Operator & Safety Manual Keep this manual with machine at all times.
Revision Log Revision Log REVISION LOG October 3, 2005 - A - Original Issue of Manual February 27, 2006 - B - Added 4017 information.
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.
Read This First This product must comply with all safety related bulletins. Contact JLG Industries, Inc. or the local authorized JLG 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.
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Table of Contents Table of Contents TABLE OF CONTENTS Revision Log Read This First Operator Qualifications ...................................................... b Modifications ...................................................................... b Other Publications Available .............................................. c Table of Contents Section 1 - General Safety Practices 1.1 General Precautions ............................................................1-1 1.2 Hazard Classification system.....
Table of Contents 2.5 2.6 2.7 2.8 Load Moment Indicator (LMI) ....................................... 2-32 Control & Indicator Console.......................................... 2-33 Heater and Air Conditioner (optional) Controls............. 2-34 Steer Modes ...................................................................... 2-35 Operator Seat.................................................................... 2-36 Adjustments..................................................................
Table of Contents Carriage w/Forks...........................................................4-12 Truss Boom...................................................................4-13 Side Shift Carriage........................................................4-14 Bucket ...........................................................................4-16 Fork Extension ..............................................................4-18 Platform.........................................................................
Table of Contents Section 7 - Additional Checks 7.1 Load Moment Indicator Test................................................ 7-1 7.2 Emergency Recovery System Test ..................................... 7-2 Section 8 - Specifications 8.1 Product Specifications......................................................... 8-1 Fluid & Lubrication Capacities ........................................ 8-1 Tires................................................................................ 8-2 Performance ..........
Section 1 - General Safety Practices SECTION 1 - GENERAL SAFETY PRACTICES 1.1 GENERAL PRECAUTIONS WARNING Before operation, read & 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. 1.2 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.
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.
Section 1 - General Safety Practices Tip Over Hazard OW0050 • Never use an attachment without the appropriate JLG supplied capacity chart installed on the telehandler. • DO NOT exceed rated lift capacity. • Be sure that the ground conditions are able to support the machine. OW0060 • DO NOT drive with boom raised. • When driving in high speed, use only front wheel steer (if steering modes are selectable). OW0080 • DO NOT raise boom unless frame is level (0 degrees).
Section 1 - General Safety Practices 4 FT (1,2 M) OW0100 • DO NOT level machine with boom/attachment above 1,2 m (4 ft). OW0150 • Carry load as low as possible. Tether suspended loads to restrict movement. • Understand how to properly use the capacity charts located in cab (see page 4-3). • Weight of all rigging (slings, etc.) must be included as part of load. • Start, travel, turn and stop slowly to prevent load from swinging. • Beware of wind.
Section 1 - General Safety Practices OH2291 • MAINTAIN proper tire pressure at all times. If proper tire pressures are not maintained, this machine could tip over. • Refer to manufacturer’s specifications for proper fill ratio and pressure requirements for tires equipped with ballast. OH20911 • Always wear the seat belt. • Keep head, arms, hands, legs and all other body parts inside operator’s cab at all times.
Section 1 - General Safety Practices Travel Hazard 4-Wheel Steer Pivot Steer OW0120 • Steering characteristics differ between 4-Wheel Steer & Pivot Steer telehandlers as shown above. Identify the telehandler you are operating & others on the jobsite. • Ensure that adequate clearance is provided between both rear tail swing and front fork swing. • Unlike a conventional 4-wheel steer telehandler the rear wheels of a pivot steer telehandler turn a wider circle than the front wheels.
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.
Section 1 - General Safety Practices Lifting Personnel OW0170 • When lifting personnel, USE ONLY a JLG manufactured personnel work platform, with proper capacity chart displayed in the cab. OW0190 • DO NOT drive machine from cab when personnel are in platform. • DO NOT use the personnel work platform until you study & understand the “capacity chart.” If your telehandler does not have the correct “personnel work platform capacity chart,” ask your supervisor to get one before using the attachment.
Section 1 - General Safety Practices Preparation and Setup 1. Check to ensure the personnel platform is securely attached at the Quick Switch™. Follow installation procedure on page 4-7. 2. Ensure the telehandler is on a firm surface and is level. 3. Engage the park brake. Blocking the wheels is also recommended. 4. Level the platform, both side to side (frame sway) and front to back (attachment tilt). 5. Keep area under the platform free from personnel. 6.
Section 1 - General Safety Practices Driving Hazards On Slopes OW0200 To maintain sufficient traction and braking capabilities, travel on slopes as follows: 1. When unloaded, the rear of the machine is the “heavy end.” Drive with forks pointed downhill. 2. When loaded, the front of the machine is the “heavy end.” Drive with the forks pointed uphill.
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.
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.
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 3-4 has been performed. OW0290 • DO NOT carry riders. Riders could fall off machine causing death or serious injury.
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. Flammable Fuel OW0300 • DO NOT fill the fuel tank or service the fuel system near an open flame, sparks or smoking materials.
Section 2 - Pre-Operation and Controls SECTION 2 - PRE-OPERATION AND CONTROLS 2.1 PRE-OPERATION CHECKS & 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. Failure to comply could result in death or serious injury. Walk around inspection must be performed at beginning of each work shift or at each change of operator. Ensure all Safety decals are legible and in place.
Section 2 - Pre-Operation and Controls 3513 & 4013 Begin your walk-around inspection at item 1. Continue to your (counterclockwise when viewed from top) checking each item in sequence. right 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.
Section 2 - Pre-Operation and Controls 3. Front Work Lights - Clean, undamaged and work properly. 4. Front Axle - Steer cylinders undamaged, not leaking; pivot pins secure; hydraulic hoses undamaged, not leaking. 5. Wheel/Tire Assembly - No loose or missing lug nuts; proper inflation. 6. Cab & Electrical • General appearance; no visible damage; proper load charts and applicable Operator & Safety manual located in manual holder. • Window glass undamaged and clean.
Section 2 - Pre-Operation and Controls 4017 3 2 18 2 1 17 16 15 4 5 14 6 13 7 12 8 9 10 10 11 OZ0400 Begin your walk-around inspection at item 1. Continue to your (counterclockwise when viewed from top) checking each item in sequence. right 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.
Section 2 - Pre-Operation and Controls 4. Front Axle - Steer cylinders undamaged, not leaking; pivot pins secure; hydraulic hoses undamaged, not leaking. 5. Wheel/Tire Assembly - No loose or missing lug nuts; proper inflation. 6. Cab & Electrical • General appearance; no visible damage; proper load charts and applicable Operator & Safety manual located in manual holder. • Window glass undamaged and clean. • Gauges, switches, joystick, foot controls, park brake & horn operational.
Section 2 - Pre-Operation and Controls 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. 3513 & 4013 8008657 8008657 8005616 35 8005616 8005675 A A Optional 8009377 (35) 2603207 (20) 8009890 (22) 8009885 (12) 8003198 AERIAL PLATFORM APPLICATION PLATE S/N TRUCK S/N This truck can be combined with the aerial platform: MODEL 8003198 8003198 8005617 8005670 P/N HOMOLOGATION No.
