2. Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as
"DANGER", "WARNING" or "CAUTION". The Safety Alert "WARNING" label is shown below.
The meaning of this safety alert symbol is as follows:
Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by "NOTICE" labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that was
available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar®
dealers have the most current information available.
When replacement parts are required for this
product Caterpillar recommends using
Caterpillar replacement parts or parts with
equivalent specifications including, but not
limited to, physical dimensions, type, strength
and material.
Failure to heed this warning can lead to
premature failures, product damage, personal
injury or death.
3. EFFECTIVITY PAGE
31200245 i
July 14, 2006 - A - Original Issue Of Manual
February 2, 2007 - B - Added Tier III information. Revised pages 9, 18, 19, 36, 76, 94, 109, 124, 125, 126,
127, 129 and 130.
July 10, 2007 - C - Added LSI Cutout information on pages 46 & 47. Revised Tire Information on page 91 and revised
Boom Chain Adjustment Procedure on pages 99 thru 101.
4. 31200245 1
Table of Contents
Table of Contents
Foreword
Literature Information ............................................ 5
Safety .................................................................... 5
Operation .............................................................. 5
Maintenance.......................................................... 5
Maintenance Intervals...................................... 5
Certified Engine Maintenance ............................... 5
Machine Capacity.................................................. 5
Contact Information............................................... 6
Safety Section
Safety Messages................................................... 7
Do Not Operate (1)........................................... 9
Do Not Stand Under the Load (2) .................. 10
No Hands (3).................................................. 10
Do Not Operate (4)......................................... 11
Forks (5)......................................................... 11
ROPS/FOPS Structure (6) ............................. 12
No Hands (7).................................................. 12
Crushing Hazard (8)....................................... 13
Seat Belt (9) ................................................... 13
Crushing Hazard (10)..................................... 14
Crushing Hazard (11)..................................... 14
Engine Coolant (12) ....................................... 15
Avoid Power Lines (13).................................. 15
Low Bridge (14).............................................. 16
Jump Start Cables (15) .................................. 16
Ether (16) ....................................................... 17
Crushing Hazard (17)..................................... 17
Crushing Hazard (18)..................................... 17
Crushing Hazard (19)..................................... 18
Ether (20) ....................................................... 18
Universal Warning (21) .................................. 19
Hand (High Pressure) (22)............................. 19
Additional Messages...................................... 19
General Hazard Information................................ 23
Pressurized Air and Water ............................. 24
Trapped Pressure .......................................... 24
Fluid Penetration............................................ 24
Containing Fluid Spillage ............................... 24
Dispose of Waste Properly............................. 25
Crushing Prevention and Cutting Prevention ...... 25
Burn Prevention .................................................. 25
Coolant........................................................... 25
Oils................................................................. 25
Batteries......................................................... 25
Fire Prevention and Explosion Prevention .......... 26
Fire Extinguisher ............................................ 27
Lines, Tubes and Hoses ................................ 27
Fire Extinguisher Location.............................. 27
Tire Information.............................................. 27
Electrical Storm Injury Prevention.................. 28
Before Starting Engine................................... 28
Engine Starting.................................................... 28
Before Operation................................................. 29
Operation ............................................................ 29
Machine Operating Temperature Range........ 29
Machine Operation......................................... 29
Travel..............................................................29
Lifting Capacities ............................................29
Work Tools......................................................30
Engine Stopping...................................................30
Work Tools...........................................................30
Parking.................................................................31
Equipment Lowering with Loss of Hydraulic
Power...................................................................31
Sound Information and Vibration Information ......31
Sound Level....................................................31
Vibration Level................................................31
Operator Station .............................................32
Guards (Operator Protection) ..............................32
Rollover Protective Structure (ROPS), Falling
Object Protective Structure (FOPS)................32
Other Guards (If Equipped) ............................32
Product Information Section
General Information .............................................33
Lifting Capacities ............................................33
Examples of Estimating the Lift Operation from
the Load Chart................................................34
Specifications.......................................................35
Intended Use ..................................................35
Application/Configuration Restrictions ............36
Identification Information......................................36
Plate Locations and Film Locations ................36
Serial Number.................................................36
Certification.....................................................37
Sound .............................................................37
ROPS/FOPS Film ...........................................37
Machine Security System ...............................38
