CATERPILLAR’ Operation & Maintenance Manual Original Instructions Keep this manual with machine at all times. Models TL642C€ TL943C SIN THGOO150 & After -200281.000. soe 01/28 Ci Ske: SEXES. ow eHWCOVER | ee 160 oa} ‘Bosy: 204 BOND te. enrect Fou. om HOLE foo Fn we ano other” SEBU9289 04 CATPOORead _saiiortens ql TABLE OF CONTENTS othe Pal jtabie Revision Log gr * av Service Manual. 1200784 (UENREZE1) Read This First a iMustrated Parts Manual 1e ‘Operator Qualifications... Betere SN THGO!209, Before SN THLO0221, Modifications Before SN THHOTEY® Boor S¥ SEO. steams Cither Publications Available SN THGOT209 & Aftor, SN THLG * SN THHO1519 & After, SN SXHO0253 & After ‘SEBP7161 Table of Contents Section 1 - General Safety Practices 14 Note: The following standards may be referenced in this manual ‘ANSI Is compliant to ANSI/ITSDF B56.6 ‘AUS is compliant fo AS 1418.19 GE is compliant to EN1459 Refer to the machine Serial Number Plate to identity the applicable compliance standard. 12 1.3 er ae 24 en 22 au 23 24 25 26 34 a2 31200747 31200747 Section 2- Section 3 - Hazard Classification System... Safety Alert System and Safety Sin Words General Precautions. Operation Sefety... Electrical Hazards Tip Over Hazard. Travel Hazard .. Load Falling Hazard Lifting Personnel. Driving Hazards On Slopes... Pinch Points and Crush Hazards. Fall HAzatth nen ‘Chemical Hazards. Pre-Operation and Inspection Pre-Operation Check and Inspection. Safety Decals.............ilue...... ANSI (THGOOt8 }50 & After, THHoot 508 After) ISO (THLO0150 & Aflier, SXHOO150 & Asi Walk-Around Inspection. Z Warm-Up and Operational Checks. Warm-Up Check Operational Check. Operator Cab. Windows... ‘Cab Door ‘Window (if equipped). Controls and Indicators General Controls Dash Controls and Indicators... Ignition Park Brake .. Parking Procedure .. ‘Transmission Control Lever:ick (TL642Q)).3... ae ¢ oovetck (TL948C),.. S12 Frame Level Joystick. 344 ‘Auxiliary Hydraulic Joystigk (TL642C) 315 ‘Outrigger Joysticks (if eqpipped) ae Right Hand Panel ‘Accessory Control Lever (if sauinpedh 33. Steer Modes... ‘Steer Mode Change 348 3-20 3-20 3-22 3-23 5 Reverse Sensor Sysiom (ii Equipped. 3.6 Boom Angle and Extension Indicators... Section 4 - Operation 4.3. Operating with a Non- 4.1 Engine Starting the Engine Extreme Cold Weather Staring (if equipped). Battery Boosted Starting... Normal Engine Operation. Shut-Down Procedure 42. After-Treatment System {THGOOYED 8. Afar THHODISO 8 Ate) ‘Automatic Regeneration Manual Regeneration 46 46 47 4-8 48 Aa nded Load Lift Load Safely. Picking Up a Load: Transporting a Loa Leveling Procedure... Placing a Load. Disengaging a Load. : 4-10 4.4. Operating with a Suspended Load. : sade Lift Load Safely... naiinciculeade dt] Picking Up a Suspended Load icin deld Transporting a Suspended Load... 12 Leveling Procedute n.rnn-n nA Placing @ Suspended Load. an 13 Disengaging a Suspended Load 413 4.5 Loading and Securing for Transport 414 Tiedown, ‘ sme eV Lifting. 415 31200747 Section 5 - 51 52 53 5.4 55 56 57 58 59 ort Section 6 - 0 a 62 63 31200747 Attachments om ‘Approved Attachments... Unapproved Attachments JLG Supplied Attachments... Telehandler/Attachient/Fork Capac. Use of the Load Chart. Capacity Indicator Locations. Sample Load Chat .nn Example. Attachment installation Mechanical Quick Coupler... Hydraulic Quick Coupler. Hydraulic Operated Attachmen Adjusting/Moving Forks... ‘Attachment Operation Carriage with Forks... Side Shift Carriage... Rotate/Side Tit Carriage... Swing Carriage .. Dual Fork Positioning Carriage Fork Extension. BUCKEL cs Multi-Purpose Bucket. Fork Mounted Hook... ‘Coupler Mounted Hook. Truss Boom. Personnel Wark Plallon - Fork Mounted Material Handling Arto, Boom Head-Mounted Winch Emergency Procedures Towing a Disabled Product. Moving Short Distances... ‘Moving Longer Distances Emergency Lowering of Boom. Emergency Exit from Enclosed Gab Fixed Window (if equipped) Latch Window (if equipped)Section 7 - Lubleation and Mainteffance 7.4. Intreduetion. a Clothing and Safety Ge 7.2. General Maintenance Instrudtions.... 