Section 2 - Pre-Operation and Controls 8005675 8005616 8008657 8008657 8005616 B 35 C Optional 8009377 (35) 2603207 (20) 8009890 (22) 8009885 (12) B C 8003198 8003198 8003198 8009816 8005617 8005671 8008195 8005671 8006038 8005617 8005617 VIEW C-C VIEW B-B 31200028 OZ1000 2-7
Section 2 - Pre-Operation and Controls 8005671 8005609 8005673 LOAD CHARTS 4017 8008613 8005608 (Optional) P/N 1170001 P/N 2340029 P/N 4802111 P/N 8008014 14 70° 13 11 G F E 50° 10 2.000kg 1.500kg 1.000kg 500kg 10° 400kg 2 4.000kg B A 750kg 20° 4 3 2.500kg 30° 6 5 8005609 8008613 C 40° 8 7 8005608 8005671 D 9 3.000kg 3.
Section 2 - Pre-Operation and Controls 4017 8005616 8008657 8008657 8005616 A 35 A 8009377 (optional) 8003198 8003198 8005617 8005670 8005617 1706227 8005671 8005671 1706277 35 8009815 3931579 8005869 8009377 (optional) OZ0860 VIEW A-A 31200028 2-9
Section 2 - Pre-Operation and Controls 8005675 8005616 8008657 8008657 8005616 35 8009377 (optional) 8003198 8003198 8005617 8009816 8005617 8003198 8005671 8005671 8006038 8008195 8008195 OZ0870 2-10 31200028
Section 2 - Pre-Operation and Controls 8005671 8005609 8005673 LOAD CHARTS 4017 8008613 8005608 (Optional) P/N 1170001 P/N 2340029 P/N 4802111 P/N 8008014 14 70° 13 12 11 G F E 50° 10 2 2.000kg 1.000kg 1.500kg 500kg 10° 400kg 3 8005609 4.000kg B A 750kg 20° 4 2.500kg 30° 6 5 8008613 C 40° 7 8005608 8005671 D 9 8 3.000kg 3.
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Section 2 - Pre-Operation and Controls 2.3 OPERATOR CAB The telehandler is equipped with an enclosed FOPS/ROPS cab. WARNING Never operate telehandler unless the overhead guard and cab structure are in good condition. Any modification to this machine must be approved by JLG to assure compliance with FOPS/ROPS certification for this cab/machine configuration. If damaged, the CAB CANNOT BE REPAIRED. It must be REPLACED.
Section 2 - Pre-Operation and Controls 2.4 CONTROLS 1. Parking Brake: See page 2-23 for details. 2. Accelerator Pedal: Pressing down the pedal increases engine and hydraulic speed. 3. Service Brake Pedal: The further the pedal is depressed, the slower the travel speed. 4. Steering Column Adjuster: See page 2-27 for details. 5. Wipers, Lights, Turn Signal Lever: See page 2-26 for details. 6. Transmission Control Lever: See page 2-24 for details.
Section 2 - Pre-Operation and Controls 7. Round Air Vents: Three individually adjustable round vents. 8. Brake Fluid Reservoir: The brake fluid level should be between the MIN and MAX marks. The sight gauge is on the left side of the reservoir. 9. Air Louvers: Four individually adjustable air louvers. 10. Instrument Panel: Controls and indicates some machine functions and displays the output of the machine. See page 2-16 for details. 11.
Section 2 - Pre-Operation and Controls Instrument Panel 3 2 4 OK C 5 6 1 7 ! 12 11 10 9 8 OZ0020 1. Steer Mode Selection LED lit while activated. Blinks during change to another steer mode. See page 2-35 for details. 2. C Key Returns user interface one level during navigation and deletes user inputs. 3. Up/Down Arrows Scroll up and down in the user interface. 4. OK Key Confirms user interface inputs. 5.
Section 2 - Pre-Operation and Controls 7. Road Use Operation LED lit while activated: The outrigger, boom, sway and auxiliary hydraulic systems are disengaged. No functions can be operated with the joystick. The Declutch Shutoff is not lit and Front-Wheel Steer Mode must be active to proceed to Road Use Operation. Note: Activate this function before traveling on public roads. See “Road Operation” on page 3-8. 8. Warning Indicator The RED LED illuminates for high priority problems.
Section 2 - Pre-Operation and Controls Display Screen 1 2 0 0 718 12° 1 min km/h P 3 4 5 OZ0030 The display screen consists of five sections: 1. Speed Indicator (km/h) 2. Symbol Display 3. Engine Speed Indicator (rpm) 4. Operating Hours Indicator (Bh) 5. Boom Angle, Aux Hydraulic and Common Message Display Symbol Display (Section 2) a. Parking Brake Displayed permanently when parking brake is applied (see page 2-23). Parking brake must be applied to start engine.
Section 2 - Pre-Operation and Controls e. Engine Temperature Symbol displayed and buzzer sounds when engine oil temperature is too high. Stop engine immediately. OZ0250 f. Transmission Temperature Symbol displayed and buzzer sounds when transmission temperature is too high. Stop engine immediately. OT0990 g. Air Filter Symbol displayed and buzzer sounds when air filter is clogged. Stop engine immediately. OZ0260 h. Hydraulic Oil Filter Symbol displayed when the hydraulic oil filter requires cleaning.
Section 2 - Pre-Operation and Controls Boom Angle, Auxiliary Hydraulic & Message Window (Section 5) a. Boom Angle Indicator Displays the boom angle in degrees. (0 degrees indicates horizontal) OZ0330 b. Auxiliary Hydraulics When the permanent auxiliary hydraulic function is active, the display shows the percentage value (-100% to +100%) of the auxiliary hydraulic for 30 seconds. Also displays for 30 seconds at each change. See Section 4 - Attachments & Hitch Options for details. c.
Section 2 - Pre-Operation and Controls Anti Theft Device The anti theft device requires entering a numeric code for operation to prevent unauthorized use. Button Values 4 5 C 6 7 OK 8 3 9 2 1 0 ! OZ0350 Changing the Anti Theft Code The anti theft device is set to a numeric code of 0000 when delivered from the factory. To prevent unauthorized access change the code upon first use. 1. Turn on the ignition key and wait for the LEDs to go out. 2.
Section 2 - Pre-Operation and Controls Ignition P 0 I II III OZ1100 • Position 0 - Engine off • Position I - Voltage is available for all electrical functions. • Position II - Engine preheat at temperature below 0°C. Wait until icon on display screen goes out. • Position III - Engine start. • Position P - Accessory position, power is transferred to the platform.
Section 2 - Pre-Operation and Controls Park Brake 3513 & 4013 4017 • The Park Brake Lever (1) controls the application and release of the park brake. • Pull back to activate. • Push forward to deactivate. WARNING MACHINE ROLL-AWAY HAZARD. Always move park brake lever to "ON" position, lower boom to ground and stop engine before leaving cab. Machine roll-away could cause death or serious injury. WARNING CRUSH HAZARD. Turning engine off applies the park brake.
Section 2 - Pre-Operation and Controls Transmission Control Direction of Travel Selection 2 1 3 OZ0060 • This lever (1) engages forward or reverse travel. Push lever forward (2) for forward travel; pull lever rearward (3) 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.
Section 2 - Pre-Operation and Controls Gear Selection 4 OZ0070 • Gear selection is located on the twist grip handle (4) 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.
Section 2 - Pre-Operation and Controls Wiper, Lights and Turn Signal Control Lever 1. Flash-to-Pass: Pull the lever back completely. The high beam indicator will light. 2. High/Low Beam: With the lights on, pull the lever to switch to high or low beam. The high beam indicator will light when the high beam lights are on. 3. Left Turn Signal: Push the lever forward. 4. Right Turn Signal: Pull the lever backward. 5. Horn: Push the button. 6. Windshield Washer: Slide the sleeve toward the steering column. 7.