Italian Roading Homologation.........................38
Emissions Certification Film.................................39
Operation Section
Before Operation..................................................41
Mounting and Dismounting.............................41
Alternate Exit ..................................................41
Daily Inspection ..............................................41
Machine Operation...............................................42
Alternate Exit ..................................................42
Seat ................................................................42
Air Suspension (If Equipped)..........................43
Seat Belt .........................................................43
Operator Controls (Side Console) ..................46
Operator Controls ...........................................48
Battery Disconnect Switch (If Equipped) ........58
Boom Cylinder Lock (If Equipped)..................59
Operation Information .....................................60
Work Tools......................................................67
Monitoring System ..........................................72
Backup Alarm .................................................75
Cab Door ........................................................75
Engine Starting ....................................................76
Engine Starting ...............................................76
Starting Below 0 °C (32°F)..............................76
Engine and Machine Warm-Up.......................77
Parking.................................................................77
Stopping the Machine .....................................77
Table of
5. 31200245 2
Table of Contents
Stopping the Engine............................................ 77
Stopping the Engine if an Electrical Malfunction
Occurs............................................................ 78
Leaving the Machine...................................... 78
Transportation Information .................................. 78
Shipping the Machine..................................... 78
Roading the Machine ..................................... 79
Lifting and Tying Down the Machine.............. 79
Towing Information.............................................. 80
Towing the Machine....................................... 80
Engine Starting (Alternate Methods) ................... 82
Engine Starting with Jump Start Cables......... 82
Equipment Lowering with Loss of Hydraulic
Power............................................................. 83
Procedure for Retracting the Boom without Hand
Pump.............................................................. 84
Procedure for Lowering the Boom with Hand
Pump.............................................................. 85
Procedure for Lowering the Boom without Hand
Pump.............................................................. 85
Resetting the Load Control System ............... 86
Maintenance Section
Maintenance Access ........................................... 89
Access Doors and Covers.............................. 89
Tire Inflation Information ..................................... 89
Tire Inflation with Air....................................... 89
Tire Pressure.................................................. 90
Tire Inflation Pressure Adjustment................. 91
Tire Damage .................................................. 91
Tire Replacement........................................... 91
Wheel and Tire Installation............................. 92
Lubricant Viscosities and Refill Capacities.......... 92
Lubricant Viscosities ...................................... 92
Capacities (Refill)........................................... 94
SOS Information............................................. 94
Maintenance Support .......................................... 95
Welding on Machines and Engines with
Electronic Controls......................................... 95
Maintenance Interval Schedule........................... 95
Axle Breathers - Clean/Replace.......................... 97
Backup Alarm - Test............................................ 97
Battery - Recycle................................................. 97
Battery or Battery Cable -Inspect/Replace.......... 97
Belt - Inspect/Replace ......................................... 97
Inspect ........................................................... 97
Replace.......................................................... 98
Boom Chain - Inspect/ Lubricate......................... 98
Boom Chain Tension -Check/Adjust ................... 99
Check Condition............................................. 99
Check and Adjust the Chain Tension............. 99
Measure the Chain for Wear........................ 101
Boom Head Section - Lubricate ........................ 102
Boom Pivot Shaft - Lubricate ............................ 102
Boom Telescoping Cylinder Air - Purge ............ 102
Boom Wear Pad Clearance -Inspect/Adjust...... 103
Adjustment ................................................... 104
Boom and Frame - Inspect................................ 105
Braking System - Test....................................... 106
Service Brake ...............................................106
Parking Brake ...............................................107
Cab Air Filter - Clean/Replace ...........................107
Primary Cab Air Filter ...................................107
Secondary Cab Air Filter...............................108
Circuit Breakers - Test .......................................108
Cooling System Coolant -Change......................109
Cooling System Coolant Level - Check .............110
Cooling System Coolant Sample (Level 1) -
Obtain ................................................................111
Cooling System Coolant Sample (Level 2) -
Obtain ................................................................111
Cooling System Pressure Cap - Clean/Replace 112
Cooling System Water Temperature Regulator
Replace..............................................................112
Differential Oil - Change.....................................113
Rear Axle Differential....................................113
Front Axle Differential ...................................113
Differential Oil Level - Check .............................114
Rear Axle Differential....................................114
Front Axle Differential ...................................114
Differential Oil Sample - Obtain .........................115
Drive Shaft Spline - Lubricate ............................115
Drive Shaft Universal Joint Bolts - Check ..........116
Engine Air Filter Primary Element - Clean/Replace .
