unapproved A

Section 5 - Attachments5-16 3126018Hydraulic Operated Attachment1. Install attachment (see page 5-13).2. Lower attachment to ground and perform “Shut-

Section 5 - Attachments5-1731260185.7 ADJUSTING/MOVING FORKSCarriages may have different locations where forks can be positioned. Two differentmethods

Section 5 - Attachments5-18 31260185.8 ATTACHMENT OPERATION• Capacities and range limits for the telehandler change depending on theattachment in use.

Section 5 - Attachments5-193126018Carriage w/ForksUse Carriage Attachment Capacity ChartTo determine maximum capacity, refer to “Telehandler/Attachmen

Section 5 - Attachments5-20 3126018Side Tilt CarriageUse Side Tilt Carriage Capacity ChartTo determine maximum capacity, refer to “Telehandler/Attachm

Section 5 - Attachments5-213126018Operation:• Approach load with forks centered on load and stop telehandler.• Level telehandler before side tilting c

Section 5 - Attachments5-22 3126018Swing CarriageUse Swing Carriage Capacity ChartTo determine maximum capacity, refer to “Telehandler/Attachment/Fork

Section 5 - Attachments5-233126018Operation:• To drive with a load, keep forks pointed forward and travel in accordance with therequirements set forth

Section 5 - Attachments5-24 3126018Dual Fork Positioning CarriageUse Carriage Load ChartTo determine maximum capacity, refer to “Telehandler/Attachmen

Section 5 - Attachments5-253126018Operation:• Travel in accordance with the requirements set forth in Section 1 - GeneralSafety Practices.Equipment Da