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Front End Loaders
MMV
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Revision Log
a
8990504
Revision Log
REVISION LOG
December 17, 2004 - B - Replaced all branding with JLG.
October 12, 201
1 - C - Revi
sed pages 22, 27, 66,
67, 70, 157, 170, 171, 18
2 thru
185, 193, 201, 218, 219, 221, 222 & 24
6.
2
4
Table of Contents
Main Page
Default Chapter
5
Table of Contents
5
Revision Log
6
Replacement Parts
6
Reports
6
Introduction
6
The Manual
6
Safety Practices
7
Hazard Classification System
7
Disclaimer
7
Signal Word
8
Accident Prevention Tags
9
New or Additional Operators
9
Instructional Symbols
10
Hazard Symbols
11
Avoidance Symbols
12
Avoidance Symbols (Cont'D)
13
Personal Considerations
14
Ether or High Energy Starting Aids
15
Hydraulic Fluid
15
Batteries
16
Moving Parts Hazard
17
Lowering Boom or Falling Load Hazard
17
Operational Considerations
18
Preparation and Prevention
18
Clearances
18
Visual Obstruction
18
Underground Hazards
19
Electrocution Hazards
19
Elevating Personnel
20
Tip over Hazard
21
Emergency Exit Rear Window
21
Tire Pressure
22
Slopes
23
Falling Load Hazard
23
Ventilation
23
Equipment Considerations
24
Operator Controls
27
Accelerator Pedal
27
Service Brake Pedal
27
Horn Button
27
Operation
27
Ignition Switch
28
Steering Mode Selector
29
Three Mode Steer Select
29
Parking Brake Switch
30
Battery Disconnect Switch (S/N MV1210 & After)
31
Transmission Disconnect Switch
31
Neutral Lock Lever
32
Travel Select Lever
33
Gear Select Lever
34
Attachment Tilt Mode Switch
35
Multi-Function Joystick Operation
36
Boom Control (Default)
37
Attachment Tilt Up/Down & Boom Extend/Retract
39
Boom Lift/Lower & Attachment Tilt Up/Down
40
Boom Lift/Lower & Frame Sway Right/Left
41
Fork Shift Control Switches
42
Seat Belt
42
Backrest Angle Adjustment
44
Fore and Aft Adjustment
44
Operators Seat Adjustments
44
Suspension Adjustment
44
Interior Cab Light
45
Worklights
45
Parking Lights, Headlights & High/Low Beam Switch
46
Blackout Drive/Marker Lights
47
Blackout Light System Activation Switch
47
Directional Signals
48
Emergency Flashers
48
Door Latches
49
Door Window Latch
49
Rear Window Latch
50
Rifle Mount
50
Front Windshield Wiper
51
Windshield Washer Control
52
Rear Window Wiper
53
Skylight Wiper/Washer & Rear Window Washer
53
Cab Heater/Air Conditioning Controls
54
To Cool the Cab
55
To Defrost the Cab
55
To Heat the Cab
55
Cab Circulation Fan
56
Engine Function Indicator Lights
56
Cummins ECM Diagnostic System Activation
57
ECM Light Code Identification
57
Front Dash Panel
58
Front Dash Panel Light Test
58
Engine Air-Intake Heater Indicator
59
Function Indicator Lights
59
Parking Brake Indicator
59
Stabil-TRAK Mode Indicator Lights
59
Engine Oil Pressure Warning Indicator
60
Hydraulic Oil Temperature Warning Indicator
60
Transmission Temperature Warning Indicator
60
Warning Indicator Lights
60
Alternator Charging Warning Indicator
61
Engine Air Filter Restriction Warning Indicator
61
Hydraulic Oil Filter Restriction Warning Indicator
61
Low Brake Pressure Warning Indicator
62
Engine Coolant Temperature Gauge
63
Engine Tachometer
63
Fuel Level Gauge
63
Tachometer
63
Additional Indicator Lights
64
High Beam Indicator
64
Turn Signal Indicator
64
Boom Angle Indicator
65
Frame Level Indicator
65
Instruments and Indicators
65
Rear View Mirrors
66
Load Moment Indicator
67
Changing Display Settings
69
Load Moment Indicator System Test
69
Pre-Operation Inspection
70
Normal Starting
71
Cold Starting
72
Slave Starting
74
Alternate Fuel Types
75
Fuel Types
75
Refueling
75
Fuel Cap
76
To Install the Fuel Cap
76
To Remove the Fuel Cap
76
Free Pivot Mode
77
Operating
77
Understanding the Stabil-TRAK System
77
Locked Mode
78
Slow Pivot Mode
79
Changing Travel Direction
80
Starting Travel
80
Shifting Gears
81
Stopping Travel
82
Steering Modes
83
Four Wheel Steer Indexing
84
Four Wheel Steering
84
Front Wheel Steering
85
Crab Steering
86
Leveling the Vehicle
87
Maximum Fork Sweep
87
Attachment Removal
88
Carriages
88
Quick Attach
88
Attachment Reconnect
90
Loading the 11K Carriage for Transport
92
Transport Position - 11K Fork Carriage
92
Removing the 11K Carriage from the 7K Carriage
93
Installing the 11K Carriage on the 7K Carriage
94
Using the Capacity Chart
96
Load Capacity to Travel Speed Tables