116
Cleaning Primary Air Filter Elements............117
Inspecting the Primary Air Filter Elements....117
Engine Air Filter Primary Element - Replace .....118
Engine Air Filter Secondary Element - Replace.118
Engine Mounts - Inspect ....................................118
Engine Oil Level - Check ...................................119
Engine Oil Sample - Obtain ...............................119
Engine Oil and Filter - Change...........................119
Engine Valve Lash - Check................................121
Final Drive Oil - Change.....................................121
Final Drive Oil Level - Check .............................122
Final Drive Oil Sample - Obtain .........................122
Fork Leveling Cylinder Pin -Lubricate ................123
Frame Leveling Cylinder Pin - Lubricate............123
Fuel System - Prime ..........................................123
Fuel System Water Separator - Drain................124
Fuel System Water Separator Element - Replace
(Tier II) ...............................................................124
Fuel System Water Separator Element - Replace
(Tier III) ..............................................................125
Fuel Tank Cap - Clean.......................................126
Fuel Tank Water and Sediment - Drain .............127
Fuses and Relays - Replace..............................127
Fuses ............................................................127
Relays...........................................................129
Indicators and Gauges - Test.............................130
Longitudinal Stability Indicator - Calibrate..........130
Longitudinal Stability Indicator -Test..................130
Initial Test .....................................................130
Second Test..................................................131
Oil Filter - Inspect...............................................131
Inspect a Used Filter for Debris ....................131
Parking Brake - Adjust .......................................131
6. 3 31200245
Table of Contents
Pulley for Boom Extension Chain - Lubricate.... 132
Pulley for Boom Retraction Chain - Lubricate ... 132
Radiator Core - Clean ....................................... 132
Refrigerant Dryer - Replace .............................. 133
Rollover Protective Structure (ROPS) and Falling
Object Protective Structure (FOPS) - Inspect .. 133
Seat Belt - Inspect............................................. 134
Seat Belt - Replace ........................................... 134
Stabilizer and Cylinder Bearings - Lubricate ..... 134
Tire Inflation - Check ......................................... 135
Transmission and Hydraulic System Oil -
Change.............................................................. 135
Transmission and Hydraulic System Oil Filter -
Replace ............................................................. 136
Transmission and Hydraulic System Oil Level -
Check ................................................................ 137
Transmission and Hydraulic System Oil Sample -
Obtain................................................................ 138
Transmission and Hydraulic System Tank Breather -
Clean................................................................. 138
Turbocharger - Inspect...................................... 139
Wheel Nut Torque - Check................................ 139
Window Washer Reservoir -Fill......................... 139
Window Wiper -Inspect/Replace ....................... 140
Windows - Clean ............................................... 140
Work Tool - Inspect/Replace............................. 140
Forks ............................................................ 140
Buckets ........................................................ 142
Reference Information Section
Approved Work Tools........................................ 143
7. 31200245 5
Foreword
Foreword
Literature Information
This manual should be stored in the operator's
compartment in the literature holder or seat back
literature storage area.
This manual contains safety information, operation
instructions, transportation information, lubrication
information and maintenance information.
Some photographs or illustrations in this publication
show details or attachments that can be different from
your machine. Guards and covers might have been
removed for illustrative purposes.
Continuing improvement and advancement of product
design might have caused changes to your machine
which are not included in this publication. Read, study
and keep this manual with the machine.
Whenever a question arises regarding your machine, or
this publication, please consult your Caterpillar dealer
for the latest available information.
Safety
The safety section lists basic safety precautions. In
addition, this section identifies the text and locations of
warning signs and labels used on the machine.
Read and understand the basic precautions listed in
the safety section before operating or performing
lubrication, maintenance and repair on this machine.
Operation
The operation section is a reference for the new
operator and a refresher for the experienced operator.
This section includes a discussion of gauges,
switches, machine controls, attachment controls,
transportation and towing information.
Photographs and illustrations guide the operator
through correct procedures of checking, starting,
operating and stopping the machine.
Operating techniques outlined in this publication are
basic. Skill and techniques develop as the operator
gains knowledge of the machine and its capabilities.
Maintenance
The maintenance section is a guide to equipment care.
