Operation &

Maintenance Manual
Original Instructions
Keep this manual with machine at all times.

Models
TH314D
TH417D
S/N MYT00150 to Present
S/N MYF00150 to Present
S/N MLZ00150 to Present
S/N MKY00150 to Present

31211299
SEBU9292-03

Revised
March 25, 2019 - Rev D
 Revision Log

Revision Log
REVISION LOG
May 16, 2017 - A - Original Issue of Manual.
August 3, 2017 - B - Revised pages 9-5, 9-6 & 9-11.
September 28, 2018 - C - Revised pages c, 1-3, 2-4 thru 2-6, 2-8, 2-11, 3-5, 3-10, 3-12, 3-13,
3-16, 3-18 thru 3-20, 3-22 thru 3-25, 3-27, 3-29, 4-5, 4-8, 4-11, 5-1, 5-16, 5-29, 7-12, 8-1, 8-2,
9-2, 9-3 & 9-12.
March 25, 2019 - D- Revised pages 2-4, 2-6, 3-24, 3-25, 4-4, 4-5 & 5-2.

31211299 a
Read This First

Read This First

This manual is a very important tool! Keep it with the machine at all times.
The purpose of this manual is to provide owners, users, operators, lessors, and lessees
with the precautions and operating procedures essential for the safe and proper machine
operation for its intended purpose.
Due to continuous product improvements, the manufacturer reserves the right to make
specification changes without prior notification. Contact the local Caterpillar dealer for
updated information.

Operator Qualifications

The operator of the machine must not operate the machine until this manual has been
read, training is accomplished and operation of the machine has been completed under
the supervision of an experienced and qualified operator. Operation within the U.S.A.
requires training per OSHA 1910.178.
Operators of this equipment must possess a valid, applicable driver’s license, be in good
physical and mental condition, have normal reflexes and reaction time, good vision and
depth perception and normal hearing. Operator must not be using medication which
could impair abilities nor be under the influence of alcohol or any other intoxicant during
the work shift.
In addition, the operator must read, understand and comply with instructions contained
in the following material furnished with the material handler:
• This Operation & Maintenance Manual
• Telehandler Safety Manual (ANSI only)
• All instructional decals and plates
• Any optional equipment instructions furnished
The operator must also read, understand and comply with all applicable Employer,
Industry and Governmental rules, standards and regulations.

Modifications

Modifications to this machine may affect compliance with Industry Standards and/
or Governmental Regulations. Any modification must be approved by the
manufacturer.
This product must comply with all safety related bulletins. Contact the local Caterpillar
dealer representative for information regarding safety-related bulletins which may have
been issued for this product.

b 31211299
 Read This First

Other Publications Available

Service Manual ....................................................................................................UENR6270 (31211300)

Parts Manual
TH314D.................................................................................................................................. M0079632
TH417D.................................................................................................................................. M0079624

Note: The following standards may be referenced in this manual:

ANSI is compliant to ANSI/ITSDF B56.6
AUS is compliant to AS 1418.19
CE is compliant to 2006/42/EC
EAC is compliant to TR CU 010/2011
Refer to the machine Serial Number Plate to identify the applicable compliance standard.

31211299 c
Read This First

This Page Intentionally Left Blank

d 31211299
 Table of Contents

Table of Contents
TABLE OF CONTENTS
Revision Log
Read This First
Operator Qualifications ........................................................................... b
Modifications............................................................................................... b
Other Publications Available ..................................................................c
Table of Contents
Section 1 - General Safety Practices
1.1 Hazard Classification System ....................................................................1-1
Safety Alert System and Safety Signal Words...............................1-1
1.2 General Precautions .....................................................................................1-1
1.3 Operation Safety............................................................................................1-2
Electrical Hazards....................................................................................1-2
Tip Over Hazard .......................................................................................1-4
Travel Hazard............................................................................................1-7
Load Falling Hazard ...............................................................................1-8
Lifting Personnel .....................................................................................1-9
Driving Hazards on Slopes................................................................ 1-10
Pinch Points and Crush Hazards..................................................... 1-11
Fall Hazard.............................................................................................. 1-13
Chemical Hazards ................................................................................ 1-14
Section 2 - Pre-Operation and Inspection
2.1 Preparation, Inspection and Maintenance...........................................2-1
2.2 Pre-Operation Check and Inspection.....................................................2-2
2.3 Safety Decals ...................................................................................................2-4
2.4 Walk-Around Inspection.............................................................................2-8
2.5 Warm-Up and Operational Checks ...................................................... 2-10
Warm-Up Check ................................................................................... 2-10
Operational Check............................................................................... 2-10
2.6 Operator Cab................................................................................................ 2-11
2.7 Windows........................................................................................................ 2-12
Cab Door Window ............................................................................... 2-12
Rear Window ......................................................................................... 2-13

31211299 i
Table of Contents
Section 3 - Controls and Indicators
3.1 General..............................................................................................................3-1
3.2 Controls ............................................................................................................3-2
Instrument Cluster .................................................................................3-4
Ignition .......................................................................................................3-6
Park Brake..................................................................................................3-7
Parking Procedure..................................................................................3-7
Transmission Control Lever (if equipped) .....................................3-8
Load Stability Indicator - LSI ............................................................ 3-10
Steering Column Adjuster................................................................ 3-14
Joystick .................................................................................................... 3-16
Console Switches................................................................................. 3-24
Accessory Control Lever.................................................................... 3-26
3.3 Anti Theft ...................................................................................................... 3-27
3.4 Steer Modes ................................................................................................. 3-28
Manual Steering Alignment Mode Change ............................... 3-28
3.5 Operator Seat .............................................................................................. 3-29
Operator Presence .............................................................................. 3-29
Adjustments .......................................................................................... 3-30
Seat Belt .................................................................................................. 3-31
3.6 Boom Indicators ......................................................................................... 3-32
Boom Extension ................................................................................... 3-32
Section 4 - Operation
4.1 Engine ...............................................................................................................4-1
Starting the Engine ................................................................................4-1
Battery Boosted Starting......................................................................4-2
Normal Engine Operation ...................................................................4-3
Shut-Down Procedure ..........................................................................4-3
4.2 After-Treatment System (ATS) (SN MYT00500 to Present,
SN MLZ00500 to Present)...........................................................................4-4
Stationary Exhaust System Cleaning...............................................4-4
4.3 Operating with a Non-Suspended Load...............................................4-6
Lift Load Safely ........................................................................................4-6
Picking Up a Load...................................................................................4-6
Transporting a Load ..............................................................................4-7
Leveling Procedure................................................................................4-7
Placing a Load..........................................................................................4-8
Disengaging a Load...............................................................................4-8
4.4 Operating with a Suspended Load.........................................................4-9
Lift Load Safely ........................................................................................4-9
Picking Up a Suspended Load ...........................................................4-9
Transporting a Suspended Load.................................................... 4-10
Leveling Procedure............................................................................. 4-10

ii 31211299
 Table of Contents
Placing a Suspended Load ............................................................... 4-11
Disengaging a Suspended Load .................................................... 4-11
4.5 Road Operation (CE).................................................................................. 4-12
4.6 Loading and Securing for Transport ................................................... 4-13
Tiedown................................................................................................... 4-13
Lifting ....................................................................................................... 4-14
Section 5 - Attachments & Hitches
5.1 Approved Attachments...............................................................................5-1
5.2 Unapproved Attachments .........................................................................5-1
5.3 JLG Supplied Attachments.........................................................................5-2
CAT Quick Coupler .................................................................................5-2
Manitou Coupler .....................................................................................5-2
5.4 Telehandler/Attachment/Fork Capacity ...............................................5-4
5.5 Use of the Capacity Chart ...........................................................................5-5
Capacity Indicator Locations ..............................................................5-5
Sample Load Chart .................................................................................5-6
Example......................................................................................................5-8
5.6 Attachment Installation ........................................................................... 5-10
CAT Quick Coupler .............................................................................. 5-10
Manitou Coupler .................................................................................. 5-12
JCB Coupler............................................................................................ 5-14
Hydraulic Operated Attachment.................................................... 5-16
5.7 Adjusting/Moving Forks .......................................................................... 5-17
5.8 Attachment Operation ............................................................................. 5-18
Carriage w/Forks .................................................................................. 5-19
Side Shift Carriage ............................................................................... 5-20
Bucket ...................................................................................................... 5-22
Multi-Purpose Bucket......................................................................... 5-24
Fork Mounted Hook............................................................................ 5-26
Coupler Mounted Hook..................................................................... 5-27
Truss Boom............................................................................................. 5-28
5.9 Hitches............................................................................................................ 5-29
Retrieval Hitch....................................................................................... 5-29
Section 6 - Emergency Procedures
6.1 Towing a Disabled Product........................................................................6-1
Moving Short Distances .......................................................................6-1
Moving Longer Distance......................................................................6-1
6.2 Emergency Lowering of Boom.................................................................6-2
6.3 Cab Emergency Exit......................................................................................6-2

31211299 iii
Table of Contents
Section 7 - Lubrication and Maintenance
7.1 Introduction ....................................................................................................7-1
Clothing and Safety Gear.....................................................................7-1
7.2 General Maintenance Instructions..........................................................7-2
7.3 Service and Maintenance Schedules .....................................................7-3
10 & 1st 50 Hour Maintenance Schedule.......................................7-3
50 & 1st 250 Hour Maintenance Schedule ....................................7-4
250 & 500 Hour Maintenance Schedule .........................................7-5
1000 & 3000 Hour Maintenance Schedule ....................................7-6
6000 Hour Maintenance Schedule...................................................7-7
7.4 Lubrication Schedules.................................................................................7-8
TH314D.......................................................................................................7-8
TH417D.......................................................................................................7-9
7.5 Operator Maintenance Instructions .................................................... 7-10
Fuel System............................................................................................ 7-10
Tires .......................................................................................................... 7-12
Engine Oil ............................................................................................... 7-14
Engine Cooling System ..................................................................... 7-15
Hydraulic Oil .......................................................................................... 7-16
Transmission Oil................................................................................... 7-17
Air Intake System ................................................................................. 7-18
Cab Air Filters (if equipped) ............................................................. 7-20
Battery ..................................................................................................... 7-22
Windshield Washer System (if equipped)................................... 7-23
Section 8 - Additional Checks
8.1 General..............................................................................................................8-1
8.2 Load Stability Indicator System ...............................................................8-1
8.3 Boom Interlock...............................................................................................8-3
Section 9 - Specifications
9.1 Product Specifications.................................................................................9-1
Fluids...........................................................................................................9-1
Capacities ..................................................................................................9-5
Tires .............................................................................................................9-7
Performance .............................................................................................9-8
Dimensions ............................................................................................ 9-10
Declaration of Vibration.................................................................... 9-12
Noise Emission Level (CE) ................................................................. 9-12
Machine Towing Capacity ................................................................ 9-12
Index
Inspection, Maintenance and Repair Log
Transfer Of Ownership

iv 31211299
 Section 1 - General Safety Practices
SECTION 1 - GENERAL SAFETY PRACTICES
1.1 HAZARD CLASSIFICATION SYSTEM

Safety Alert System and Safety Signal Words

DANGER OW0010

DANGER indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury.

WARNING OW0021

WARNING indicates a potentially hazardous situation which, if not avoided, could result
in death or serious injury.

CAUTION OW0031

CAUTION indicates a potentiality hazardous situation which, if not avoided, may result in
minor or moderate injury.

1.2 GENERAL PRECAUTIONS

WARNING
Before operation, read and understand this manual. Failure to comply with the safety
precautions listed in this manual could result in machine damage, property damage,
personal injury or death.
• Hydraulic cylinders are subject to thermal expansion and contraction. This may result
in changes to the boom and/or attachment position while the machine is stationary.
Factors affecting thermal movement can include the length of time machine is
stationary, hydraulic oil temperature, ambient air temperature and boom and/or
attachment position.
• Precautions to avoid all hazards in the work area must be taken by the user before and
during operation of the machine.

31211299 1-1
Section 1 - General Safety Practices

1.3 OPERATION SAFETY

Note: The manufacturer has no direct control over machine application and operation.
Therefore, safety issues listed in this manual are non-exhaustive. The user and operator are
responsible for conforming with good safety practices.

Electrical Hazards

10 ft
(3m)

OD0891

• This machine is not insulated and does not provide protection from contact or being
near electrical current.
• Always check for power lines before raising the boom.
• Maintain distance from electrical lines, apparatus, or any energized (exposed or
insulated) parts according to the Minimum Approach Distance (MAD).

Voltage Range Minimum Approach Distance

(Phase to Phase) (MAD)
0 to 50 KV 10 ft (3 m)
Over 50KV to 200 KV 15 ft (5 m)
Over 200 KV to 350 KV 20 ft (6 m)
Over 350 KV to 500 KV 25 ft (8 m)
Over 500 KV to 750 KV 35 ft (11 m)
Over 750 KV to 1000 KV 45 ft (14 m)
Note: This requirement shall apply except where employer, local or governmental
regulations are more stringent.
• Allow for machine movement and electrical line swaying.
• Maintain a clearance of at least 10 ft (3m) between any part of the machine and its
occupants, their tools and their equipment from any electrical line or apparatus
carrying up to 50,000 volts. One foot additional clearance is required for every
additional 30,000 volts or less.

1-2 31211299
 Section 1 - General Safety Practices
• The minimum approach distance may be reduced if insulating barriers are installed to
prevent contact, and the barriers are rated for the voltage of the line being guarded.
These barriers shall not be part of (or attached to) the machine. The minimum
approach distance shall be reduced to a distance within the designed working
dimensions of the insulating barrier. This determination shall be made by a qualified
person in accordance with the employer, local, or governmental requirements for
work practices near energized equipment.

DANGER
Do not maneuver machine or personnel inside prohibited zone (MAD). Assume all
electrical parts and wiring are energized unless known otherwise.

• It is not recommended to use the machine during lightning. To prevent injury or

machine damage if lightning occurs during operation, lower the boom and shut down
the machine in a safe and secure location.

31211299 1-3
Section 1 - General Safety Practices
Tip Over Hazard

General
• For additional load requirements, refer to the appropriate capacity chart.

OW0050

• Never use an attachment without the appropriate original equipment manufacturer

(OEM) approved capacity chart installed on the telehandler.
• Understand how to properly use the capacity charts located in cab.
• DO NOT exceed rated lift capacity.
• Be sure that the ground conditions are able to support the machine.
• Be aware of wind conditions. Wind may cause load swing and dangerous side loads.
• Keep the machine a minimum of 2 ft (0,6 m) from holes, drop-offs, obstructions,
debris, concealed holes and other potential hazards at ground level.

OW0080

• DO NOT raise boom unless frame is level (0 degrees), unless otherwise noted on
capacity chart.

4 FT
(1,2 M)

OW0100

• DO NOT level machine with boom/attachment above 1,2 m (4 ft).

(AUS - DO NOT level machine with load more than 300 mm (11.8 in) above ground
surface.)

1-4 31211299
 Section 1 - General Safety Practices

OH2291

• MAINTAIN proper tire pressure at all times. If proper tire pressures are not
maintained, this machine could tip over.
• Refer to manufacturer’s specifications for proper fill ratio and pressure requirements
for tires equipped with ballast.

OH20911

• Always wear the seat belt.

• Keep head, arms, hands, legs and all other body parts inside operator’s cab at all times.

OH2221

If the telehandler starts 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

31211299 1-5
Section 1 - General Safety Practices
Non-Suspended Load

OW0060

• DO NOT drive with boom raised.

Suspended Load

OW0150

• Tether suspended loads to restrict movement.

• Weight of all rigging (slings, etc.) must be included as part of load.
• DO NOT attempt to use telehandler frame-leveling to compensate for load swing.
• Keep heavy part of load closest to attachment.
• Never drag the load; lift vertically.
When driving with a suspended load:
• Start, travel, turn and stop slowly to prevent load from swinging.
• DO NOT extend boom.
• DO NOT raise the load more than 300 mm (11.8 in) above ground surface or the
boom more than 45°.
• DO NOT exceed walking speed.

1-6 31211299
 Section 1 - General Safety Practices
Travel Hazard

2-Wheel Front Steer 4-Wheel Circle Steer 4-Wheel Crab Steer

OAL2030

• Steering characteristics differ between steer modes. Identify the steer mode settings
of the telehandler being operated.
• DO NOT change steer modes while traveling. Steer modes must be changed while
telehandler is stationary.
• Visually verify proper wheel alignment after each steer mode change.
• Ensure that adequate clearance is provided for both rear tail swing and front fork
swing.
• Look out for and avoid other personnel, machinery and vehicles in the area. Use a
spotter if you DO NOT have a clear view.
• Before moving be sure of a clear path and sound horn.
• When driving, retract boom and keep boom/attachment as low as possible while
maintaining visibility of mirrors and maximum visibility of path of travel.
• Always look in the direction of travel.
• Always check boom clearances carefully before driving underneath overhead
obstructions. Position attachment/load to clear obstacles.
• When driving in high speed, use only front wheel steer (if steering modes are
selectable).
• Telehandlers equipped with solid or foam filled tires should not be used in
applications requiring excessive roading or driving extended distances. In the event
an application requires excessive roading or driving expanded distances, it is
recommended to use telehandlers not equipped with solid or foam filled tires.

31211299 1-7
Section 1 - General Safety Practices
Load Falling Hazard

OW0130

• Never suspend load from forks or other parts of carriage weldment. Use only
approved lift points.
• DO NOT burn or drill holes in fork(s).
• Forks must be centered under load and spaced apart as far as possible.

