Operation &

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

Models
TL1055,
TL1255
S/N TBM00100 & After
S/N TBN00100 & After
31200249
Revised
March 10, 2011

CALIFORNIA PROPOSITION 65

BATTERY WARNING
Battery posts,
terminals and related
accessories contain
lead and lead compounds,
chemical known to the
State of California
to cause cancer and
reproductive harm.

WASH HANDS
AFTER HANDLING!
CALIFORNIA PROPOSITION 65

EXHAUST WARNING
Diesel Engine exhaust and
some of its constituents
are known to the State of
California to cause cancer,
birth defects and other
reproductive harm.

Revision Log
Revision Log

REVISION LOG

September 29, 2006 - A - Original Issue of Manual

October 27, 2006 - B - Revised pages 3-10, 5-13 thru 5-22, 9-2, 9-4 and 9-5.
January 19, 2007 - C - Revised pages 2-3 thru 2-5, 3-10, 3-11 and 7-1.
May 2, 2007 - D - Added attachment information. Revised pages 2-5, 2-6, 2-7, 2-10,
3-5, 5-12, 5-16, 5-18 thru 5-25, 9-1 and 9-5.
October 1, 2008 - E - Revised page 9-2.
October 16, 2009 - F - Revised covers and pages b, c, d, 1-1 thru 1-6, 1-8, 1-9, 2-1,
2-2, 2-3, 2-6 thru 2-10, 3-1 thru 3-18, 4-1 thru 4-12, 5-1, 5-2, 5-4 thru 5-12, 5-14 thru
5-32, 6-1, 6-2, 7-1 thru 7-5, 7-7, 7-8, 7-13 thru 7-16, 7-18, 7-19, 7-20, 8-1 & 9-1 thru
9-5.
December 20, 2010 - G - Revised pages 7-14, 9-3 & 9-5.
February 14, 2011 - H - Revised pages 1-9, 2-3, 2-4, 2-5, 2-9, 2-10, 2-11, 3-4, 3-5,
3-10, 4-3, 4-9, 4-10, 5-2, 5-30, 6-1, 7-3, 7-4, 7-5, 7-7, 7-8, 7-10 thru 7-15, 7-18 thru
7-22, 8-1 & 9-1 thru 9-4.
March 10, 2011 - I - Revised pages 2-3, 2-5, 2-9, 7-11 thru 7-15, 7-19 thru 7-22 &
9-3.

31200249

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, JLG Industries, Inc. reserves the right to
make specification changes without prior notification. Contact JLG Industries, Inc.
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 drivers 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 telehandler:
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
Any modification to this machine must be approved by JLG.

31200249

Read This First

This product must comply with all safety related bulletins. Contact JLG Industries,
Inc. or the local Caterpillar dealer representative for information regarding safetyrelated bulletins which may have been issued for this product.
JLG Industries, Inc. sends safety related bulletins to the owner of record of this
machine. Contact JLG Industries, Inc. to ensure that the current owner records are
updated and accurate.
JLG Industries, Inc. must be notified immediately in all instances where JLG
products have been involved in an accident involving bodily injury or death of
personnel or when damage has occurred to personal property or the JLG product.

FOR:
Accident Reporting and Product Safety Publications
Current Owner Updates
Questions Regarding Product Applications and Safety
Standards and Regulations Compliance Information
Questions Regarding Product Modifications

CONTACT:
Product Safety and Reliability Department
JLG Industries, Inc.
13224 Fountainhead Plaza
Hagerstown, MD 21742
USA
In USA:
Toll Free: 1-877-JLG-SAFE (1-877-554-7233)
Outside USA:
Phone:
+1-717-485-6591
E-mail:
ProductSafety@JLG.com

31200249

Read This First

Other Publications Available
Service Manual..........................................................................................31200293
Illustrated Parts Manual.............................................................................31200257

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 EN1459
Refer to the machine Serial Number Plate to identify the applicable compliance
standard.

31200249

Table of Contents

Table of Contents

TABLE OF CONTENTS
Revision Log
Read This First
Operator Qualifications ...................................................... b
Modifications ...................................................................... b
Other Publications Available .............................................. d

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..............................................................1-3
Travel Hazard .................................................................1-6
Load Falling Hazard........................................................1-7
Lifting Personnel .............................................................1-8
Driving Hazards On Slopes.............................................1-9
Pinch Points and Crush Hazards ..................................1-10
Fall Hazard....................................................................1-12
Chemical Hazards.........................................................1-13

Section 2 - Pre-Operation and Inspection

2.1
2.2
2.3
2.4

Pre-Operation Check and Inspection...................................2-1

Safety Decals.......................................................................2-3
Walk-Around Inspection.......................................................2-8
Warm-Up and Operational Checks ....................................2-10
Warm-Up Check ...........................................................2-10
Operational Check ........................................................2-10
2.5 Operator Cab .....................................................................2-11
2.6 Windows ............................................................................2-12
Cab Door Window (if equipped) ....................................2-12

Section 3 - Controls and Indicators

3.1 General ................................................................................3-1
3.2 Controls ...............................................................................3-2
Dash Controls and Indicators..........................................3-4
Ignition ............................................................................3-6
Park Brake ......................................................................3-7
Parking Procedure ..........................................................3-7
Transmission Control Lever ............................................3-8

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Table of Contents
Boom Joystick .............................................................. 3-10
Frame Level Joystick.................................................... 3-11
Auxiliary Hydraulic Joystick .......................................... 3-12
Outrigger Joysticks ....................................................... 3-13
Right Hand Panel ......................................................... 3-14
Accessory Control Lever (if equipped) ......................... 3-16
3.3 Steer Modes ...................................................................... 3-17
Steer Mode Change ..................................................... 3-17
3.4 Operator Seat.................................................................... 3-18
Adjustments.................................................................. 3-18
Seat Belt ....................................................................... 3-19
3.5 Boom Angle and Extension Indicators .............................. 3-20

Section 4 - Operation
4.1 Engine ................................................................................. 4-1
Starting the Engine ......................................................... 4-1
Extreme Cold Weather Starting (if equipped)................. 4-2
Battery Boosted Starting................................................. 4-3
Normal Engine Operation ............................................... 4-4
Shut-Down Procedure .................................................... 4-4
4.2 Operating with a Non-Suspended Load .............................. 4-5
Lift Load Safely............................................................... 4-5
Picking Up a Load .......................................................... 4-5
Transporting a Load ....................................................... 4-6
Leveling Procedure......................................................... 4-6
Placing a Load................................................................ 4-7
Disengaging a Load........................................................ 4-7
4.3 Operating with a Suspended Load ...................................... 4-8
Lift Load Safely............................................................... 4-8
Picking Up a Suspended Load ....................................... 4-8
Transporting a Suspended Load .................................... 4-9
Leveling Procedure......................................................... 4-9
Placing a Suspended Load........................................... 4-10
Disengaging a Suspended Load .................................. 4-10
4.4 Loading and Securing for Transport.................................. 4-11
Tiedown ........................................................................ 4-11
Lifting ............................................................................ 4-12

Section 5 - Attachments
5.1
5.2
5.3
5.4

ii

Approved Attachments ........................................................ 5-1

Unapproved Attachments.................................................... 5-1
JLG Supplied Attachments.................................................. 5-2
Telehandler/Attachment/Fork Capacity ............................... 5-4

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Table of Contents
5.5 Use of the Load Chart..........................................................5-5
Capacity Indicator Locations...........................................5-5
Sample Load Chart .........................................................5-6
Example ..........................................................................5-8
5.6 Attachment Installation ........................................................5-9
Mechanical Quick Coupler ............................................5-10
Hydraulic Quick Coupler ...............................................5-11
5.7 Hydraulic Operated Attachment.........................................5-12
5.8 Adjusting/Moving Forks......................................................5-13
5.9 Attachment Operation ........................................................5-14
Carriage with Forks .......................................................5-15
Side Shift Carriage........................................................5-16
Rotate/Side Tilt Carriage...............................................5-18
Swing Carriage .............................................................5-20
Bucket ...........................................................................5-22
Multi-Purpose Bucket ....................................................5-24
Fork Mounted Hook ......................................................5-26
Coupler Mounted Hook .................................................5-28
Truss Boom...................................................................5-29
Personnel Work Platform - Fork Mounted.....................5-30
Boom Head-Mounted Winch.........................................5-32

Section 6 - Emergency Procedures

6.1 Towing a Disabled Product..................................................6-1
Moving Short Distances ..................................................6-1
Moving Longer Distances ...............................................6-1
6.2 Emergency Lowering of Boom.............................................6-2
6.3 Emergency Exit from Enclosed Cab ....................................6-2

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 Schedule ....................................7-3
10, 1st 50 & 50 Hour Maintenance Schedule .................7-3
1st 250, 250 & 500 Hour Maintenance Schedule ...........7-4
1000 & 1500 Hour Maintenance Schedule .....................7-5
7.4 Lubrication Schedules .........................................................7-6
50 Hour Lubrication Schedule.........................................7-6
250 Hour Lubrication Schedule.......................................7-7
1000 Hour Lubrication Schedule.....................................7-8

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Table of Contents
7.5 Operator Maintenance Instructions ................................... 7-10
Fuel System.................................................................. 7-10
Air Intake System ......................................................... 7-12
Engine Oil ..................................................................... 7-14
Hydraulic Oil ................................................................. 7-15
Tires.............................................................................. 7-16
Transmission Oil........................................................... 7-19
Engine Cooling System ................................................ 7-20
Battery .......................................................................... 7-22
Windshield Washer System (if equipped)..................... 7-23

Section 8 - Additional Checks

8.1 General................................................................................ 8-1
8.2 Auto-Frame Level System (TL1055 Before S/N TBM01168,
TL1255 Before S/N TBN00658) .......................................... 8-1

Section 9 - Specifications
9.1 Product Specifications......................................................... 9-1
Fluids .............................................................................. 9-1
Capacities....................................................................... 9-3
Tires................................................................................ 9-4
Performance ................................................................... 9-5
Dimensions..................................................................... 9-6

Index
Inspection, Maintenance and Repair Log

iv

31200249

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.

31200249

1-1

Section 1 - General Safety Practices

1.3

OPERATION SAFETY

Electrical Hazards

10 FT
(3 M)

OW0040

This machine is not insulated and does not provide protection from contact or
being near electrical current.
NEVER operate the telehandler in an area where overhead power lines,
overhead or underground cables, or other power sources may exist without
ensuring the appropriate power or utility company de-energizes the lines.
Always check for power lines before raising the boom.
Follow employer, local and governmental regulations for clearance from
powerlines.

1-2

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Section 1 - General Safety Practices

Tip Over Hazard
General
For additional load requirements, refer to the appropriate load chart.

OW0050

Never use an attachment without the appropriate JLG approved load chart
installed on the telehandler.
Understand how to properly use the load charts located in cab.
DO NOT exceed rated lift capacity.
Be sure that the ground conditions are able to support the machine.