The Maintenance Interval Schedule (MIS) lists the
items to be maintained at a specific service interval.
Items without specific intervals are listed under the
"When Required" service interval. The Maintenance
Interval Schedule lists the page number for the step-
by-step instructions required to accomplish the
scheduled maintenance. Use the Maintenance Interval
Schedule as an index or "one safe source" for all
maintenance procedures.
Maintenance Intervals
Use the service hour meter to determine servicing
intervals. Calendar intervals shown (daily, weekly,
monthly, etc.) can be used instead of service hour
meter intervals if they provide more convenient
servicing schedules and approximate the indicated
service hour meter reading. Recommended service
should always be performed at the interval that occurs
first.
Under extremely severe, dusty or wet operating
conditions, more frequent lubrication than is specified
in the maintenance intervals chart might be necessary.
Certified Engine Maintenance
Proper maintenance and repair is essential to keep the
engine and machine systems operating correctly. As the
heavy duty off-road diesel engine owner, you are
responsible for the performance of the required
maintenance listed in the Owner Manual, Operation
and Maintenance Manual, and Service Manual.
It is prohibited for any person engaged in the business
of repairing, servicing, selling, leasing, or trading
engines or machines to remove, alter, or render
inoperative any emission related device or element of
design installed on or in an engine or machine that is in
compliance with the regulations (40 CFR Part 89).
Certain elements of the machine and engine such as
the exhaust system, fuel system, electrical system,
intake air system and cooling system may be emission
related and should not be altered unless approved by
Caterpillar.
Machine Capacity
Additional attachments or modifications may exceed
machine design capacity which can adversely affect
performance characteristics. Included would be stability
and system certifications such as brakes, steering, and
rollover protective structures (ROPS). Contact your
Caterpillar dealer for further information.
8. 6 31200245
Foreword
Contact Information
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.
1 JLG Drive
McConnellsburg, PA 17233
USA
or Your Local JLG Office
In USA:
Toll Free: 877-JLG-SAFE (877-554-7233)
Outside USA:
Phone: 717-485-5161 or 717-485-6591
E-mail: ProductSafety@JLG.com
11. 31200245 9
Safety Section
Illustration 5 g01212851
Illustration 6 g01212853
Tier II
Tier III
Tier III
There are several specific safety messages on these
machines. The exact location of the messages and the
description of the messages are reviewed in this
section. Please become familiarized with all safety
messages.
Make sure that all of the safety messages are legible.
Clean the safety messages or replace the safety
messages if you cannot read the words. Replace the
illustrations if the illustrations are not legible. When
you clean the safety messages, use a cloth, water and
soap. Do not use solvent, gasoline, or other harsh
chemicals to clean the safety messages. Solvents,
gasoline, or harsh chemicals could loosen the adhesive
that secures the safety message. Loose adhesive will
allow the safety message to fall.
Replace any safety message that is damaged, or
missing. If a safety message is attached to a part that
is replaced, install a safety message on the
replacement part. Any Caterpillar dealer can provide
new safety messages.
Do Not Operate (1)
This safety message is positioned on the panel at the
right side of the operator station.
g00931194
Do not operate or work on this equipment unless you
have read and understand the instructions and
warnings in the Operation and Maintenance Manual.
Failure to follow the instructions or heed the warnings
could result in injury or death. Contact any Caterpillar
dealer for replacement manuals. Proper care is your
responsibility.
12. 10 31200245
Safety Section
Do Not Stand Under the Load (2)
This message is positioned on the side of the boom
head on both sides of the machine.
g00930659
A crushing hazard exists when the boom is lowered or
from a falling load. Stay clear of the boom when the
machine is in operation. Failure to stay clear of the
boom can cause injury or death.
No Hands (3)
The message is positioned on the side of the number
one boom section on both sides of the machine.
g00930870
A crushing hazard exists when the boom sections are
being retracted or extended. Stay clear of the boom
when the machine is in operation. Failure to stay clear of
the boom when the machine is operation can cause
injury or death.
13. 31200245 11
Safety Section
Do Not Operate (4)
This safety message is located on the front dash in
the operator compartment.
g00936539
Improper operation or maintenance of the machine
could result in injury or death. Do not operate or work
on this machine unless you have been properly trained
and authorized and have read and understood the
warnings and instructions in the Operation and
Maintenance Manual.