7.3 Service and Maintenance Sghtedule..... 10, 1st 50 & 50 Hour Maintenance Schedule... : 1st 250, 250 & 1st 500 Hour Maintenance Schadule ... 7-4 00, 1000 & 1600 Hour Maintenance Schedule... 7-5 3000 Hour Maintenance Schedule... sea 76 7.4 Lubrication Schedules 77 7A TA 72 50 Hour Lubrication Schedule... 77 250 Hour Lubrication Schedule... 78 1000 Hour Lubrication Schedule 79 7.5. Operator Maintenance Instructions. 710 Fuel System sc 740 Air Intake System. 7-42 Engine Oi 744 Hydraulic Oil 715 Tics... Transmission Oil... Engine Cooling System... " 3 Battery . ssi 721 OE. ‘Windshield Washer System (it equipped). vo 122 ‘Bebtion 8 - Additional Checks General ; a a4 % : Gee 82 Reverse Sensor Sysomh if equipped) a4 (Beotion 9-Specifications 9.1 Product Specifications! Fluids... Capacities. i THOS. ese Performance... Dimensions, Index Inspection, Maintenance and Repair Log 31200747 Table ob Contatti _ : Section 1- GenerahSatety Practices SECTION 1 - GENERAL SAFETY-PRACTICES 1.1 HAZARD CLASSIFICATION SYSTEM 75((@ Sefety Alert system and Safety Signal Words 4 DANGER ANGER indicates an imminenty hazardous situation which, it not avoided, wl | result in death or serious injury. A WARNING WARNING indicates 2 potentially hazardous situation which, if not avo result in death or serious injury, , could CAUTION CAUTION indicates a potentiality hazardous situation which, if not avoided, may roeult in minor or moderate injury : ote a Before operation, read and understand this manual, Failure to comply with the safety precautions listed inthis manual could result in machine damage, property damage, personal injury or death, 31200747Section - Genteeal Safety Practices 3 OPERATI FETY Electrical Hazards 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 ulity company de-energizes the lines. Always check for power lines before raising the boom. + Follow employer, local and governmental regulations for clearance from “powerlines. 91200747 Tip Over Hazard Gon ‘+ For additional load requirements, Yefer to the appropriate load chart, \ + Never use an attachment without the appropriate JLG approved load chart installed on the telehandir. + Understand how to properly use the load charts located in cab, ‘+ DO NOT exceed rated lit capacity, + Be sure that the ground conditions are able to support the machine, Ql *+ DO NOT raise boom unless frame is level (0 degrees), unless otherwise noted ‘on load chert. z + DO NOT level machine with boomvattachment above 4 ft (1,2 m). (AUS - DO NOT level machine with load more than 300mm (11.8 in) above ‘ground surface.) 31200747‘+ MAINTAIN propor tire pressure al all limes. If proper tre pressures are not ‘maintained, this machine could tip over. + Refer to manufacturer's specifications for proper fil ralio and prossure requirements for tres equipped with ballast, * Always wear the seat belt, * Keep head, arms, hands, legs and all other body parts inside operator's cab at all times, Ay the telehandler stars to tip over: + DO NOT JUMP * BRACE YOURSELF and STAY WITH THE MACHINE + KEEP YOUR SEAT BELT FASTENED * HOLD ON FIRMLY * LEAN AWAY FROM THE POINT OF IMPACT 31200747 Non-Suspended Load ‘+ DO NOT drive with boom raised, Suspended Load ‘Tether suspended loads to wstrict movement Weight of al rigging (slings, etc.) must be Included as part of load. av Beware of wind. Wind can cause a suspended load to swing and eause dangerous side loads - even with taglines. at. DO NOT attempt to use telehanalerframe-leveling to compensate for load swing. Keep heavy part of load closest to attachment. Never drag the load; it vertically, When driving with a suspended load: * Stat, travel, tur and stop slowly to prevent load from swinging. + DONOT extend boom, ‘+ DO NOT raise the load more than 1.8 in (300 mm) above ground surface or the boom more than 45°, + DONOT exceed waiking speed. 