OW0080

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

4 FT
(1,2 M)

OW0100

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

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

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1-3

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 manufacturers 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 operators 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

1-4

31200249

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.
Beware of wind. Wind can cause a suspended load to swing and cause
dangerous side loads - even with tag lines.
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 11.8 in (300 mm) above ground surface or
the boom more than 45.
DO NOT exceed walking speed.

31200249

1-5

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).

1-6

31200249

Section 1 - General Safety Practices

Load Falling Hazard

OW0130

Never suspend load from forks or other parts of carriage.

DO NOT burn or drill holes in fork(s).
Forks must be centered under load and spaced apart as far as possible.

31200249

1-7

Section 1 - General Safety Practices

Lifting Personnel

OW0170

When lifting personnel, USE ONLY a JLG approved personnel work platform,
with proper load chart displayed in the cab.

OW0190

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

1-8

31200249

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 load chart.
To avoid overspeeding the engine and drivetrain when driving down slopes,
downshift to a lower gear 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.

31200249

1-9

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.

1-10

31200249

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.

31200249

1-11

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 4-4 has been
performed.

OW0290

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

1-12

31200249

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 by JLG and site owner. Sparks from the electrical system and the
engine exhaust can cause an explosion.
If spark arrestors are required, ensure they are in place and in good working
order.

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.

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1-13

Section 1 - General Safety Practices

This Page Intentionally Left Blank

1-14

31200249

Section 2 - Pre-Operation and Inspection

SECTION 2 - PRE-OPERATION AND INSPECTION

2.1

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 2-3 for details.
4. Operation and Safety Manuals - Operation & Maintenance Manual and AEM
Safety Manual (ANSI only) are located in cab manual holder.
5. Walk-Around Inspection - See page 2-8 for details.
6. Fluid Levels - Check fluids, including fuel, hydraulic oil, engine oil, transmission
fluid 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 load 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.

31200249

2-1

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.

2-2

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Section 2 - Pre-Operation and Inspection

2.2

SAFETY DECALS

Ensure all DANGER, WARNING, CAUTION and instructional decals and proper
capacity charts are legible and in place. Clean and replace as required.
Note: Part numbers referenced are for inspection and identification purposes only.
Refer to the Parts Manual when ordering replacement parts.

1706768
(ENCLOSED CAB)

1001001581
(TL1055 BEFORE S/N TBM00718)
(TL1255 BEFORE S/N TBM00369)

1706300
(TL1055 S/N TBM00620 THRU
TBM01319 EXCLUDING TBM01298)
(TL1255 S/N TBM00330 THRU
TBN00800 EXCLUDING TBN00785)

1001100586
(TL1055 S/N TBK00718 & AFTER)
(TL1255 S/N TBK00369 & AFTER) A

ENGINE EXPLOSION
could result in death
or serious injury.

Model

1706300C
Serial Number

Maximum Weight Without Attachments (lbs/kg)

DO NOT use Ether or

other high energy
starting aids.
Engine equipped with
Pre-heating system.

Year Of Manufacture

Maximum Capacity (lbs/kg)

Refer to load capacity chart for truck with attachment, and individual load ratings stamped
on forks, if equipped. Use lowest capacity of all ratings.
As released from factory this truck meets specifications in ASME B56.6-2002 Part III.

One or more of the following patents may apply to this truck: U.S. Nos. 4,954,041 6,349,969
5,639,119 5,813,697 5,230,399 5,052,532. Other patents pending.

Manufactured by JLG under license from

Manufactured by 1001100586 A
JLG Industries Inc.
McConnellsburg, PA
17233-9533 USA

9150-3112 REV -

91503112

1706768
(OPEN CAB)

1706306
1706306A

1706299
CONTACTING
POWER LINES
will result in death
or serious injury.

1706299A

1706850
WARNING
CRUSHING HAZARD
Lowering boom or falling load could
cause death or serious injury.

Keep others
away while
operating.
1706850A

OAL0434

VIEW A-A

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2-3

Section 2 - Pre-Operation and Inspection

TL1055 BEFORE S/N TBM01169
TL1255 BEFORE S/N TBN00653
XXXXX

91163028

1001092897 1001092896
1001092896 A
1001092897 A

1001090216

10
D

50

LB-FT

(Nm)

50

VIEW B-B

1706767
Fasten
seat
belt.

1706767A

Operator must be trained and

must read and understand
all capacity charts, operator
and safety manuals.

1706303A

1706303

1706851

1706851A

1706304

91513201

RUN-OVER
HAZARD
could cause
death or
serious
injury.

9151-3201 REV. (-)

1706304A

VIEW OF DECALS LOCATED INSIDE

CAB ON RIGHT HAND WALL
TL1055 S/N TBM01169 & AFTER
TL1255 S/N TBN00653 & AFTER
Operator must be trained and
must read and understand
all capacity charts, operator
and safety manuals.

1001092896 A
1001092897 A

10

Fasten
seat
belt.

1706303A

1706303

1001121126 1001121125
D

91513201

50

LB-FT

1706851

1706767

(Nm)

50

1706767A

9151-3201 REV. (-)

91163028

1706851A

1706304
1001090216

RUN-OVER
HAZARD
could cause
death or
serious
injury.

1706304A

OAL2830

2-4

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Section 2 - Pre-Operation and Inspection

TL1055 BEFORE S/N TBM01320 EXCLUDING TBM01298
TL1255 BEFORE S/N TBN00801 EXCLUDING TBN00785

1706301

91563220

4100181

4100181

9156-3220 REV A

1706301A

4109801

4109801

1706296

4109801
4109801

VIEW D-D

VIEW C-C

VIEW E-E

1706301
91563220

1706300

4100181

ENGINE EXPLOSION
could result in death
or serious injury.
1706301A

9156-3220 REV A

4100181

1706300C

DO NOT use Ether or

other high energy
starting aids.
Engine equipped with
Pre-heating system.

OAL0441

TL1055 S/N TBM01320 & AFTER INCLUDING TBM01298

TL1255 S/N TBN00801 & AFTER INCLUDING TBN00785

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2-5

Section 2 - Pre-Operation and Inspection

1706302

50 60
70 80

4105262
40
20
-10 0 10 30

50

60

70

80

E
40
30
-10

10

20

1001090240

1706302

1706302

1706302

1706302

1706302

1706302
1706298

VIEW F-F

1706298A

OAL0421

VIEW E-E

2-6

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Section 2 - Pre-Operation and Inspection

This Page Intentionally Left Blank

31200249

2-7

Section 2 - Pre-Operation and Inspection

2.3

WALK-AROUND INSPECTION

17
16

15

14
4
5
5

13
6

7
12

8
9
10

11

OW0322

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. Left Outrigger - Pins secure; hydraulic hoses and cylinder undamaged, not
leaking.
3. Front Axle - Steer cylinders undamaged, not leaking; pivot pins secure;
hydraulic hoses undamaged, not leaking.

2-8

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Section 2 - Pre-Operation and Inspection

4. Wheel/Tire Assembly - Properly inflated and secured; no loose or missing lug
nuts. Inspect for worn tread, cuts, tears or other discrepancies.
5. Mirrors - Clean and undamaged.
6. Cab and Electrical General appearance; no visible damage.
Frame level indicator and window glass undamaged and clean.
Gauges, switches, joysticks, foot controls and horn operational.
Emergency escape hammer in place (enclosed cab only).
Check seat belt for damage, replace belt if frayed or cut webbing, damaged
buckles or loose mounting hardware.
7. Air Cleaner (TL1055 Before S/N TBM01320 excluding TBM01298, TL1255
Before S/N TBN00801 excluding TBN00785)- Air cleaner element condition
indicator, check for clogged condition. Replace element as required.
8. Main Control Valve - See inspection note.
9. Wheel/Tire Assembly - Properly inflated and secured; no loose or missing lug
nuts. Inspect for worn tread, cuts, tears or other discrepancies.
10. Stabilizer Cylinder - Pins secure; hydraulic hoses undamaged, not leaking.
11. Rear Axle - Steer cylinders undamaged, not leaking; pivot pins secure;
hydraulic hoses undamaged, not leaking.
12. Wheel/Tire Assembly - Properly inflated and secured; no loose or missing lug
nuts. Inspect for worn tread, cuts, tears or other discrepancies.
13. Engine Compartment Air Cleaner (TL1055 S/N TBM01320 & After including TBM01298,
TL1255 S/N TBN00801 & After including TBN00785)- Air cleaner element
condition indicator, check for clogged condition. Replace element as required.
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.
14. Wheel/Tire Assembly - Properly inflated and secured; no loose or missing lug
nuts. Inspect for worn tread, cuts, tears or other discrepancies.
15. Frame Level Cylinder - Pins secure; hydraulic hoses undamaged, not leaking.
16. Right Outrigger - Pins secure; hydraulic hoses and cylinder undamaged, not
leaking.
17. Attachment - Properly installed, see See Attachment Installation on page 5-9.

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Section 2 - Pre-Operation and Inspection

2.4

WARM-UP AND OPERATIONAL CHECKS

Warm-Up Check
During warm-up period, check:
1. Heater, defroster and windshield wiper (if equipped).
2. Check all lighting systems (if equipped) for proper operation.
3. Voltmeter should show 13.5 to 14 volts.
4. Adjust mirror(s) for maximum visibility.

WARNING
CUT/CRUSH/BURN HAZARD. Keep engine cover closed while engine is running
except when checking transmission oil level.

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 operator cab with engine
running.
6. All boom and attachment functions - operate smoothly and correctly.
7. Perform any additional checks described in Section 8.

2-10

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Section 2 - Pre-Operation and Inspection

2.5

OPERATOR CAB

The telehandler is equipped with an open or 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 JLG 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.

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Section 2 - Pre-Operation and Inspection

2.6

WINDOWS

Keep all windows and mirrors clean and unobstructed.

Cab Door Window (if equipped)

3
4
2
1

OAL0011

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 and secure it in the latch (3).
Press release button inside the cab or pull on lever (4) outside the cab to unlatch
the window.

2-12

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Section 3 - Controls and Indicators

SECTION 3 - CONTROLS AND INDICATORS

3.1

GENERAL

This section provides the necessary information needed to understand control

functions.
Note: The manufacturer has no direct control over machine application and
operation. The user and operator are responsible for conforming with good safety
practices.

NOTICE
EQUIPMENT DAMAGE. When a red light illuminates, immediately bring machine
to a stop, lower boom and attachment to ground and stop the engine. Determine
cause and correct before continued use.