Refer to Operation and Maintenance Manual, "Load
Charts" for more information.
Forks (5)
This safety message is positioned on the panel at the
right side of the operator station.
g01059274
Side loading of the forks may cause premature
failure of the forks and thus a crush hazard which
may cause personal injury or death. Never push
loads with the forks and inspect the forks daily for
any twisting or bending observed in the forks.
Should twisting or bending be observed, change the
fork(s) prior to any lifting operation. Read the
Operation and Maintenance Manual for more
information about the correct use of the forks.
14. 12 31200245
Safety Section
ROPS/FOPS Structure (6)
This safety message is positioned behind the seat
near the window.
g01211890
Structural damage, an overturn, modification,
alteration, or improper repair can impair this
structure's protection capability thereby voiding this
certification. Do not weld on or drill holes in the
structure. This will void the certification. Consult a
Caterpillar dealer to determine this structure's
limitations without voiding its certification.
This machine has been certified to the standards
that are listed on the certification film. The maximum
mass of the machine, which includes the operator
and the attachments without a payload, should not
exceed the mass on the certification film.
A typical example of the warning film and certification
film are shown above.
Refer to Operation and Maintenance Manual,
"Guards (Operator Protection)" for more information.
No Hands (7)
The message is positioned on the top of stabilizer
cylinders on both sides of the machine.
g00930870
A crushing hazard exists when raising or lowering
the stabilizers. Ensure that personnel stand clear
when the stabilizers are being raised or lowered.
Operating the stabilizers when personnel are nearby
could result in personal injury or death.
15. 31200245 13
Safety Section
Crushing Hazard (8)
The message is positioned on the underside of the
stabilizer beam on both sides of the machine.
g00930659
A crushing hazard exists when raising or lowering
the stabilizers. Ensure that personnel stand clear
when the stabilizers are being raised or lowered.
Operating the stabilizers when personnel are nearby
could result in personal injury or death.
Seat Belt (9)
This safety message is positioned on the panel at the right
side of the operator station.
g00931188
A seat belt should be worn at all times during
machine operation to prevent serious injury or death
in the event of an accident or machine overturn.
Failure to wear a seat belt during machine operation
may result in serious injury or death.
Refer to Operation and Maintenance Manual, "Seat
Belt" for more information.
16. Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING
NOTE:
If there is no response to
click on the link above,
please download the PDF
document first and then
click on it.
17. 14 31200245
Safety Section
Crushing Hazard (10)
This message is positioned on the chassis on the
right side of the machine.
g01212730
A crushing hazard exists when the boom is lowered
or from a falling load. Stay clear of the boom when
the machine is in operation. Failure to stay clear of
the boom can cause injury or death.
Refer to the "Procedure for Retracting and Lowering
the Boom with the Emergency Lower System (If
Equipped)" topic in Operation and Maintenance
Manual, "Equipment Lowering with Loss of Hydraulic
Power" for more information.
Crushing Hazard (11)
This message is positioned on the chassis on the
right side of the machine.
g00930659
A crushing hazard exists when the boom is lowered
or from a falling load. Stay clear of the boom when
the machine is in operation. Failure to stay clear of
the boom can cause injury or death.
18. 31200245 15
Safety Section
Engine Coolant (12)
This safety message is positioned on the coolant
tank in the engine enclosure.
g00931247
Pressurized system! Hot coolant can cause serious
burns, injury or death. To open the cooling system
filler cap, stop the engine and wait until the cooling
system components are cool. Loosen the cooling
system pressure cap slowly in order to relieve the
pressure. Read and understand the Operation and
Maintenance Manual before performing any cooling
system maintenance.
Refer to Operation and Maintenance Manual,
"Cooling System Coolant - Change" for the correct
procedure to remove the pressure cap.
Avoid Power Lines (13)
This safety message is positioned in the operator
station on the right side of the window.
g00936329
Electrocution Hazard! Keep the machine and
attachments a safe distance from electrical power.
Stay clear 3 m (10 ft) plus twice the line insulator
length. Read and understand the instructions and
warnings in the Operation and Maintenance Manual.
Failure to follow the instructions and warnings will
cause serious injury or death
Always check for power lines before raising the boom.
Failure to check for power lines before raising the
boom could result in injury or death by electrocution.
Refer to Operation and Maintenance Manual, "Before
Starting Engine" for more information.