1-8 31211299
 Section 1 - General Safety Practices
Lifting Personnel

OW0170

• When lifting personnel, USE ONLY an approved personnel work platform, with proper
capacity chart displayed in the cab.

OW0190

• DO NOT drive machine from cab when personnel are in platform.

31211299 1-9
Section 1 - General Safety Practices
Driving Hazards on Slopes

OW0200

To maintain sufficient traction and braking capabilities, travel on slopes as follows:

• When unloaded, drive with forks pointed downhill.
• When loaded, drive with the forks pointed uphill.
• For additional travel requirements, refer to the appropriate capacity chart.
• To avoid overspeeding the engine and drivetrain when driving down slopes,
downshift to a lower gear before going downhill and use the service brake as
necessary to maintain a slow speed. DO NOT shift into neutral and coast downhill.
• Avoid excessively steep slopes or unstable surfaces. To avoid tip over DO NOT drive
across excessively steep slopes under any circumstances.
• Avoid turning on a slope. Never engage “inching” or shift to “Neutral” when going
downhill.
• DO NOT park on a slope.

1-10 31211299
 Section 1 - General Safety Practices
Pinch Points and Crush Hazards

Stay clear of pinch points and rotating parts on the telehandler.

OW0210

• Stay clear of moving parts while engine is running.

OW0220

• Keep clear of steering tires and frame or other objects.

OW0230

• Keep clear from under boom.

31211299 1-11
Section 1 - General Safety Practices

OW0240

• Keep clear of boom holes.

OW0250

• Keep arms and hands clear of attachment tilt cylinder.

OW0260

• Keep hands and fingers clear of carriage and forks.

OW0960

• Keep others away while operating.

1-12 31211299
 Section 1 - General Safety Practices
Fall Hazard

OW0280

• Enter using the proper hand holds and steps provided. Always maintain 3-point
contact when mounting or dismounting. Never grab control levers or steering wheel
when mounting or dismounting the machine.
• DO NOT get off the machine until the shutdown procedure on page 4-3 has been
performed.

OW0290

• DO NOT carry riders. Riders could fall off machine causing death or serious injury.

31211299 1-13
Section 1 - General Safety Practices
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. Sparks from the electrical system and the engine exhaust can cause an
explosion.

Flammable Fuel

OW0300

• DO NOT fill the fuel tank or service the fuel system near an open flame, sparks or
smoking materials. Engine fuel is flammable and can cause a fire and/or explosion.

Hydraulic Fluid

OW0950

• DO NOT attempt to repair or tighten any hydraulic hoses or fittings 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 it can penetrate the skin.
• DO NOT use your hand to check for leaks. Use a piece of cardboard or paper to search
for leaks. Wear gloves to protect hands from spraying fluid.

1-14 31211299
 Section 2 - Pre-Operation and Inspection
SECTION 2 - PRE-OPERATION AND INSPECTION
2.1 PREPARATION, INSPECTION AND MAINTENANCE
The following table covers the periodic machine inspections and maintenance required.
Consult local regulations for further requirements for telehandlers. The frequency of
inspections and maintenance must be increased as necessary when the machine is used
in a harsh or hostile environment, if the machine is used with increased frequency, or if
the machine is used in a severe manner.

Inspection and Maintenance

Primary Service
Type Frequency Reference
Responsibility Qualification
Beginning of each Operation &
Pre-Operation User or User or
work shift or at each Maintenance
Inspection Operator Operator
change of operator. Manual
Pre-Delivery Before each sale, Service Manual
Owner, Dealer Qualified
Inspection lease or rental and applicable
or User Mechanic
(see note) delivery. Inspection form.
At intervals as
specified in the Service Manual
Preventative Service Manual and/ Owner, Dealer Qualified and
Maintenance or the Maintenance or User Mechanic Maintenance
Charts located on the Charts
machine.
Note: Inspection forms are available.

31211299 2-1
Section 2 - Pre-Operation and Inspection

2.2 PRE-OPERATION CHECK AND INSPECTION

Note: Complete all required maintenance before operating unit.

WARNING
FALL HAZARD. Use extreme caution when checking items beyond your normal reach.
Use an approved ladder.
The pre-operation check and inspection, performed at beginning of each work shift or at
each change of operator, should include the following:
1. Cleanliness - Check all surfaces for leakage (oil, fuel or battery fluid) or foreign
objects. Report any leakage to the proper maintenance personnel.
2. Structure - Inspect the machine structure for dents, damage, weld or parent metal
cracks or other discrepancies.

OAH1000
PARENT METAL CRACK WELD CRACK

3. Safety Decals - Ensure all safety decals are legible and in place. Clean or replace as
required. See page 2-4 for details.
4. Operation and Safety Manuals - Operation & Maintenance Manual and AEM Safety
Manual (ANSI only) located in cab manual holder.
5. Walk-Around Inspection - See page 2-7 for details.
6. Fluid Levels - Check fluids, including fuel, hydraulic oil, engine oil and coolant. When
adding fluids, refer to Section 7 - Lubrication and Maintenance and Section
9 - Specifications to determine proper type and intervals. Before removing filler caps
or fill plugs, wipe all dirt and grease away from the ports. If dirt enters these ports, it
can severely reduce component life.
7. Attachments/Accessories - Ensure correct capacity charts are installed on the
telehandler. If provided, reference the Operation & Maintenance Manual of each
attachment or accessory installed for specific inspection, operation and maintenance
instructions.

2-2 31211299
 Section 2 - Pre-Operation and Inspection
8. Operational Check - Once the walk-around inspection is complete, perform a warm-
up and operational check (see page 2-10) of all systems in an area free of overhead
and ground level obstructions. See Section 3 - Controls and Indicators for more
specific operating instructions.

WARNING
If telehandler does not operate properly, immediately bring machine to a stop, lower
boom and attachment to ground and stop the engine. Determine cause and correct
before continued use.

31211299 2-3
Section 2 - Pre-Operation and Inspection

2.3 SAFETY DECALS

Ensure all DANGER, WARNING, CAUTION and instructional decals and proper capacity
charts are legible and in place. Clean and replace as required.

1001191487 1001138051
(INSIDE POWER (IF EQUIPPED -
GERMANY)
DISTRIBUTION TYPE/MODEL:
TIPO/MODELLO:
JLG MANUFACTURING EUROPE BVBA

BOX ON FRAME)
TYP/MODELL:
TIPO/MODELO:

HOMOLOGATION NUMBER:
NUMERO DI OMOLOGAZIONE:
GENEHMIGUNGS NUMMER:
NÚMERO DE HOMOLOGACIÓN:

VEHICLE IDENTIFICATION NUMBER:

NUMERO IDENTIFICAZIONE:
FAHRZEUG-IDENTIFIZIERUNGS-NUMMER:
NÚMERO DE IDENTIFICACIÓN:

ALLOWED TOTAL WEIGHT: Kg

MASSA TOTALE AMMISSIBILE:
ZUL. GESAMTGEWICHT:
MASA TOTAL AUTORIZADA:

8008657
ALLOWED FRONT AXLE WEIGHT: Kg
CARICO AMMISSIBILE SULL’ASSE ANTERIORE:

F3 80A ZUL. ACHSLAST VORN:

CARGA AUTORIZADA SOBRE EL EJE DELANTERO:

ALLOWED REAR AXLE WEIGHT: Kg

CARICO AMMISSIBILE SULL’ASSE POSTERIORE:

8008657
ZUL. ACHSLAST HINTEN:

8005671 8006612
F4 80A
CARGA AUTORIZADA SOBRE EL EJE TRASERO:

8005675
PERMISSIBLE TOWABLE MASS:
MASSA RIMORCHIABILE AMMISSIBILE:
TECHNISCH ZULAESSIGE ANHAENGELAST:
MASA REMOLCABLE ADMISIBLE:

F6 25A F5 80A -UNBRAKED TOWABLE MASS:

MASSA RIMORCHIABILE NON FRENATA:
Kg

8005616
UNGEBREMSTE ANHAENGELAST:

F7 15A MASA REMOLCABLE NO FRENADA:

-INDEPENDENTLY-BRAKED TOWABLE MASS: Kg

MASSA RIMORCHIABILE CON FRENATURA INDIPENDENTE:

F8 30A ANHAENGELAST FUER UNABHAENGIGE BREMSUNG:

MASA REMOLCABLE CON FRENADO INDEPENDIENTE:

F2 150A
F9 25A
-INERTIA-BRAKED TOWABLE MASS: Kg
MASSA RIMORCHIABILE CON FRENATURA AD INERZIA:
AUFLAUFGEBREMSTE ANHAENGELAST:
MASA REMOLCABLE FRENADA POR INERCIA:

K6 K7 K8 F10 30A -TOWABLE MASS FITTED WITH AN ASSISTED BRAKING

SYSTEM:
Kg
(HYDRAULIC OR PNEUMATIC)

F11 30A MASSA RIMORCHIABILE CON FRENATURA ASSISTITA:

F1 200A (IDRAULICA O PNEUMATICA)

HYDRAULSCH ODER PNEUMATISCH GEBREMSTE
ANHAENGELAST:

30A 30A 30A F12 30A MASA REMOLCABLE CON FRENADO ASISTID:
(HIDRÁULICO-NEUMÁTICO)

1001191487 A YEAR OF MANUFACTURE:

ANNO DI FABRICAZIONE:
BAUJAHR:
AÑO DE FABRICACIÓN:

1001138051

8008657B

8008657B 8005671 8006612

3700016
3700016

20
3700016 MP13
1001121555 A

1001121555
1001168718A

20 - 2603207 JLG Manufacturing Europe BVBA

1001168718
8005617
Industrieterrein Oude Bunders 1034
Breitwaterstraat 12
3630 Maasmechelen - Belgium

(GERMANY) (RUSSIA) Model:

Year of Manufacture:

LE 8005616
Product Identication Number

SAMP
Model Year:
Serial Number
Nominal engine power, kW:

25 - 1001153442
Unladen mass: kg
Maximum capacity: kg
Maximum capacity at max. Height: kg
100100YYY A
1001138666 B

(FRANCE) SERIAL NUMBER PLATE

1001173703
1001223875 1001237054 (RUSSIA)
(INSIDE FRAME - IF EQUIPPED)
1001189154

1706098
AU2105
! 1001139164

1001223875 A

1001189154A
AU2105

1001139164A

1706098 B

1706285

8005617
VIEW OF ENGINE
1001241674 A

1001241674 A

COMPARTMENT
1001241674 1001241674 OAM4002

2-4 31211299
 Section 2 - Pre-Operation and Inspection

1705980
(74,4 kW)
20 - 2603207 8008657
8005675 8005671 8005616
L WA (GERMANY)
A - 1706753 25 - 1001153442
B - 1706754
C - 1706755
106 dB
1001102782
(FRANCE)
D - 1706756 8007508

ABCD
(55,0 kW) 20 8008657B

8005671

L WA

104 dB 8007508

3700016

1001129842 A
A

S 15 mg/kg
3700016
D 3700016
8005617 1001139654 A

1001139654
1001168718A

8005616 8008657B

(SN MYT00150 to Present)

1001168718
8006612

8006612 8008657 (SN MLZ00150 to Present)

1001217135
(GERMANY)

8005870 1706292
1 2

1001104319
8005870C

20 - 2603207
(GERMANY)
25 - 1001153442
(FRANCE)

20 8006612

8006612

1001241674 A

1001241674
8006612

8006612 (IF EQUIPPED WITH HITCH)

3700015 OAM4011

31211299 2-5
Section 2 - Pre-Operation and Inspection

1001241952
(LIFT PATTERN)
1001241951
1001101895 1001158309 (LOADER PATTERN)

3m

F
N 1001217134
(GERMANY)
R

1001101895A

1001241952A

1001092878
A C A

B
1001129842 A

1001250530
F1 10A 5A F6 F11 10A 10A F16
F2 30A 5A F7 F12 10A 10A F17
F3 10A 10A F8 F13 10A 25A F18
F4 5A 10A F9 F14 10A 10A F19
F5 5A 5A F10 F15 25A 5A F20
1001250530 A

1001172035

!
B
1001189154A

1001189154
1001092877
1706288

3m

1706284
VIEW C-C

TH314D - 1001161264 CAPACITY

TH417D - 1001165433 CHARTS
XXXX
XXX mm
- XXX mm

EVERY
XXX kg MAX
50 A
o
50 75
B 14m
o
60
500 C
13m D
o
2000kg
12m 50
A A
11m C
o
10m 40
2500kg B
B 9m
B B
B o
B
8m
30 A
7m 3700kg
1000kg

B
A 6m
1500kg
500kg

o
5m
20
750kg

A 4m
350kg

A 3m
A A A 10
o

2m

A 1m

A A o
0m 0
C C XXX mm
-1m
9m 8m 7m 6m 5m 4m 3m 2m 1m 0m

EN 1459:1998-ANNEX B

1001094708 10 XXXX
XXX
D

50
LB-FT
(N m
)

50
XX

1001094708B

150

1001161263
XXXXXX

EN 15830
CHARTS
1001130323 P

VIEW B-B VIEW A-A P

1001214206A

OAM4022 1001214206

2-6 31211299
 Section 2 - Pre-Operation and Inspection

This Page Intentionally Left Blank

31211299 2-7
Section 2 - Pre-Operation and Inspection

2.4 WALK-AROUND INSPECTION

21

1
3 2
4 20
5 5
19

6 18

17

7
8
16

10 15

14

11 11
OZ3893
12 13

Begin your walk-around inspection at item 1, as noted below. Continue to your right
(counterclockwise when viewed from top) checking each item in sequence.
INSPECTION NOTE: On all components, make sure there are no loose or missing parts, that
they are securely fastened and no visible leaks or excessive wear exists in addition to any
other criteria mentioned. Inspect all structural members including attachment for cracks,
excessive corrosion and other damage.
1. Boom Sections and Lift, Tilt, Extend/Retract, Compensating (Slave) Cylinders -
• Check front, top, side and rear wear pads for presence of grease.
• Pivot pins secure; hydraulic hoses undamaged, not leaking.
2. Boom Prop - See inspection note.
2-8 31211299
 Section 2 - Pre-Operation and Inspection
3. Front Axle - Steer cylinders undamaged, not leaking; pivot pins secure (if equipped);
hydraulic hoses undamaged, not leaking.
4. Left Outrigger - Pins secure; hydraulic hoses and cylinder undamaged, not leaking.
5. Front Lights (if equipped) - Clean and undamaged.
6. Wheel/Tire Assembly - Properly inflated and secured; no loose or missing lug nuts.
Inspect for worn tread, cuts, tears or other discrepancies.
7. Mirror - Clean and undamaged.
8. Cab and Electrical -
• General appearance; no visible damage.
• Frame level indicator(s) and window glass undamaged and clean.
• Gauges, switches, joystick, foot controls and horn operational.
• Check seat belt for damage, replace belt if frayed or cut webbing, damaged
buckles or loose mounting hardware.
9. Wheel Chock (if equipped) - See inspection note.
10. Wheel/Tire Assembly - Properly inflated and secured; no loose or missing lug nuts.
Inspect for worn tread, cuts, tears or other discrepancies.
11. Rear Lights (if equipped) - Clean and undamaged. For road use, orientate in the
horizontal position. For off-road use, orientate in the horizontal or down position.
See “Road Operation (CE)” on page 4-12.
12. LSI Sensor - See inspection note.
13. Main Control Valve - See inspection note.
14. Rear Axle - Steer cylinders undamaged, not leaking; pivot pins secure; hydraulic
hoses undamaged, not leaking.
15. Wheel/Tire Assembly - Properly inflated and secured; no loose or missing lug nuts.
Inspect for worn tread, cuts, tears or other discrepancies.
16. Engine Compartment -
• Drive belts, check condition and replace as required.
• Engine mounts - See inspection note.
• Battery cables tight, no visible damage or corrosion.
• Engine cover properly secured.
17. Mirrors - Clean and undamaged.
18. Wheel/Tire Assembly - Properly inflated and secured; no loose or missing lug nuts.
Inspect for worn tread, cuts, tears or other discrepancies.
19. Frame Level Cylinder - Pins secure; hydraulic hoses undamaged, not leaking.
20. Right Outrigger - Pins secure; hydraulic hoses and cylinder undamaged, not leaking.
21. Attachment - Properly installed, see “Attachment Installation” on page 5-10.

31211299 2-9
Section 2 - Pre-Operation and Inspection

2.5 WARM-UP AND OPERATIONAL CHECKS

Warm-Up Check

During warm-up period, check:

1. Heater, air conditioning and wipers (if equipped).
2. Check all lighting systems (if equipped) for proper operation.
3. Adjust mirrors for maximum visibility.

WARNING
CUT/CRUSH/BURN HAZARD. Keep engine cover closed while engine is running.

Operational Check

When engine warms, perform an operational check:

1. Service brake and parking brake operation.
2. Forward and reverse travel.
3. Each gear.
4. Steering in both directions with engine at low idle (steering lock to lock will not be
reached). Check in each steering mode
5. Horn and back-up alarm. Must be audible from inside operators cab with engine
running.
6. All joystick functions - operate smoothly and correctly.
7. Perform any additional checks described in Section 8.

2-10 31211299
 Section 2 - Pre-Operation and Inspection

2.6 OPERATOR CAB

The telehandler is equipped with an enclosed ROPS/FOPS cab.