98
Recommended Gear/Speed for Various Load/Travel Conditions
98
Reduced Tire
99
Reading Capacity Charts
101
Capacity Chart 24" Load Center (11K Carriage)
102
Fork Rating
108
How to Pick, Carry & Place a Load
109
Elevating Personnel
111
Defining Platforms for Elevating Personnel
113
Capacity Limitations
114
Platform Preparation and Set-Up
115
Shut-Off
117
Emergency Operations
118
Towing a Disabled Vehicle
118
Short Distance Towing
118
Long Distance Towing
122
Emergency Boom Lowering
127
Loss of Engine Power or Hydraulic Pump Failure
127
Hydraulic Line Failure
128
Boom Retract Line Failure
138
General Maintenance
141
Introduction
141
Maintenance Schedule and Checklist
142
10 Hour Intervals
142
At First 50 Hours of Use
142
250 Hour Intervals
143
500 Hour Intervals
143
1000 Hour Intervals
144
2000 Hour Intervals
144
Carriage Fork Shaft and Wear Bar Lubrication
145
Lubrication Points
145
Air Cleaner
147
Inner Safety Element
147
Outer Primary Element
147
To Change Elements
148
Air Intake System-Inspection
150
Closed Cab Air Filters
151
Fresh Air Intake Filter
151
Recirculation Air Filter
151
Engine Coolant Level Check
152
Engine Cooling System
152
Drain and Flush Radiator
153
Purge the Air from the Cooling System
155
Engine Oil and Filter
156
Engine Oil Recommendations
156
Oil Level Check
156
Recommended Engine Oil/Temperature Range
156
Oil and Filter Change
157
Engine Oil Sample Point
160
Drain Water from Fuel Water Separator/Filter
161
Engine Fuel System
161
Change Fuel Filter
162
Replace In-Line Fuel Strainer
163
Bleeding Fuel System
164
Engine Fan Belt
166
Engine Fan Belt Check
166
Air Conditioner Compressor Belt
167
Hydraulic Oil and Filter
168
Hydraulic Oil Level Check
168
Hydraulic Oil & Filter Change
170
Recommended Transmission Oil/Temperature Range
173
Transmission Oil and Filter
173
Transmission Oil Level Check
173
Transmission Oil & Filter Change
174
Axle Oil
176
Axle Oil Level Check
176
Axle Oil Change
177
Brake Disk Inspection
179
Front Axle
179
Rear Axle
182
Recommended Wheel End Oil/Temperature Range
183
Wheel End Oil
183
Wheel End Oil Change
184
If Equipped with ZF Transfer Case
186
Recommended Transfer Case Oil/Temperature Range
186
Transfer Case Oil
186
Transfer Case Oil Level Check
186
Transfer Case Oil Change
187
If Equipped with Carraro Transfer Case
188
Tire Air Pressure Check
190
Wheels and Tires
190
Replacing Tires
191
Wheel Lug Nut Torque Check
191
Drain Water from Emergency Tire Inflation Tank
192
Emergency Tire Inflation System
192
Tire Inflation
193
Batteries
196
Battery Charging
197
Battery Electrolyte First Aid
197
Extended Storage (S/N MV1210 & After)
197
Fuse & Relay Replacement
198
Fuses and Relays (Fuse Block)
198
Fuses, Relays and Flasher (Right Side Console)
202
Cold Start Grid Heater Fuse (under Engine Cover)
203
ECM Fuses (under Engine Cover)
204
Battery Equalizer Fuses (under Engine Cover)
205
Relay and Fuse (Inside Rear Door)
206
Boom Chain Tension Check
207
Boom Chains and Wear Pads
207
Top Boom Chain Tension Adjustment
211
Boom Chain Inspection
213
Edge Wear - Extend Chain
215
Elongation
216
Distorted or Battered Link Plates
217
Turning or Protruding Pins
217
Cracked Plates
218
Fatigue Cracking
218
Other Modes of Failure
218
Stress Corrosion Cracking
218
Chain Lubrication
219
Wear Pad Inspection
220
Wear Pad Replacement
221
Storage and Transport
222
Short Term Storage
222
Before Storing
222
Removing from Short Term Storage
223
Long Term Storage
224
Removing from Long Term Storage
225
Counterweight Removal and Reassembly
227
Transport
230
Truck Transportability
232
Rail Transportability and GIC Clearance
233
Air Transport, C-17, C141 or C-5 Tiedowns
234
Air Transport, C-130 Configuration
236
Axle and Tire Data
237
463L Pallet Data
237
Marine Transportability
238
External Transport/Slinging
239
Stabil-TRAK System Test
240
Test Procedures
240
Stabil-TRAK System Test Procedures
241
Parking Brake/Transmission De-Clutch Test Procedures
245
Park Brake Hold Performance
247
Four Wheel Steer Indexing Procedure
248
Test Procedures
248
Engine Crankcase Oil
249
Fluid & Lubrication Capacities
249
Specifications
249
Tires
251
Weights
252
Vehicle Dimensions
253
Electrical System
254
Engine
256
Index
259
Accident Prevention Tags
265
Replacement Manuals
267
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