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Section 3 - Controls and Indicators

3.2

CONTROLS
4

9
10

14
13

12
11
OAL0371

1. Transmission Control Lever: See page 3-8.

2. Instrument Panel: See page 3-4.
3. 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 3-17.
4. Frame Level Indicator: Enables the operator to determine the left to right level
condition of the telehandler.
5. Accessory Control Lever (if equipped): See page 3-16.
6. Right Hand Panel: See page 3-14.
7. Boom Joystick: See page 3-10.
8. Frame Level Joystick: See page 3-11.
9. Auxiliary Hydraulic Joystick: See page 3-12.
10. Outrigger Joysticks: See page 3-13.

3-2

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Section 3 - Controls and Indicators

11. Decompression Valve: Depress button to relieve pressure in auxiliary hydraulic
circuit. See Hydraulic Operated Attachment on page 5-12.
12. Accelerator Pedal: Pressing down the pedal increases engine and hydraulic
speed.
13. Service Brake Pedal: The further the pedal is depressed, the slower the travel
speed.
14. Ignition Switch: Key activated. See page 3-6.

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Section 3 - Controls and Indicators

Dash Controls and Indicators
TL1055 BEFORE S/N TBM00938
TL1255 BEFORE S/N TBN00482

3 4

1 2

TL1055 S/N TBM00938 & AFTER

TL1255 S/N TBN00482 & AFTER

OAL0382

10

6 7 9

1. Hourmeter: Indicates total time of engine operation in hours and tenths of

hours.
2. 4-in-1 Gauge:
(TL1055 Before S/N TBM00938, TL1255 Before S/N TBN00482)
a. Engine Coolant Temperature Gauge
b. Engine Oil Pressure Gauge
c. Fuel Gauge
d. Voltmeter indicates alternator output and battery condition.
3. Transmission Temperature Light: Illuminates when transmission temperature is
too high.
4. Engine Pre-Heat Indicator Light: Illuminates with ignition key in the RUN
position. Light goes out when start temperature is reached. At temperatures
below 32F (0C), do not start until light goes out.
5. Warning and Check Engine Lights: Any combination of illumination indicates an
engine fault and/or a parameter that is outside of acceptable range. Engine may
derate or shutdown.
6. Steer Select Switch: Three positions: 4-wheel circle steer, 4-wheel crab steer
and 2-wheel steer. See page 3-17 for details.

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Section 3 - Controls and Indicators

7. Park Brake Switch: See page 3-7 for details.
8. Quick Coupler Switch (if equipped): Use in conjunction with the auxiliary
hydraulic joystick to hydraulically lock or unlock an attachment. See Hydraulic
Quick Coupler on page 5-11.
9. Horn Button: Depress button to sound horn.
10. 3-in-1 Gauge and Display:
(TL1055 S/N TBM00938 & After, TL1255 S/N TBN00482 & After)
a. Engine Coolant Temperature Gauge
b. Engine Oil Pressure Gauge
c. Fuel Gauge
d. Display - Displays engine operating hours, battery voltage and engine rpm.
Engine fault codes displayed when detected. See Service Manual for details.

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Section 3 - Controls and Indicators

Ignition

OFF
ACC
RUN
START

OAL0411

In "ACC" or "RUN" position, voltage is available for all electrical functions.

Full clockwise rotation to "START" engages starter motor.
Counter-clockwise rotation to "OFF" stops engine and removes voltage from all
electrical functions.

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Section 3 - Controls and Indicators

Park Brake

OAL0471

Park brake switch controls the application and release of the park brake. Indicator
light on switch illuminates to indicate brake is applied.
With the engine running and the park brake switch in "OFF" position (1), park
brakes are disengaged.
With switch in "ON" position (2), park brake is engaged and transmission will not
engage forward or reverse.

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

WARNING
CRUSH HAZARD. Turning engine off applies the park brake. Applying park brake
or turning engine off while traveling will cause unit to stop abruptly and could
cause load loss. Either may be used in an emergency situation.

Parking Procedure
1. Using service brake, stop telehandler in an appropriate parking area.
2. Follow Shut-Down Procedure on page 4-4.

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Section 3 - Controls and Indicators

Transmission Control Lever
Direction of Travel Selection

F
N
R

OAL0481

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

Lift and push lever forward for forward travel; lift and pull lever rearward for
reverse travel. Move lever to centered position for neutral.
Forward or reverse travel can be selected while in any gear.
When traveling in reverse, the back-up alarm will automatically sound.
Drive in reverse and turn only at slow rates of speed.
Do not increase engine speed with the transmission in forward or reverse and the
service brake depressed in an attempt to get quicker hydraulic performances.
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.

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Section 3 - Controls and Indicators

Gear Selection

1st

2nd
3rd
4th

OAL0491

Gear selection is located on the twist grip handle (2) of transmission control lever.
Twist hand grip to select gear.
Select the appropriate gear for the task being performed. Use a lower gear
when transporting a load. Use a higher gear only when driving unloaded for
longer distances.
Slow down prior to downshifting. Do not downshift more than one gear at a
time.

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Section 3 - Controls and Indicators

Boom Joystick

3
1

OAL0500

The boom joystick (1) controls the boom and attachment tilt 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.
Attachment Function
Tilt control is actuated by the switch (2).
Depress the left side of the switch to tilt up; depress the right side of switch to tilt
down.
Use knob (3) to regulate the speed of the tilt. Rotate knob counter-clockwise to
increase speed; rotate knob clockwise to decrease speed.

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.

3-10

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Section 3 - Controls and Indicators

Frame Level Joystick

OAL0510

The frame level joystick (4) controls the left to right frame level.
Move the joystick left to rotate frame left, move the joystick right to rotate frame
right.
A level indicator is located above the front cab window to permit operator to
determine whether the telehandler frame is level.

WARNING
TIP OVER HAZARD. Always move boom as low as possible while allowing for
best visibility of right hand mirror before leveling frame. Attempting to level
machine with boom raised could cause it to tip over.

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Section 3 - Controls and Indicators

Auxiliary Hydraulic Joystick

OAL0520

The auxiliary hydraulic joystick (1) controls function of attachments that require
hydraulic supply for operation. See Section 5 - Attachments for approved
attachments and control instructions.

3-12

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Section 3 - Controls and Indicators

Outrigger Joysticks

OAL0530

The rear joysticks (2) control the outriggers.

The left joystick controls left outrigger and the right joystick controls right
outrigger.
Push joysticks forward to lower outriggers; push joysticks back to raise
outriggers.
Use outriggers to increase stability and/or load capacity and in leveling the
telehandler. Study load charts to determine maximum load capacities, with and
without outriggers.

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.

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Section 3 - Controls and Indicators

Right Hand Panel

10
9

2
1

11

6
12

13

OAL0541

Heater and Air Conditioning Controls (if equipped)

1. Air Vent: Two individually adjustable round vents.
2. Air Louver: Three individually adjustable air louvers.
3. Defroster Fan: Two speed fan. Press fan switch down for slow speed; press
switch up for fast speed. Return switch to middle position to turn off.
4. Temperature Control Switch: Adjustable rotary switch
5. Fan Speed: Four-position rotary switch.
6. Air Conditioning Switch: On/Off switch.
7. Air Louver (TL1055 S/N TBM01168 & After, TL1255 S/N TBN00653 & After):
Two individually adjustable air louvers.
8. Recirculation Vent (TL1055 S/N TBM01168 & After, TL1255 S/N TBN00653 &
After): Open louvers when operating heat. Close louvers when operating air
conditioning.

3-14

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Section 3 - Controls and Indicators

Other Controls (if equipped)
9. Work Light Switch: On/Off switch.
10. Beacon Light Switch: On/Off switch.
11. Hazard Light Switch: On/Off switch.
12. Windshield Wiper and Washer Switch: Two speed rotary switch. Depress to
activate washer. Return to first position to turn off wiper.
13. Attachment Tilt Speed Switch: See Boom Joystick on page 3-10.

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Section 3 - Controls and Indicators

Accessory Control Lever (if equipped)
The accessory control lever (1) operates the turn signals, parking lights and
headlights.

2
5 7
1

OY1350

Turn Signal
Push the lever forward (2) to activate the left turn signal.
Pull the lever back (3) to activate the 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.

Parking Lights and Headlights

Turn the twist grip (4) of the lever counterclockwise to the first position (5) to turn
on the parking lights.
Turn the twist grip to the second position (6) to turn on the headlights.
Raise/lower the lever to switch between low beam and high beam.
Turn the twist grip clockwise to the OFF position (7) to turn all lights off.

3-16

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Section 3 - Controls and Indicators

3.3

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.

Steer Mode Change

3
OY1490

1. Bring machine to a stop using service brake while either circle steer mode (1) or
crab steer mode (3) is selected.

OAM2400

2. 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.

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Section 3 - Controls and Indicators

3.4

OPERATOR SEAT

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

3
4
1
2
OW0480

1. Suspension: Use knob to adjust suspension to the appropriate setting. Turn

clockwise to increase stiffness. Turn counterclockwise to reduce stiffness.
2. Fore/Aft: Pull up on handle to move seat fore and aft.
3. Arm Rest: Arm rest can be moved up or down for comfort.
4. Seat Belt: Always fasten seat belt during operation. If required, a 3 in (76 mm)
seat belt is available.

3-18

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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.

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Section 3 - Controls and Indicators

3.5

BOOM ANGLE AND EXTENSION INDICATORS

1
50 60
70 80

40
20
-10 10 30

OAL0580

The boom angle indicator (1) is located on the left side of the boom. Use this
indicator to determine the boom angle when using the capacity chart (see Use
of the Load Chart on page 5-5).
The boom extension indicators (2) 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 Load Chart on page 5-5).

3-20

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Section 4 - Operation

SECTION 4 - OPERATION
4.1

ENGINE

Starting the Engine

This machine can be operated under normal conditions in temperatures of 0F to
104F (-20C to 40C). Consult the local Caterpillar dealer for operation outside this
range or under abnormal conditions.
If equipped for extreme cold weather, -40F to 0F (-40C to -20C), see page 4-2
for starting procedure.
1. Make sure all controls are in Neutral and all electrical components (lights,
heater, defroster, etc.) are turned off. Apply park brake.
2. If the temperature is below 32 F (0 C), turn the ignition switch to ACC
position. Wait until the preheat indicator light goes out.
3. Turn ignition switch to START 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 oil pressure gauge. If gauge remains on zero for
more than ten seconds, stop engine and determine cause before restarting
engine. Reference engine manual for minimum pressure at operating
temperature.
5. Warm up engine at approximately 1/2 throttle.

Note: Engine will not start unless transmission control lever is in Neutral and park
brake switch is applied.

WARNING
ENGINE EXPLOSION. Do not use ether for cold weather starting.

WARNING
UNEXPECTED MOVEMENT HAZARD. Always ensure that transmission control
lever 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.