WARNING
Never operate telehandler unless the overhead guard, cab structure and right side
glass or screen are in good condition. Any modification to this machine must be
approved by the manufacturer to assure compliance with ROPS/FOPS certification for
this cab/machine configuration. If the overhead guard or cab structure is damaged,
the CAB CANNOT BE REPAIRED. It must be REPLACED.

WARNING
Never drill, cut, and/or weld to cab. Any modification to this machine must be
approved by the manufacturer to assure compliance with machine configuration. If
unauthorized drilling, cutting and/or welding is present, the cab must be REPLACED.

31211299 2-11
Section 2 - Pre-Operation and Inspection

2.7 WINDOWS
Keep all windows clean and unobstructed.

Cab Door Window

OAM3880

• Cab door (1) must be closed during operation.

• During operation the cab door window (2) must either be latched open or closed.
• Open the cab door window using lever (3) and secure it in the latch (4).
• Press the release inside the cab to unlatch the window.

2-12 31211299
 Section 2 - Pre-Operation and Inspection
Rear Window

6
5

OAM2110

• Lift lever (5) and push to open the rear window (6).
• Lift lever and pull to close.

31211299 2-13
Section 2 - Pre-Operation and Inspection

This Page Intentionally Left Blank

2-14 31211299
 Section 3 - Controls and Indicators
SECTION 3 - CONTROLS AND INDICATORS
3.1 GENERAL
This section provides the necessary information needed to understand control functions.

31211299 3-1
Section 3 - Controls and Indicators

3.2 CONTROLS

14
13
10
8 9
11 5
7 12
6
5

4 3
2
1

OZ4010

1. Park Brake: See page 3-7.

2. Accelerator Pedal: Pressing down the pedal increases engine and hydraulic speed.
3. Ignition Switch: Key activated. See page 3-6.
4. Service Brake Pedal: The further the pedal is depressed, the slower the travel speed.
5. Console Switches: See page 3-24.
6. Climate Controls: See page 3-25.
7. Transmission Control Lever: See page 3-8.
8. Steering Wheel: Turning the steering wheel to the left or right steers the machine in
the corresponding direction. Three steering modes are available. See “Steer Modes”
on page 3-28.
9. Steering Column Adjuster: See page 3-14.
10. Instrument Cluster: See page 3-4.

3-2 31211299
 Section 3 - Controls and Indicators
11. Accessory Control Lever: See page 3-26.
12. Joystick: See page 3-16.
13. LSI Indicator: See page 3-10.
14. Frame Level Indicator: Enables operator to determine the left to right level condition
of the telehandler.

31211299 3-3
Section 3 - Controls and Indicators
Instrument Cluster

3
1

DISPLAY SCREEN

8 9
11 KPH

1127 RPM 127°C

11 10
DISPLAY SHOWN WITH ANTI THEFT
7 ACTIVE AT SYSTEM START

6 0000
4

12
OZ4081 5

NOTICE
EQUIPMENT DAMAGE. When a red indicator illuminates (except park brake),
immediately bring machine to a stop, lower boom and attachment to ground and stop
the engine. Determine cause and correct before continued use.
1. Low Fuel Indicator: Illuminates when fuel level is low.
2. Fuel Gauge: Indicates amount of fuel in fuel tank.
3. Engine Warning Light: Illuminates when the engine is in a critical state. Immediately
bring machine to a stop, retract and lower boom and stop the engine. Determine
cause and correct before continued use.
4. Engine Preheat Indicator: Illuminates with ignition key in position 1. Indicator goes
out when start temperature is reached.
5. Steer Mode Indicators: Illuminates active steering mode.
6. System Distress Indicator: Illuminates when an issue with the fuel level or machine
system is present. Flashes when an issue with the machine charge system is present.
7. Park Brake Indicator: Illuminates when park brake is applied.

3-4 31211299
 Section 3 - Controls and Indicators
8. Check Engine Indicator: Illuminates when maintenance is required. See Service
Manual for details.
Note: All indicators perform a bulb check at system start up.

Display Screen
9. Speed, Boom Angle and Operating Hours:
a. Speed - Telehandler travel speed displayed in kilometers per hour (km/h) or miles
per hour (m/h).
b. Boom Angle - Displays boom angle in degrees.
c. Operating Hours - Displays total hours of telehandler operation. Displays when
ignition is in ON position and engine is not started.
10. Engine Coolant Temperature and Fault Codes:
a. Engine Coolant Temperature - Displays engine coolant temperature.
b. Fault Codes - Replaces the engine coolant temperature. Displays fault codes of
engine and machine systems. See Service Manual for details.
11. Driving Direction and Gear, Engine Speed and Battery Voltage:
a. Driving Direction and Gear - Displays current driving condition.
Direction - Forward (F), Neutral (N) or Reverse (R).
Gear - First (1), Second (2) or Third (3).
b. Engine Speed - Displays engine speed in revolutions per minute (rpm).
c. Battery Voltage - Displays voltage supplied by battery. Displays when ignition is
in ON position and engine is not started.
12. Anti Theft Code Entry: If active, the four digit code must be entered prior to starting
the engine. See “Anti Theft” on page 3-27.

31211299 3-5
Section 3 - Controls and Indicators
Ignition

0
P I

II

III

OZ2300

• Position 0 - Engine off.

• Position I - Voltage available for all electrical functions.
• Position II - Wait to start engine until preheat indicator on instrument panel goes out.
• Position III - Engine start. In the event the engine does not start, rotate key to position
0 then back to position III to re-engage the starter.
• Position P - Not active, reserved for future use.
Note: Key is removable in the 0 and P positions.

3-6 31211299
 Section 3 - Controls and Indicators
Park Brake

TH314D TH417D

1
4
3
1
2

OZ4091

The park brake lever (1) controls the application and release of the park brake.
• Pull lever back to apply park brake.
• TH314D - Squeeze release (2) and push lever forward to release park brake.
TH417D - Lift detent ring (3) and push lever forward to release park brake.
• TH314D - The park brake may be adjusted with the knob (4). Turn clockwise to
increase park brake force. Turn counterclockwise to decrease park brake force.

WARNING
MACHINE ROLL-AWAY HAZARD. Always move park brake lever to "ON" position,
lower boom to ground and stop engine before leaving cab.

WARNING
CRUSH HAZARD. Applying park brake while traveling will cause unit to stop abruptly
and could cause load loss. To stop the machine in an emergency, apply the park brake.

Parking Procedure

1. Using service brake, stop telehandler in an appropriate parking area.

2. Follow “Shut-Down Procedure” on page 4-3.

31211299 3-7
Section 3 - Controls and Indicators
Transmission Control Lever (if equipped)

Direction of Travel Selection

R
OZ4131

Transmission control lever (1) engages forward or reverse travel.

• Push lever forward for forward travel; 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.
• If clutch lock is activated 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. This could cause unexpected machine movement.

WARNING
TIP OVER/CRUSH HAZARD. Bring telehandler to a complete stop before shifting
transmission control lever. A sudden change in direction of travel could reduce
stability and/or cause load to shift or fall.

3-8 31211299
 Section 3 - Controls and Indicators

1 st
2 nd

3 rd

OZ4142

Gear Selection
Gear selection is located on the twist grip handle (2) of transmission control lever.
• Twist hand grip to select gear.
• The Transmission is equipped with three forward and three reverse gears.
• 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 a time.
Downshifting is not permitted if current gear is flashing on display. Intended
downshifting speeds are 9 kph (5.5 mph) for third to second gear and 4 kph (2.5 mph)
for second to first gear.

31211299 3-9
Section 3 - Controls and Indicators
Load Stability Indicator - LSI

WARNING
TIP OVER HAZARD. The LSI considers only longitudinal stability limitations, observe
all operating parameters. Failure to follow operating parameters of the telehandler
could damage the equipment and/or cause tip over.
Prior to SN MYT00161, Prior to SN MYF00164 excluding MYF00154,
Prior to SN MLZ00151, Prior to SN MKY00191 excluding MKY00189

4
5

1
3
6

OZ4100

The LSI (1) provides visual and audible indication of forward stability limitations when
machine is static on firm, level surface.
• Green LED (2) will illuminate when LSI power is on.
• When approaching forward stability limitations LEDs progressively illuminate, green
(3), then orange (4) and finally red (5).
• If the red LED illuminates the warning buzzer also sounds.
• As the telehandler reaches forward stability limitations and the red LED (5) illuminates,
the automatic function cut-out is activated. All boom, frame level and outrigger
functions are disabled except for boom retract (CE & AUS) and boom lift (CE). Retract
boom to re-enable functions.
• In some instances the LSI system may slow down or stop boom functions if operated
close to forward stability limitations. When LEDs begin to flash, certain functions can
not be operated.

3-10 31211299
 Section 3 - Controls and Indicators
• Travel in accordance with the requirements set forth in Section 1- General Safety
Practices.
• Test LSI (6) ate the beginning of each work shift. See Section 8 - Additional Checks.
• When placing a load, ensure axles are not fully steered in either direction.

WARNING
TIP OVER HAZARD. If the green, orange and red LEDs flash and warning buzzer
sounds, retract and lower boom immediately. Determine cause and correct before
continued use.

31211299 3-11
Section 3 - Controls and Indicators
SN MYT00161 to Present, SN MYF00164 to Present including MYF00154,
SN MLZ00151 to Present, SN MKY00191 to Present including MKY00189

4
3

2
1
X

1001243215 B

OZ4600

The LSI (1) provides visual and audible indication of forward stability limitations when
machine is static on firm, level surface.
• When approaching forward stability limitations LEDs progressively illuminate, green
(2), then yellow (3) and finally red (4).
• If the red LED illuminates the warning buzzer also sounds.

The LSI has two modes:

Active Mode
• As the telehandler reaches forward stability limitations and the red LED (4)
illuminates, the automatic function cut-out is activated. All boom functions are
disabled except for boom retract and boom lift (CE) and boom retract, boom lift
and boom lower (AUS). Retract boom to re-enable functions.
Note: When functions are cut-out, the LSI Override Switch can be used to temporarily
re-enable them. See “Console Switches” on page 3-24.
• In some instances the LSI system may slow down or stop boom functions if
operated close to forward stability limitations.

3-12 31211299
 Section 3 - Controls and Indicators
Passive Mode
• The orange LED (5) on the instrument panel illuminates when the boom is fully
retracted.
• When approaching forward stability limitations, visual and audible indication is
provided and the automatic function cut-out and/or slow down feature is
disabled.
• Travel in accordance with the requirements set forth in Section 1- General Safety
Practices.
• When placing a load, ensure axles are not fully steered in either direction.

WARNING
TIP OVER HAZARD. If the green, yellow and red LEDs flash and warning buzzer
sounds, retract and lower boom immediately. Determine cause and correct before
continued use.

31211299 3-13
Section 3 - Controls and Indicators
Steering Column Adjuster

OZ4120

• Follow “Shut-Down Procedure” on page 4-3.

• Turn lever (1) counterclockwise to unlock.
• Place steering column in desired position.
• Turn lever clockwise to lock.

WARNING
TIP OVER/CRUSH HAZARD. Bring telehandler to a complete stop and shutdown
engine before adjusting steering column. A sudden change in direction of travel could
reduce stability and/or cause load to shift or fall.

3-14 31211299
 Section 3 - Controls and Indicators

This Page Intentionally Left Blank

31211299 3-15
Section 3 - Controls and Indicators
Joystick

Verify the joystick decal located inside the cab matches the machine controls.
Lift Joystick Pattern

5 4
F 5
N
1
R
2
3 6
7
8 9

OZ4670

The joystick (1) controls the boom, attachment, auxiliary hydraulics, outrigger and
transmission functions.
Boom Functions
• Move the joystick back to lift boom; move joystick forward to lower boom; move
joystick right to extend boom; move joystick left to retract boom.
• 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 left will lower and retract boom
simultaneously.

3-16 31211299
 Section 3 - Controls and Indicators

WARNING
TIP OVER/CRUSH HAZARD. Rapid, jerky operation of controls will cause rapid, jerky
movement of the load. Such movements could cause the load to shift or fall or could
cause the machine to tip over.
Attachment Functions
Attachment tilt is controlled by the roller switch (2).
• Push the roller switch up to tilt attachment down; push the roller switch down to tilt
attachment up.

Auxiliary Hydraulic Functions (if equipped)

Auxiliary Hydraulics roller switch (3) controls function of attachments that require
hydraulic supply for operation. See Section 5 - Attachments & Hitches for approved
attachments and control instructions.

Continuous Auxiliary Hydraulic Functions (if equipped)

• Depress and release joystick button (4) for continuous operation of hydraulic powered
attachments.
• Set continuous auxiliary hydraulic level (-100% to 100%) using the auxiliary hydraulic
roller switch (3). Push the roller switch up to increase or down to decrease hydraulic
flow.
• Depress and release joystick button (4) again to stop continuous operation.

Outrigger Functions
Joystick button (5) controls both outriggers.
• Press and hold the button; move the joystick forward to lower both outriggers; move
the joystick back to raise both outriggers.
• Press and hold the button; move the joystick left then forward to lower the left
outrigger; move the joystick left then back to raise the left outrigger.
• Press and hold the button; move the joystick right then forward to lower the right
outrigger; move the joystick right then back to raise the right outrigger.
• Outriggers operable with boom at any extension and below 20 degrees or with boom
fully retracted and below 55 degrees.

WARNING
TIP OVER HAZARD. Outriggers increase stability and load capacity only if they are
used properly. Using outriggers on soft surfaces could cause telehandler to tip over.
Always ensure surface can support telehandler and load.

31211299 3-17
Section 3 - Controls and Indicators
Transmission Control (if equipped)
Transmission roller switch (6) engages forward or reverse travel.
• Press switch up for forward travel; Press switch down for reverse travel. Move switch 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.
• Travel at slow rates of speed when making turns and driving in reverse.

WARNING
TIP OVER/CRUSH HAZARD. Bring telehandler to a complete stop before shifting
transmission. A sudden change in direction of travel could reduce stability and/or
cause load to shift or fall.

Gear selection is controlled by buttons (7 & 8).

• Depress upshift button (8) to select a higher gear; Depress downshift button (7) to
select a lower gear.
• The Transmission is equipped with three forward and three reverse gears.
• 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 a time.
Downshifting is not permitted if current gear is flashing on display. Intended
downshifting speeds are 9 kph (5.5 mph) for third to second gear and 4 kph (2.5 mph)
for second to first gear.

3-18 31211299
 Section 3 - Controls and Indicators
Clutch Lock is controlled by button (9).
Prior to SN MYT00161, Prior to SN MYF00164 excluding MYF00154,
Prior to SN MLZ00151, Prior to SN MKY00191 excluding MKY00189
• Squeeze and hold trigger to deactivate system and have transmission disengage
while depressing service brake. Release trigger to activate system and keep
transmission engaged while depressing service brake.
SN MYT00161 to Present, SN MYF00164 to Present including MYF00154,
SN MLZ00151 to Present, SN MKY00191 to Present including MKY00189
• While applying service brake, depress and release button to enable transmission
declutch function and disengage transmission.
While applying service brake, depress and release button to disable transmission
declutch function and engage transmission.

31211299 3-19
Section 3 - Controls and Indicators
Loader Joystick Pattern

5 4
F 5
N
1
R
2
3 6
7
8 9

OZ4680

The joystick (1) controls the boom, attachment, auxiliary hydraulics, outrigger and
transmission functions.
Boom Functions
• Move the joystick back to lift boom; move joystick forward to lower boom.
• Extend/retract is controlled by the roller switch (2). Push roller switch up to extend
boom; push roller switch down 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 left will lower boom and tilt
attachment up simultaneously.

3-20 31211299
 Section 3 - Controls and Indicators

WARNING
TIP OVER/CRUSH HAZARD. Rapid, jerky operation of controls will cause rapid, jerky
movement of the load. Such movements could cause the load to shift or fall or could
cause the machine to tip over.
Attachment Functions
Attachment tilt is controlled by the joystick.
• Move joystick right to tilt down; move joystick left to tilt up.

Auxiliary Hydraulic Functions (if equipped)

Auxiliary Hydraulics roller switch (3) controls function of attachments that require
hydraulic supply for operation. See Section 5 - Attachments & Hitches for approved
attachments and control instructions.

Continuous Auxiliary Hydraulic Functions (if equipped)

• Depress and release joystick button (4) for continuous operation of hydraulic powered
attachments.
• Set continuous auxiliary hydraulic level (-100% to 100%) using the auxiliary hydraulic
roller switch (3). Push the roller switch up to increase or down to decrease hydraulic
flow.
• Depress and release joystick button (4) again to stop continuous operation.

Outrigger Functions
Joystick button (5) controls both outriggers.
• Press and hold the button; move the joystick forward to lower both outriggers; move
the joystick back to raise both outriggers.
• Press and hold the button; move the joystick left then forward to lower the left
outrigger; move the joystick left then back to raise the left outrigger.
• Press and hold the button; move the joystick right then forward to lower the right
outrigger; move the joystick right then back to raise the right outrigger.
• Outriggers operable with boom at any extension and below 20 degrees or with boom
fully retracted and below 55 degrees.

WARNING
TIP OVER HAZARD. Outriggers increase stability and load capacity only if they are
used properly. Using outriggers on soft surfaces could cause telehandler to tip over.
Always ensure surface can support telehandler and load.