Section 2 - Pre-Operation and Controls Steering Column Adjuster • Follow “Shut-Down Procedure” on page 3-4. • Loosen the knob (8). • Place the steering column in the desired position. • Retighten the knob. WARNING TIP OVER/CRUSH HAZARD. Bring telehandler to a complete stop and shutdown engine before adjusting steering column. A sudden change in direction of travel could reduce stability and/or cause load to shift or fall. Failure to comply could result in death or serious injury.
Section 2 - Pre-Operation and Controls Joystick Standard Controls The joystick (1) controls the boom, attachment and outrigger 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.
Section 2 - Pre-Operation and Controls Attachment Functions • Attachment tilt is control by the rocker switch (2). Push the rocker switch up to tilt attachment forward (down); push the rocker switch down to tilt attachment back (up). • Auxiliary Hydraulics (optional) button (6) controls function of attachments that require hydraulic supply for operation. See Section 4 - Attachments & Hitch Options for approved attachments and control instructions.
Section 2 - Pre-Operation and Controls Optional Controls 3 4 5 6 1 2 OZ1900 The joystick (1) controls the boom, attachment and outrigger functions. Boom Functions • Move the joystick back to lift boom; move joystick forward to lower boom. • Boom extend/retract is controlled by the rocker switch (2). Push the rocker switch up to extend boom; push the rocker switch down to retract boom. • The speed of boom functions depends upon the amount of joystick travel in corresponding direction.
Section 2 - Pre-Operation and Controls Attachment Functions • Move the joystick right to tilt attachment forward (down); move joystick left to tilt attachment back (up). • Auxiliary Hydraulics (optional) button (6) controls function of attachments that require hydraulic supply for operation. See Section 4 - Attachments & Hitch Options for approved attachments and control instructions. Outrigger Functions • Button (3) controls the left outrigger.
Section 2 - Pre-Operation and Controls Load Moment Indicator (LMI) The Load Moment Indicator (1) provides a visual indication for forward stability limitations. • All five LEDs (2) will light (three green, yellow & red) and the warning buzzer sounds as the telehandler reaches its forward stability limitations. • When the red LED is illuminated the automatic overload protection function is activated. Boom extension, boom lower and outrigger functions are disabled.
Section 2 - Pre-Operation and Controls Control & Indicator Console Controls and indicates the electrical accessories of the telehandler. 4. High Beam Indicator: Illuminates when high beam lights are on. 5. Battery Charge Indicator: Illuminates when battery is at low charge. 6. Telehandler Turn Signal Indicator 7. Trailer Turn Signal Indicator (optional) 8. Rear Work Light Switch 9. Boom Work Light Switch 10. Rear Wiper Switch: Press and hold for 2 seconds or more to turn on.
Section 2 - Pre-Operation and Controls Heater and Air Conditioner (optional) Controls 1. Fan Speed: 3-position rotary switch for heater and air conditioner. 2. Temperature Control: Adjustable rotary switch. 3. Air Conditioner (optional): On/Off switch. 4. Recirculate (optional): On/Off switch used for optimum air conditioner performance. In this mode no outside air is drawn into the cab. 5. Round Vent 6. Air Louver Heater Turn the temperature control to the desired temperature and set the fan speed.
Section 2 - Pre-Operation and Controls 2.5 STEER MODES Stop the telehandler before changing steering modes. An LED will indicate the steering mode selected. All-Wheel Steer C OZ0180 Front-Wheel Steer Note: This mode is required for travel on public roads.
Section 2 - Pre-Operation and Controls 2.6 OPERATOR SEAT Adjustments 1 2 3 4 6 5 OZ0830 Prior to starting the engine adjust seat for position and comfort as follows: Fore/Aft Use the handle (1) to move seat fore and aft. Height Use the knob (2) to adjust the height of the seat. Suspension Use the knob (3) to adjust the suspension to the appropriate weight setting (4). Backrest Use knob (5) to adjust backrest angle. Seat Belt Always fasten seat belt (6) during operation.
Section 2 - Pre-Operation and Controls 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.
Section 2 - Pre-Operation and Controls 2.7 MIRRORS & WINDOWS Keep all windows and mirrors clean and unobstructed. Cab Door Window 1 2 OZ0210 • During operation the window must either be latched open or closed. • Open the cab door window (1) and secure it in the latch. • Press the release button (2) inside the cab to unlatch the window. Rear Window 4 3 OZ0220 • Lift lever (3) and push to open the rear window (4). • Lift lever and pull to close.
Section 2 - Pre-Operation and Controls Mirrors 5 OZ1680 • Adjust mirrors (5) as required for maximum visibility, before and during operation.
Section 2 - Pre-Operation and Controls 2.8 HOOD • To close the hood, slide the gas cylinder lock (1) to one side. • Close and secure the hood.
Section 3 - Operation SECTION 3 - OPERATION 3.1 WARM-UP AND OPERATIONAL CHECKS This section outlines the checks to be performed at the beginning of each work shift or at each change of operator. During warm-up period, check: 1. Heater, defroster and windshield wiper (if equipped). 2. Check all lighting systems (if equipped) for proper operation. WARNING CUT/CRUSH/BURN HAZARD.
Section 3 - Operation 3.2 ENGINE Starting the Engine This machine can be operated in temperatures of -20°C to 40°C (0°F to 104°F). Consult JLG for operation outside this range. 1. If equipped, turn on the battery disconnect switch located in engine compartment. 2. Make sure all controls are in “Neutral” and all electrical components (lights, heater, defroster, etc.) are turned off. Set parking brake and ensure emergency stop button is pulled out. 3. Turn ignition switch to position I.
Section 3 - Operation Battery Boosted Starting OW0530 If battery-boost starting (jump-start) is necessary, proceed as follows: • Never allow vehicles to touch. • 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.
Section 3 - Operation Normal Engine Operation • Observe gauges and display screen frequently to be sure all engine 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. See “Shut-Down Procedure”. Report condition to your supervisor or maintenance personnel. • Avoid prolonged idling. If the engine is not being used, turn it off.
Section 3 - Operation 3.3 OPERATING WITH A 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 resulting in death or serious injury.
Section 3 - Operation Transporting The 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 4 - Attachments & Hitch Options. 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. Move boom/attachment to 1,2 m (4 ft) off ground. 4.
Section 3 - Operation Placing The Load Before placing any load be sure that: • The landing point can safely support the weight of the load. • The landing point is level; front to back and side to side. • Use the capacity chart (see page 4-3) to determine safe boom extension range. • 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.
Section 3 - Operation 3.4 ROAD OPERATION 1. Preparation a. Empty bucket. b. Remove any large amounts of dirt from machine c. Check lights and mirrors and adjust if necessary. d. Safety equipment to be carried: Warning Triangle, First Aid Kit and Chock. 2. Lower boom. Front edge of attachment should be approximately 30-40 cm (12-16 in) above the ground. 3. Fully tilt attachment back 4.
Section 3 - Operation 3.5 LOADING AND SECURING FOR TRANSPORT WITH PLATFORM ATTACHED 8005617 8005617 OZ1691 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.
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Section 4 - Attachments & Hitch Options SECTION 4 - ATTACHMENTS & HITCH OPTIONS 4.1 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 model/option number on the attachment identification plate must match the attachment number on a capacity chart located in the operator cab. • The model on the capacity chart must match the model telehandler being used.
Section 4 - Attachments & Hitch Options 4.3 TELEHANDLER/ATTACHMENT/FORK CAPACITY 3 1 2 OZ0810 Prior to installing the attachment verify it is approved and the telehandler is equipped with the proper capacity chart. See “Approved Attachments” on page 4-1. 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).