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Section 4 - Operation
Extreme Cold Weather Starting (if equipped)
If equipped with extreme cold weather components, machine can be operated in
temperatures of -40F to 0F (-40 C to -20 C).
1. Machine must be equipped with heating components and extreme cold weather
fluids. See Section 9 - Specifications for fluid details.
2. Locate two yellow heating component extension cords stored behind batteries
in engine compartment. Connect each to separate A/C power supplies with a
minimum rating of 15 Amps each.
3. Allow heating components to operate a minimum of 12 hours prior to machine
operation.

3
1

OAL2221

4. Locate recirculation hoses stored behind seat in cab.

5. Connect recirculation hose (1) to tilt circuit quick disconnects (2). Connect the
other recirculation hose (1) to auxiliary hydraulic quick disconnects (3).
6. Follow start-up procedure on page 4-1 and allow engine to idle 20 minutes.
7. Operate tilt and auxiliary hydraulic functions continuously for five minutes to
circulate the warm hydraulic fluid.
8. Operate all boom functions continuously for another five minutes.
9. Perform Shut-Down Procedure on page 4-4.
10. Disconnect recirculation hoses and A/C power supplies and place back in
storage locations.
11. Machine is ready for operation.

4-2

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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.

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Section 4 - Operation
Normal Engine Operation
Observe instrument panel 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 local Caterpillar dealer.
Avoid prolonged idling. If the engine is not being used, turn it off.

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. Block wheels (if necessary).

4-4

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Section 4 - Operation
4.2

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 (see 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 5-13.
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 load chart in the
operator cab for the telehandler/attachment combination you are using.

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4-5

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.

Leveling Procedure
1. Position machine in best location to lift or place load.
2. Apply parking brake and move transmission control lever to NEUTRAL.
3. Observe level indicator to determine whether machine must be leveled prior to
lifting load.
4. Move boom/attachment to 4 ft (1,2 m) off ground.
(AUS - Move boom so forks are no more than 300 mm (11.8 in) above ground
surface.)

Important things to remember:

Never raise the boom/attachment more than 4 ft (1,2 m) 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 side tilt and load could cause the telehandler to tip over.

4-6

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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 load chart to determine safe boom extension range. See Use of the
Load Chart on page 5-5.
Align forks at the level load is to be placed, then extend 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.

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Section 4 - Operation
4.3

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 load 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 Load Chart on page 5-5 for proper lifting guidelines in
addition to the appropriate load chart in the operator cab.

4-8

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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.
For additional requirements, refer to the appropriate load chart in the operator
cab.

Important things to remember:

Ensure the boom is fully retracted.
Never raise the load more than 11.8 in (300 mm) 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, 0.9 mph (0.4 m/s), or less.

Leveling Procedure
1. Position machine in best location to lift or place load.
2. Apply parking brake and move transmission control lever to NEUTRAL.
3. Observe level indicator to determine whether machine must be leveled prior to
lifting load.
4. Move boom so load is no more than 11.8 in (300 mm) above ground surface
and boom/or boom is raised no more than 45.

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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 load chart to determine safe boom extension range. Use of the Load
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.

4-10

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Section 4 - Operation
4.4

LOADING AND SECURING FOR TRANSPORT

OAL0591

Tiedown
1. 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 tie down
points as shown in the figure.
5. Do not tie down 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 manufacturers
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.

31200249

4-11

Section 4 - Operation
Lifting
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 JLG Product Safety for information.
Make adjustments to the lifting device and equipment to ensure the machine will
be level when elevated. The machine must remain level at all times while being
lifted.
Ensure that the lifting device and equipment is adequately rated and suitable for
the intended purpose. See Section 9 - Specifications for machine weight or
weigh machine.
Remove all loose items from machine prior to lifting.
Lift machine with smooth, even motion. Set machine down gently. Avoid quick or
sudden motions that could cause shock loads to machine and/or lifting devices.

4-12

31200249

Section 5 - Attachments

SECTION 5 - ATTACHMENTS
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 load chart located in the operator cab.
The model on the load 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 load chart or the attachment may
not be approved for the model telehandler being used. Contact JLG or 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.

31200249

5-1

Section 5 - Attachments
5.3

JLG SUPPLIED ATTACHMENTS

Note: Part numbers referenced are for inspection and identification purposes only.
Refer to the Parts Manual when ordering replacement parts.

Part Number

TL1055

TL1255

Carriage, 50 in (1270 mm)

301-9757

Carriage, 72 in (1829 mm)

301-9758

Side Shift Carriage, 48 in (1220 mm)

314-8479

309-4315

X
X

Rotate/Side Tilt Carriage, 50 in (1270 mm)

341-3590

Rotate/Side Tilt Carriage, 72 in (1829 mm)

309-4316

100 Swing Carriage, 72 in (1829 mm)

318-9222

180 Swing Carriage, 72 in (1829 mm)

341-3591

Fork, Pallet 2.36x4x48 in (60x100x1220 mm)

301-9755

Fork, Pallet 2.36x5x48 in (60x125x1220 mm)

301-9753

Fork, Lumber 2.36x6x60 in (60x150x1539 mm)

301-9754

Fork, Lumber 1.75x7x60 in (45x180x1539 mm)

301-9756

Fork, Dual Taper 2x6x72 in (50x150x1829 mm)

311-2854

Fork, Block 2x2x48 in (50x50x1220 mm)

301-9752

X
X

Hook, Fork Mounted

321-0556

Winch, Boom Head-Mounted

305-3773

314-9439

343-9736

328-7286

343-9738

328-7287

343-9737

Platform, Fork Mounted (ASME)

Platform, Fork Mounted (ASME - French)
Platform, Fork Mounted (ISO)

5-2

Applicable Model

Attachment

31200249

Section 5 - Attachments

This Page Intentionally Left Blank

31200249

5-3

Section 5 - Attachments
5.4

TELEHANDLER/ATTACHMENT/FORK CAPACITY
1
3

2
OW0550

Prior to installing the attachment verify it is approved and the telehandler is equipped
with the proper load 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 load 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 load chart to determine maximum capacity at various machine
configurations. Lifting and placing a load may require use of more than one load
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 JLG approved load chart
installed on the telehandler.

5-4

31200249

Section 5 - Attachments
5.5

USE OF THE LOAD CHART

To properly use the load 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 Load Chart(s).
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 load 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 load chart and keep within
these limits.

Capacity Indicator Locations

BOOM EXTENSION
INDICATOR

50 60 80
70

ATTACHMENT
IDENTIFICATION
PLATE

BOOM ANGLE
INDICATOR

-10

40
20 30
10

DO NOT GO NEAR LEAKS

C

* High pressure oil easily punctures skin causing serious injury, gangrene or death.
* If injured, seek emergency medical help. Immediate surgery is required to remove oil.
* Do not use finger or skin to check for leaks.
* Lower load or relieve hydraulic pressure before loosening fittings.
10814B

FORK
WEIGHT
STAMP
OAL0600

31200249

5-5

Section 5 - Attachments
Sample Load Chart
This Load Chart may be used with this model ONLY.
The telehandler model is indicated on the boom or chassis.
Model XXXXX is used for demonstration purposes only.

XXXXX

XX XX

Attachment type,
weight and
dimensions must
be equal to or less
than the data
shown.

XXXX
XX
XX
XX
XX

XXXX XX

XXXX XX

XX
XX
XX

XXXX XX

Boom Extension
Indicator (arc)

XXXX XX

XX

Boom Angle

XXXX XX

XX

XXXX XX

XX

XX
XX
XX

XX
XX

XX

XX

XX

XX

XX

XX

XX

XX

Load center must

be equal to or less
than value shown.

XX

Load zones indicate the

maximum weight that
may be safely lifted.

OAL1071

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 4-6); 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

31200249

Section 5 - Attachments
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

31200249

5-7

Section 5 - Attachments
Example
A contractor owns a model xxxxx 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 xxxxx 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

2500 lb (1134 kg)

16 ft (4,9 m)

12 ft (3,6 m)

Yes

2000 lb (907 kg)

21 ft (6,4 m)

20 ft (6,1 m)

NO

4000 lb (1814 kg)

10 ft (3,0 m)

18 ft (5,5 m)

Yes

6500 lb (2948 kg)

8 ft (2,4 m)

28 ft (8,5 m)

NO

XXXXX

XX XX

XXXX

Example 4

Example 3
Example 2

Example 1

XX

OAL1080

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

5-8

31200249

Section 5 - Attachments
5.6

ATTACHMENT INSTALLATION
MECHANICAL

HYDRAULIC

1
2

6
5

3
4
6
4

OAL2230

1. Attachment
2. Attachment Pin Recess
3. Attachment Pin
4. Lock Pin
5. Retainer Pin (mechanical quick coupler)
6. Quick Coupler (attachment tilt control in cab, see page 3-10)

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.

31200249

5-9

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

1. Tilt quick coupler forward to provide clearance.

Check to be sure lock pin and retainer pin are
out.

OAL0171

2. Align attachment pin with recess in attachment.

Raise boom slightly to engage attachment pin in
recess.

OAL0181

3. Tilt quick coupler back to engage attachment.

OAL0191

4. Insert lock pin and secure with retainer pin.

OAL0201

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

Operated Attachment on page 5-12.

5-10

31200249

Section 5 - Attachments
Hydraulic Quick Coupler
This installation procedure is designed for one-person operation.

6. Tilt quick coupler forward to provide clearance.

Check to be sure lock pin is disengaged.

OAL0171

7. Align attachment pin with recess in attachment.

Raise boom slightly to engage attachment pin in
recess.

OAL0181

8. Tilt quick coupler back to engage attachment.

OAL0191

9. Unlock the quick coupler switch (1), press and

hold. At the same time push auxiliary hydraulic
joystick (2) left to engage lock pin. Push
auxiliary hydraulic joystick right to disengage
lock pin.

OAL0621

DISENGAGED

10. Raise boom to eye level and visually check

that the lock pins protrude through the holes
on both sides of the quick coupler. If the lock
pins do not protrude through the holes,
place the attachment on the ground and
return to step 2.
ENGAGED

OAL0221

11. If attachment is equipped, connect auxiliary hydraulic hoses. See Hydraulic

Operated Attachment on page 5-12.

31200249

5-11

Section 5 - Attachments
5.7

HYDRAULIC OPERATED ATTACHMENT

1
OAL0240
OAL0630

1. Install attachment (see page 5-9).

2. Lower attachment to ground and perform Shut-Down Procedure on page 4-4.
3. Press the decompression valve button (1) to relieve auxiliary hydraulic pressure.
4. Connect attachment hoses to both auxiliary fittings (2).

5-12

31200249

Section 5 - Attachments
5.8

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 5-9.
2. Elevate attachment to approximately 5 ft (1,5 m) and tilt carriage forward until
fork heel is free from attachment.
3. 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.
If removing fork bar is necessary:
1. Rest forks on ground.
2. Remove fork bar.
3. Reposition forks.
4. Reinstall the fork bar and fork bar retaining mechanism(s).

31200249

5-13

Section 5 - Attachments
5.9

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.