31211299 3-21
Section 3 - Controls and Indicators
Transmission Control (if equipped)
Transmission roller switch (6) engages forward or reverse travel.
• Press switch up for forward travel; Press switch down for reverse travel. Move switch 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.
• Travel at slow rates of speed when making turns and driving in reverse.

WARNING
TIP OVER/CRUSH HAZARD. Bring telehandler to a complete stop before shifting
transmission. A sudden change in direction of travel could reduce stability and/or
cause load to shift or fall.

Gear selection is controlled by buttons (7 & 8).

• Depress upshift button (8) to select a higher gear; Depress downshift button (7) to
select a lower gear.
• The Transmission is equipped with three forward and three reverse gears.
• 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 a time.
Downshifting is not permitted if current gear is flashing on display. Intended
downshifting speeds are 9 kph (5.5 mph) for third to second gear and 4 kph (2.5 mph)
for second to first gear.

3-22 31211299
 Section 3 - Controls and Indicators
Clutch Lock is controlled by button (9).
Prior to SN MYT00161, Prior to SN MYF00164 excluding MYF00154,
Prior to SN MLZ00151, Prior to SN MKY00191 excluding MKY00189
• Squeeze and hold trigger to deactivate system and have transmission disengage
while depressing service brake. Release trigger to activate system and keep
transmission engaged while depressing service brake.
SN MYT00161 to Present, SN MYF00164 to Present including MYF00154,
SN MLZ00151 to Present, SN MKY00191 to Present including MKY00189
• While applying service brake, depress and release button to enable transmission
declutch function and disengage transmission.
While applying service brake, depress and release button to disable transmission
declutch function and engage transmission.

31211299 3-23
Section 3 - Controls and Indicators
Console Switches

1 2 18 19 3 4 5 6 7 8
9

10
11
17
13
12
16
14

15

OZ4611

1. Joystick Function Switch: On/Off switch. All hydraulic functions are disabled and
steer mode is forced to two wheel steer when on.
2. LSI Override Switch: Momentarily disables the automatic function cut-out. Depress
and hold up to 30 seconds while operating joystick to momentarily disable the
automatic function cut-out.
3. Rear Wiper Switch: On/Off switch.
4. Roof Wiper Switch: On/Off switch.
5. Hazards Lights Switch: On/Off switch.
6. Driving Lights Switch (if equipped): On/Off switch.
7. Fog Lights Switch (if equipped): On/Off switch.
8. Beacon Light Switch (if equipped): On/Off switch. Place magnetic base of beacon on
cab roof. Power supplied by 12V receptacle at rear left of cab roof.
9. Front and Rear Cab Work Lights Switch (if equipped): On/Off switch.
10. High Beam and Turn Signal Indicators: Illuminates when high beams or turn signals
are active.

3-24 31211299
 Section 3 - Controls and Indicators
11. Continuous Auxiliary Hydraulics Indicator (SN MYT00161 to MYT00499,
SN MYF00164 to Present including MYF00154, SN MLZ00151 to MLZ00499,
SN MKY00191 to Present including MKY00189): Illuminates when continuous
auxiliary hydraulics are active.
High Exhaust System Temperature (HEST) Indicator/Diesel Particulate Filter (DPF)
Regeneration Indicator/Switch (SN MYT00500 to Present, SN MLZ00500 to Present):
• HEST Indicator: Top of switch illuminates during exhaust system cleaning. See
page 4-4 for details.
• DPF Regeneration Indicator/Switch: Press bottom of switch to initiate stationary
exhaust system cleaning. See page 4-4 for details.
12. Outrigger Position Indicator (SN MYT00161 to Present, SN MYF00164 to Present
including MYF00154, SN MLZ00151 to Present, SN MKY00191 to Present including
MKY00189) - Outriggers stowed position icon will illuminate solid when both
outriggers are fully raised and flash when either outrigger is not fully raised or
lowered. Outriggers deployed position icon will illuminate solid when both
outriggers are fully lowered.
Note: When both outriggers are indicated as fully lowered, observe level indicator(s) to
determine whether machine must be leveled. Level machine with frame level switch (see
page 3-25) or outrigger controls (see page 3-16).
13. Steer Select Switch: Three positions: 4-wheel circle steer, 4-wheel crab steer and
2-wheel steer. See page 3-28.
14. Power Outlet: 12V receptacle.
15. Frame Level Switch: Controls the left to right frame level. Depress right side of switch
to rotate frame right; depress left side of switch to rotate frame left. Frame level
operable with boom below 20 degrees or with boom fully retracted and between 20
and 55 degrees.
16. Emissions System Malfunction Indicator/Continuous Auxiliary Hydraulics Indicator
(SN MYT00500 to Present, SN MLZ00500 to Present):
• Emissions System Malfunction Indicator: Top of indicator illuminates when
emissions system malfunctions. See Service Manual for details.
• Continuous Auxiliary Hydraulics Indicator: Bottom of indicator illuminates when
continuous auxiliary hydraulics are active.

Climate Controls
17. Air Conditioning Switch: On/Off switch.
18. Fan Speed Switch: Adjustable rotary switch.
19. Temperature Control: Adjustable lever.

31211299 3-25
Section 3 - Controls and Indicators
Accessory Control Lever

Turn Signals and Low/High Beam Headlights

4
2

1
OZ4340

• Push accessory control lever (1) forward (2) to activate left turn signal.
• Pull lever backward (3) to activate right turn signal.
• The lever must be manually returned to the center position to deactivate either turn
signal. The lever will not cancel automatically after a turn.
• Pull lever up (4) to switch between low and high beam headlights.

Front Windshield Wiper

5
II
I
6
O

1
OZ4350

• Rotate hand grip (5) to activate front windshield wiper.

O - Off, I - Continuous or II - Fast
• Push hand grip (5) towards column to activate windshield wiper fluid.

Horn
• Depress button (6) at end of lever to sound horn.

3-26 31211299
 Section 3 - Controls and Indicators

3.3 ANTI THEFT

Machines with the anti theft feature active require entering a numeric code before
operation to prevent unauthorized use. Code entry is accomplished using the display and
joystick.

0000 2

OZ4460 1

OZ4470

1. Turn ignition switch to position I. If anti theft is active, the display (1) will prompt the
operator for a numeric code.
2. Use the joystick roller switch (2) to select the first digit. Push roller switch up to
increase the number; push roller switch down to decrease the number.
3. Depress and release joystick button (3) to enter the current number.
4. Continue until the code is complete.
5. If an incorrect code is entered, the display will prompt the operator again for the
numeric code.
6. If the correct code is entered, normal start up can continue.
Note: If the anti theft feature is active and the current access code is not known, it may be
viewed in Diagnostics > Datalog Menu or changed in Operator Tools Menu (level 2 password
required for both). See Service Manual for information.

31211299 3-27
Section 3 - Controls and Indicators

3.4 STEER MODES

Three steer modes are available for operator use.

2-Wheel Front Steer 4-Wheel Circle Steer 4-Wheel Crab Steer

OAL2030

Note: 2-Wheel Front Steer mode is required for travel on public roads.

Manual Steering Alignment Mode Change

Note: Steer mode will change immediately after selection.

1
OZ4160

1. Bring machine to a stop using service brake. If front steer mode (2) is active and rear
wheels are aligned, go directly to step 4.

4 5 OAM2400

2. With circle steer (1) or crab steer (3) mode active, turn the steering wheel until the
left rear wheel (4) is aligned with the side of the machine.
3. Select front steer mode (2).
4. Turn the steering wheel until the left front wheel (5) is aligned with the side of the
machine.
5. Wheels are now aligned. Select desired steer mode.

3-28 31211299
 Section 3 - Controls and Indicators

3.5 OPERATOR SEAT

Operator Presence

1 3 (IF EQUIPPED)

2
3
(IF EQUIPPED)

OZ4181

The operator seat (1) is equipped with an operator presence system. Engine start and
hydraulic functions are prohibited if operator is not present. If the system detects a loss of
pressure during operation, after a two second delay one of the following will occur:
1. With the park brake (2) engaged and transmission in neutral (3):
• Hydraulic controls are disabled. (Continuous Auxiliary function permitted)
• Upon returning to seated position, hydraulic controls are enabled.
2. With the park brake (2) disengaged and transmission in neutral (3):
• Hydraulic controls are disabled and buzzer sounds continuously. (Continuous
Auxiliary function permitted)
• Upon returning to seated position, hydraulic controls are enabled and buzzer will
cease.
3. With the park brake (2) disengaged and transmission in forward or reverse (3):
• Hydraulic controls are disabled, buzzer sounds continuously and transmission
shifts to neutral.
• Upon returning to seated position, hydraulic controls are enabled and buzzer will
cease. Return transmission to neutral to allow system to reset prior to reengaging
forward or reverse travel.

31211299 3-29
Section 3 - Controls and Indicators
Adjustments

Prior to starting the engine adjust seat for position and comfort.

2
OZ4170
3

1. Fore/Aft: Use handle to move seat fore and aft.

2. Suspension: Use the handle to adjust the suspension to the appropriate weight
setting.
3. Weight: Displays current weight setting.
4. Backrest: Use lever to adjust backrest angle.
5. Seat Belt: Always fasten seat belt during operation.

3-30 31211299
 Section 3 - Controls and Indicators
Seat Belt

OH20912

Fasten seat belt as follows:

1. Grasp both free ends of the belt making certain that belt webbing is not twisted or
entangled.
2. With back straight in the seat, couple the retractable end (male end) of the belt into
the receptacle (buckle) end of the belt.
3. With belt buckle positioned as low on the body as possible, pull the retractable end
of the belt away from the buckle until it is tight across the lap.
4. To release belt latch, depress red button on the buckle and pull free end from buckle.

31211299 3-31
Section 3 - Controls and Indicators

3.6 BOOM INDICATORS

A B

OAM3750

Boom Extension

• The boom extension indicators (1) are located on the left side of the boom. Use these
indicators to determine boom extension when using the capacity chart (see “Use of
the Capacity Chart” on page 5-5).

3-32 31211299
 Section 4 - Operation
SECTION 4 - OPERATION
4.1 ENGINE
Note: Refer to Engine Operation & Maintenance Manual for additional information.

Starting the Engine

This machine can be operated under normal conditions in temperatures of -20°C to 48°C
(0°F to 118°F). Consult the local Caterpillar dealer for operation outside this range or
under abnormal conditions.
1. Make sure all controls are in “Neutral” and all electrical components (lights, heater,
etc.) are turned off. Apply park brake.
2. Turn ignition switch to position II and wait for engine preheat indicator on
instrument panel to go out. If active, enter anti theft code.
3. Turn ignition switch to position III to engage starting motor. Release key immediately
when engine starts. If engine fails to start within 20 seconds, release key and allow
starting motor to cool for a few minutes before trying again.
4. After engine starts, observe indicators. If indicators remain on for more than five
seconds, stop engine and determine cause before restarting engine.
5. Warm up engine at approximately 1/2 throttle.
Note: Engine will not start unless transmission is in neutral and park brake is applied.

WARNING
UNEXPECTED MOVEMENT HAZARD. Always ensure that transmission is in neutral
and the service brake is applied before releasing park brake. Releasing park brake in
either forward or reverse could cause the machine to move abruptly.

WARNING
ENGINE EXPLOSION. Do not spray ether into air intake for cold weather starting.

31211299 4-1
Section 4 - Operation
Battery Boosted Starting

OW0530

If battery-boost starting (jump-start) is necessary, proceed as follows:

• Never allow vehicles to touch.
• Ensure boosting vehicle engine is running.
• Connect the positive (+) jumper cable to positive (+) post of discharged battery.
• Connect the opposite end of positive (+) jumper cable to positive (+) post of booster
battery.
• Connect the negative (-) jumper cable to negative (-) post on booster battery.
• Connect opposite end of negative (-) jumper cable to ground point on machine away
from discharged battery.
• Follow standard starting procedures.
• Remove cables in reverse order after machine has started.

WARNING
BATTERY EXPLOSION HAZARD. Never jump start or charge a frozen battery as it
could explode. Keep sparks, flames and lighted smoking materials away from the
battery. Lead acid batteries generate explosive gases when charging. Wear safety
glasses.

4-2 31211299
 Section 4 - Operation
Normal Engine Operation

• Observe instrument panel and display frequently to be sure all systems are
functioning properly.
• Be alert for unusual noises or vibration. When an unusual condition is noticed, park
machine in safe position and perform shut-down procedure. Report condition to your
supervisor or maintenance personnel.
• Avoid prolonged idling. If the engine is not being used, turn it off.
• When operating a machine at high altitudes, a decrease in machine performance may
occur due to a decrease in air density. When operating a machine at high
temperatures, a decrease in machine performance and an increase in engine coolant
temperature may occur. Contact the local Caterpillar dealer for operation under
abnormal conditions.

Shut-Down Procedure

When parking the telehandler, park in a safe location on flat level ground and away from
other equipment and/or traffic lanes.
1. Apply the park brake.
2. Shift the transmission to “Neutral.”
3. Lower forks or attachment to the ground.
4. Operate engine at low idle for 3 to 5 minutes. DO NOT over rev engine.
5. Shut off engine and remove ignition key.
6. Exit telehandler properly.
7. Turn off electrical master switch (if equipped).
8. Block wheels (if necessary).

31211299 4-3
Section 4 - Operation

4.2 AFTER-TREATMENT SYSTEM (ATS) (SN MYT00500 TO PRESENT,

SN MLZ00500 TO PRESENT)
This machine is equipped with an exhaust After-Treatment System. Diesel Particulate
Filter (DPF) Regeneration Indicator (2) will slowly blink when a maintenance regeneration
cycle is required. Prior to a stationary exhaust system cleaning, ensure all stationary
conditions are met.
1. Move telehandler to a level area free of flammables and people that could be
exposed to hot exhaust.
2. Keep engine warm (coolant temperature above 60°C) and at idle speed and ensure
no engine system faults are active.
3. Shift transmission to neutral, retract and lower boom and engage park brake.

1 3

OZ4700
2 OZ4690

Stationary Exhaust System Cleaning

To initiate stationary exhaust system cleaning, press and hold DPF Regeneration
Switch (2) for at least 3 seconds.
Note: High Exhaust System Temperature (HEST) Indicator (1) will briefly flash when DPF
Regeneration Switch (2) is held for 3 seconds. This confirms stationary exhaust system
cleaning is being requested.

WARNING
HIGH EXHAUST TEMPERATURE. Keep flammables and people away from hot exhaust.

1. DPF Regeneration Indicator (2) and High Exhaust System Temperature (HEST)
Indicator (1) will illuminate during stationary exhaust system cleaning. Elevated idle
will occur when cleaning begins.
Note: Do not operate boom controls, park brake or accelerator pedal during exhaust
system cleaning. Stationary exhaust system cleaning will stop and may be incomplete if
any controls are inadvertently moved or activated.
4-4 31211299
 Section 4 - Operation
2. If exhaust system cleaning is interrupted, the DPF Regeneration Indicator (2) will
resume blinking and the DPF Regeneration Switch (2) must be depressed again for 3
seconds to resume regeneration.
3. Exhaust system cleaning takes approximately 45-60 minutes. Stationary exhaust
system cleaning is complete after DPF Regeneration (2) and HEST (1) Indicators go
off. When complete, normal idle will resume.
4. If exhaust system cleaning is unsuccessful, DPF Regeneration Indicator (2) will turn
off for 2 seconds before resuming a slow blink. Ensure all stationary conditions have
been met.

NOTICE
EQUIPMENT DAMAGE. If exhaust system cleaning is ignored, Engine Fault Warning
Indicator (3) will illuminate and a 25% power derate will begin. Immediately bring
machine to a stop and perform stationary exhaust system cleaning. If cleaning is still
ignored, Engine Fault Critical Indicator (4) will illuminate and engine will go into idle
speed lock. Contact the local dealer.

31211299 4-5
Section 4 - Operation

4.3 OPERATING WITH A NON-SUSPENDED LOAD

Lift Load Safely

• You must know the weight and load center of every load you lift. If you are not sure of
the weight and load center, check with your supervisor or with the supplier of the
material.

WARNING
TIP OVER HAZARD. Exceeding lift capacity of the telehandler could damage the
equipment and/or cause tip over.
• Know the rated load capacities (refer to Section 5) of the telehandler to determine the
operating range in which you can safely lift, transport and place a load.

Picking Up a Load

• Note the conditions of the terrain. Adjust travel speed and reduce amount of load if
conditions warrant.
• Avoid lifting double-tiered loads.
• Make sure load is clear of any adjacent obstacles.
• Adjust spacing of forks so they engage the pallet or load at maximum width. See
“Adjusting/Moving Forks” on page 5-17.
• Approach load slowly and squarely with fork tips straight and level. NEVER attempt to
lift a load with just one fork.
• NEVER operate telehandler without a proper and legible capacity chart in the
operator cab for the telehandler/attachment combination you are using.

4-6 31211299
 Section 4 - Operation
Transporting a Load

OW0540

• After engaging the load and resting it against the backrest, tilt the load back to
position it for travel. Travel in accordance with the requirements set forth in Section
1 - General Safety Practices and Section 5 - Attachments & Hitches.

Leveling Procedure

1. Position machine in best location to lift or place load.

2. Apply parking brake and shift transmission to NEUTRAL.
3. Observe level indicator(s) to determine whether machine must be leveled prior to
lifting load.
4. If equipped, level machine with frame level switch (see page 3-24) or outrigger
controls (see page 3-17 or 3-21).