31200747onze + Steering characteristics difler between steer modes. dently the steer mode ‘settings ofthe telehandler being operated DO NOT change steer modes while traveling. Steer modes must be changed while tlehandler is stationary. ‘Visually verity proper wheel alignment ater each steer mode change, Ensure that adequate clearance is provided for both rear tall swing and front fork swing. Look out for andl avoid ether personnel, machinery and vehicles inthe area. Use a spotter ifyou DO NOT have a clear view. Before moving be sure of a clear path and sound her, \when driving, retract boom and keep boonvattachment as ow as possible while ‘maintaining visibility of mirors and maximum visibly of path of travel ‘Aways lookin the direction ot travel * Always check boom clearances carelully before driving undemeath overhead yebstructons. Position attachmentioad to clear obstacles, * Wien crving in high speed, use only front whee! steer (it steering modes ‘aqme seloctabe). * Telehandlors equipped with solid ties should not be used in applications Fequirng excessive roading or driving extended distances. In the event an application requites excessive roading or driving expanded distances, itis ‘ecommended to use telehandlers not equipped with sold tres. 91200747 Load Falling Hazard ‘+ Never suspend load from forks or other parts of carria approved lit points, + DO NOT burn or dill holes in fork(s). * Forks must be centered under load and spaced apart as far as possible. Weldment, Use only 31200747| Section 1 - General Satety Practices Section 1 - GenerabSatety Practices Lifting Personnel Driving Hazards On Slopes - ko ® _ ‘To maintain sufcient traction and braking capabilities, travel on slopes as follows: + When unloaded, chive with forks pointed downhil. + When loaded, dive with the forks pointed uphil, + For additional travel requirements, refer tothe appropriate load chart. + To avoid overspeeding the engine and drivetrain when dtiving down slopes, downshift to @ lower gear and use the service brake as necessary to maintain 2 slow speed. DO NOT shift into neutral and coast downhill. ‘Avoid excessively steep slopes or unstable suraces, To avoid tip over DO NOT drive across excessively steep slopes under any cicumstances, ‘Avoid turing on a slope. Never engage ‘inching’ or shit to “Neutra when going ‘+ DO NOT drive machine from cab when personnel ate in platform. aan DO NOT perk on a siope. + When liting personnel, USE ONLY an approved personnel work platform, with proper load chart displayed in the cab. ‘oneiee 31200747 31200747Section 1 - General Safety Practices ‘Section 1 - General Safety Practices Pinch Points and Crush Hazards ‘Stay clear of pinch points and rotating parts on the telehandler. el os Loym + keep clear of boom holes. + Stay clear of moving parts while engine is running. &) + Keep arms and hands clear of attachment tit cylinder. + Keep clear of steering tres and frame or other objects (iy) + Keep hands and fingers clear of carriage and forks. + eop clear from under boom, - - > + Keep others away while operating 31200747 | 31200747‘Section 1 - General Safety Practices Fall Hazard Chemical Hazards Exhaust Fumes ® + 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 sito owner. Sparks from the electrical system and the a engine exhaust can cause an explosion. Flammable Fust + Enter using the proper hand holds and steps