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.

5-14

31200249

Section 5 - Attachments
Carriage with Forks
Use Carriage Attachment Load Chart
To determine maximum capacity, refer
Attachment/Fork Capacity on page 5-4.

to

Telehandler/

OY0690

OAL0662

The joystick (1) controls lift/lower and extend/retract movement of the boom.
The tilt switch (2) controls fork tilt.
Press the left side of the switch to tilt up.
Press the right side of the switch to tilt down.

Installation Procedure:
Refer to Attachment Installation on page 5-9.

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.

31200249

5-15

Section 5 - Attachments
Side Shift Carriage
Use Side Shift Carriage Load Chart
To determine maximum capacity, refer
Attachment/Fork Capacity on page 5-4.

to

Telehandler/

OAL1540

1
3

OAL1581

The joystick (1) controls lift/lower and extend/retract movement of the boom.
The tilt switch (2) controls fork tilt.
Press the left side of the switch to tilt up.
Press the right side of the switch to tilt down.

To Side Shift:
The auxiliary hydraulic joystick (3) controls carriage side shift.
Move joystick left to shift left.
Move joystick right to shift right.

Installation Procedure:
Refer to Attachment Installation on page 5-9.

5-16

31200249

Section 5 - Attachments

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.

31200249

5-17

Section 5 - Attachments
Rotate/Side Tilt Carriage
Use Rotate/Side Tilt Carriage Load Chart
To determine maximum capacity, refer
Attachment/Fork Capacity on page 5-4.

to

Telehandler/

OAL1550

1
3

OAL0731

The joystick (1) controls lift/lower and extend/retract movement of the boom.
The tilt switch (2) controls fork tilt.
Press the left side of the switch to tilt up.
Press the right side of the switch to tilt down.

To Rotate:
The auxiliary hydraulic joystick (3) controls carriage rotation.
Move joystick left to rotate left.
Move joystick right to rotate right.

Installation Procedure:
Refer to Attachment Installation on page 5-9.

5-18

31200249

Section 5 - Attachments

WARNING
CRUSH HAZARD. Do not use rotation 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.

31200249

5-19

Section 5 - Attachments
Swing Carriage
Use Swing Carriage Load Chart
To determine maximum capacity, refer
Attachment/Fork Capacity on page 5-4.

to

Telehandler/

OU2150

1
3

OAL1591

The joystick (1) controls lift/lower and extend/retract movement of the boom.
The tilt switch (2) controls fork tilt.
Press the left side of the switch to tilt up.
Press the right side of the switch to tilt down.

To Swing:
The auxiliary hydraulic joystick (3) controls carriage swing.
Move joystick left to swing left.
Move joystick right to swing right.

Installation Procedure:
Refer to Attachment Installation on page 5-9.

5-20

31200249

Section 5 - Attachments

WARNING
CRUSH HAZARD. Always level forks (horizontally) and telehandler frame before
swinging load to side. Swinging unlevel forks could cause load to slide off forks.

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

WARNING
CRUSH HAZARD. Use retaining pin (if equipped) for locking swing frame to fixed
frame when carrying loads greater than 5000 lb. Failure to comply could cause
object or load to fall.

Operation:
To drive with a load, keep forks pointed forward and travel in accordance with the
requirements set forth in Section 1 - General Safety Practices.

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.

31200249

5-21

Section 5 - Attachments
Bucket
Use Bucket Load Chart
To determine maximum capacity, refer
Attachment/Fork Capacity on page 5-4.

to

Telehandler/

OZ0730

OAL0692

The joystick (1) controls lift/lower and extend/retract movement of the boom.
The tilt switch (2) controls bucket tilt.
Press the left side of the switch to tilt up.
Press the right side of the switch to tilt down.

Installation Procedure:
Refer to Attachment Installation on page 5-9.

5-22

31200249

Section 5 - Attachments
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
load 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 quick coupler or machine structure.
Do not use bucket for "back dragging." This could cause severe damage to quick
coupler and retraction cables/chains.

31200249

5-23

Section 5 - Attachments
Multi-Purpose Bucket
Use Multi-Purpose Bucket Load Chart
To determine maximum capacity, refer
Attachment/Fork Capacity on page 5-4.

to

Telehandler/

OZ2540

1
3

OAL2260

The joystick (1) controls lift/lower and extend/retract movement of the boom.
The tilt switch (2) controls bucket tilt.
Press the left side of the switch to tilt up.
Press the right side of the switch to tilt down.

To Open/Close Bucket:
The auxiliary hydraulic joystick (3) controls open/close movement of the bucket.
Move joystick left to close.
Move joystick right to open.

Installation Procedure:
Refer to Attachment Installation on page 5-9.

5-24

31200249

Section 5 - Attachments
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
load 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 quick coupler or machine structure.
Do not use bucket for "back dragging." This could cause severe damage to quick
coupler and retraction cables/chains.

31200249

5-25

Section 5 - Attachments
Fork Mounted Hook
Use Appropriate Carriage Attachment Load Chart
To determine maximum capacity, refer
Attachment/Fork Capacity on page 5-4.

to

Telehandler/

OY0640

Suspend loads in accordance with requirements set forth in Section

1 - General Safety Practices.

OAL0672

The joystick (1) controls lift/lower and extend/retract movement of the boom.
The tilt switch (2) controls fork tilt.
Press the left side of the switch to tilt up.
Press the right side of the switch to tilt down.

Installation Procedure:
Ensure carriage is properly installed. Refer to Attachment Installation on
page 5-9.
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.

5-26

31200249

Section 5 - Attachments
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 with mast carriage attachment.
Do not use fork mounted hook with attachments capable of rotating (i.e. side tilt
and swing carriages) without disabling the rotation feature(s).

31200249

5-27

Section 5 - Attachments
Coupler Mounted Hook
Use Coupler Mounted Hook Load Chart
To determine maximum capacity, refer
Attachment/Fork Capacity on page 5-4.

to

Telehandler/

OAL1510

Suspend loads in accordance with requirements set forth in Section

1 - General Safety Practices.

OAL1571

The joystick (1) controls lift/lower and extend/retract movement of the boom.
The tilt switch (2) controls the coupler mounted hook tilt.
Press the left side of the switch to tilt up.
Press the right side of the switch to tilt down.

Installation Procedure:
Refer to Attachment Installation on page 5-9.

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

5-28

31200249

Section 5 - Attachments
Truss Boom
Use Truss Boom Load Chart

OY0570

To determine maximum capacity, refer

Attachment/Fork Capacity on page 5-4.

to

Telehandler/

Suspend loads in accordance with requirements set forth in Section

1 - General Safety Practices.

OAL0701

The joystick (1) controls lift/lower and extend/retract movement of the boom.
The tilt switch (2) controls truss boom tilt.
Press the left side of the switch to tilt up.
Press the right side of the switch to tilt down.

Installation Procedure:
Refer to Attachment Installation on page 5-9.

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

31200249

5-29

Section 5 - Attachments
Personnel Work Platform - Fork Mounted
Use Appropriate Carriage Attachment Load Chart
To determine maximum capacity, refer
Attachment/Fork Capacity on page 5-4.

to

Telehandler/

OY1610

The operator and personnel in platform must read and understand the
separate personnel work platform manual prior to installing and using a
platform.

OAL2240

The joystick (1) controls lift/lower and extend/retract movement of the boom.
The tilt switch (2) controls platform tilt.
Press the left side of the switch to tilt up.
Press the right side of the switch to tilt down.

Installation Procedure:
Ensure carriage is properly installed. Refer to Attachment Installation on
page 5-9.
Secure the fork mounted platform to the forks by sliding the fork mounted
platform onto the parent forks and install the retaining pin behind the vertical
shank of the fork.

5-30

31200249

Section 5 - Attachments
Preparation and Setup:
1. Ensure the telehandler is on a firm surface and is level.
2. Engage the park brake. Blocking the wheels is also recommended.
3. Level the platform, both side to side (frame level) and front to back (attachment
tilt).
4. Keep area under platform free from personnel.
5. When personnel are on platform, the operator must remain seated in cab with
personnel in direct line of sight.
6. DO NOT lift or carry persons in a bucket or on forks.

WARNING
FALL HAZARD. Never tilt the platform forward, rearward, or level the machine
when the platform is occupied.

31200249

5-31

Section 5 - Attachments
Boom Head-Mounted Winch
Use Carriage Attachment Load Chart
To determine maximum capacity, refer
Attachment/Fork Capacity on page 5-4.

to

Telehandler/

OY0650

Suspend loads in accordance with requirements set forth in Section

1 - General Safety Practices.

1
3

OAL0712

The joystick (1) controls lift/lower and extend/retract movement of the boom.
The auxiliary hydraulic joystick (3) controls the winch.
Move joystick left to lower cable.
Move joystick right to raise cable.

WARNING
CRUSH HAZARD. Maintain a minimum of three wraps of wire rope on the cable
drum at all times. Failure to comply could cause object or load to fall.
Operation:
Weight of rigging must be included as part of total load being lifted.

5-32

31200249

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 trailer towing devices.
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 4 ft (1,2 m).

Moving Short Distances

If it is only necessary to move telehandler a short distance, less than 100 ft
(30 m), it is permissible to use a vehicle of sufficient capacity to tow the unit with
no previous preparation. Drive wheels will not roll.

Moving Longer Distances

See Service Manual for details.

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

31200249

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. Engage the parking brake. Place the transmission control lever in NEUTRAL.
3. Block all four wheels.
4. Section off a large area under the boom with string or tape to restrict any
personnel from entering this area.

6.3

EMERGENCY EXIT FROM ENCLOSED CAB

ANGUS-PALM 005413

OWO740

In an emergency, an escape hammer located directly below the rear window in

an enclosed cab can be used to exit the telehandler.

6-2

31200249

Section 7 - Lubrication and Maintenance

SECTION 7 - LUBRICATION AND MAINTENANCE

7.1

INTRODUCTION

Service the product in accordance with the maintenance schedule on the following
pages.

1
2

OAL1180

The lubrication (1) and maintenance (2) charts 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.

31200249

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 4-4 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.
Drain engine and gear cases after operating when oil is hot.
Check all lubricant levels when lubricant is cool, with the exception of the
transmission fluid. 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, with the exception of the transmission level and
hydraulic return filter indicator checks.