Important things to remember:

• Never raise the boom/attachment more than 1,2 m (4 ft) above ground unless
telehandler is level.
(AUS - Never raise the forks more than 300 mm (11.8 in) above ground surface unless
telehandler is level.)
• The combination of frame leveling and load could cause the telehandler to tip over.

31211299 4-7
Section 4 - Operation
Placing a Load

Before placing any load be sure that:

• The landing point can safely support the weight of the load.
• The landing point is level; front to back and side to side.
• Use the capacity chart to determine safe boom extension range. See “Use of the
Capacity Chart” on page 5-5.
• Align forks at the level load is to be placed, then position boom slowly until load is just
above area where it is to be placed.
• Lower the boom until the load rests in position and the forks are free to retract.

Disengaging a Load

Once the load has been placed safely at the landing point, proceed as follows:
1. With the forks free from the weight of the load, the boom can be retracted
and/or the telehandler can be backed away from under the load if surface will not
change level condition of telehandler.
2. Lower the carriage.
3. The telehandler can now be driven from the landing location to continue work.

4-8 31211299
 Section 4 - Operation

4.4 OPERATING WITH A SUSPENDED LOAD

Lift Load Safely

• You must know the weight and load center of every load you lift. If you are not sure of
the weight and load center, check with your supervisor or with the supplier of the
material.

WARNING
TIP OVER HAZARD. Exceeding lift capacity of the telehandler could damage the
equipment and/or cause tip over.
• Know the rated load capacities (refer to Section 5) of the telehandler to determine the
operating range in which you can safely lift, transport and place a load.

Picking Up a Suspended Load

• Note the conditions of the terrain. Adjust travel speed and reduce amount of load if
conditions warrant.
• Avoid lifting double-tiered loads.
• Make sure load is clear of any adjacent obstacles.
• NEVER operate telehandler without a proper and legible capacity chart in the
operator cab for the telehandler/attachment combination you are using.
• Only use approved lifting devices rated for the lifting of the load.
• Identify the proper lifting points of the load, taking into consideration the center of
gravity and load stability.
• Ensure to always properly tether loads to restrict movement.
• Refer to “Use of the Capacity Chart” on page 5-5 for proper lifting guidelines in addition
to the appropriate capacity chart in the operator cab.

31211299 4-9
Section 4 - Operation
Transporting a Suspended Load

OZ3160
OW0130

• Travel in accordance with the requirements set forth in Section 1 - General Safety
Practices and Section 5 - Attachments & Hitches.
• For additional requirements, refer to the appropriate capacity chart in the operator
cab.

Important things to remember:

• Ensure the boom is fully retracted.
• Never raise the load more than 300 mm (11.8 in) above ground surface or the boom
more than 45°.
• The combination of frame leveling and load could cause the telehandler to tip over.
• The guide persons and operator must remain in constant communication (verbal or
hand) and be in visual contact with the operator at all times.
• Never place the guide persons between the suspended load and the telehandler.
• Only transport the load at walking speed, 1.4 kph (0.9 mph), or less.

Leveling Procedure

1. Position machine in best location to lift or place load.

2. Apply parking brake and shift transmission to NEUTRAL.
3. Observe level indicator(s) to determine whether machine must be leveled prior to
lifting load.
4. If equipped, level machine with frame level switch (see page 3-24) or outrigger
controls (see page 3-17 or 3-21).

4-10 31211299
 Section 4 - Operation
Placing a Suspended Load

Before placing any load be sure that:

• The landing point can safely support the weight of the load.
• The landing point is level; front to back and side to side.
• Use the capacity chart to determine safe boom extension range. See “Use of the
Capacity Chart” on page 5-5.
• Align load at the level load is to be placed, then position boom slowly until load is just
above area where it is to be placed.
• Ensure that the guide persons and operator remain in constant communication
(verbal or hand) when placing the load.

Disengaging a Suspended Load

• Never place the guide persons between the suspended load and the telehandler.
• Once at the destination of the load, ensure to bring the telehandler to a complete stop
and apply the park brake prior to disengagement of the lifting devices and tethers.

31211299 4-11
Section 4 - Operation

4.5 ROAD OPERATION (CE)

1. Preparation
a. Remove load from attachment.
b. Remove any large amounts of dirt from machine.
c. Check lights and mirrors and adjust if necessary. Rear lights must be oriented in
the horizontal position.
Note: Be sure to follow all local and federal/provincial traffic regulations.
2. Lower boom. Lowest part of attachment should be approximately 30 cm (12 in)
above the ground.
3. Fully tilt attachment back.
4. Place protective shield over front bucket edge: remove or reposition carriage forks
toward the machine and secure to the carriage.

2
1

OZ4190

5. Depress button (1) to deactivate joystick function and disable all joystick controlled
functions.
6. Changes steer mode to front wheel steering (2). See “Steer Modes” on page 3-28 for
details.
7. Machine is now ready for road operation.

4-12 31211299
 Section 4 - Operation

4.6 LOADING AND SECURING FOR TRANSPORT

OAM3862

Tiedown

1. If equipped, level the telehandler prior to loading.

2. Using a spotter, load the telehandler with boom as low as possible.
3. Once loaded, apply parking brake and lower boom until boom or attachment is
resting on deck. Move all controls to “Neutral,” stop engine and remove ignition key.
4. Secure machine to deck by passing chains through the designated tiedown points as
shown in the figure.
5. Do not tiedown front of boom.
Note: The user assumes all responsibility for choosing the proper method of transportation
and tie-down devices, making sure the equipment used is capable of supporting the weight of
the vehicle being transported and that all manufacturer’s instructions and warnings,
regulations and safety rules of their employer, the Department of Transportation and/or any
other local, state or federal/provincial laws are followed.

WARNING
TELEHANDLER SLIDE HAZARD. Before loading telehandler for transport, make sure
deck, ramps and telehandler wheels are free of mud, snow and ice. Failure to do so
could cause telehandler to slide.

31211299 4-13
Section 4 - Operation
Lifting

The weight of the machine is listed on the serial number plate located at the front of the
frame. Actual machine weight and center of gravity will vary depending on attachment,
fluid levels and machine options. Actual weight and center of gravity should be verified
prior to lifting.
The following precautions must be taken when lifting the machine with a mobile crane:
• When lifting machine, it is very important that the lifting device and equipment is
attached only to designated lifting points. If machine is not equipped with lifting lugs
contact the local Caterpillar dealer for information.
• Make adjustments to the lifting device and equipment to ensure that the machine will
be level when elevated. The machine must remain level at all times while being lifted.
• Machine must never be lifted by any point on the boom.
• Take care not to let cables, chains, slings, etc. contact any part of the vehicle during lift.
• Ensure that the boom is retracted and lowered.
• Ensure that the lifting device and equipment is adequately rated and suitable for the
intended purpose.
• Remove all loose items from machine prior to lifting of the machine.
• Lift at a slow, even pace.
• Obtain any additional training regarding the proper lifting procedures that may be
required. Please consult the local, state, and employer regulations.

4-14 31211299
 Section 5 - Attachments & Hitches
SECTION 5 - ATTACHMENTS & HITCHES
5.1 APPROVED ATTACHMENTS
To determine if an attachment is approved for use on the specific telehandler you are
using, perform the following prior to installation.
• The attachment type, weight, dimensions and load center must be equal to or less
than the data shown on a capacity chart located in the operator cab.
• The model on the capacity chart must match the model telehandler being used.
• Hydraulically powered attachments must only be used on machines equipped with
auxiliary hydraulics.
If any of the above conditions are not met, do not use the attachment. The telehandler
may not be equipped with the proper capacity chart or the attachment may not be
approved for the model telehandler being used. Contact the local Caterpillar dealer for
further information.

5.2 UNAPPROVED ATTACHMENTS

Do not use unapproved attachments for the following reasons:
• Range and capacity limitations for “will fit,” homemade, altered, or other
non-approved attachments cannot be established.
• An overextended or overloaded telehandler can tip over with little or no warning and
cause serious injury or death to the operator and/or those working nearby.
• The ability of a non-approved attachment to perform its intended function safely
cannot be assured.

WARNING
Use only approved attachments. Attachments which have not been approved for use
with your telehandler could cause machine damage or an accident.

31211299 5-1
Section 5 - Attachments & Hitches

5.3 JLG SUPPLIED ATTACHMENTS

CAT Quick Coupler

Attachment Part Number TH314D TH417D

Carriage, 1185 mm (47 in) 326-2013 X X
Side Shift Carriage, 1200 mm (47.2 in) 222-6210 X X
Fork, Pallet 50x100x1070 mm (1.8x4x42 in) 463-1675 X X
Fork, Pallet 50x100x1200 mm (2x4x47.2 in) 326-1997 X X
Fork, Pallet 50x100x1525 mm (2x4x60 in) 252-1456 X X
Fork, Pallet 50x120x1200 mm (2x4.7x47.2 in) 364-5356 X X
456-0498 X X
Bucket, General Purpose 1,0 m3 (1,3 yd3)
163-4261 X X
456-0507 X X
Bucket, Light Material 1,5 m3 (1,9 yd3)
186-5838 X X
486-0141 X X
Bucket, Multi-Purpose 1,0 m3 (1,3 yd3)
163-4265 X X
456-0465 X X
Coupler Mounted Hook
169-6460 X X
456-0473 X X
Truss Boom, 4 m (13.1 ft)
169-3945 X X
Fork Mounted Hook 309-9182 X X

Manitou Coupler

Attachment Part Number TH314D TH417D

Carriage, 1200 mm (47.2 in) 487-0690 X X

5-2 31211299
 Section 5 - Attachments & Hitches

This Page Intentionally Left Blank

31211299 5-3
Section 5 - Attachments & Hitches

5.4 TELEHANDLER/ATTACHMENT/FORK CAPACITY

1
2

OZ0810

Prior to installing the attachment verify it is approved and the telehandler is equipped
with the proper capacity chart. See “Approved Attachments” on page 5-1.
To determine the maximum capacity of the telehandler and attachment, use the smallest
of the following capacities:
• Capacity stamped on the attachment identification plate (1).
• Fork capacities and load centers are stamped on the side of each fork (2) (if equipped).
This rating specifies the maximum load capacity that the individual fork can safely
carry at the maximum load center (3). Total attachment capacity is multiplied by the
number of forks on the attachment (if equipped), up to the maximum capacity of the
attachment.
• Maximum capacity as indicated on the proper capacity chart. See “Approved
Attachments” on page 5-1.
• When the load rating of the telehandler differs from the capacity of the forks or
attachment, the lower value becomes the overall load capacity.
Use the proper capacity chart to determine maximum capacity at various machine
configurations. Lifting and placing a load may require use of more than one capacity chart
based on machine configuration.
Other than block forks, all forks should be used in matched pairs, block forks used in
matched sets.

WARNING
Never use an attachment without the appropriate manufacturer approved capacity
chart installed on the telehandler.

5-4 31211299
 Section 5 - Attachments & Hitches

5.5 USE OF THE CAPACITY CHART

To properly use the capacity chart (see page 5-6), the operator must first determine and/
or have the following:
1. An approved attachment. See “Approved Attachments” on page 5-1.
2. The proper Capacity Chart.
3. Weight of the load being lifted.
4. Load placement information:
a. HEIGHT where the load is to be placed.
b. DISTANCE from the front tires of the telehandler where the load is to be placed.
5. On the capacity chart, find the line for the height and follow it over to the distance.
6. The number in the load zone where the two cross is the maximum capacity for this
lift. If the two cross at a division between zones, the smaller number must be used.
The number in the load zone must be equal to or greater than the weight of the load to be
lifted. Determine the limits of the load zone on the capacity chart and keep within these
limits.

Capacity Indicator Locations

BOOM ANGLE
INDICATOR
BOOM (INSIDE CAB)
EXTENSION
ATTACHMENT INDICATOR
IDENTIFICATION
PLATE

A
FORK
WEIGHT
STAMP

OAM3830

31211299 5-5
Section 5 - Attachments & Hitches
Sample Load Chart

This Load Chart may be used with this model ONLY.

The telehandler model is indicated on the boom or chassis. Model
XXXX is used for demonstration purposes only.

XXXX
XXX xx
- XXX xx

XXX xx MAX
Attachment type,
weight and
75
o dimensions must be
XX
o
equal to or less than
60 the data shown.
XX D
o
XXXX
XX 50
XX C
o
XX 40
XXXX B
XX

o
XX
30 A
XXXX Boom Extension
XX
Indicator (arc)
XXXX

Boom Angle XX
XXXX
XXXX

o
XX
20
XXXX

XX
XXXX

XX o
10
XX

XX Load center must be

o equal to or less than
XX 0
XXX mm value shown.
XX
XX XX XX XX XX XX XX XX XX XX

XXXX XXXX
OAM1801 Load zones indicate the
maximum weight that may
be safely lifted.

Note: This is a sample load chart only! DO NOT use this chart, use the one located in your
operator cab.

WARNING
TIP OVER HAZARD. All loads shown on rated load chart are based on machine being
on firm ground with frame level (see page 4-7 or 4-10); the forks being positioned
evenly on carriage; the load being centered on forks; proper size tires being properly
inflated; and the telehandler being in good operating condition.

5-6 31211299
 Section 5 - Attachments & Hitches
To identify the proper load chart on telehandlers equipped with outriggers, refer to the
following icons which may be located on the load chart.

• Use when lifting a load with outriggers up.

OAL1090

• Use when lifting a load with outriggers down.

OAL1100

31211299 5-7
Section 5 - Attachments & Hitches
Example

A contractor owns a model xxxx telehandler with a fork carriage. He knows this
attachment may be used with his model since:
• The attachment style, weight, dimensions and load center match the attachment data
on the load chart.
• The load chart is clearly marked for model xxxx and corresponds with machine
configuration being used.
Below are examples with various conditions the contractor may encounter and whether
or not the load may be lifted.

Load Weight Distance Height OK to Lift

1 1250 kg (2755 lb) 4,0 m (13.1 ft) 3,5 m (11.5 ft) Yes
2 750 kg (1653 lb) 6,0 m (19.7 ft) 9,0 m (29.5 ft) NO
3 2500 kg (5512 lb) 2,0 m (6.6 ft) 6,5 m (21.3 ft) Yes
4 3000 kg (6614 lb) 1,5 m (4.9 ft) 10,5 m (34.4 ft) NO

XXXX
XXX mm
- XXX mm

XXX kg MAX

o
75
14m
o
60
13m D
o
2000kg
12m 50 Example 4
11m C
o
10m 40
2500kg B
9m

o
8m
30 A Example 3
Example 2 7m 3700kg
1000kg

6m
1500kg
500kg

o
5m
20
750kg

4m
350kg

3m o
10
2m
Example 1
1m
o
0m 0
XXX mm
-1m
9m 8m 7m 6m 5m 4m 3m 2m 1m 0m

XXXX XXXX
OAM1921

Note: This is a sample load chart only! DO NOT use this chart, use the one located in your
operator cab.

5-8 31211299
 Section 5 - Attachments & Hitches

This Page Intentionally Left Blank

31211299 5-9
Section 5 - Attachments & Hitches

5.6 ATTACHMENT INSTALLATION

CAT Quick Coupler

2 3
1

6
5 4 OAM3700

1. Attachment
2. Attachment Pin Recess
3. Attachment Pin
4. Lock Pin
5. Retainer Pin
6. Quick Coupler (attachment tilt control in cab, see page 3-17 or 3-21)

WARNING
CRUSH HAZARD. Always be certain that carriage or attachment is properly positioned
on boom and is secured by lock pin and retainer pin. Failure to ensure proper
installation could permit carriage/attachment/load to disengage.

5-10 31211299
 Section 5 - Attachments & Hitches
Mechanical Quick Coupler
This installation procedure is designed for one-person operation. Prior to exiting cab,
perform “Shut-Down Procedure” on page 4-3.

1. Tilt quick coupler forward to provide clearance.

Check to be sure lock pin is out.

OAM3720

2. Align attachment pin with recess in attachment.

Raise boom slightly to engage attachment pin in
recess.

OAM3730

3. Tilt quick coupler back to engage attachment.

OAM3740

4. Insert lock pin and secure with retainer pin.

OAM3710

5. If attachment is equipped, connect auxiliary hydraulic hoses. See “Hydraulic Operated

Attachment” on page 5-16.

31211299 5-11
Section 5 - Attachments & Hitches
Manitou Coupler

1 2 3

6
4 5 OZ3920

1. Attachment
2. Attachment Pin
3. Attachment Pin Recess
4. Lock Pin
5. Retainer Pin
6. Manitou Coupler (attachment tilt control in cab, see page 3-17 or 3-21)

WARNING
CRUSH HAZARD. Always be certain that carriage or attachment is properly positioned
on boom and is secured by lock pin. Failure to ensure proper installation could permit
carriage/attachment/load to disengage.

5-12 31211299
 Section 5 - Attachments & Hitches
This installation procedure is designed for one-person operation. Prior to exiting cab,
perform “Shut-Down Procedure” on page 4-3.

1. Tilt coupler forward to provide clearance. Check to

be sure lock pin and retainer pin is out.

OAM2780

2. Align attachment pin recess with attachment pin.

Raise boom slightly to engage attachment pin in
recess.

OAM2790

3. Tilt coupler back to engage attachment.

OAM2800

4. Insert lock pin and secure with retainer pin.

OAM2810

5. If attachment is equipped, connect auxiliary hydraulic hoses. See “Hydraulic Operated

Attachment” on page 5-16.