provided. Always maintain 3-point ‘contact when mounting of dismounting. Never grab control levers or steering ‘wheel when mounting or dismounting the machine. + DO NOT get off the machine until the shutdown procedure on page 4-4 has been perormes Q .o *+ DO NOT fil the fuel tank or service the fuel system near an open flame, sparks or smoking materials. Engine fuel is fammablo and can cause a fire andlor explosion. EF nse Hydraulic Fluid + DO NOT carry riers. Riders could falloff machine causing death or serious a Injury. + DO NOT attempt to repair or tighten any hydraulic hoses or fitings while the engine is running or when the hydraulic system is under pressure. + Stop engine and relieve trapped pressure. Fluid in the hydraulic system is under ‘enough pressure that itcan penetrate the skin. + DO NOT use your hand to check for leaks. Use a piace of cardboard or paper to ‘search for leaks. Wear gloves fo protect hands from spraying fluid. 31200747 | 31200747‘Section 2 - Pre-Operation and Inspection Section 1 - General Safety Practices en SECTION 2 - PRE-OPERATION AND INSPECTION —————— 2.1 PRE-OPERATION CHECK AND INSPECTION ® Note: Complete ail required maintenance before operating unt, A WARNING FALL HAZARD. Use extreme caution when checking items beyond your normal ‘each. Use an approved ladder. ‘The pre-operation check and inspection, performed at beginning of each work shift or at each change of operator, should include the following; 1. Cleanliness - Check all surfaces for leakage (ol, fuel or battery Mud) oF foreign ‘objects. Report any leakage to the proper maintenance personnel. 2, Structure - Inspect the machine structure for dents, damage, weld or parent ‘metal cracks of other discrepancies. This Page Intentionally Left Blank ‘PARENT METAL CRACK . Safety Decals - Ensure all safety decals are legible and in place. Clean or replace as required. See page 2-3 for details, . Operation and Safety Manuals - Operation & Maintenance Manual and AEM Safety Manual (ANS! only) are located in cab manual holder. Walk-Around Inspection - See page 2-10 for details. . Fluid Levels - Check fuids, including fuel, hydraulic ol, engine oil, transmission {uid and coolant. When adding fluids, refer to Section 7 - Lubrication and ‘Maintenance and Section 9- Specifications to determine proper type and intervals. Before removing filer caps or fil plugs, wipe all dit and grease away from the ports. If dit enters these ports, itcan severely reduce component le, . Attachments/Accessories - Ensure correct load charts are installed on the telehandier. i provided, reference the Operation & Maintenance Manual of each attachment or accessory installed for specific inspection, operation and ‘maintenance instructions 31200747 | 31200747Section 2- Pre-Operation and Inspection 8. Operational Gheek--Once te walk-around inspection is comet, Mrurmrup and sbuigna check (se page 212) al eytrenanaea ree of overhead and ground level obstructions. See Section 3 - Controls and Indicators for more spect operatng instructions A WARNING if telehandler does not operate properly, immediately bring machine to a stop, ower boom and attachment to ground and stop the engine. Determine cause and correct before continued use. Section 2 - Pre-Operation and Inspection 2.2 SAFETY DECALS: Ensure all DANGER, WARNING, CAUTION and instructional decals and proper ‘capacity charts are legible and in place. Clean and replace as required, ‘Note: Parl numbers referenced are for inspection and identification purposes ony. Feter to the Parts Manual when ordering replacement parts. 