Section 4 - Attachments & Hitch Options 4.4 USE OF THE CAPACITY CHART To properly use the capacity chart (see page 4-4), the operator must first determine and/or have the following: 1. A JLG approved attachment. See “Approved Attachments” on page 4-1. 2. The proper Capacity Chart. 3. Weight of the load being lifted. 4. Load placement information: a. HEIGHT where the load is to be placed. b. DISTANCE from the front tires of the telehandler where the load is to be placed. 5.
Section 4 - Attachments & Hitch Options Sample Capacity Chart These numbers must match the model/option number stamped on the attachment ID Plate. This Capacity Chart may be used with this model ONLY. The model of your telehandler is indicated on the boom or chassis. Model XXXX is used for demonstration purposes only. XXXX P/N 1234567 P/N 9876543 P/N 1122334 P/N 9988776 14 70° 13 60° 11 kg F 10 D C 40° 2 10° 500kg 400kg 3 2.000kg B A 750kg 20° 4 1.000kg 6 1.500kg 30° 2.
Section 4 - Attachments & Hitch Options To identify the proper capacity chart, refer to the following icons which may be located on the capacity chart. • Use when lifting a load with outriggers up. OW0930 • Use when lifting a load with outriggers down. OW0940 80" 1" • Use for any forward movement (1 to 80 in) of the transfer carriage. OW0910 0" • Use for no forward movement (0 in) of the transfer carriage. Fully retracted position only.
Section 4 - Attachments & Hitch Options Example A contractor owns a model xxxx telehandler with a fork carriage. He knows this attachment may be used with his model since: • The attachment model/option number, matches the attachment number on the capacity chart. • The capacity chart is clearly marked for model xxxx and corresponds with machine configuration being used. Below are examples with various conditions the contractor may encounter and whether or not the load may be lifted.
Section 4 - Attachments & Hitch Options 4.5 ATTACHMENT INSTALLATION 1. Attachment 2. Attachment Pin Recess 3. Attachment Pin 4. Lock Pin 5. Retainer Pin 6. Quick-Switch device (attachment tilt control in cab, see page 2-28 for details) 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 causing death or serious injury.
Section 4 - Attachments & Hitch Options Mechanical Quick-Switch Device This installation procedure is designed for one-person operation. 1. Retract quick-switch device to provide clearance. Check to be sure lock pin and retainer pin is out. 2. Align attachment pin with recess in attachment. Raise boom slightly to engage attachment pin in recess. 3. Engage quick-switch device. 4. Shut off engine. Exit cab and insert lock pin and secure with retainer pin. 5.
Section 4 - Attachments & Hitch Options Hydraulic Operated Attachment 1 2 OZ0620 1. Install attachment (see page 4-8). 2. Lower attachment to ground. Set parking brake, shut off engine and turn key back to the "ON" position. 3. Relieve pressure in the hydraulic system by actuating the joystick (1), (2). 4. Connect the quick-disconnect fittings (3). 5. Start the engine. Platform Attachment 5 4 OZ1190 1. Install platform and connect hydraulic lines (see pages 4-8 thru 4-9). 2.
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Section 4 - Attachments & Hitch Options 4.6 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 4-7. 2.
Section 4 - Attachments & Hitch Options Carriage w/Forks OZ0770 P/N 1170001 2340029 2340030 1170028 2340040 2340041 Description Weight Carriage............................................... 218 kg (481 lb) Forks 45x125 mm.................................. 72 kg (159 lb) Forks 50x100 mm............................... 64,1 kg (141 lb) Carriage............................................... 169 kg (373 lb) Forks 50x120 mm.................................. 82 kg (181 lb) Forks 50x100 mm.....................
Section 4 - Attachments & Hitch Options Truss Boom P/N Description Weight 0240110 Truss Boom 3,6 m - 650 kg.................. 205 kg (452 lb) 0240063 Truss Boom 3,4 m - 1000 kg................ 250 kg (551 lb) OZ0780 Use Truss Boom Attachment Capacity Chart To determine maximum capacity, refer to “Telehandler/Attachment/Fork Capacity” on page 4-2. Suspend loads in accordance with requirements set forth in Section 1 - General Safety Practices. The joystick (1) controls movement of the boom.
Section 4 - Attachments & Hitch Options Side Shift Carriage OZ0800 P/N 1170002 2340029 2340030 Description Weight Side Shift Carriage............................ 410,6 kg (905 lb) Forks 45x125 mm - 4 ton ....................... 72 kg (159 lb) Forks 50x100 mm - 4 ton .................... 64,1 kg (141 lb) Use Side Shift Carriage Attachment Capacity Chart To determine maximum capacity, refer to “Telehandler/Attachment/Fork Capacity” on page 4-2. The joystick (1) controls movement of the boom.
Section 4 - Attachments & Hitch Options To Side Shift: Use the button (3) to select the auxiliary hydraulic circuit. While pressing and holding the joystick button (4), move the joystick to the left (5) to shift forks left or move the joystick to the right (6) to shift forks right. Installation Procedure: • Refer to “Attachment Installation” on page 4-7. WARNING CRUSH HAZARD. Do not use side shift to push or pull objects or load.
Section 4 - Attachments & Hitch Options Bucket OZ0730 P/N 4805670 4802100 0930001 0930003 0930002 0930015 0930016 Description Weight Bucket w/Teeth 0.8 m3 ......................... 370 kg (816 lb) Bucket w/Teeth 1.0 m3 ...................... 520 kg (1,146 lb) Bucket 1.0 m3 ...................................... 370 kg (816 lb) Bucket, 4 in 1 - 1 m3 ......................... 819 kg (1,806 lb) Bucket 2.0 m3 ................................... 650 kg (1,433 lb) Bucket 0.9 m3 ................................
Section 4 - Attachments & Hitch Options Equipment Damage Precautions • Drive into stockpile smoothly with boom fully retracted to load bucket. Loading bucket with boom extended could damage boom or extension chains/cables. Do not corner-load bucket. • Distribute material evenly within the bucket. Bucket capacity charts are for evenly distributed loads only. • Do not use bucket as a lever to pry material. Excessive prying forces could damage bucket. • Do not use bucket for "back dragging".
Section 4 - Attachments & Hitch Options Fork Extension P/N Description Weight 2340034 Fork Extension 2 m...................... 44,1 kg (97 lb) each OZ0750 Use Carriage Attachment Capacity Chart To determine maximum capacity of the carriage, refer to “Telehandler/Attachment/ Fork Capacity” on page 4-2. The maximum capacity of the carriage when equipped with fork extensions may be reduced to the capacity indicated on the fork extensions.
Section 4 - Attachments & Hitch Options Equipment Damage Precautions • Inspect the fork extension at the beginning of each work shift for wear or damage. • The heavy part of the load must be against the carriage backrest. • Do not place the center of gravity of the load in front of the tip of the supporting fork. • Do not pick up a load or pry materials with the tip of a fork extension.
Section 4 - Attachments & Hitch Options Platform P/N Description Weight 3510871 Platform ............................................. 560 kg (1235 lb) OZ1210 Use Platform Capacity Chart To determine maximum capacity, refer to capacity decal on platform. The joystick (1) controls movement of the boom. The attachment tilt rocker switch (2) located on the boom joystick controls platform tilt. • Push rocker switch down to tilt up. • Push rocker switch up to tilt down.