7-2

31200249

Section 7 - Lubrication and Maintenance

7.3

SERVICE AND MAINTENANCE SCHEDULE

10, 1st 50 & 50 Hour Maintenance Schedule

EVERY

10

Check Fuel
Level

Air Filter
Restriction
Indicator

Check
Transmission
Oil Level

Additional
Checks Section 8

Check Engine
Oil Level

Check Hydraulic
Oil Level

Check Tire
Condition &
Pressure

Check
Battery

Check Washer
Fluid Level
(if equipped)

Lubrication
Schedule

1st

50
LB/F
T (N
m)

Check Wheel
Lug Nut
Torque

EVERY

50

Drain Fuel/
Water
Separator

Check Engine
Coolant Level

OAL2650

31200249

7-3

Section 7 - Lubrication and Maintenance

1st 250, 250 & 500 Hour Maintenance Schedule

1st

250

Change
Axle Oil

Change Wheel
End Oil

Change
Transmission
Oil & Filter

Change
Transfer Case
Oil

EVERY

250

Change Engine
Oil and Filter*

Check Axle
Oil Level

Check Wheel
End Oil Levels

Air Filter
Vacuator
Valve

Check
Fan Belt

Check Boom
Extend Chains

Check Boom
Wear Pads

Check Transfer
Case Oil Level

Check
Rear Axle
Stabilization

Lubrication
Schedule

EVERY

500

LB/F
T (N
m)

Change Fuel
Filters

Check Wheel
Lug Nut
Torque
OAL2840

Note: Engine oil and filter service interval can be extended, see page 7-14 for
details.

7-4

31200249

Section 7 - Lubrication and Maintenance

1000 & 1500 Hour Maintenance Schedule

EVERY

1000

Change
Transmission
Oil & Filter

Change
Transfer Case
Oil

Check Boom
Retract Chains

Lubrication
Schedule

Change
Axle Oil

Change Wheel
End Oil

Check
Air Intake
System

EVERY

1500

Change
Engine Coolant

Change
Hydraulic
Fluid & Filters

Change
Hydraulic Tank
Breather
OAL2850

31200249

7-5

Section 7 - Lubrication and Maintenance

7.4

LUBRICATION SCHEDULES

50 Hour Lubrication Schedule

EVERY

50

OAL0450

7-6

31200249

Section 7 - Lubrication and Maintenance

250 Hour Lubrication Schedule

EVERY

250

OW1211

31200249

7-7

Section 7 - Lubrication and Maintenance

1000 Hour Lubrication Schedule

EVERY

1000

OY2080

7-8

31200249

Section 7 - Lubrication and Maintenance

This Page Intentionally Left Blank

31200249

7-9

Section 7 - Lubrication and Maintenance

7.5

OPERATOR MAINTENANCE INSTRUCTIONS

Fuel System

10

A. Fuel Level Check

OW0970

OW0990

TL1055 BEFORE S/N TBM00938

TL1255 BEFORE S/N TBN00482

TL1055 S/N TBM00938 & AFTER

TL1255 S/N TBN00482 & AFTER

OAL0751

1. Check fuel gauge (1) located on instrument panel in cab.

2. If fuel is low, proceed to fuel source and perform Shut-Down Procedure on
page 4-4.
3. If equipped, unlock and remove padlock. Lift hasp (2) and turn fuel tank cap (3)
to remove from filler neck.
4. Add diesel fuel as needed.
5. Replace and secure fuel tank cap.
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

31200249

Section 7 - Lubrication and Maintenance

B. Drain Fuel/Water Separator

50

OW0980

OW1000

TL1055 BEFORE S/N TBM01320 EXCLUDING TBM01298

TL1255 BEFORE S/N TBN00801 EXCLUDING TBN00785

6
OAL0780

TL1055 S/N TBM01320 & AFTER INCLUDING TBM01298

TL1255 S/N TBN00801 & AFTER INCLUDING TBN00785

6
OAL2860

1. Perform Shut-Down Procedure on page 4-4.

2. Open the engine cover.
3. Loosen drain cock (5) on underside of fuel filter (6) and allow all water to drain
into a glass until clear fuel is visible.
4. Tighten drain cock.
5. Close and secure the engine cover.

31200249

7-11

Section 7 - Lubrication and Maintenance

Air Intake System

10

A. Air Filter Restriction Indicator Check

OW0970

OW1010

TL1055 BEFORE S/N TBM01320 EXCLUDING TBM01298

TL1255 BEFORE S/N TBN00801 EXCLUDING TBN00785

6
3

OAL1000

TL1055 S/N TBM01320 & AFTER INCLUDING TBM01298

TL1255 S/N TBN00801 & AFTER INCLUDING TBN00785

6
4 3

OAL2810

1. Perform Shut-Down Procedure on page 4-4.

2. Open the engine cover. (TL1055 S/N TBM01320 & After including TBM01298,
TL1255 S/N TBN00801 & After including TBN00785)
3. Locate air cleaner (1) and check restriction indicator (2). If red band is visible,
filter(s) must be replaced.
4. Remove dust from vacuator valve (3) by squeezing bottom of valve to allow
loose particles to fall out.
5. Close and secure the engine cover. (TL1055 S/N TBM01320 & After including
TBM01298, TL1255 S/N TBN00801 & After including TBN00785)

7-12

31200249

Section 7 - Lubrication and Maintenance

Note: Only remove canister cover to service the elements as restriction indicator
indicates. Excessive access to check an element can lead to premature element
failure.

B. Element Change (as restriction indicator indicates)

1. Perform Shut-Down Procedure on page 4-4.
2. Open the engine cover. (TL1055 S/N TBM01320 & After including TBM01298,
TL1255 S/N TBN00801 & After including TBN00785)
3. Unlock air cleaner cover (4), turn counterclockwise and remove from air cleaner
canister (5).
4. Remove outer primary element (6) and inspect for damage. Damaged elements
should not be reused.
5. Thoroughly clean the interior of the air cleaner canister and vacuator valve.
6. Replace inner safety element (7) after every third primary element change. If
replacing the inner safety element at this time, carefully slide the element out
and replace with new element.
7. Slide the new primary element over the inner element making sure the sealing
edge is flush with the base of the air cleaner.
8. Position air cleaner cover in place, turn clockwise and lock into position.
9. Depress button on restriction indicator to reset.
10. Close and secure the engine cover. (TL1055 S/N TBM01320 & After including
TBM01298, TL1255 S/N TBN00801 & After including TBN00785)

Note: An inner safety element should never be washed or reused. Always install a
new element.

31200249

7-13

Section 7 - Lubrication and Maintenance

Engine Oil

10

A. Engine Oil Level Check

OW0970

TL1055 BEFORE S/N TBM01320 EXCLUDING TBM01298

TL1255 BEFORE S/N TBN00801 EXCLUDING TBN00785

OW1020

2
AD

OAL0821

TL1055 S/N TBM01320 & AFTER INCLUDING TBM01298

TL1255 S/N TBN00801 & AFTER INCLUDING TBN00785

AD

2
3

1
OAL2821

1. Perform Shut-Down Procedure on page 4-4.

2. Open the 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. If oil is low, remove oil fill cap (4) and add motor oil to bring oil up to the full mark
in the crosshatch area.
5. Replace oil fill cap and dipstick.
6. Close and secure the engine cover.
Note: The standard service interval for engine oil and filter is 250 hours maximum.
If an extended service interval is desired, contact the local Caterpillar dealer for
specific guidelines for optimizing oil change intervals.

7-14

31200249

Section 7 - Lubrication and Maintenance

Hydraulic Oil

10

A. Hydraulic Oil Level Check

OW0970

OW1030

7
5

A
REV A
REV
9156-3220
9156-3220

A
REV A
REV
9156-3220
9156-3220

A
REV A
REV
9156-3220
9156-3220

TL1055 BEFORE S/N TBM00776

TL1255 BEFORE S/N TBN00388

TL1055 S/N TBM00776 THRU

TBM01319 EXCLUDING TBM01298
TL1255 S/N TBN00388 THRU
TBN00800 EXCLUDING TBN00758

A
REV
9156-3220

7
6

OW0853

TL1055 S/N TBM01320 & AFTER INCLUDING TBM01298

TL1255 S/N TBN00801 & AFTER INCLUDING TBN00785

1. Be sure all cylinders are fully retracted and machine is level.

2. Perform Shut-Down Procedure on page 4-4.
3. Open the engine cover.
4. Check level of hydraulic oil at the sight gauge (6) on the hydraulic tank (5). The
oil level should be visible in the gauge window.
5. If hydraulic oil is low, remove oil fill cap (7) from filler neck. Add hydraulic fluid to
bring oil up to the upper mark on the sight gauge.
6. Replace hydraulic oil fill cap.
7. Close and secure the engine cover.

31200249

7-15

Section 7 - Lubrication and Maintenance

Tires

A. Tire Air Pressure Check

10

OW0970

OW1040

1. Perform Shut-Down Procedure on page 4-4.

2. Remove valve stem cap.
3. Check tire pressure.
4. Add air if required.
14.00 x 24, G-2/L-2 Bias-Ply Traction - 12 Ply (TL1055 only) ..... 65 psi (4,5 bar)
14.00 x 24, G-3/L-3 Bias-Ply Rock - 12 Ply (TL1055 only).......... 65 psi (4,5 bar)
14.00 x 24, G-2/L-2 Radial - 1 Star (TL1055 only) ...................... 70 psi (4,8 bar)
17.50 x 25, G-2/L-2 Bias-Ply Traction - 12 Ply ............................ 65 psi (4,5 bar)
17.50 x 25, G-3/L-3 Bias Ply Rock - 12 Ply ................................. 65 psi (4,5 bar)
17.50 x 25, G-2/L-2 Radial - 1 Star ............................................. 70 psi (4,8 bar)
400/75-28, 16 Ply ........................................................................ 76 psi (5,2 bar)
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 piles which exceeds 3 in (7,5 cm) in total
length.
any tears or rips (ragged edges) in the cord plies which exceeds 1 in (2,5 cm) in
any direction
any punctures which exceed 1 in (2,5 cm) 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.

7-16

31200249

Section 7 - Lubrication and Maintenance

C. Tire and Wheel Replacement
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).
Unless specifically approved by JLG, do not replace a foam filled or ballast filled tire
assembly with a pneumatic tire. 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.

31200249

7-17

Section 7 - Lubrication and Maintenance

E. 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. Start all nuts by hand to prevent cross threading. DO NOT use a lubricant on
threads or nuts.
2. Tighten lug nuts in an alternating pattern as indicated in figure. Torque to
350-400 lb-ft (475-542 Nm).

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.

7-18

31200249

Section 7 - Lubrication and Maintenance

Transmission Oil

10

A. Transmission Oil Level Check

OW0970

OW1050

2
T

HO
CO

LD

MIN

OAL2870

TL1055 BEFORE S/N TBM01320

EXCLUDING TBM01298
TL1255 BEFORE S/N TBN00801
EXCLUDING TBN00785

TL1055 S/N TBM01320 & AFTER

INCLUDING TBM01298
TL1255 S/N TBN00801 & AFTER
INCLUDING TBN00785

1. Apply park brake, shift transmission to "Neutral" and lower forks or attachment
to the ground.
2. Check transmission oil level with engine at idle and oil at normal operating
temperature.
3. Open the engine cover.
4. Remove the transmission dipstick (1) and check oil level. The oil level should be
within the "HOT" zone (2).
5. If oil is low, add hydraulic fluid to bring oil up to the "HOT" zone.
6. Replace transmission dipstick.
7. Close and secure the engine cover.