31200747, 31200747Section 2 - Pre-Operation and Inspection ANSI (THG00150 & After, THHOO15O & After) ANSI (THG00150 & After, THHOOTSO & After) s7os7ee-eNaLish ‘so01163900ENGL (ENCLOSED CAB) soor1g0071-ENQLISH 001160787 ENOLISHFRENCH {WEEQUIPPED) 17oss00 ENGLISH 10011622 12-ENGLISHFRENCH a i +! t D A) gs T7OTE4® co1125087-ENELISH *1001163365-ENGLISHFRENCH ne Ave rise iF Eaioned) rosie cts ooriesv NtISHPRENCH (oven cat) 702000 7 s EWES (WITHOUT OUTRIGGER) view D0 1705006-ENGLISH 1001163205 ENGLISHIRENCH Balcw i ealom| 1706209-ENGLISH "oor 69210- ENGLISWFRENCH {7oseso ENGLISH “oortes303- ENGLISHIFRENCH 31200747 Section 2 - Pre-Operation and Inspection sony oer ruses s7osest-eNGUsH e soonasiie 100116011 ‘705767. ENGLISH “001163291. ENGLISHRENICH ‘7Os206 ENGLISH “001163276. ENGLISHRENCH soorrs1229 (OF EQUPPED var ‘OUTRIGGERS) soort60072 ENGLISH $o0rt60s45 ENGLISHFRIENCH [=| oF equpreo wr REVERSE SENSOR SYSTEM) 1706901-ENGLISH | ENGLISHFRENCH ‘s00r130578-ENGLISH 004169929. 10011691 74ENGUISHIFRENCH ‘VIEW OF ENGINE COMPARTHENT (COMPONENTS REMOVED FOR CLARITY) 31200747 UNDERSIDE VIEW OF ENGINE COVER 25Section 2 - Pre-Operation and Inspection Section 2 - Pre-Operation and inspection ISO (THL00150 & After, SXHO0150 & After) s7oso02-eNOLISH ‘o01189223-ENGLISHFRENCH 4110190 +705302-ENGLISH 1001169229-ENGLISWFRENCH [2 {705002 ENGLISH 1001163223-ENGLISHFRENCA 3003002078, (encLoseD CAB) S)] srsosti2 (TiswC IF Equipped) (SEN ERS) Leo) view ec (Tusesc- ITH OUTRIGGER) 31200747) 91200747Section 2 - Pre-Operation and Inspection 1001300474 tases) soors08047 oorss1229 (EQUIPPED wre ‘ourRicceRs) GEE cum SEES MEE xm Am 8 ie Section 2 - Pre-Operation and InspectionSection 2 - Pre-Operation and Inspection 23 WALK-AROUND INSPECTION ) fj 9 CET to one Begin your walk-around inspection at item 1, a8 noted below. Continue to your right {counterclockwise when viewed from top) checking each item in sequence, INSPECTION NOTE: On all components, make sure there are no loose or missing parts, that they are securely fastened and no visible leaks or excessive wear exists in addition to any other criteria mentioned. Inspect all structural members including tachment for cracks, excessive corrosion and other damage. + Check front, top, side and rear wear pads for presence of grease, + Pivot pins secure; hydraulic hoses undamaged, not leaking, 2. Lett Outrigger (if equipped) - Pins secure; hydraulic hoses and cyindst ‘undamaged, not leaking. 3. Etant Axle - Steer cylinders undamaged, not leaking; pivot pins secure; hydraulic hoses undamaged, not leaking 4. Wheel Tire Assembly - Property inflated and secured: no loose or missing lug Nuts. Inspect for Worn read, cuts, tears or other eiserepancis. 240 Section 2 - Pre-Operation and Inspection 5. Mitts - Clean and undamaged, 6. Gaband Electrical - + General appearance; no visible damage. * Frame level indicator and window glass undamaged and clean. *+ Gauges, switches, joysticks, foot controls and horn operational. + Emergency escape hammer in place (enclosed cab oniy). * Check seat belt for damage, replace bel if frayed or cut webbing, damaged ‘buckles or loose mounting hardw . Bi Cleaner - Air cleaner element condition indicator, check for clogged ‘condition. Replace element as required. 3. WheelTire Assembly - Properly inflated and secured; no loose or missing lug nuts. Inspect for wom tread, cuts, tears or other discrepancies. Main Control Valve - See inspection note. ear Axle - Steer cylinders undamaged, not leaking; pivot pins secure; hydraulic hoses undamaged, not leaking. |. Wheel/Tice Assembly - Properly inlated and secured; no loose or missing lug ‘nuts. Inspect for worn tread, cuts, tears or other discrepancies. . Engine Compartment - * Drive beits, check condition and replace as required. + Engine mounts - See inspection note. + Battery cables tight, no visible damage or corrosion. + Engine cover properly secured Qutriager Control Valve it equipped) - See inspection note. Wheel/Tita Assembly - Properly inflated and secured; no loose or missing lug nuts. Inspect for worn tread, cuts, tears or other discrepancies. . Frama Level Cylinder - Pins secure; hydraulic hoses undamaged, not leaking 16, Right Outrigger (if equipped) - Pins secure; hydraulic hoses and cylinder ‘undamaged, not leaking, . Altachment - Property installed, see “Attachment Installation” on page 5-9. 