Section 4 - Attachments & Hitch Options Transfer to Platform Control: • Apply parking brake. • Shift the transmission control lever to neutral and lock in place with the lock lever. • Lower outriggers, lift front tires and ensure machine is level. • Shut off engine and rotate key to position P. • Verify the platform ON indicator is lit. • Remove ignition key. Installation Procedure: • Refer to “Attachment Installation” on page 4-7.
Section 4 - Attachments & Hitch Options Fork Hook P/N Description Weight 2700097 Fork Hook 4 ton.................................... 33,6 kg (74 lb) OZ0740 Use Fork Hook Attachment Capacity Chart To determine maximum capacity, refer to “Telehandler/Attachment/Fork Capacity” on page 4-2. Suspend loads in accordance with requirements set forth in Section 1 - General Safety Practices. The joystick (1) controls movement of the boom.
Section 4 - Attachments & Hitch Options Adjustable Truss Boom P/N Description Weight 0240145 Adjustable Truss Boom ........................ 180 kg (397 lb) OAH0550 Use Adjustable Truss Boom Attachment Capacity Chart To determine maximum capacity, refer to “Telehandler/Attachment/Fork Capacity” on page 4-2. Suspend loads in accordance with requirements set forth in Section 1 - General Safety Practices. The joystick (1) controls movement of the boom.
Section 4 - Attachments & Hitch Options 4.8 HITCH OPTIONS Mechanical Hitch P/N 8010199 8010198 4805932 Description Weight Hitch.........................................................25 kg (55 lb) Automatic Hitch......................................58 kg (128 lb) Draw Bar Coupling...............................6,6 kg (14.6 lb) OZ1890 Installation Procedure: If not previously installed, secure hitch to machine with hardware supplied with installation.
Section 5 - Emergency Procedures SECTION 5 - EMERGENCY PROCEDURES 5.1 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. • The steering system permits manual steering if engine or power assist feature fails; however, steering will be slow and will require much greater force.
Section 5 - Emergency Procedures 5.2 EMERGENCY LOWERING OF BOOM In case of an emergency, engine or hydraulic failure an emergency recovery system (ERS) is available at ground level. 1 6 3 2 4 5 OZ1720 ERS with Standard Attachment 1. Verify the emergency stop switch in the cab is not depressed. 2. Open the engine cover. 3. Locate the ERS control panel (1). Push the enable button (2) and verify the green light (3) illuminates. 4.
Section 5 - Emergency Procedures ERS with Platform 1. Verify the emergency stop switch in the cab is not depressed. 2. Open the engine cover. 3. Locate the ERS control panel (1). Push the enable button (2) and verify the green light (3) illuminates. If platform is overloaded, the red light (6) will remain on and alarm will sound. 4. While depressing the enable button rotate either the lift/lower (4) or the extend/ retract (5) switches. Hold in place until the platform is at ground level.
Section 5 - Emergency Procedures 5.3 CAB EMERGENCY EXIT 1 OZ0240 • In an emergency the rear window can be used to exit the telehandler. • Remove the latch pin (1). The window is then free to swing open.
Section 6 - Lubrication & Maintenance SECTION 6 - LUBRICATION & MAINTENANCE 6.1 INTRODUCTION Service the product in accordance with the maintenance schedule on the following pages. Service intervals are based on machine usage of 1500 hours annually. Use of your product may vary significantly and you must adjust service frequency for your usage to obtain maximum service life. Note: Failure To Use JLG Hydraulic Filter Elements Could Void Warranty.
Section 6 - Lubrication & Maintenance WARNING CUT/CRUSH/BURN HAZARD. Do not perform service or maintenance on the machine with the engine running, with the exception of the transmission fluid level check. Failure to comply could cause death or serious injury. 6.2 GENERAL MAINTENANCE INSTRUCTIONS Prior to performing any service or maintenance on the telehandler, follow the “Shut-Down Procedure” on page 3-4 unless otherwise instructed. Ensure telehandler is level for proper fluid readings.
Section 6 - Lubrication & Maintenance 6.
Section 6 - Lubrication & Maintenance 50, 250 & 500 Hour Maintenance Schedule EVERY 50 Drain Fuel/ Water Separator Check Engine Coolant Level Lubrication Schedule EVERY 250 Change Engine Oil and Filter Check Axle Oil Level Check Wheel End Oil Levels Check Boom Chain Tension (4017 only) Check Boom Bearing Pads Check Transfer Case Oil Level Air Filter Vacuator Valve Check Fan Belt EVERY 500 LB/F T (N m) Change Fuel Filter Check Wheel Lug Nut Torque OZ1491 6-4 31200028
Section 6 - Lubrication & Maintenance 1000 & 1500 Hour Maintenance Schedule EVERY 1000 Change Transmission Oil & Filter Change Transfer Case Oil Change Axle Oil Change Wheel End Oil Check Boom Chain (4017 only) EVERY 1500 Change Engine Coolant Change Hydraulic Fluid & Filters Change Hydraulic Tank Breather Change Brake Fluid OZO891 31200028 6-5
Section 6 - Lubrication & Maintenance 6.
Section 6 - Lubrication & Maintenance 50 Hour Lubrication Schedule - 3513 & 4013 31200028 6-7
Section 6 - Lubrication & Maintenance 8 Hour Lubrication Schedule - 4017 6-8 31200028
Section 6 - Lubrication & Maintenance 50 Hour Lubrication Schedule - 4017 31200028 6-9
Section 6 - Lubrication & Maintenance 6.5 OPERATOR MAINTENANCE INSTRUCTIONS Fuel System A. Fuel Level Check 8 OW1150 OW0990 2 4 3 OZ0660 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 3-4. 3. Open the rear access door (2). 4. Turn fuel tank cap (3) and remove from filler neck (4). Add diesel fuel as needed. Replace fuel tank cap. 5. Close and secure the rear access door.
Section 6 - Lubrication & Maintenance 50 B. Drain Fuel/Water Separator OW0980 6 5 OW1000 OZ0360 1. Perform “Shut-Down Procedure” on page 3-4. 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. Tighten drain cock. 4. Close and secure the engine cover.
Section 6 - Lubrication & Maintenance Air Intake System 8 A. Air Filter Restriction Indicator Check OW1150 OW1010 2 5 7 6 8 9 4 3 10 1 OZ0390 1. Perform “Shut-Down Procedure” on page 3-4. 2. Open the engine cover. 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.
Section 6 - Lubrication & 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. Unlock air cleaner cover (4), turn counterclockwise and remove from air cleaner canister (5). 2. Remove outer primary element (6) and inspect for damage. Damaged elements should not be reused. 3.
Section 6 - Lubrication & Maintenance Engine Oil 8 A. Engine Oil Level Check OW1150 OW1020 4 AD D 2 3 1 OZ0480 1. Perform “Shut-Down Procedure” on page 3-4. 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.
Section 6 - Lubrication & Maintenance Battery 8 A. Battery Check OW1150 6 5 OW1080 OZ1710 1. Perform “Shut-Down Procedure” on page 3-4. 2. Open the engine cover. 3. Wearing eye protection, visually inspect the battery (5). Charge indicator (6) must be green. Check terminals for corrosion. Replace battery if it has a cracked, melted or damaged case. 4. Close and secure the engine cover.
Section 6 - Lubrication & Maintenance Brake System A. Brake Fluid Level Check 8 OW1150 OZ0540 1. Perform “Shut-Down Procedure” on page 3-4. 2. The brake fluid level should be between the MIN and MAX marks on the reservoir. 3. If brake fluid level is low, add fluid as needed (1). Note: All other work on the brake system must be performed by qualified personnel.