31200249

7-19

Section 7 - Lubrication and Maintenance

Engine Cooling System

A. Engine Coolant Level Check

50

OW0980

OW1070

TL1055 Before S/N TBM01320 excluding TBM01298

TL1255 Before S/N TBN00801 excluding TBN00785

OAL0830

1. Perform Shut-Down Procedure on page 4-4.

2. Open the engine cover.
3. Check coolant level in overflow bottle (3). When coolant is hot, bottle should be
1/2 to 3/4 full. When coolant is cool, bottle should be 1/4 to 1/2 full.
4. If coolant is low, remove overflow bottle cap (4) and add coolant as required.
5. Replace overflow bottle cap.
6. Close and secure the engine cover.

Note: When filling the engine with coolant, the maximum fill rate is 2.4 gallon per
minute (9 liters per minute).

7-20

31200249

Section 7 - Lubrication and Maintenance

TL1055 S/N TBM01320 & After including TBM01298
TL1255 S/N TBN00801 & After including TBN00785

OAL2890

1. Perform Shut-Down Procedure on page 4-4.

2. Open the engine cover.
3. Coolant should be visible in sight glass (1).
4. When coolant is low, allow system to cool. Remove radiator cap (2) and add
coolant as required.
5. Replace radiator cap.
6. Close and secure the engine cover.

31200249

7-21

Section 7 - Lubrication and Maintenance

Battery

50

A. Battery Check

OW0980

OW1080

OAL2880

1
TL1055 BEFORE S/N TBM01320
EXCLUDING TBM01298
TL1255 BEFORE S/N TBN00801
EXCLUDING TBN00785

TL1055 S/N TBM01320 & AFTER

INCLUDING TBM01298
TL1255 S/N TBN00801 & AFTER
INCLUDING TBN00785

1. Perform Shut-Down Procedure on page 4-4.

2. Open the 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 the engine cover.

7-22

31200249

Section 7 - Lubrication and Maintenance

Windshield Washer System (if equipped)

A. Windshield Washer Fluid Level Check

50

OW0980

OAL2040

OAL2300

1. Perform Shut-Down Procedure on page 4-4.

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

31200249

7-23

Section 7 - Lubrication and Maintenance

This Page Intentionally Left Blank

7-24

31200249

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

AUTO-FRAME LEVEL SYSTEM

(TL1055 BEFORE S/N TBM01168, TL1255 BEFORE S/N
TBN00658)

A. Auto-Frame Level Function Check

10

OW0970

A
OW0900

The auto-frame level function engages when the machine is out of level side to side
by more than 15 degrees, and the boom is level. When this condition exists, the
machine automatically rotates back to 14.7 degrees. To check this feature, perform
the following:
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. Locate a 12 in (30,5 cm) curb, and drive the left front and left rear tires up onto
curb. This will set the machine at an 8 degree angle.
4. Rotate machine frame to the right.
5. When the frame is out of level by 15 degrees, the auto-frame level circuit will
energize, and rotate the machine frame in the opposite direction back to 14.7
degrees. This will be your indication that the system is functioning properly. If
you are able to rotate the machine frame fully, the system is not functioning
properly and the machine must be removed from service and repaired before
continued operation.
6. Repeat this procedure for the right side, to check the opposite side sensor.

Note: A sensor on the mast plate will trip when the boom is raised above 7 degrees,
and render the auto-frame level function inoperable.

31200249

8-1

Section 8 - Additional Checks

This Page Intentionally Left Blank

8-2

31200249

Section 9 - Specifications

SECTION 9 - SPECIFICATIONS
9.1

PRODUCT SPECIFICATIONS

Fluids

Compartment
or System

Engine
Crankcase

Transmission
and Transfer
Case
Axle
Differential*
and Wheel
End

Hydraulic
System

Boom Wear
Pad Grease
Cylinder and
Axle Grease
Engine
Coolant

31200249

Type and
Classification

Viscosities

Cat DEO Multigrade

Cat DEO SYN
Cat Arctic DEO SYN
Cat ECF-1
API CG-4 Multigrade

SAE 0W-20
SAE 0W-30
SAE 0W-40
SAE 5W-30
SAE 5W-40
SAE 10W-30
SAE 10W-40
SAE 15W-40

Cat MTO
Dextron or Mercron
ATF
Cat Synthetic Gear Oil
SAE 75W-140
(GO)
Cat Gear Oil (GO)
SAE 80W-90
Cat Gear Oil (GO)
SAE 85W-140
Cat TDTO-TMS
Cat TDTO-TMS
SAE 0W-20
SAE 0W-30
SAE 5W-30
Cat TDTO
SAE 5W-40
Cat TDTO-TMS
SAE 10W
Cat Arctic TDTO SYN
SAE 30
commercial TO-4
SAE 10W-30
SAE 15W-40
Cat TDTO-TMS

Ambient
Temperature Range
F
C
Min Max Min Max
-40 50 -40 10
-40 86 -40 30
-40 104 -40 40
-22 86 -30 30
-22 122 -30 50
0
104 -18 40
0
122 -18 50
15 122 -9.5 50
-10 104 -23 40
-40

14

-42

-1

-22

113

-30

45

-10
10
-4
-40
-40
-22
-22
-4
50
-4
5
-4

120
120
122
104
104
104
104
104
122
104
122
122

-23
-12
-20
-40
-40
-30
-30
-20
10
-20
-15
-20

49
59
50
40
40
40
40
40
50
40
50
50

Cat Advanced 3Moly

NLGI Grade 2

-4

104

-20

40

Cat Multipurpose

NLGI Grade 2

-22

104

-30

40

Cat DEAC
(Glycol and Water)

50/50 Mix
60/40 Mix

Standard
Cold Weather

9-1

Section 9 - Specifications
Compartment
or System

Type and
Classification

Viscosities

Fuel

#2 Diesel
Blend of #1 diesel and
#2 diesel fuels
("winterized" #2)

Low Sulfur

Air
Conditioning

Refrigerant R-134-a

Ambient
Temperature Range
F
C
Min Max Min Max
Standard
Cold Weather

Tetrafluoroethane

Note: Friction Modifier (Cat Brake Oil Additive) required for axle differential.

9-2

31200249

Section 9 - Specifications
Capacities
Engine Crankcase Oil
Capacity with Filter Change
TL1055 Before S/N TBM01320 excluding TBM01298,
TL1255 Before S/N TBN00801 excluding TBN00785...........................7 qt (6,5 L)
TL1055 S/N TBM01320 & After includingTBM01298,
TL1255 S/N TBN00801 & After including TBN00785 ...........................8 qt (7,6 L)
Fuel Tank
Capacity ................................................................................................38 gal (144 L)
Anti-gel Fluid
-40 to 0 F (-40 to -20 C) ...............................................................16 oz (0,5 L)
Cooling System
System Capacity
TL1055 Before S/N TBM01320 excluding TBM01298,
TL1255 Before S/N TBN00801 excluding TBN00785....................20.5 qt (19,4 L)
TL1055 S/N TBM01320 & After includingTBM01298,
TL1255 S/N TBN00801 & After including TBN00785 .......................19 qt (18,0 L)
Overflow Bottle Capacity
TL1055 Before S/N TBM01320 excluding TBM01298,
TL1255 Before S/N TBN00801 excluding TBN00785...........................3 qt (2,8 L)
Hydraulic System
System Capacity
TL1055 ............................................................................................63 gal (238 L)
TL1255 ............................................................................................65 gal (246 L)
Reservoir Capacity to Full Mark
TL1055 Before S/N TBM01320 excluding TBM01298,
TL1255 Before S/N TBN00801 excluding TBN00785......................35 gal (132 L)
TL1055 S/N TBM01320 & After includingTBM01298,
TL1255 S/N TBN00801 & After including TBN00785 ...................37.5 gal (142 L)
Auxiliary Hydraulic Circuit Max Flow ..............................................10 gpm (37.9 lpm)
Transmission
Capacity with Filter Change .................................................................4.23 gal (16 L)
Transfer Case
Capacity ..................................................................................................1.5 qt (1,4 L)

31200249

9-3

Section 9 - Specifications
Axles
Differential Housing Capacity
Front Axle...................................................................................... 20.9 qt (19.8 L)
Rear Axle ......................................................................................... 16.9 qt (16 L)
Friction Modifier (Differential Only)
Front Axle........................................................................................32 oz (946 ml)
Rear Axle ........................................................................................26 oz (768 ml)
Wheel End Capacity .................................................................................. 2 qt (1,9 L)
Air Conditioning System (if equipped)
System Capacity...................................................................................2.5 lb (1134 g)

Tires
Pressure
14.00 x 24, G-2/L-2 Bias-Ply Traction - 12 Ply (TL1055 only)
Pneumatic......................................................................................65 psi (4,5 bar)
Foam................................................................................. Approx 720 lb (327 kg)
14.00 x 24, G-3/L-3 Bias Ply Rock - 12 Ply (TL1055 only)
Pneumatic......................................................................................65 psi (4,5 bar)
Foam................................................................................. Approx 720 lb (327 kg)
14.00 x 24, G-2/L-2 Radial - 1 Star (TL1055 only)
Pneumatic......................................................................................70 psi (4,8 bar)
Foam................................................................................. Approx 720 lb (327 kg)
17.50 x 25, G-2/L-2 Bias-Ply Traction - 12 Ply
Pneumatic......................................................................................65 psi (4,5 bar)
Foam................................................................................. Approx 785 lb (356 kg)
17.50 x 25, G-3/L-3 Bias Ply Rock - 12 Ply
Pneumatic......................................................................................65 psi (4,5 bar)
Foam................................................................................. Approx 785 lb (356 kg)
17.50 x 25, G-2/L-2 Radial - 1 Star
Pneumatic......................................................................................70 psi (4,8 bar)
Foam................................................................................. Approx 785 lb (356 kg)
400/75-28, 16 Ply
Pneumatic......................................................................................76 psi (5,2 bar)
Foam................................................................................. Approx 570 lb (259 kg)
Wheel Lug Nut
Torque.............................................................................. 350-400 lb-ft (475-542 Nm)

9-4

31200249

Section 9 - Specifications
Performance
Note: Values shown are per machine as originally manufactured. Reference load
charts in operator cab for specific model and attachment configuration values.