31200747, 31200747Section 2 - Pre-Operation and Inspection Section 2 - Pre-Operation and inspection ee 24 WARN-UP AND OPERATIONAL CHECKS 25 OPERATOR CAB ‘The telohandler is equipped with an open or enclosed ROPS/FOPS cab. Warm-Up Check Dusing warmup pred, cok: A WARNING 1. Heater, defroster and windshield wiper (if equipped). : Never operate telehancler unless the overhead guard, cab structure and right 2, Check al ighting systems (i equipped) for proper operation 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 ° ccab/machine configuration. If the overhead guard or cab structure is damaged, 4, Adjust mirrors) for maximum visibility the CAB CANNOT BE REPAIRED. It must be REPLACED. A WARNING ICUT/CRUSH/BURN HAZARD. Keep engine cover closed while engine is running except when checking transmission oil level 3, Voltmeter should show 13.5 to 14 volts. Operational Check When engine warms, perform an operational check: 1, Service brake and parking brake operation. 2. Forward and reverse travel 8, Each gear. 4 . Steering in both directions with engine at low idle (steering lock to ock will not be reached). Check in each steering mode. Brive a Most re ribs ores oc och eas 6. All boom and attachment functions - operate smoothly and correctly. Perform any additional checks described in Section 8. 31200747, 31200747er. and inepection Section 3- Controls and indicators wes SECTION 3 - CONTROLS AND INDICATORS ‘ep all windows and mirrors clean and un 7 Keep all windows and mirrors clean and unobstructed. Ta GENERAG This section provides the necessary information needed to understand contro! @ wretions. Cab Door Window (if equipped) Note: The manufacturer has no direct control over machine application and eperation. The user and operator are responsible for conforming with good safety practices. Cab door (1) must be closed during operation, ‘During operation the cab door window (2) must either be latched open or closed. (pen the cab door window and secure it in the latch (3) ’ Press release butlon inside the cab or pull on laver (4) outside the cab to unlatch the window, 31200747, 31200747Section 3 - Controls and indicators 32 CONTROLS: Section 3 - Controls and Indicators 1, Transmission Control Lever: See page 3-8. 2, Instrument Panel: See page 3-4, 8, Steering Wheel: Tuming the steering whee! to the lef or right staers the: ‘machine in the corresponding direction. Three steering modes are available. See “Steer Modes" on page 3-19. 4, Erame Level indicator Enables the operator to determine the left to right level condition ofthe telehandler, 5. Accessory Gantt! Lever (if equipped): See page 3-18. 6. Bight Hand Pane!: See page 3-17. 7, Boom Joystick (TL642C}: See page 3-10. 8. Boom Joystick (TL94SC): See page 3-12. 9, Etame Level Joystick: See page 3-14, 10, Qutvioger Joysticks (if equipped): See page 3-16. 11, Decompression Valve: Depress button to relieve pressure in auxiliary hycraulic Circuit. See “Hydraulic Operated Attachment’ on page 5-12, 12, Accelerator Pedal: Pressing down the pedal increases engine and hydraulic ‘speed. 18, Service Brake Pedal: The further the pedal is depressed, the slower the travel peed. 14. Ignition Switch: Key activated. See page 3-6. 18. Auxiliary Hydraulic Joystick (TL642C): See page 9-16, 31200747, 31200747Section 3 - Controls and Indicators Dash Controls and Indicators 10 9 jon Switch (THG00150 & After, THHOO150 & Aer): Momentary Snitch used to inhibit regeneration or perform a manual regeneration. See page 4-6 for details. 