Section 6 - Lubrication & Maintenance Hydraulic Oil A. Hydraulic Oil Level Check 8 OW1150 OW1030 4 3 2 OZ1510 1. Be sure all cylinders are fully retracted and machine is level. 2. Perform “Shut-Down Procedure” on page 3-4. 3. Check level of hydraulic oil at the sight gauge (2) on the hydraulic tank (3). The oil level should be visible in the gauge window. 4. If hydraulic oil is low, remove oil fill cap (4) from filler neck.
Section 6 - Lubrication & Maintenance Tires A. Tire Air Pressure Check 8 OW1150 OW1040 1. Perform “Shut-Down Procedure” on page 3-4. 2. Remove valve stem cap. 3. Check tire pressure using a good quality gauge. 4. Add air if required. 405/70-24 ...........................................................................4.5 bar (65 psi) 5. Replace valve stem cap.
Section 6 - Lubrication & Maintenance Transmission Oil A. Transmission Oil Level Check 8 OW1150 OW1050 2 FUL L ADD 1 OZ0430 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 “FULL & ADD" marks (2). 5.
Section 6 - Lubrication & Maintenance Engine Cooling System 50 A. Engine Coolant Level Check OW0980 OW1070 3 OZ0440 1. Perform “Shut-Down Procedure” on page 3-4. 2. Open the engine cover. 3. Check coolant level in radiator. When coolant is cool, remove cap. (3) 4. If coolant is low, add coolant (50/50 mixture of ethylene glycol and water) as required. 5. Replace radiator cap. 6. Close and secure the engine cover.
Section 7 - Additional Checks SECTION 7 - ADDITIONAL CHECKS 7.1 LOAD MOMENT INDICATOR TEST 8 OW1150 OZ0840 The Load Moment Indicator (LMI) is intended to continuously monitor the forward stability of the telehandler. 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. Press the test button on the LMI display. This will cause all LEDs to flash on and an audible warning to sound.
Section 7 - Additional Checks 7.2 EMERGENCY RECOVERY SYSTEM TEST 8 OW1150 ERS OZ1500 The Emergency Recovery System (ERS) is available in case of emergency, engine or hydraulic failure. To check this feature, perform the following: 1. Perform “Shut-Down Procedure” on page 3-4. 2. Make sure the emergency stop switch in the cab is not depressed. 3. Open the engine cover. 4. Push the enable button on the ERS control panel and verify the green light illuminates. 5.
Section 8 - Specifications SECTION 8 - SPECIFICATIONS 8.1 PRODUCT SPECIFICATIONS Fluid & Lubrication Capacities Engine Crankcase Oil Capacity with Filter Change ..........................................................8,5 liters (9 quarts) Type of Oil .................................................................................................15W-40 CE Fuel Tank Capacity ....................................................................................140 liters (37 gallons) Type of Fuel..........
Section 8 - Specifications Axles 3513 & 4013 Differential Housing Capacity .....................................................7,3 liters (7.8 quarts) Wheel End Capacity ...................................................................1,4 liters (1.5 quarts) Type of Fluid ................................................... Mobilfluid® 424 Tractor Hydraulic Fluid 4017 Differential Housing Capacity (Front Axle).....................................8 liters (8.
Section 8 - Specifications Capacity at Maximum Height On Ouriggers 3513.................................................................................. 3.500 kg (7,716 lb) 4013.................................................................................. 4.000 kg (8,818 lb) 4017.................................................................................. 3.000 kg (6,614 lb) Without Ouriggers 3513.................................................................................. 1.
Section 8 - Specifications Dimensions Overall Height 3513 & 4013.............................................................................2.450 mm (96.5 in) 4017 .........................................................................................2.520 mm (99.2 in) Overall Width .................................................................................2.380 mm (93.7 in) Cab Width............................................................................................
Section 8 - Specifications Noise Emission Level • The telehandler is approved under the applicable EC directives. • The LWA sound power level is shown on the machine. • To avoid any increase in noise emission, after maintenance and repair work, all panels and other sound absorbing materials must be replaced in their original condition. Do not modify the machine in such a manner as to increase noise emissions.
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Index Index A D Additional Checks............................. 7-1 Decals ........................................2-6, 2-9 Adjustable Truss Boom .................. 4-23 Dimensions .......................................8-4 Adjusting/Moving Forks .................. 4-11 Disengaging The Load......................3-7 Air Cleaner ..................................... 6-12 Display Screen................................2-18 Air Conditioner Controls ................. 2-34 Driving Hazards On Slopes.....
Index I P Ignition ............................................ 2-22 Park Brake ......................................2-23 Instrument Panel ............................ 2-16 Parking Procedure ..........................2-23 J Joystick........................................... 2-28 Optional Controls ...................... 2-30 Standard Controls ..................... 2-28 L Leveling Procedure........................... 3-6 Lifting Personnel............................... 1-8 Performance...............
Index T Telehandler Vibration ....................... 8-5 Tip Over Hazard ............................... 1-3 Tire Pressure.................................. 6-18 Tires ................................................. 8-2 Towing.............................................. 5-1 Transfer Case................................... 8-1 Transmission .................................... 8-1 Transmission Control ..................... 2-24 Transmission Oil Level ................... 6-19 Transport ...................
Index 4 31200028
Inspection, Maintenance & Repair Log Inspection, Maintenance & Repair Log Serial Number ______________________________ Date 31200028 Comments 1
Inspection, Maintenance & Repair Log Date 2 Comments 31200028
JLG Industries, Inc. TRANSFER OF OWNERSHIP To: JLG, Gradall, Lull and SkyTrak 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.
Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA Phone: (717) 485-5161 Customer Support Toll Free: (877) 554-5438 Fax: (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W.
Operator & Safety Manual Keep this manual with machine at all times.
Revision Log Revision Log REVISION LOG October 3, 2005 - A - Original Issue of Manual February 27, 2006 - B - Added 4017 information.
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.
Read This First This product must comply with all safety related bulletins. Contact JLG Industries, Inc. or the local authorized JLG 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.
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Table of Contents Table of Contents TABLE OF CONTENTS Revision Log Read This First Operator Qualifications ...................................................... b Modifications ...................................................................... b Table of Contents Section 1 - General Safety Practices 1.1 General Precautions ............................................................1-1 1.2 Hazard Classification system...............................................
Table of Contents Section 4 - Platform 4.1 4.2 4.3 4.4 Approved Platforms............................................................. 4-1 Unapproved Platforms......................................................... 4-1 Telehandler/Platform Capacity ............................................ 4-2 Platform Installation............................................................. 4-3 Mechanical Quick-Switch Device ................................... 4-4 Platform Attachment .................................
Section 1 - General Safety Practices SECTION 1 - GENERAL SAFETY PRACTICES 1.1 GENERAL PRECAUTIONS • DO NOT use the machine with platform attached for any purpose other than positioning personnel, their tools and equipment. • DO NOT place boom or platform against any structure to steady the platform or to support the structure. • DO NOT assist a stuck or disabled machine by using boom functions. WARNING Before operation, read & understand this manual.
Section 1 - General Safety Practices 1.3 OPERATION SAFETY Electrical Hazards OZ1760 • This machine is not insulated and does not provide protection from contact or proximity to electrical current.
Section 1 - General Safety Practices Tip Over Hazard OZ1340 • DO NOT exceed rated lift capacity. Distribute loads evenly on platform floor. • Be sure that the ground conditions are able to support the machine. OW0080 • DO NOT raise boom unless frame is level (0 degrees). 12.5 m/s MAX OZ1280 • DO NOT operate machine when wind conditions exceed 12.5 m/s (28 mph). OH2291 • MAINTAIN proper tire pressure at all times. If proper tire pressures are not maintained, this machine could tip over.