Maximum Lift Capacity

TL1055 ................................................................................... 10,000 lb (4500 kg)
TL1255 ................................................................................... 12,000 lb (5443 kg)
Maximum Lift Height...............................................................................55 ft (16,8 m)
Capacity at Maximum Height
Outriggers Engaged ................................................................. 5,000 lb (2250 kg)
Outriggers Not Engaged
TL1055
Before S/N TBM01169 .................................................. 4,000 lb (1814 kg)
S/N TBM01169 & After............................................................... 0 lb (0 kg)
TL1255
Before S/N TBN00653 .................................................. 4,000 lb (1814 kg)
S/N TBN00653 & After............................................................... 0 lb (0 kg)
Maximum Forward Reach ......................................................................42 ft (12,8 m)
Capacity at Maximum Forward Reach
Outriggers Engaged
TL1055
Before S/N TBM01169 .................................................. 3,000 lb (1360 kg)
S/N TBM01169 & After.................................................. 2,850 lb (1250 kg)
TL1255................................................................................ 3,500 lb (1587 kg)
Outriggers Not Engaged........................................................................ 0 lb (0 kg)
Reach at Maximum Height ......................................................................8.7 ft (2,6 m)
Maximum Travel Speed ..............................................................18.9 mph (30,4 kph)
Towing Capacity ........................................................................... 10,000 lb (4536 kg)
Frame Leveling.......................................................................................... 10 degrees
Maximum Travel Grade (boom in travel position)
Gradeability.....................................................................................................45%
Side Slope ...................................................................................................8.75%

31200249

9-5

Section 9 - Specifications
Dimensions
Overall Height..................................................................................101 in (2565 mm)
Overall Width
TL1055.......................................................................................101 in (2565 mm)
TL1255.......................................................................................102 in (2591 mm)
Cab Width............................................................................................37 in (940 mm)
Track Width ....................................................................................85.4 in (2169 mm)
Wheelbase.......................................................................................144 in (3658 mm)
Length at Front Wheels ...................................................................201 in (5105 mm)
Overall Length (less Forks) .............................................................254 in (6452 mm)
Ground Clearance
TL1055...........................................................................................18 in (457 mm)
TL1255...........................................................................................19 in (482 mm)
Turning Radius Over Tires.............................................................. 156 in (3962 mm)
Turning Radius at Forks ................................................................. 168 in (4267 mm)
Gross Vehicle Weight (no attachment) ......................................34,340 lb (15.576 kg)
Front Axle Weight with 74 in (1,9 m) Carriage and Pallet Forks
(boom level and fully retracted) ....................................................16,950 lb (7688 kg)
Rear Axle Weight with 74 in (1,9 m) Carriage and Pallet Forks
(boom level and fully retracted) ....................................................17,450 lb (7915 kg)
Maximum Ground Bearing Pressure
TL1055
14.00 x 24 Foam Filled ...............................................202 lb/in (14,2 kg/cm)
17.50 x 25 Foam Filled ...............................................205 lb/in (14,4 kg/cm)
400/75-28 Foam Filled ................................................ 159 lb/in (11,2 kg/cm)
TL1255
17.50 x 25 Foam Filled ...............................................216 lb/in (15.2 kg/cm)
400/75-28 Foam Filled ................................................ 160 lb/in (11,2 kg/cm)

9-6

31200249

Index

Index
A
Accessory Control Lever ................ 3-16
Additional Checks............................. 8-1
Adjusting/Moving Forks .................. 5-13
Air Conditioning
Controls..................................... 3-14
Attachment Installation
Hydraulic Quick Coupler ........... 5-11
Mechanical Quick Coupler ........ 5-10

Coupler Mounted Hook ...................5-28

D
Dash Controls and Indicators............3-4
Decals ...............................................2-3
Dimensions .......................................9-6
Disengaging a Load ..........................4-7
Disengaging a Suspended Load.....4-10
Driving Hazards on Slopes ...............1-9

Attachments
Approved..................................... 5-1
JLG Supplied .............................. 5-2
Operation .................................. 5-14
Unapproved ................................ 5-1

Electrical Hazards .............................1-2

Auto-Frame Level Function

Check ............................................... 8-1

Emergency Lowering of Boom..........6-2

Auxiliary Hydraulic Joystick ............ 3-12

E
Emergency Exit from
Enclosed Cab....................................6-2
Emergency Procedures ....................6-1

Battery ............................................ 7-22

Engine
Extreme Cold Weather Starting...4-2
Normal Operation ........................4-4
Starting ........................................4-1

Boom Head-Mounted Winch .......... 5-32

Engine Oil Level..............................7-14

Boom Indicator
Angle......................................... 3-20
Extension .................................. 3-20

F
Fall Hazard......................................1-12

Boom Joystick ................................ 3-10

Fork Mounted Hook ........................5-26

Bucket ............................................ 5-22

Frame Level Joystick ......................3-11

Fuel Level .......................................7-10

Capacities
Air Conditioning System.............. 9-3
Axles ........................................... 9-3
Cooling System........................... 9-3
Engine Oil ................................... 9-3
Fuel Tank .................................... 9-3
Hydraulic System ........................ 9-3
Transfer Case ............................. 9-3
Transmission............................... 9-3

Fuel/Water Separator......................7-11

Capacity ........................................... 5-4

Capacity Indicator Locations ............ 5-5
Carriage with Forks ........................ 5-15

G
General Maintenance........................7-2

H
Hazard Classification System ...........1-1
Headlights .......................................3-16
Heater Controls...............................3-14
Hydraulic Oil Level ..........................7-15
Hydraulic Operated Attachment......5-12

Chemical Hazards .......................... 1-13

Controls ............................................ 3-2

Ignition ..............................................3-6

Coolant Level ................................. 7-20

31200249

Index
L

Leveling Procedure.................... 4-6, 4-9

Restriction Indicator ........................7-12

Lifting Personnel............................... 1-8

Right Hand Panel ............................3-14

Load Chart
Example ...................................... 5-8
Sample........................................ 5-6

Rotate/Side Tilt Carriage.................5-18

Load Falling Hazard ......................... 1-7

Safety Decals ....................................2-3

Lubrication and Maintenance ........... 7-1

Safety Practices ................................1-1

Lubrication Schedule
1000 Hour ................................... 7-8
250 Hour ..................................... 7-7
50 Hour ....................................... 7-6

Safety Signal Words..........................1-1

M
Multi-Purpose Bucket ..................... 5-24

O
Operating with a Non-Suspended
Load.................................................. 4-5

Seat Belt..........................................3-19
Service and Maintenance Schedule
10 Hour ........................................7-3
1000 Hour ....................................7-5
1500 Hour ....................................7-5
1st 50 Hour .......................... 7-3, 7-4
250 Hour ......................................7-4
50 Hour ........................................7-3
500 Hour ......................................7-4
Shut-Down Procedure.......................4-4

Operating with a Suspended Load ... 4-8

Side Shift Carriage ..........................5-16

Operational Check.......................... 2-10

Specifications ....................................9-1

Operator Cab.................................. 2-11

Steer Modes....................................3-17

Operator Maintenance
Instructions ..................................... 7-10

Swing Carriage................................5-20

Operator Seat ................................. 3-18

Outrigger Joysticks ......................... 3-13

Tip Over Hazard................................1-3

Parking Lights................................. 3-16

Tires ........................................ 7-16, 9-4

Air Pressure ...............................7-16
Damage .....................................7-16
Replacement..............................7-17

Parking Procedure............................ 3-7

Towing...............................................6-1

Performance ..................................... 9-5

Transmission Control Lever

Direction of Travel........................3-8
Gear Selection .............................3-9

P
Park Brake........................................ 3-7

Personnel Work Platform Fork Mounted ................................. 5-30

Picking Up a Suspended Load ......... 4-8

Transport
Lifting .........................................4-12
Tiedown .....................................4-11

Pinch Points and Crush Hazards.... 1-10

Transporting a Load ..........................4-6

Placing a Load.................................. 4-7

Transporting a Suspended Load.......4-9

Placing a Suspended Load............. 4-10

Travel Hazard....................................1-6

Pre-Operation Check and

Inspection ......................................... 2-1

Truss Boom.....................................5-29

Picking Up a Load ............................ 4-5

Turn Signal......................................3-16

31200249

Index
W
Walk-Around Inspection ................... 2-8
Warm-Up Check............................. 2-10
Wheel Installation ........................... 7-18
Wheel Lug Nut.................................. 9-4
Wheel Replacement ....................... 7-17
Windows......................................... 2-12
Windshield Washer Fluid Level ...... 7-23

31200249

Index

31200249

Inspection, Maintenance and Repair Log

Inspection, Maintenance and Repair Log

Serial Number ______________________________

Date

Comments

Inspection, Maintenance and Repair Log

Date

Comments

TRANSFER OF OWNERSHIP
An Oshkosh Corporation Company

To Product Owner:
If you now own but ARE NOT the original purchaser of the product covered by this
manual, we would like to know who you are. For the purpose of receiving safety-related
bulletins, it is very important to keep JLG Industries, Inc. updated with the current
ownership of all JLG products. JLG maintains owner information for each JLG product
and uses this information in cases where owner notification is necessary.
Please use this form to provide JLG with updated information with regard to the
current ownership of JLG products. Please return completed form to the JLG Product
Safety & Reliability Department via facsimile or mail to address as specified below.
Thank You,
Product Safety & Reliability Department
JLG Industries, Inc.
13224 Fountainhead Plaza
Hagerstown, MD 21742
USA
Telephone: +1-717-485-6591
Fax: +1-301-745-3713
NOTE: Leased or rented units should not be included on this form.
Mfg. Model: _______________________________________________________________
Serial Number: ____________________________________________________________
Previous Owner: ___________________________________________________________
Address: _________________________________________________________________
_________________________________________________________________________
Country: _________________________ Telephone: (_______) ____________________
Date of Transfer: _________________________________
Current Owner: ____________________________________________________________
Address: _________________________________________________________________
_________________________________________________________________________
Country: _________________________ Telephone: (_______) ____________________

Who in your organization should we notify?

Name: ___________________________________________________________________
Title: _____________________________________________________________________

Hand Signals

OY1090

EMERGENCY STOP - With both

arms extended laterally, hands
open downward, move arms back
and forth.

OY1120

RAISE BOOM - With either arm

extended horizontally, fingers
closed, point thumb upward.

OY1150

EXTEND BOOM - With both

hands clenched, point thumbs
outward.

OY1180

TILT FORKS UP - With one arm

held at side, extend other arm
upward at about 45 degrees.

OY1100

STOP - With either arm extended

laterally, hand open downward,
move arm back and forth.

OY1130

LOWER BOOM - With either arm

extended horizontally, fingers
closed, point thumb downward.

OY1160

RETRACT BOOM - With both

hands clenched, point thumbs
inward.

OY1110

STOP ENGINE - Draw thumb or

forefinger across throat.

OY1140

MOVE SLOWLY - Place one hand

motionless in front of hand giving
motion signal. (Raise load slowly
shown)

OY1170

THIS FAR TO GO - With hands

raised and open inward, move
hands laterally, indicating distance
to go.

OY1190

TILT FORKS DOWN - With one

arm held at side, extend other arm
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.

31200249