31211299 5-13
Section 5 - Attachments & Hitches
JCB Coupler

2
5
1 3

6 7
OZ3930

1. Attachment
2. Attachment Pin Recess
3. Attachment Pin
4. Hook
5. Lock Pin Handle
6. Lock Pin
7. JCB Coupler (attachment tilt control in cab, see page 3-17 or 3-21)

WARNING
CRUSH HAZARD. Always be certain that carriage or attachment is properly positioned
on boom and is secured by lock pin. Failure to ensure proper installation could permit
carriage/attachment/load to disengage.

5-14 31211299
 Section 5 - Attachments & Hitches
This installation procedure is designed for one-person operation. Prior to exiting cab,
perform “Shut-Down Procedure” on page 4-3.

1. Tilt coupler forward to provide clearance. Unhook

lock pin handle and pull to disengage lock pin.

OAM2850

2. Align attachment pin with recess in attachment.

Raise boom slightly to engage attachment pin in
recess.

OAM2860

3. Tilt coupler back to engage attachment.

OAM2870

4. Push lock pin handle to engage coupler lock pin and

secure with hook.

OAM2870

5. If attachment is equipped, connect auxiliary hydraulic hoses. See “Hydraulic Operated

Attachment” on page 5-16.

31211299 5-15
Section 5 - Attachments & Hitches
Hydraulic Operated Attachment

OZ4200

OAM3691

1. Install attachment (see page 5-10, 5-12 or 5-14).

2. Lower attachment to ground.
3. Quickly depress and release the continuous auxiliary hydraulics switch (1) twice.
Immediately depress again and hold at least one second to relieve pressure at both
auxiliary fittings (2).
Note: Depressing the continuous auxiliary hydraulics switch three times must be
accomplished within two seconds. Buzzer will sound while auxiliary decompression is in
progress.
4. Perform “Shut-Down Procedure” on page 4-3.
5. Connect attachment hoses to both auxiliary fittings.

5-16 31211299
 Section 5 - Attachments & Hitches

5.7 ADJUSTING/MOVING FORKS

Carriages may have different locations where forks can be positioned. Two different
methods can be used for repositioning, depending upon the carriage structure.
Note: Apply a light coating of appropriate lubricant to ease sliding of forks or fork bar.
To slide forks:
1. Ensure attachment is properly installed. See “Attachment Installation” on page 5-10.
2. If equipped, loosen fork locking bolt.
3. Elevate attachment to approximately 1,5 m (5 ft) and tilt carriage forward until fork
heel is free from attachment.
4. Stand at the side of the carriage. To slide fork toward the center of the carriage, push
the fork near the fork eye. To slide fork toward the edge of the carriage, pull the fork
near the fork eye. To avoid pinching, do not place fingers or thumb between the fork
and carriage structure.
5. If equipped, tighten fork locking bolt.
If removing fork bar is necessary:
1. Rest forks on ground.
2. If equipped, loosen fork locking bolt.
3. Remove fork bar.
4. Reposition forks.
5. Reinstall the fork bar and fork bar retaining mechanism(s).
6. If equipped, tighten fork locking bolt.

31211299 5-17
Section 5 - Attachments & Hitches

5.8 ATTACHMENT OPERATION

• Capacities and range limits for the telehandler change depending on the attachment
in use.
• Separate attachment instructions must be kept in manual holder in cab with this
Operation & Maintenance Manual. An additional copy must be kept with the
attachment if it is equipped with a manual holder.

Note: Operations described within this section reference the Lift joystick pattern. Refer to
page 3-20 if utilizing the Loader joystick pattern.

NOTICE
EQUIPMENT DAMAGE. Some attachments may contact the front tires or machine
structure when the boom is retracted and the attachment is rotated. Improper use of
attachment may result in attachment or machine structural damage.

NOTICE
EQUIPMENT DAMAGE. Avoid contact with any structure or object when lifting a load.
Maintain clearance around boom structure and load. Failure to maintain clearance
may result in attachment or machine structural damage.

5-18 31211299
 Section 5 - Attachments & Hitches
Carriage w/Forks

Use Carriage Attachment Capacity Chart

To determine maximum capacity, refer to “Telehandler/Attachment/
Fork Capacity” on page 5-4.
OZ0770

1
2

OZ4210

The joystick (1) controls movement of the boom.

The attachment tilt roller switch (2) controls carriage tilt.
• Push roller switch down to tilt up.
• Push roller switch up to tilt down.

Installation Procedure:
• Refer to “Attachment Installation” on page 5-10.

Equipment Damage Precautions:

• Do not use forks as a lever to pry material. Excessive prying forces could damage forks
or machine structure.
• Do not attempt to lift loads that are attached or connected to another object.

31211299 5-19
Section 5 - Attachments & Hitches
Side Shift Carriage

Use Side Shift Carriage Capacity Chart

To determine maximum capacity, refer to “Telehandler/Attachment/
Fork Capacity” on page 5-4.

OAL1540

1
2

OZ4210

The joystick (1) controls movement of the boom.

The attachment tilt roller switch (2) controls carriage tilt.
• Push roller switch down to tilt up.
• Push roller switch up to tilt down.

OZ4530

To Side Shift:
The attachment auxiliary hydraulic roller switch (3) controls side shift.
• Push roller switch down to shift forks left.
• Push roller switch up to shift forks right.

5-20 31211299
 Section 5 - Attachments & Hitches
Installation Procedure:
• Refer to “Attachment Installation” on page 5-10.

WARNING
CRUSH HAZARD. Do not use side shift to push or pull objects or load. Failure to
comply could cause object or load to fall.

Equipment Damage Precautions:

• Do not use forks as a lever to pry material. Excessive prying forces could damage forks
or machine structure.
• Do not attempt to lift loads that are attached or connected to another object.

31211299 5-21
Section 5 - Attachments & Hitches
Bucket

Use Appropriate Bucket Capacity Chart

To determine maximum capacity, refer to “Telehandler/Attachment/
Fork Capacity” on page 5-4.

OZ0730

1
2

OZ4220

The joystick (1) controls movement of the boom.

The attachment tilt roller switch (2) controls bucket tilt.
• Push roller switch down to tilt up.
• Push roller switch up to tilt down.

Installation Procedure:
• Refer to “Attachment Installation” on page 5-10.

5-22 31211299
 Section 5 - Attachments & Hitches
Operation:
• Raise or lower boom to appropriate height for loading material from stockpile.
• Align telehandler with face of stockpile and drive slowly and smoothly into pile to load
bucket.
• Tilt bucket up far enough to retain load and back away from pile.
• Travel in accordance with requirements set forth in Section 1 - General Safety
Practices.
• Tilt bucket down to dump load.

Equipment Damage Precautions

• Except for lifting or dumping a load, the boom must be fully retracted for all bucket
operations.
• Do not corner-load bucket. Distribute material evenly within the bucket. Bucket
capacity charts are for evenly distributed loads only.
• Do not use bucket as a lever to pry material. Excessive prying forces could damage
bucket or machine structure.
• Do not attempt to load material which is hard or frozen. This could cause severe
damage to coupler or machine structure.
• Do not use bucket for "back dragging." This could cause severe damage to coupler.

31211299 5-23
Section 5 - Attachments & Hitches
Multi-Purpose Bucket

Use Multi-Purpose Bucket Capacity Chart

To determine maximum capacity, refer to “Telehandler/Attachment/
Fork Capacity” on page 5-4.

OZ2540

1
2

OZ4220

The joystick (1) controls movement of the boom.

The attachment tilt roller switch (2) controls bucket tilt.
• Push roller switch down to tilt up.
• Push roller switch up to tilt down.

Oz4230

To open/close bucket:
The attachment auxiliary hydraulic roller switch (3) controls open/close movement of the
bucket.
• Push roller switch down to open bucket.
• Push roller switch up to close bucket.

5-24 31211299
 Section 5 - Attachments & Hitches
Installation Procedure:
Refer to “Attachment Installation” on page 5-10.

Operation:
• Raise or lower boom to appropriate height and close bucket for loading material from
stockpile.
• Align telehandler with face of stockpile and drive slowly and smoothly into pile to load
bucket.
• Tilt bucket up far enough to retain load and back away from pile.
• Travel in accordance with requirements set forth in Section 1 - General Safety
Practices.
• Open bucket or tilt bucket down to dump load.

Equipment Damage Precautions

• Except for lifting or dumping a load, the boom must be fully retracted for all bucket
operations.
• Do not corner-load bucket. Distribute material evenly within the bucket. Bucket
capacity charts are for evenly distributed loads only.
• Do not use bucket as a lever to pry material. Excessive prying forces could damage
bucket or machine structure.
• Do not attempt to load material which is hard or frozen. This could cause severe
damage to coupler or machine structure.
• Do not use bucket for "back dragging." This could cause severe damage to coupler.

31211299 5-25
Section 5 - Attachments & Hitches
Fork Mounted Hook

Use Fork Mounted Hook Load Chart

To determine maximum capacity, refer to “Telehandler/Attachment/
Fork Capacity” on page 5-4.
OY0640

Suspend loads in accordance with requirements set forth in Section 1 - General

Safety Practices.

1
2

OZ4490

The joystick (1) controls movement of the boom.

The attachment tilt roller switch (2) controls fork mounted hook tilt.
• Push roller switch down to tilt up.
• Push roller switch up to tilt down.

Installation Procedure:
• Ensure carriage is properly installed. Refer to “Attachment Installation” on page 5-10.
• Secure the fork mounted hook to the forks by sliding the fork mounted hook onto the
parent forks and install the retaining pin behind the vertical shank of the fork.

Operation:
• Pallet or lumber forks of an appropriate load rating must be used. Do not use with
cubing or block forks.
• Weight of fork mounted hook and rigging must be included as part of total load being
lifted.
• Do not use fork mounted hook with attachments capable of rotating (i.e. side tilt and
swing carriages) without disabling the rotation features.
5-26 31211299
 Section 5 - Attachments & Hitches
Coupler Mounted Hook

Use Coupler Mounted Hook Load Chart

To determine maximum capacity, refer to “Telehandler/Attachment/
Fork Capacity” on page 5-4.

OAL1510

Suspend loads in accordance with requirements set forth in Section 1 - General

Safety Practices.

1
2

OZ3760

The joystick (1) controls movement of the boom.

The attachment tilt roller switch (2) controls coupler mounted hook tilt.
• Push roller switch down to tilt up.
• Push roller switch up to tilt down.

Installation Procedure:
• Refer to “Attachment Installation” on page 5-10.

Operation:
• Weight of rigging must be included as part of total load being lifted.

31211299 5-27
Section 5 - Attachments & Hitches
Truss Boom

Use Truss Boom Capacity Chart

To determine maximum capacity, refer to “Telehandler/Attachment/
Fork Capacity” on page 5-4.
OAM1960

Suspend loads in accordance with requirements set forth in Section 1 - General

Safety Practices.

1
2

OZ4240

The joystick (1) controls movement of the boom.

The attachment tilt roller switch (2) controls truss boom tilt.
• Push roller switch down to tilt up.
• Push roller switch up to tilt down.

Installation Procedure:
• Refer to “Attachment Installation” on page 5-10.

Operation:
• Weight of rigging must be included as part of total load being lifted.

5-28 31211299
 Section 5 - Attachments & Hitches

5.9 HITCHES
Machine may be equipped with retrieval hitch. If not previously installed, secure hitch to
machine with hardware supplied with installation.

Retrieval Hitch

1
OZ4620 3

Connecting for retrieval:

1. Remove safety pin (1) and pull pin (2) from hitch (3).
2. Place pin through hitch and retrieval device. Secure pin with safety pin.
Note: Retrieval devices are not intended for trailer towing applications.

31211299 5-29
Section 5 - Attachments & Hitches

This Page Intentionally Left Blank

5-30 31211299
 Section 6 - Emergency Procedures
SECTION 6 - EMERGENCY PROCEDURES
6.1 TOWING A DISABLED PRODUCT
The following information assumes the telehandler cannot be moved under its own
power.

• Before moving the telehandler, read all of the following information to understand
options available. Then select the appropriate method.
• Machine mounted retrieval devices provide suitable means to attach a tow rope, chain
or tow bar only in the event the telehandler becomes stuck or disabled.
• Retrieval devices are not intended for on-road trailer towing applications.
• The steering system permits manual steering if engine or power assist feature fails;
however, steering will be slow and will require much greater force.
• DO NOT attempt to tow a telehandler that is loaded or the boom/attachment is raised
above 1,2 m (4 ft).

Moving Short Distances

• If it is only necessary to move telehandler a short distance, less than 30 m (100 ft), it is
permissible to use a vehicle of sufficient capacity to tow the unit with no previous
preparation.

Moving Longer Distance

• See Service Manual for information.

• Dependant on local regulations the appropriate machine Service Manual should be
kept in the cab of homologated machines at all times.

Contact the local Caterpillar dealer for specific instructions if neither of these
methods are applicable.

31211299 6-1
Section 6 - Emergency Procedures

6.2 EMERGENCY LOWERING OF BOOM

In the event of total loss of engine power or hydraulic pump failure with an elevated load,
the situation must be properly evaluated and dealt with on an individual basis. Contact
the local Caterpillar Dealer for specific instructions.
Secure the telehandler using the following procedures:
1. Clear the area around telehandler of all personnel.
2. Apply the parking brake. Place the transmission in “NEUTRAL”.
3. Block all four wheels.
4. Section off a large area under the boom to restrict any personnel from entering this
area.

6.3 CAB EMERGENCY EXIT

OZ0240

• In an emergency the rear window can be used to exit the telehandler.

• Remove the latch pin (1). The window is then free to swing open.

6-2 31211299
 Section 7 - Lubrication and Maintenance
SECTION 7 - LUBRICATION AND MAINTENANCE
7.1 INTRODUCTION
This section is intended as information to assist the operator to perform maintenance
tasks only. Service product in accordance with maintenance schedule on the following
pages.

OZ4040

The lubrication and maintenance charts (1) contain instructions that must be followed to
keep this product in good operating condition. The Operation & Maintenance Manual and
Service Manual contain more detailed service information with specific instructions.

Clothing and Safety Gear

• Wear all the protective clothing and personal safety devices issued to you or called for
by job conditions.
• DO NOT wear loose clothing or jewelry that can get caught on controls or moving
parts.

31211299 7-1
Section 7 - Lubrication and Maintenance

7.2 GENERAL MAINTENANCE INSTRUCTIONS

Prior to performing any service or maintenance on the telehandler, follow the shut-
down procedure on page 4-3 unless otherwise instructed. Ensure telehandler is
level, for proper fluid readings.
• Clean lubrication fittings before lubricating.
• After greasing telehandler, cycle all functions several times to distribute lubricants.
Perform this maintenance procedure without attachment installed.
• Apply a light coating of engine oil to all linkage pivot points.
• Intervals shown are for normal usage and conditions. Adjust intervals for abnormal
usage and conditions.
• Check all lubricant levels when lubricant is cool. For ease of filling hydraulic reservoir,
use a funnel with a hose or flexible tube for best results.

WARNING
CUT/CRUSH/BURN HAZARD. Do not perform service or maintenance on the machine
with the engine running.

7-2 31211299
 Section 7 - Lubrication and Maintenance

7.3 SERVICE AND MAINTENANCE SCHEDULES

10 & 1st 50 Hour Maintenance Schedule

EVERY
10

Check Fuel Check Engine Check Hydraulic Check Tire Check Engine
Level Oil Level Oil Level Condition & Coolant Level
Pressure

Check Additional
Transmission Checks -
Oil Level Section 8

1st
50
LB/F
T (N
m)

Check Axle Check Wheel Check Boom Check Wheel

Differential Oil End Oil Levels Chain & Tension Lug Nut
Level Torque
OZ4251

31211299 7-3
Section 7 - Lubrication and Maintenance
50 & 1st 250 Hour Maintenance Schedule

EVERY
50

Drain Fuel/ Check Air Filter Lubrication Check Check Washer

Water Schedule Battery Fluid Level
Separator (if equipped)

Check Cab
Air Filter

1st
250

Change Change Change Axle Change Wheel

Transmission Transfer Case Differential Oil End Oil
Oil & Filter Oil
OB0440

7-4 31211299
 Section 7 - Lubrication and Maintenance
250 & 500 Hour Maintenance Schedule

EVERY
250

Check Transfer Check Check Axle Check Wheel Check Boom

Case Oil Level Fan Belt Differential Oil End Oil Levels Wear Pads
Level

Check Boom
Chain & Tension

EVERY
500
LB/F
T (N
m)

Change Fuel Change Engine Change Check Wheel Lubrication

Filters Oil and Air Filter Lug Nut Schedule
Filter Elements Torque

Check LSI
Calibration

OZ4260

31211299 7-5
Section 7 - Lubrication and Maintenance
1000 & 3000 Hour Maintenance Schedule

EVERY
1000

Change Change Check Change Change Axle

Transmission Transfer Case Air Intake Hydraulic Differential Oil
Oil & Filter Oil System Fluid & Filters

Change Wheel
End Oil

EVERY
3000

Change
Belt

OAM3771

7-6 31211299
 Section 7 - Lubrication and Maintenance
6000 Hour Maintenance Schedule

EVERY
6000
or
4 Years

Change
Engine Coolant

OAM3523

Note: If hour and year intervals are listed, use the interval that occurs first. Refer to Engine
Operation & Maintenance Manual for additional information.

