JLG 4009 Operator Manual
Operation & Safety
Manual
Keep this manual with machine at all times.
Suspended Load
Supplement
for
3509, 3513,
4009, 4013
& 4017
31200487
Revised
April 29, 2009
An Oshkosh Corporation Company
Revision Log
Revision Log
October 23, 2008 - A - Original Issue of Manual
April 29, 2009 - B - Revised pages 2-3, 2-4 & 2-5.
REVISION LOG
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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 driver’s license, be in
good physical and mental condition, have normal reflexes and reaction time, good
vision and depth perception and normal hearing. Operator must not be using
medication which could impair abilities nor be under the influence of alcohol or any
other intoxicant during the work shift.
In addition, the operator must read, understand and comply with instructions
contained in the following material furnished with the telehandler:
• This Operation & Safety Manual
• Telehandler Safety Manual (as required)
• 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.
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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. 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
or Your Local JLG Office
(Addresses on back cover)
In USA:
Toll Free: 1-877-JLG-SAFE (1-877-554-7233)
Outside USA:
Phone: +1-717-485-6591
E-mail:
ProductSafety@JLG.com
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Other Publications Available
For detailed machine operation procedures and safety information, please refer to
the appropriate machine Operation & Safety Manual.
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.
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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
Table of Contents
Section 2 - Load Management Indicator System (LMIS)
2.1 General ................................................................................2-1
2.2 Control Panel .......................................................................2-2
Display ............................................................................2-3
2.3 Operation .............................................................................2-4
System Start Up ..............................................................2-4
Attachment Selection ......................................................2-5
Lifting Conditions and Alarms .........................................2-6
2.4 Diagnostic Data ...................................................................2-7
Alarms and Warnings......................................................2-7
LMI Values ......................................................................2-7
Pressure Values..............................................................2-8
Angle and Length Transducers.......................................2-8
LMI Status .......................................................................2-9
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Table of Contents
Section 3 - Machine Operation
3.1 Operating With A Suspended Load..................................... 3-1
Lift Load Safely............................................................... 3-1
Picking Up A Suspended Load....................................... 3-1
Transporting a Suspended Load .................................... 3-2
Leveling Procedure......................................................... 3-2
Placing a Suspended Load............................................. 3-3
Disengaging A Suspended Load .................................... 3-3
Section 4 - Attachments
4.1 Use of the Capacity Chart ................................................... 4-1
Capacity Indicator Locations .......................................... 4-1
Sample Capacity Chart................................................... 4-2
Example.......................................................................... 4-4
Truss Boom .................................................................... 4-5
Section 5 - LMIS Service and Maintenance
5.1 Auto-Diagnostic System ...................................................... 5-1
Alarm Codes................................................................... 5-2
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Section 1 - General Safety Practices
SECTION 1 - GENERAL SAFETY PRACTICES
1.1 HAZARD CLASSIFICATION SYSTEM
Safety Alert System and Safety Signal Words
DANGER
DANGER indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION
CAUTION indicates a potentiality hazardous situation which, if not avoided, may
result in minor or moderate injury.
OW0010
OW0021
OW0031
1.2 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.
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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.
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Section 1 - General Safety Practices
Tip Over Hazard
General
• For additional load requirements, refer to the appropriate capacity chart.
OW0050
• Never use an attachment without the appropriate JLG approved capacity chart
installed on the telehandler.
• Understand how to properly use the capacity charts located in cab.
• DO NOT exceed rated lift capacity.
• Be sure that the ground conditions are able to support the machine.
OW0080
• DO NOT raise boom unless frame is level (0 degrees), unless otherwise noted on
capacity chart.
4 FT
(1,2 M)
OW0100
• DO NOT level machine with boom/attachment above 1,2 m (4 ft).
(AUS - DO NOT level machine with load more than 300 mm (11.8 in) above
ground surface)
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Section 1 - General Safety Practices
OH2291
• MAINTAIN proper tire pressure at all times. If proper tire pressures are not
maintained, this machine could tip over.
• Refer to manufacturer’s specifications for proper fill ratio and pressure
requirements for tires equipped with ballast.
OH20911
• Always wear the seat belt.
• Keep head, arms, hands, legs and all other body parts inside operator’s cab at all
times.
OH2221
If the telehandler starts to tip over:
• DO NOT JUMP
• BRACE YOURSELF and STAY WITH THE MACHINE
• KEEP YOUR SEAT BELT FASTENED
•HOLD ON FIRMLY
• LEAN AWAY FROM THE POINT OF IMPACT
Trying to escape from a tipping machine could result in death or serious injury.
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Section 1 - General Safety Practices
Suspended Load
OW0150
• Tether suspended loads to restrict movement.
• DO NOT raise the load more than 300 mm (11.8 in) above ground surface or the
boom more than 45°.
• Weight of all rigging (slings, etc.) must be included as part of load.
• Start, travel, turn and stop slowly to prevent load from swinging.
• When driving with the boom raised, DO NOT exceed walking speed.
• 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.
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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.
• Ensure that adequate clearance is provided between 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).
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