Section 1 - General Safety Practices Load Falling Hazard OZ1350 • Never suspend load from platform or supports. • DO NOT carry materials directly on platform railing unless approved by JLG. • Always ensure that power tools are properly stowed and never left hanging by their cord from the platform work area.
Section 1 - General Safety Practices Lifting Personnel OW0170 • USE ONLY a JLG manufactured personnel work platform. OW0190 • DO NOT drive machine from cab when personnel are in platform. • DO NOT allow personnel to tamper with or operate the machine from the cab when personnel are in the platform. • Never sway the machine when the platform is occupied.
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 tires and platform or other objects. OW0230 • Keep clear from under boom. OW0240 • Keep clear of boom holes.
Section 1 - General Safety Practices OW0250 • Keep arms and hands clear of attachment tilt cylinder. OZ1330 • During operation, keep all body parts inside platform railing. OZ1320 • Keep others away while operating. OZ1310 • Approved head gear must be worn by all operating personnel. • Check work area for clearances overhead, on sides and bottom of platform when lifting or lowering platform. • Be sure that operators of other overhead and floor level machines are aware of the machine’s presence.
Section 1 - General Safety Practices Fall Hazard OZ1290 • During operation, occupants in the platform must wear a full body harness with a lanyard attached to an authorized lanyard anchorage point. Attach only one lanyard per lanyard anchorage point. OZ1300 • Before operating the machine, make sure all gates are closed and fastened in their proper position. • Keep both feet firmly positioned on the platform floor at all times.
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. Flammable Fuel OW0300 • DO NOT fill the fuel tank or service the fuel system near an open flame, sparks or smoking materials.
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Section 2 - Pre-Operation and Controls SECTION 2 - PRE-OPERATION AND CONTROLS 2.1 PRE-OPERATION CHECKS & 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. Failure to comply could result in death or serious injury. A walk-around inspection of the telehandler is to be completed first. Refer to the Operator & Safety Manual supplied with telehandler.
Section 2 - Pre-Operation and Controls 2 1 3 4 5 OZ1660 Begin your platform 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.
Section 2 - Pre-Operation and Controls 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.
Section 2 - Pre-Operation and Controls 1706604A 1706604A 1706604 1706604 1706604A 1706604 1706603 2-4 1706602A 1706602 OZ1780 31200029
1704277 B Section 2 - Pre-Operation and Controls 1704277 1701509 1701509 AERIAL PLATFORM MODEL P/N S/N 1706627 SERIAL NO. M/S kg kg = MAX M/S N MAX kg Producer: JLG Manufacturing Europe BVBA Industrieterrein Oude Bunders 1034, Breitwaterstraat 12 3630 Maasmechelen - Belgium N G.V.W.
Section 2 - Pre-Operation and Controls 2.3 CONTROLS 2 1 3 2 7 5 6 4 8 OZ1730 1. Emergency Stop Button: Push in to shut off power to platform controls and stop engine. 2. Indicator Panels: Indicator, caution and warning lights. See page 2-10 for details. 3. Fuel Gauge: Gauge for the diesel fuel tank. 4. Boom Joystick: See page 2-8 for details. 5. ERS Controller: See page 5-2 for details. 6. Horn: Push button to sound. 7. Ignition: Key activated. See page 2-7 for details. 8.
Section 2 - Pre-Operation and Controls Ignition ERS 0 IGN PHT STR OZ1740 • Position 0 - Engine off • Position IGN - Voltage is available for all electrical functions. • Position PHT - Engine preheat at temperature below 0°C. • Position STR - Engine start. • Position ERS - ERS controls are enabled.
Section 2 - Pre-Operation and Controls Joystick 1 5 6 2 4 3 OZ1530 The joystick (1) controls the boom and attachment functions. Note: Buttons (5) & (6) are not used. Boom Functions • Boom functions are enabled by button (2). Press and hold the button; move the joystick forward to lift boom; move joystick back 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.
Section 2 - Pre-Operation and Controls Platform Functions • Platform tilt is enabled by button (2) and controlled by the rocker switch (3). Press and hold the button; push the rocker switch up to tilt platform back (up); push the rocker switch down to tilt platform forward (down). • Attachment rotate is enabled by button (4). Press and hold the button; move the joystick left to rotate platform left; move the joystick right to rotate the platform right. WARNING CRUSH HAZARD.
Section 2 - Pre-Operation and Controls Indicator Panels 1 2 10 3 4 9 8 7 6 5 OZ1540 1. Engine Temperature: Illuminates red when engine temperature is high. 2. Battery Charge: Illuminates red when battery charge is low. 3. Engine Oil Pressure: Illuminates red when engine oil pressure is low. 4. Glow Indicator: Illuminates yellow when ignition key is at position PHT; engine preheat. 5. Wait Indicator: Illuminates yellow when system diagnostics are in process.
Section 2 - Pre-Operation and Controls 9. System Distress Indicator: a. Flashes yellow and buzzer sounds intermittently when pressure is low in either outrigger. b. Illuminates yellow and buzzer sounds when one of the following items is out of range. • Engine Oil Pressure • Engine Temperature • Transmission Temperature • Air Filter • Hydraulic Oil Filter • CAN Bus • Engine Speed Sensor • Hydraulic Pump Pressure • Short Circuit Main Control Valve • Boom Angle Sensor c.
Section 2 - Pre-Operation and Controls 2.4 PLATFORM GATE Keep gate clean and unobstructed. 1 OZ1820 • Pull the black hook (1) away from the gate and push/pull the gate to open. • During operation the gate must be latched closed.
Section 2 - Pre-Operation and Controls 2.5 LANYARD ANCHORAGE POINTS 2 2 2 2 OZ1650 • Attach lanyard to one of the lanyard anchorage points (2). • Only attach one lanyard per lanyard anchorage point.
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Section 3 - Operation SECTION 3 - OPERATION 3.1 WARM-UP AND OPERATIONAL CHECKS This section outlines the checks to be performed at the beginning of each work shift or at each change of operator. Warm-up and operational checks of the telehandler are to be completed before entering the platform. Refer to the Operator & Safety Manual supplied with telehandler. After start-up from platform and engine warms, check: 1. Horn must be audible with engine running. 2.
Section 3 - Operation 3.2 ENGINE Starting the Engine This machine can be operated in temperatures of -20°C to 40°C (0°F to 104°F). Consult JLG for operation outside this range. Note: Initial starting of engine should be performed from the cab. Refer to the Operator & Safety Manual supplied with telehandler. 1. In the cab make sure transmission control lever is in neutral and locked, emergency stop button is pulled out, outriggers are lowered, machine is level and ignition is turned to position P. 2.
Section 3 - Operation Normal Engine Operation • Observe indicator panels frequently to be sure all engine systems are functioning properly. • Be alert for unusual noises or vibration. When an unusual condition is noticed, perform shut-down procedure. See “Shut-Down Procedure”. Report condition to your supervisor or maintenance personnel. • Avoid prolonged idling. If the engine is not being used, turn it off. Shut-Down Procedure 1. Lower platform to ground. 2. Release footswitch. 3.
Section 3 - Operation 3.3 PLATFORM OPERATION • After engine start-up from the platform is successful, activate the footswitch to enable the platform controls. The controls enable indicator will illuminate. • If a control function is not operated within a seven second period, the controls enable indicator will go out and the controls are disabled. Release the footswitch and activate again to re-enable the controls.