31211299 7-7
Section 7 - Lubrication and Maintenance

7.4 LUBRICATION SCHEDULES

TH314D

OAM3780

7-8 31211299
 Section 7 - Lubrication and Maintenance
TH417D

OAM3790

31211299 7-9
Section 7 - Lubrication and Maintenance

7.5 OPERATOR MAINTENANCE INSTRUCTIONS

Fuel System

A. Fuel Level Check 10 OW0970 OW0990

2
3 OZ4060

1. Check fuel gauge (1) located in cab.

2. If fuel is low, proceed to fuel source and perform “Shut-Down Procedure” on page 4-3.
3. Unlock and open access panel (2).
4. Turn fuel tank cap (3) to remove from filler neck.
5. Add fuel as needed.
6. Replace fuel tank cap.
7. Close and secure access panel.
Note: Replenish diesel fuel at end of each work shift to minimize condensation.

NOTICE
EQUIPMENT DAMAGE. Do not allow machine to run out of fuel during operation. See
Engine Operation & Maintenance Manual for details prior to servicing.

7-10 31211299
 Section 7 - Lubrication and Maintenance

B. Drain Fuel/Water Separator 50 OW0980

OW1000

OZ3950

1. Perform “Shut-Down Procedure” on page 4-3.

2. Open engine cover.
3. Loosen drain cock (3) on underside of fuel filter (4) and allow all water to drain into a
glass until clear fuel is visible. Tighten drain cock.
4. Close and secure engine cover.

31211299 7-11
Section 7 - Lubrication and Maintenance
Tires

A. Tire Air Pressure Check 10 OW0970

OW1040

1. Perform “Shut-Down Procedure” on page 4-3.

2. Remove valve stem cap.
3. Check tire pressure.
4. Add air if required. See page 9-7 for tire pressures.
5. Replace valve stem cap.

B. Tire Damage
For pneumatic tires, when any cut, rip or tear is discovered that exposes sidewall or tread
area cords in the tire, measures be taken to remove the product from service immediately.
Arrangements must be made for replacement of the tire or tire assembly.
For polyurethane foam filled tires, when any of the following are discovered, measures
must be taken to remove the product from service immediately. Arrangements must be
made for replacement of the tire or tire assembly.
• a smooth even cut through the cord plies which exceeds 7,5 cm (3 in) in total length.
• any tears or rips (ragged edges) in the cord plies which exceeds 2,5 cm (1 in) in any
direction
• any punctures which exceed 2,5 cm (1 in) in diameter.
If a tire is damaged but within the above noted criteria, the tire must be inspected daily to
ensure the damage has not propagated beyond the allowable criteria.

C. Tire and Wheel Replacement

Machines equipped with pneumatic tires from the manufacturer must use pneumatic
replacements. Machines equipped with foam filled or ballast filled tires from the
manufacturer must use foam filled or ballast filled replacements.
It is recommended that a replacement tire to be the same size, ply and brand as originally
installed. Refer to the appropriate parts manual for ordering information. If not using an
approved replacement tire, the replacement tires must have the following characteristics:
• Equal or greater ply/load rating and size of original.
• Tire tread contact width equal or greater than original.
• Wheel diameter, width and offset dimensions equal to the original.
• Approved for the application by the tire manufacturer (including inflation pressure
and maximum tire load).

7-12 31211299
 Section 7 - Lubrication and Maintenance
Due to size variations between tire brands, when selecting and installing a replacement
tire ensure both tires on the axle are the same.
The rims installed have been designed for stability requirements which consist of track
width, tire pressure and load capacity. Size changes such as rim width, center piece
location, larger or smaller diameter, etc., without written factory recommendations, may
result in unsafe condition regarding stability.

D. Wheel Installation
Torque lug nuts after first 50 hours and after each wheel installation.
Note: If machine is equipped with directional tire assemblies, the wheel and tire assemblies
must be installed with the directional tread pattern “arrows” facing in the direction of forward
travel.
1. Install wheel lug washers.
2. Start all nuts by hand to prevent cross threading. DO NOT use a lubricant on threads
or nuts.
3. Tighten lug nuts in an alternating pattern as indicated in figure. See page 9-7 for
torque value.

3 5
1 7

10 9

8 2
6 4

OY1220

WARNING
TIP OVER HAZARD. Lug nuts must be installed and maintained at the proper torque
to prevent loose wheels, broken studs and possible separation of wheel from the axle.

31211299 7-13
Section 7 - Lubrication and Maintenance
Engine Oil

A. Engine Oil Level Check 10 OW0970

OW1020

3
D
AD

OZ3990

1. Perform “Shut-Down Procedure” on page 4-3.

2. Open engine cover.
3. Remove dipstick (1) and check oil mark. The oil should be between the full (2) and
add (3) marks within the crosshatched area of the dipstick.
4. Replace dipstick.
5. If oil is low, remove oil fill cap (4) and add oil to bring oil up to the full mark in the
crosshatch area.
6. Replace oil fill cap.
7. Close and secure engine cover.

7-14 31211299
 Section 7 - Lubrication and Maintenance
Engine Cooling System

A. Engine Coolant Level Check 10OW0970 OW1070

1
3

OZ4000

1. Perform “Shut-Down Procedure” on page 4-3.

2. Open engine cover.
3. Check coolant level in surge tank (1). Coolant should be between the Min and Max
(2) marks.
4. If coolant is low, allow fluid to cool.
5. Remove surge tank cap (3) slowly. Add coolant as required.
6. Replace surge tank cap.
7. Close and secure engine cover.

31211299 7-15
Section 7 - Lubrication and Maintenance
Hydraulic Oil

A. Hydraulic Oil Level Check 10 OW0970 OW1030

4
1
2

OZ4070

1. Be sure all cylinders are fully retracted, outriggers are fully raised and machine is
level.
2. Perform “Shut-Down Procedure” on page 4-3.
3. If hydraulic oil is cold, check fluid level at the sight gauge (1) on the hydraulic tank (2).
The oil level should be visible in the gauge window.
4. If hydraulic oil is low, unlock and open access panel (3).
5. Remove fill cap (4). Add fluid to bring oil up to the center of the sight gauge.
6. Replace hydraulic oil fill cap.
7. Close and secure access panel.

7-16 31211299
 Section 7 - Lubrication and Maintenance
Transmission Oil

A. Transmission Oil Level Check 10 OW0970 OW1050

OZ3960

1. Check transmission oil level with engine at idle and transmission oil at normal
operating temperature.
2. Apply park brake, shift transmission to "Neutral" and lower attachment to the
ground.
3. Open engine cover.
4. Remove the transmission dipstick (1) and check oil level. The oil level should be
between the Min and Max marks.
5. If oil is low, add fluid as required.
6. Replace transmission dipstick.
7. Close and secure engine cover.

31211299 7-17
Section 7 - Lubrication and Maintenance
Air Intake System

A. Air Filter Check 50 OW0980

OW1010

OZ3970

1. Perform “Shut-Down Procedure” on page 4-3.

2. Open engine cover.
3. Locate air cleaner (1) and remove dust from vacuator valve (2) by squeezing bottom
of valve to allow loose particles to fall out.
4. Close and secure engine cover.

NOTICE
EQUIPMENT DAMAGE. Only remove air cleaner cover to service elements. Excessive
access to check elements can lead to premature element and/or engine failure.

7-18 31211299
 Section 7 - Lubrication and Maintenance
B. Element Change
Note: Change elements as air cleaner restriction indicator indicates or every two years. Use
the interval that occurs first.
If Air Filter Restriction Indicator remains on after start up or illuminates while operating
machine, perform the following:
1. Perform “Shut-Down Procedure” on page 4-3.
2. Open engine cover.
3. Unlock air cleaner cover (3) and remove from air cleaner canister (4).
4. Remove outer primary element (5). Inspect for damage then discard.
5. Thoroughly clean the interior of the air cleaner canister and vacuator valve.
6. Replace inner safety element (6) every third primary element change or if primary
element was found to be damaged. If replacing inner safety element at this time,
carefully slide element out and replace with new element.
7. Slide new primary element over inner element making sure sealing edge is flush with
base of air cleaner.
8. Position air cleaner cover in place and lock into position.
9. Close and secure engine cover.
Note: Elements should never be washed or reused. Always install new elements.

NOTICE
EQUIPMENT DAMAGE. Primary and safety elements are required to be replaced if
used in an application longer than two years regardless of hours of operation.

31211299 7-19
Section 7 - Lubrication and Maintenance
Cab Air Filters (if equipped)

A. Cab Air Filters Check 50 OW0980 OAM3670

1
1

OZ4050

1. Perform “Shut-Down Procedure” on page 4-3.

2. Remove two thumb screws (1) and panel (2) from front of cab.
3. Remove filter thumb screw (3) and filter (4).
4. If filter is not damaged, clean and place back under dash. If damaged, replace filter.
5. Secure filter with thumb screw.
6. Replace panel on front of cab and secure with thumb screws.

7-20 31211299
 Section 7 - Lubrication and Maintenance

2
3
1
OZ4020

7. Remove four thumb screws (1) and panel (2) from under dash.
8. Remove cab air filter (3) and inspect.
9. If filter is not damaged, clean and place back under dash. If damaged, replace filter.
10. Replace panel and secure with thumb screws.

31211299 7-21
Section 7 - Lubrication and Maintenance
Battery

A. Battery Check 50 OW0980 OW1080

1
OZ3980

1. Perform “Shut-Down Procedure” on page 4-3.

2. Open engine cover.
3. Wearing eye protection, visually inspect the battery (1). Check terminals for
corrosion. Replace battery if it has a cracked, melted or damaged case.
4. Close and secure engine cover.

7-22 31211299
 Section 7 - Lubrication and Maintenance
Windshield Washer System (if equipped)

A. Windshield Washer Fluid Level Check 50 OW0980

OAL2040

OZ4030

1. Perform “Shut-Down Procedure” on page 4-3.

2. The windshield washer fluid should be visible in the reservoir (1).
3. If washer fluid level is low, add fluid as needed.

31211299 7-23
Section 7 - Lubrication and Maintenance

This Page Intentionally Left Blank

7-24 31211299
 Section 8 - Additional Checks
SECTION 8 - ADDITIONAL CHECKS
8.1 GENERAL
If any of the following test results cannot be achieved, the system is not functioning
properly and the machine must be removed from service and repaired before
continued operation.

8.2 LOAD STABILITY INDICATOR SYSTEM

A. Load Stability Indicator System Test 10 OW0970

OZ0840

The Load Stability Indicator (LSI) is intended to continuously monitor the forward stability
of the telehandler. To check this feature, perform the following:
Prior to SN MYT00161, Prior to SN MYF00164 excluding MYF00154,
Prior to SN MLZ00151, Prior to SN MKY00191 excluding MKY00189

OZ4630

1. Fully retract and level boom, with no load. Do not raise the boom during this
test.
2. Level frame using level in cab.
3. Press the system check button on the LSI display. This will cause all LEDs to flash on
and an audible warning to sound. This indicates that the system is functioning
properly.

31211299 8-1
Section 8 - Additional Checks
SN MYT00161 to Present, SN MYF00164 to Present including MYF00154,
SN MLZ00151 to Present, SN MKY00191 to Present including MKY00189

1001243215 B

OZ4640

1. Remove attachment, fully retract and fully raise boom and fully lower outriggers.
2. Press LSI override switch on left control panel (see page 3-24) quickly two times
followed by a third held press.
Note: All three presses must be completed within two seconds or the switch will be ignored.
3. LSI indicator LEDs will illuminate sequentially then repeat if check is successful. LSI
indicator LEDs will resume normal functionality when control buttons are released.
4. If check fails, a fault code will appear on the dash display and must be corrected
before continued use. Repeat system check or re-calibrate machine. See Service
Manual for LSI system calibration information.

8-2 31211299
 Section 8 - Additional Checks

8.3 BOOM INTERLOCK

A. Boom Interlock System Test 10 OW0970

Boom interlock system operates in three modes. With boom at any extension and angle
below 20 degrees, outrigger and frame level functions are operable. With boom fully
retracted and raised between 20 and 55 degrees, outriggers and frame level are operable.
With boom at any extension and raised above 55 degrees, outriggers and frame level are
not operable. To check the system, perform the following:
1. Test system with machine on a level surface and no load.
2. Shift transmission to neutral and engage park brake.
3. Ensure outriggers and frame level functions are properly functioning. Lower then
raise outriggers. Rotate frame in each direction.
4. Keep outriggers raised and level machine using level in cab.
5. Raise boom to between 20 and 55 degrees and extend approximately
1 m (39 in).
6. Attempt to lower outriggers then rotate frame. Neither function should respond.
7. Fully retract boom and raise above 55 degrees.
8. Attempt to lower outriggers then rotate frame. Neither function should respond.
9. Lower boom fully.

31211299 8-3
Section 8 - Additional Checks

This Page Intentionally Left Blank

8-4 31211299
 Section 9 - Specifications
SECTION 9 - SPECIFICATIONS
9.1 PRODUCT SPECIFICATIONS
Fluids
S/N MYT00150 & After and S/N MLZ00150 & After

Ambient Temperature
Compartment Range
Type and Classification Viscosities
or System °F °C
Min Max Min Max
SAE 0W-20 -22 50 -30 10
SAE 0W-30 -22 86 -30 30
SAE 0W-40 -22 104 -30 40
Engine CAT DEO ULS SAE 5W-30 -13 86 -25 30
Crankcase API CK-4 SAE 5W-40 -13 122 -25 50
SAE 10W-30 -4 104 -20 40
SAE 10W-40 -4 122 -20 50
SAE 15W-40 14 122 -10 50
Hydraulic SAE 10W -4 104 -20 40
CAT HYDO Advanced
System SAE 30 50 122 10 50
SAE 10W 0 95 -18 35
Transmission SAE 30 32 95 0 35
and Transfer CAT TDTO SAE 50 50 122 10 50
Case SAE 5W-30 -22 68 -30 20
SAE 0W-20 -40 68 -40 20
CAT Synthetic
SAE 75W-140 -22 113 -30 45
Gear Oil (GO)*
SAE 85W-140 14 122 -10 50
CAT Gear Oil (GO)*
SAE 80W-90 -4 122 -20 50
SAE140 50 122 10 50
Axle Differential
80W-140
and 14 122 -10 50
85W-140
Wheel Ends
API GL5 with SAE90
32 104 0 40
LS Additives SAE90LS
80W-90 -4 104 -20 40
75W-90 -40 104 -40 40
75W -40 50 -40 10
Boom Wear Extreme Pressure
NLGI Grade 000 -31 122 -35 50
Pad Grease Grease

31211299 9-1
Section 9 - Specifications
Ambient Temperature
Compartment Range
Type and Classification Viscosities
or System °F °C
Min Max Min Max
NLGI Grade 2 EP
with Moly
Additive
Extreme Pressure
Grease Fittings or 5 122 -15 50
Grease
NLGI Grade 3 EP
with Moly
Additive
CAT Extended Life 50/50 Mix Standard
Engine Coolant
Coolant (ELC) 60/40 Mix Cold Weather
EN590
ASTM D975 Grade 2-D Ultra Low Sulfur
Fuel
ASTM D975 Grade 1-D (S  15 mg/kg)
(Maximum B5 Biodiesel)
Brake Fluid (if
equipped with Mobil ATF 220 -40 122 -40 50
55 kW engine)
Air
Refrigerant R-134a Tetrafluoroethane
Conditioning
*Friction Modifier (197-0017) required for front axle differential. Must be pre-mixed with axle
fluid.

9-2 31211299
 Section 9 - Specifications
S/N MYF00150 & After and S/N MKY00150 & After

Ambient Temperature
Compartment Range
Type and Classification Viscosities
or System °F °C
Min Max Min Max
SAE 0W-20 -22 50 -30 10
SAE 0W-30 -22 86 -30 30
SAE 0W-40 -22 104 -30 40
Engine CAT DEO SAE 5W-30 -13 86 -25 30
Crankcase API CI-4 SAE 5W-40 -13 122 -25 50
SAE 10W-30 -4 104 -20 40
SAE 10W-40 -4 122 -20 50
SAE 15W-40 14 122 -10 50
Hydraulic SAE 10W -4 104 -20 40
CAT HYDO Advanced
System SAE 30 50 122 10 50
SAE 10W 0 95 -18 35
Transmission SAE 30 32 95 0 35
and Transfer CAT TDTO SAE 50 50 122 10 50
Case SAE 5W-30 -22 68 -30 20
SAE 0W-20 -40 68 -40 20
CAT Synthetic
SAE 75W-140 -22 113 -30 45
Gear Oil (GO)*
SAE 85W-140 14 122 -10 50
CAT Gear Oil (GO)*
SAE 80W-90 -4 122 -20 50
SAE140 50 122 10 50
Axle Differential
80W-140
and 14 122 -10 50
85W-140
Wheel Ends
API GL5 with SAE90
32 104 0 40
LS Additives SAE90LS
80W-90 -4 104 -20 40
75W-90 -40 104 -40 40
75W -40 50 -40 10
Boom Wear Extreme Pressure
NLGI Grade 000 -31 122 -35 50
Pad Grease Grease
NLGI Grade 2 EP
with Moly
Additive
Extreme Pressure
Grease Fittings or 5 122 -15 50
Grease
NLGI Grade 3 EP
with Moly
Additive

31211299 9-3
Section 9 - Specifications
Ambient Temperature
Compartment Range
Type and Classification Viscosities
or System °F °C
Min Max Min Max
CAT Extended Life 50/50 Mix Standard
Engine Coolant
Coolant (ELC) 60/40 Mix Cold Weather
EN590
ASTM D975 Grade 2-D Low Sulfur
Fuel
ASTM D975 Grade 1-D (S  500 mg/kg)
(Maximum B5 Biodiesel)
Air
Refrigerant R-134a Tetrafluoroethane
Conditioning
Note: Friction Modifier (197-0017) required for front axle differential. Must be pre-mixed with
axle fluid.