2, d:in-1 Gauge and Disolay: Engine Coolant Temperature Gauge Engine Oil Pressure Gauge Fue! Gauge 1. Display - Displays engine operating hours, battery voltage and engine rpm. Engine fault codes displayed when detected. See Service anual for details By te ¢ Mluminates 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. . (THG00160 & After; ‘THHO0150 & After: Iluminatos yellow during active regeneration. See page 4-6 A WARNING ‘5. Engina Pre-Heat indicator: Iluminates yellow with ignition Key in the "RUN" Position. Indicator goes out when start temperature is reached. 6, Steer Solect Switch: Three positions: 4-wheel circle steer, ¢-wheel crab steer ‘and 2-wheel steer, See page 3-19 for details. 7. Batk Brake Switch: See page 3-7 for details. 8. Horn Buiton: Depress button to sound horn, a4 4. Section 3 - Controls and Indicators 9, Quick Coupler Switch (f equipped): Use in conjunction with the auxiliary hydraulic joystick to hydraulically lack or unlock an attachment. See “Hyalraulic Quick Coupler”on page §-11, 40. Engine Warning Indicator: lluminates red when the engine isin a critical state. Immediately bring machine to a stop, retract and lower boom and stop the engine. Determine cause and correct before continued use. 11, Gheck Engine Indicator: luminates orange when maintenance is required, Engine may derate. See Service Manual for details. 31200747, 31200747Section 3 - Controls and Indicators Ignition Park Brake Section 3 - Controls and Indicators Perk 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, + In "ACG" oF "RUN" position, voltage is available for al electrical functicns. + With switch in °ON" position (2), park brake is engaged and transmission will not + Full clockwise rotation to “START” engages starter motor. engage forward or reverse. A WARNING MACHINE ROLL-AWAY HAZARD. Always move park brake switch to ‘ON* position, lower boom to ground and stop engine before leaving cab, A WARNING CRUSH HAZARD. Turing engine off applies the park brake. Applying park brake or turning engine off wnile traveling will cause unit to stop abruptly and ‘ould cause load loss. Either may be used in an emergency situation. + Counter-clockwise rotation to "OFF" stops engine and removes voltage from al ‘electrical functions, Parking Procedure 1, Using service brake, slop telehandler in an appropriate parking area. 2, Follow “Shut-Down Procedure” on page 4-4. 31200741, 1200747Section 3 - Controls and Indicators Transmission Control Leve! Direction of Travel Selection ‘Transmission control lever (1) engages forward or reverse travel Lift and push lever forward for forward travel lit and pull lever rearward for reverse travel. Move lever to centered position for neutral, Forward or reverse travel can be selected while in any gear. ‘When traveling in reverse, the back-up alarm will automatically sound. Drive in reverse and turn only at slow rates of speed. Do not increase engine speed with the transmission in forward or reverse and the service brake depressed in an attempt to get quicker hydraulic performances, Ths could cause unexpected machine movement. A WARNING TIP OVERICRUSH HAZARD. Bring telehandler to a complete stop before shifting transmission control lever. A sudden change in direction of travel could reduce stablity and/or cause load to shift ofall. NOTICE + Do not downshift more than one gear at atime. * Bring telehanaier to a complete stop before shifting transmission contol lever Into neutral or changing citection of travel Improper use may result in transmission damage, Section 3 - Controls and Indicators Gear Selection 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. Use