Section 3 - Operation 3.4 LOADING AND SECURING FOR TRANSPORT 2 1 OZ1861 1. To move/load the platform when detached from telehandler, use fork slots located under the platform. 2. Secure platform to deck with strap as shown in the figure.
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Section 4 - Platform SECTION 4 - PLATFORM 4.1 APPROVED PLATFORMS PLATFORM IDENTIFICATION PLATE AERIAL PLATFORM MODEL P/N TELEHANDLER IDENTIFICATION PLATE 1 2 S/N AERIAL PLATFORM APPLICATION PLATE S/N TRUCK S/N This truck can be combined with the aerial platform: MODEL P/N HOMOLOGATION No. 3 4 OZ1670 To determine if platform is approved for use on the specific telehandler you are using, perform the following prior to installation.
Section 4 - Platform 4.3 TELEHANDLER/PLATFORM CAPACITY Prior to installing the platform verify it is approved (see page 4-1) and the telehandler is equipped with the proper capacity chart. To determine the maximum capacity of the telehandler and platform, use the capacity shown on the capacity decals (see page 2-3). WARNING Never use an attachment without the appropriate JLG supplied capacity chart installed on the telehandler.
Section 4 - Platform 4.4 PLATFORM INSTALLATION Verify the platform is properly installed. Refer to the Operator & Safety Manual supplied with telehandler for complete installation instructions. 1. Platform 2. Platform Pin Recess 3. Attachment Pin 4. Lock Pin 5. Retainer Pin 6. Quick-Switch Device WARNING FALL/CRUSH HAZARD. Always be certain that platform is properly positioned on boom and secured. Failure to ensure proper installation could permit platform to disengage causing death or serious injury.
Section 4 - Platform Mechanical Quick-Switch Device Attachment pin engaged in platform pin recess and lock pin inserted and secured with retainer pin. OZ1620 Platform Attachment Platform hydraulic hoses securely connected at boom. Electric cable from the platform securely connected to electrical box on boom. OZ1600 WARNING Never use the platform without the hydraulic hoses and electric cable properly installed.
Section 5 - Emergency Procedures SECTION 5 - EMERGENCY PROCEDURES 5.1 EMERGENCY OPERATION Operator Unable to Control Machine If the platform operator is pinned, trapped or unable to operate or control machine: 1. Other personnel should operate the machine from ground ERS controls only as required. 2. Other qualified personnel on the platform may use the platform controls. DO NOT CONTINUE OPERATION IF CONTROLS DO NOT FUNCTION PROPERLY.
Section 5 - Emergency Procedures 5.2 EMERGENCY LOWERING OF BOOM In case of an emergency, engine or hydraulic failure an emergency recovery system (ERS) is available. Ground ERS Refer to the Operator & Safety Manual supplied with telehandler. Platform ERS 4 2 1 3 5 6 OZ1750 1. Verify the emergency stop switch (1) is not depressed. 2. Turn ignition switch (2) to position “ERS”. The ERS indicator (3) should illuminate.
Section 5 - Emergency Procedures 5.3 INCIDENT NOTIFICATION JLG Industries, Inc. must be notified immediately of any incident involving a JLG product. Even if no injury or property damage is evident, the factory should be contacted by telephone and provided with all necessary details. In USA: Toll Free: 877-JLG-SAFE (877-554-7233) 8:00am to 4:45pm EST Outside USA: Phone: 717-485-5161 E-mail: ProductSafety@JLG.
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Section 6 - Lubrication & Maintenance SECTION 6 - LUBRICATION & MAINTENANCE 6.1 INTRODUCTION Service the product in accordance with Section 6 of the Operator & Safety Manual supplied with telehandler and the maintenance schedule on the following pages. Service intervals are based on machine usage of 1500 hours annually. Use of your product may vary significantly and you must adjust service frequency for your usage to obtain maximum service life.
Section 6 - Lubrication & Maintenance 6.
Section 6 - Lubrication & Maintenance 6.4 OPERATOR MAINTENANCE INSTRUCTIONS Fuel System A. Fuel Level Check 8 OW1150 OW0990 2 4 3 OZ0660 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 3-3. 3. Open the rear access door (2). 4. Turn fuel tank cap (3) and remove from filler neck (4). Add diesel fuel as needed. Replace fuel tank cap. 5. Close and secure the rear access door.
Section 6 - Lubrication & Maintenance Tires A. Tire Air Pressure Check 8 OW1150 OW1040 1. Perform “Shut-Down Procedure” on page 3-3. 2. Remove valve stem cap. 3. Check tire pressure using a good quality gauge. 4. Add air if required. 405/70-24 ...........................................................................4.5 bar (65 psi) 5. Replace valve stem cap.
Section 6 - Lubrication & Maintenance Battery 8 A. Battery Check OW1150 6 5 OW1080 OZ1710 1. Perform “Shut-Down Procedure” on page 3-3. 2. Open the engine cover. 3. Wearing eye protection, visually inspect the battery (5). Charge indicator (6) must be green. Check terminals for corrosion. Replace battery if it has a cracked, melted or damaged case. 4. Close and secure the engine cover.
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Section 7 - Additional Checks SECTION 7 - ADDITIONAL CHECKS 7.1 EMERGENCY RECOVERY SYSTEM TEST 8 OW1150 ERS OZ1500 The Emergency Recovery System (ERS) is available on the platform in case of emergency, engine or hydraulic failure. To check this feature, perform the following: 1. Lower platform to ground and shut-off engine. 2. Make sure the emergency stop switch is not depressed. 3. Turn ignition switch to position “ERS”. The ERS indicator should illuminate. 4.
Section 7 - Additional Checks 7.2 LIMITED BOOM EXTENSION SWITCH TEST 8 OW1150 OZ1840 Australian machines are equipped with a switch (1) on the boom to limit extension while being operated from platform. 2 1 OZ1850 Perform the following to check for proper operation: 1. With platform just above ground level, extend unloaded platform to full extension. 2. Lower platform to ground, release footswitch and shut-off engine. 3. Exit platform properly. 4.
Section 8 - Specifications SECTION 8 - SPECIFICATIONS 8.1 PRODUCT SPECIFICATIONS For telehandler specifications refer to the Operator & Safety Manual supplied with telehandler. Performance Maximum Lift Capacity ........................................................................ 450 kg (992 lb) Maximum Lift Height 3513 & 4013 ..............................................................................13,07 m (42.88 ft) 3513 & 4013 (Australian) ......................................................
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Index Index A I Additional Checks............................. 7-1 Ignition ..............................................2-7 Approved Platforms.......................... 4-1 Incident Notification...........................5-3 B Battery Check................................... 6-5 C Indicator Panels ..............................2-10 J Joystick .............................................2-8 Capacity ........................................... 4-2 L Chemical Hazards ...........................
Index T Tip Over Hazard ............................... 1-3 Tire Pressure .................................... 6-4 V Vibration ........................................... 8-1 W Warm-Up ..........................................
Inspection, Maintenance & Repair Log Inspection, Maintenance & Repair Log Serial Number ______________________________ Date 31200029 Comments 1
Inspection, Maintenance & Repair Log Date 2 Comments 31200029
JLG Industries, Inc. TRANSFER OF OWNERSHIP To: JLG, Gradall, Lull and SkyTrak 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.
Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA Phone: (717) 485-5161 Customer Support Toll Free: (877) 554-5438 Fax: (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W.