9-4 31211299
 Section 9 - Specifications
Capacities

Engine Crankcase Oil

Capacity with Filter Change...................................................................................................8,0 L (8.5 qt)
Fuel Tank
Capacity .................................................................................................................................. 150 L (39.6 gal)
Cooling System
System Capacity....................................................................................................................... 19,0 L (20 qt)
Hydraulic System
System Capacity................................................................................................................... 180 L (47.6 gal)
Reservoir Capacity to Full Mark .........................................................................................90 L (23.8 gal)
Auxiliary Hydraulic Circuit Max Flow................................................................... 100 lpm (26.4 gpm)

Transmission System
Capacity with Filter Change..............................................................................................13,5 L (14.3 qt)

Transfer Case
Capacity ...................................................................................................................................0,75 L (0.79 qt)
Axles
Differential Housing Capacity
TH314D
Front Axle
if utilizing fluid with LS Additives .................................................................7,3 L (7.7 qt)
if utilizing fluid without LS Additives* ........................................................6,9 L (7.3 qt)
Rear Axle........................................................................................................................7,5 L (7.9 qt)
TH417D
Front Axle
if utilizing fluid with LS Additives .................................................................6,7 L (7.1 qt)
if utilizing fluid without LS Additives* ........................................................6,4 L (6.8 qt)
Rear Axle........................................................................................................................7,5 L (7.9 qt)
*If axle fluid does not contain LS Additives, Friction Modifier must be added. Pre-mix before
placing in axle differential. Not pre-mixing fluids can lead to excessive brake noise.

Friction Modifier (if needed)

TH314D
Front Axle.................................................................................Not to Exceed 365 mL (12.3 oz)
Rear Axle..................................................................................................................................... None
TH417D
Front Axle.................................................................................Not to Exceed 335 mL (11.3 oz)
Rear Axle..................................................................................................................................... None

31211299 9-5
Section 9 - Specifications
Wheel End Capacity
TH314D ................................................................................................................................. 1,4 L (1.5 qt)
TH417D
Front Axle ..................................................................................................................... 2,1 L (2.2 qt)
Rear Axle
If Equipped with Pneumatic Filled Tires .................................................... 1,4 L (1.5 qt)
If Equipped with Foam Filled Tires............................................................... 2,1 L (2.2 qt)
Brake System (if equipped with 55 kW engine)
Capacity ........................................................................................................................................ 1,7 L (1.8 qt)
Air Conditioning System (if equipped)
System Capacity ...................................................................................................................... 1,0 kg (2.2 lb)

9-6 31211299
 Section 9 - Specifications
Tires

TH314D
15.5/80-24 TR01............................................................................................................. 4,1 bar (59 psi)
15.5-25 L-2
Pneumatic................................................................................................................ 4,0 bar (58 psi)
Foam ..........................................................................................................................186 kg (410 lb)
400/80-24......................................................................................................................... 4,0 bar (58 psi)
370/75-28.......................................................................................................................5,25 bar (76 psi)
TH417D
14-24 TG02 ....................................................................................................................4,25 bar (62 psi)
14-24 SGG-2A
Pneumatic..............................................................................................................4,75 bar (69 psi)
Foam ..........................................................................................................................245 kg (540 lb)
14R24 XGLA2 .................................................................................................................. 5,5 bar (80 psi)
400/75-28.......................................................................................................................5,25 bar (76 psi)

Wheel Lug Nut

Torque
TH314D.................................................................................................... 360 ±20 Nm (265 ±15 lb-ft)
TH417D.................................................................................................... 460 ±20 Nm (340 ±15 lb-ft)

31211299 9-7
Section 9 - Specifications
Performance

Maximum Lift Capacity

TH314D ....................................................................................................................... 3600 kg (7937 lb)
TH417D ....................................................................................................................... 4000 kg (8819 lb)

Maximum Lift Height

TH314D ............................................................................................................................14,0 m (45.9 ft)
TH417D
Outriggers Engaged ............................................................................................17,2 m (56.4 ft)
Outriggers Not Engaged....................................................................................15,5 m (50.9 ft)

Capacity at Maximum Height

TH314D
Outriggers Engaged ....................................................................................... 3000 kg (6614 lb)
Outriggers Not Engaged............................................................................... 1500 kg (3307 lb)
TH417D
Outriggers Engaged ....................................................................................... 2500 kg (5512 lb)
Outriggers Not Engaged..................................................................................500 kg (1102 lb)

Maximum Forward Reach

TH314D .............................................................................................................................. 9,5 m (31.2 ft)
TH417D ............................................................................................................................13,0 m (42.7 ft)

Capacity at Maximum Forward Reach

TH314D
Outriggers Engaged ..........................................................................................900 kg (1984 lb)
Outriggers Not Engaged.................................................................................... 100 kg (220 lb)
TH417D
Outriggers Engaged ..........................................................................................500 kg (1102 lb)
Outriggers Not Engaged..............................................................................................0 kg (0 lb)

Reach at Maximum Height

TH314D .................................................................................................................................0,8 m (2.6 ft)
TH417D
Outriggers Engaged .................................................................................................1,0 m (3.3 ft)
Outriggers Not Engaged...................................................................................... 5,0 m (16.4 ft)

Auxiliary Hydraulic Circuit Max Flow....................................................................100 lpm (26.4 gpm)

Maximum Travel Speed (see note)

74,4 kW Engine....................................................................................................... 25 kph (15.5 mph)
55,0 kW Engine....................................................................................................... 20 kph (12.4 mph)

Frame Leveling............................................................................................................................. 10 degrees

Maximum Travel Grade (boom in travel position)

Gradeability .........................................................................................................................................45%
Side Slope......................................................................................................................................... 8.75%

9-8 31211299
 Section 9 - Specifications
Note: Refer to machine specific documents and/or plates for local governmental
requirements and/or restrictions.

31211299 9-9
Section 9 - Specifications
Dimensions

Note: Values will vary depending on machine configuration.

Maximum Overall Height
TH314D ................................................................................................................... 2944 mm (115.9 in)
TH417D ................................................................................................................... 2937 mm (115.6 in)
Germany.......................................................................................................... 3087 mm (121.5 in)

Maximum Overall Width

TH314D ......................................................................................................................2366 mm (93.1 in)
TH417D ......................................................................................................................2395 mm (94.3 in)

Maximum Track Width

TH314D ......................................................................................................................2354 mm (92.7 in)
TH417D ......................................................................................................................2373 mm (93.4 in)

Wheelbase
TH314D ................................................................................................................... 3150 mm (124.0 in)
TH417D ................................................................................................................... 3235 mm (127.4 in)

Length at Front Wheels

TH314D ................................................................................................................... 4232 mm (166.6 in)
TH417D ................................................................................................................... 4317 mm (170.0 in)

Overall Length (less Forks)

TH314D ................................................................................................................... 6433 mm (253.3 in)
TH417D ................................................................................................................... 6458 mm (254.3 in)

Ground Clearance
TH314D ........................................................................................................................ 375 mm (14.8 in)
TH417D ........................................................................................................................ 436 mm (17.2 in)

Turning Radius Over Tires

TH314D ................................................................................................................... 7720 mm (303.9 in)
TH417D ................................................................................................................... 8020 mm (315.7 in)

Outside Turning Radius

TH314D .................................................................................................. Not Available at Publication
TH417D .................................................................................................. Not Available at Publication

Maximum Operating Weight (no attachment)

TH314D ....................................................................................................................9880 kg (21,782 lb)
TH417D ................................................................................................................ 11 620 kg (25,618 lb)

9-10 31211299
 Section 9 - Specifications
Distribution of Maximum Operating Weight
(no attachment, boom level and fully retracted)
Front Axle
TH314D ............................................................................................................ 4870 kg (10,737 lb)
TH417D ............................................................................................................ 5510 kg (12,148 lb)
Rear Axle
TH314D ............................................................................................................ 5010 kg (11,045 lb)
TH417D ............................................................................................................ 6110 kg (13,470 lb)

Maximum Ground Bearing Pressure

TH314D
Outriggers................................................................................................... 6,4 kg/cm² (91 lb/in²)
Tires
15.5/80-24 TR01 ..............................................................................8,4 kg/cm² (119 lb/in²)
15.5-25 L-2
Pneumatic .............................................................................. 10,2 kg/cm² (145 lb/in²)
Foam......................................................................................... 11,7 kg/cm² (166 lb/in²)
400/80-24 ....................................................................................... 10,0 kg/cm² (142 lb/in²)
370/75-28 ............................................................................................ 6,7 kg/cm² (95 lb/in²)
TH417D
Outriggers.................................................................................................7,4 kg/cm² (106 lb/in²)
Tires
14-24 TG02........................................................................................8,9 kg/cm² (127 lb/in²)
14-24 SGG-2A
Pneumatic .............................................................................. 10,4 kg/cm² (148 lb/in²)
Foam......................................................................................... 11,9 kg/cm² (169 lb/in²)
14R24 XGLA2................................................................................. 10,9 kg/cm² (155 lb/in²)
400/75-28 ..........................................................................................9,8 kg/cm² (139 lb/in²)

31211299 9-11
Section 9 - Specifications
Declaration of Vibration

According to Standard EN13059

Average Weighted Whole Body Acceleration

Seat*
TH314D TH417D
2 2
Mechanical Suspension 0,90 m/s (2.95 ft/s ) 0,92 m/s2 (3.02 ft/s2)

*A seat is an essential means to reduce the vibration transmitted to the operator. In case of
replacement of the seat, refer to the manufacturer.

Noise Emission Level (CE)

Note: To avoid any increase in noise emission, after maintenance and repair work, all panels
and other sound absorbing materials must be replaced in their original condition. Do not
modify the machine in such a manner as to increase noise emissions.
LWA is A-weighted emission sound power level
LpA is A-weighted emission sound pressure level

According to Directive 2000/14/EC (Outdoor Noise) & EN 12053 (Operator Noise)

Model Net Power: 2000/14/EC EN 12053

TH314D
74,4 kW 106 dB(A) LWA 78.4 dB(A) LpA
TH417D
TH314D
55,0 kW 104 dB(A) LWA 74.5 dB(A) LpA
TH417D

Machine Towing Capacity

Note: Refer to machine specific documents and/or plates for local governmental
requirements and/or restrictions.
Off-Road ............................................................................................................................................0 kg (0 lb)
On-Road.............................................................................................................................................0 kg (0 lb)

9-12 31211299
Index

Index
A D
Accessory Control Lever ................... 3-26 Dimensions ......................................9-10
Additional Checks .............................. 8-1 Disengaging a Load ............................4-8
Adjusting/Moving Forks ................... 5-17 Disengaging a Suspended Load.........4-11
After-Treatment System ..................... 4-4 Driving Hazards on Slopes.................1-10
Air Filter........................................... 7-18
E
Attachment Installation
CAT Quick Coupler...................... 5-10 Electrical Hazards................................1-2
JCB Coupler................................ 5-14 Emergency Lowering of Boom.............6-2
Manitou Coupler......................... 5-12 Emergency Procedures .......................6-1
Attachment Operation ............ 5-18, 5-29 Engine
Attachments Normal Operation .........................4-3
Approved ..................................... 5-1 Starting.........................................4-1
JLG Supplied ................................ 5-2 Engine Crankcase Oil...........................9-5
Unapproved ................................. 5-1
Engine Oil Level ................................7-14
Axles ................................................. 9-5
F
B
Fall Hazard .......................................1-13
Battery............................................. 7-22
Fluids .................................................9-1
Battery Boosted Starting..................... 4-2 Capacities .....................................9-5
Boom Indicator Fork Mounted Hook ..........................5-26
Extension ................................... 3-32
Fuel Level .........................................7-10
Boom Interlock Test............................ 8-3
Fuel Tank............................................9-5
Bucket ............................................. 5-22
Fuel/Water Separator ........................7-11
C
G
Cab Air Filters................................... 7-20
General Maintenance ..........................7-2
Cab Emergency Exit............................ 6-2
Capacity ............................................ 5-4 H
Capacity Indicator Locations ............... 5-5 Hazard Classification System ...............1-1
Carriage w/Forks .............................. 5-19 Hitches.............................................5-29
Chemical Hazards............................. 1-14 Horn ................................................3-26
Controls............................................. 3-2 Hydraulic Oil Level ............................7-16
Coolant Level ................................... 7-15 Hydraulic Operated Attachment ........5-16
Cooling System .................................. 9-5 Hydraulic System ................................9-5
Coupler Mounted Hook .................... 5-27
I
Ignition ..............................................3-6
Instrument Cluster ..............................3-4

31211299 1
Index
J P
Joystick Park Brake...........................................3-7
Lift Pattern.................................. 3-16 Parking Procedure...............................3-7
Loader Pattern ............................ 3-20
Performance .......................................9-8
L Picking Up a Load ...............................4-6
Leveling Procedure.................... 4-7, 4-10 Picking Up a Suspended Load..............4-9
Lifting Personnel ................................ 1-9 Pinch Points and Crush Hazards .........1-11
Load Chart Placing a Load.....................................4-8
Example ....................................... 5-8 Placing a Suspended Load .................4-11
Sample ......................................... 5-6
Pre-Operation Check and Inspection ....2-2
Load Falling Hazard ............................ 1-8
Load Stability Indicator - LSI .............. 3-10 R
LSI Retrieval Hitch ..................................5-29
Test .............................................. 8-1
S
Lubrication and Maintenance.............. 7-1
Safety Decals ......................................2-4
Lubrication Schedule
TH314D ........................................ 7-8 Safety Practices...................................1-1
TH417D ........................................ 7-9 Safety Signal Words.............................1-1
Seat Belt ...........................................3-31
M
Service and Maintenance Schedule
Multi-Purpose Bucket ....................... 5-24 10 Hour.........................................7-3
1000 Hour .....................................7-6
N
1st 250 Hour..................................7-4
Noise Emission ................................. 9-12 1st 50 Hour....................................7-3
250 Hour .......................................7-5
O 3000 Hour .....................................7-6
Operating with a Non-Suspended 50 Hour.........................................7-4
Load ........................................... 4-5–4-6 500 Hour .......................................7-5
Operating with a Suspended Load ...... 4-9 6000 Hour .....................................7-7
Operational Check............................ 2-10 Shut-Down Procedure .........................4-3
Operator Cab ................................... 2-11 Side Shift Carriage.............................5-20
Operator Maintenance Instructions ... 7-10 Specifications .....................................9-1
Operator Seat................................... 3-29 Steering Alignment Mode
Adjustments ............................... 3-30 Manual........................................3-28
Operator Presence ...................... 3-29 Steering Column Adjuster .................3-14
Switches ...........................................3-24

2 31211299
 Index
T
Tip Over Hazard ................................. 1-4
Tires ......................................... 7-12, 9-7
Air Pressure ................................ 7-12
Damage ..................................... 7-12
Replacement .............................. 7-12
Towing .............................................. 6-1
Towing Capacity .............................. 9-12
Transfer Case ..................................... 9-5
Transmission Control
Clutch Lock ....................... 3-19, 3-23
Direction of Travel ...... 3-8, 3-18, 3-22
Gear Selection ............ 3-9, 3-18, 3-22
Transmission Oil Level ...................... 7-17
Transmission System .......................... 9-5
Transport
Lifting ........................................ 4-14
Tiedown..................................... 4-13
Transporting a Load ........................... 4-7
Transporting a Suspended Load........ 4-10
Travel Hazard ..................................... 1-7
Truss Boom...................................... 5-28

V
Vibration ......................................... 9-12

W
Warm-Up Check ............................... 2-10
Wheel Installation ............................ 7-13
Wheel Lug Nut ................................... 9-7
Wheel Replacement ......................... 7-12
Windshield Washer Fluid Level.......... 7-23

31211299 3
Index

4 31211299
Inspection, Maintenance and Repair Log

Inspection, Maintenance and Repair Log

Serial Number ___________________________________

Date Comments
Inspection, Maintenance and Repair Log

Date Comments
Hand Signals

OY1090 OY1100 OY1110

EMERGENCY STOP - With both STOP - With either arm extended STOP ENGINE - Draw thumb or
arms extended laterally, hands laterally, hand open downward, forefinger across throat.
open downward, move arms back move arm back and forth.
and forth.

OY1120 OY1130 OY1140

RAISE BOOM - With either arm LOWER BOOM - With either arm MOVE SLOWLY - Place one hand
extended horizontally, fingers extended horizontally, fingers motionless in front of hand giving
closed, point thumb upward. closed, point thumb downward. motion signal. (Raise load slowly
shown)

OY1150 OY1160 OY1170

EXTEND BOOM - With both hands RETRACT BOOM - With both THIS FAR TO GO - With hands
clenched, point thumbs outward. hands clenched, point thumbs raised and open inward, move
inward. hands laterally, indicating
distance to go.

OY1180 OY1190

TILT FORKS UP - With one arm TILT FORKS DOWN - With one arm
held at side, extend other arm held at side, extend other arm
upward at about 45 degrees. downward at about 45 degrees.
Special Signals - When signals for auxiliary equipment functions or conditions not
covered are required, they shall be agreed upon in advance by the operator and signalman.
31211299