a higher gear only when driving unloaded for longer distances * Slow down prior to downshifting. Do not downshift more than one gear at atime, 31200747\ *1200747Section 3 - Controls and Indicators Boom Joystick (T6420) __ 2 Q Reeea||s 3 ; “The boom joystick (1) controls the boom and attachment tit functions. Boom Functions + Move the joystick back to fit oom; move joystick foward to wer boom; move Joy not in exond Boom: move joystick ete eet boom +The sped of boom functions depends upon amount ol jystick raved incortesponding drecon, increasing engine speed wl iso increase function speed. + For wo simultaneous boom futons, move the joystick between quadrats For example; moving te joys forward and othe lft wl lower end react oom simitangousy. ‘tachment Function ) Ticonol is actuated by the switch 2). + Depress the left side ofthe switch to tit up; depress the right side of switch to tit doven *+ Use knob (8) to regulate the speed of the tit, Rotate knob counter-clockwise 10 increase speed; rotate knob clockwise to decrease speed, A WARNING TIP OVER/CRUSH HAZARD. Rapid, jerky operation of controls will cause rapid, | Jerky movement ofthe load. Such movements could cause the load to sift ofall or could cause the machine to tip over. 31200741, 91200747 Section 3 - Controls and Indicators This Page Intentionally Left BlankSebthin’s Genre aterund indlostors Section 3 - Controls and Indicators “Joystick (TL943C) Funilary Hydraulie Functions [aeealiccceil Mesa ‘uiary Hydraulics roller switch (8) contols function of attachments that require fydraulc supply for operation. See Section 5-Atlachments for approved aactiments and contol instructions. Cluteh Lock Switch Clutch Lockis controlled by tho joystck tigger (4). + Squeeze and release trigger once to deactivate system and have transmission disengage. Quickly squeeze and release trigger twice to activate system and keep transmission engaged. “The boom joystick (1) controls the boom, attachment tit, auxiliary hydraulic and clutch lock functions. Boom Functions + Move the joystick back to lit boom; move joystick forward to lower hon; move joystick right to extend boam; move joystick left to retract boom. “The speed of boom functions depends upon the amount of joystick travel in corresponding direction. Increasing engine speed will also increase function speed. For two simultaneous boom functions, move the joystick between quadrants. For example; moving the joystick forward and to the lett will lower and retrad ‘boom simultaneously. A WARNING TIP OVER/GRUSH HAZARD. Rapid, jerky operation of controls will cause rapid, Jerky movernent ofthe load. Such movements could cause the load to shift or fll Or could cause the machine to tip aver. ‘Attachment Function ‘Attachment tilt is controlled by the roller switch (2). *+ Push the roller switch up to tit attachment down; push the roller swich down 1 tilatachment up. 31200741 91200747Section 3 - Controls and indicators Section 3 - Controls and indicators Frame Level Joystick ‘Auxiliary Hydraulic Joystick (TL642C) The frame level joystick (1) controls the lef to right frame level ‘The auxiliary hydraulic joystick (1) controls function of attachments that require * Move the joystick left to rotate frame left, move the joystick right to retate hydraulic supply for operation. See Section 5- Attachments for approved frame right attachments and control instructions. * A level indicator is located above the front cab window to permit operator ts ‘determine whether the telehandler frame is level A WARNING TiP OVER HAZARD. Always move boom as low as possible while allowing for best visibility of right hhand mirror before leveling frame. Attempting to level ‘machine with boom raised could cause it to tip over 31200747, 31200747 sz -