JLG 4017 Operator Manual

Operator & Safety

Manual

Keep this manual with machine at all times.

Models

3513, 4013

& 4017

Equipped for

Platform

31200028

Revised

February 27, 2006

Revision Log

October 3, 2005 - A - Original Issue of Manual

February 27, 2006 - B - Added 4017 information.

REVISION LOG

31200028

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 Operator & Safety Manual

• Telehandler Safety Manual

• 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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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. 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. 1 JLG Drive McConnellsburg, PA 17233 USA

or Your Local JLG Office (Addresses on back cover)

In USA:

Toll Free: 877-JLG-SAFE (877-554-7233)

Outside USA:

Phone: 717-485-5161 E-mail: ProductSafety@JLG.com

Other Publications Available

Platform for 3513, 4013 & 4017 Operator & Safety Manual............. 31200029

3513 & 4013 Service Manual.............................................................3121852

3513 & 4013 Illustrated Parts Manual ................................................3121853

4017 Service Manual ......................................................................... 3121858

4017 Illustrated Parts Manual............................................................. 3121859

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This Page Intentionally Left Blank

31200028

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...............................................1-1

Safety Alert System and Safety Signal Words ................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...........................................1-10

Pinch Points and Crush Hazards ..................................1-11

Fall Hazard....................................................................1-13

Chemical Hazards.........................................................1-14

Table of Contents

Section 2 - Pre-Operation and Controls

2.1 Pre-Operation Checks & Inspection.....................................2-1

3513 & 4013....................................................................2-2

4017 ................................................................................2-4

2.2 Safety Decals....................................................................... 2-6

3513 & 4013....................................................................2-6

4017 ................................................................................2-9

2.3 Operator Cab .....................................................................2-13

2.4 Controls .............................................................................2-14

Instrument Panel ...........................................................2-16

Display Screen ..............................................................2-18

Anti Theft Device...........................................................2-21

Ignition .......................................................................... 2-22

Park Brake ....................................................................2-23

Parking Procedure ........................................................2-23

Transmission Control ....................................................2-24

Wiper, Lights and Turn Signal Control Lever ................ 2-26

Steering Column Adjuster .............................................2-27

Joystick .........................................................................2-28

i31200028

Table of Contents

Load Moment Indicator (LMI) ....................................... 2-32

Control & Indicator Console.......................................... 2-33

Heater and Air Conditioner (optional) Controls............. 2-34

2.5 Steer Modes ...................................................................... 2-35

2.6 Operator Seat.................................................................... 2-36

Adjustments.................................................................. 2-36

Seat Belt ....................................................................... 2-37

2.7 Mirrors & Windows ............................................................ 2-38

Cab Door Window ........................................................ 2-38

Rear Window ................................................................ 2-38

Mirrors .......................................................................... 2-39

2.8 Hood.................................................................................. 2-40

Section 3 - Operation

3.1 Warm-Up and Operational Checks ..................................... 3-1

3.2 Engine ................................................................................. 3-2

Starting the Engine ......................................................... 3-2

Battery Boosted Starting................................................. 3-3

Normal Engine Operation ............................................... 3-4

Shut-Down Procedure .................................................... 3-4

3.3 Operating With A Load ........................................................ 3-5

Lift Load Safely............................................................... 3-5

Before Picking Up A Load .............................................. 3-5

Transporting The Load ................................................... 3-6

Leveling Procedure......................................................... 3-6

Placing The Load............................................................ 3-7

Disengaging The Load ................................................... 3-7

3.4 Road Operation ................................................................... 3-8

3.5 Loading And Securing For Transport .................................. 3-9

Section 4 - Attachments & Hitch Options

4.1 Approved Attachments ........................................................ 4-1

4.2 Unapproved Attachments.................................................... 4-1

4.3 Telehandler/Attachment/Fork Capacity ............................... 4-2

4.4 Use of the Capacity Chart ................................................... 4-3

Capacity Indicator Locations .......................................... 4-3

Sample Capacity Chart................................................... 4-4

Example.......................................................................... 4-6

4.5 Attachment Installation ........................................................ 4-7

Mechanical Quick-Switch Device ................................... 4-8

Hydraulic Operated Attachment ..................................... 4-9

Platform Attachment ....................................................... 4-9

4.6 Adjusting/Moving Forks..................................................... 4-11

4.7 Attachment Operation ....................................................... 4-11

ii 31200028

Carriage w/Forks...........................................................4-12

Truss Boom...................................................................4-13

Side Shift Carriage ........................................................4-14

Bucket ........................................................................... 4-16

Fork Extension .............................................................. 4-18

Platform.........................................................................4-20

Fork Hook ..................................................................... 4-22

Adjustable Truss Boom .................................................4-23

4.8 Hitch Options .....................................................................4-24

Mechanical Hitch...........................................................4-24

Section 5 - Emergency Procedures

5.1 Towing A Disabled Product..................................................5-1

Moving Short Distances ..................................................5-1

Moving Longer Distances ...............................................5-1

5.2 Emergency Lowering of Boom.............................................5-2

ERS with Standard Attachment ......................................5-2

ERS with Platform ...........................................................5-3

5.3 Cab Emergency Exit ............................................................5-4

Section 6 - Lubrication & Maintenance

6.1 Introduction ..........................................................................6-1

Clothing and Safety Gear................................................6-1

6.2 General Maintenance Instructions .......................................6-2

6.3 Service & Maintenance Schedules ......................................6-3

8 & 1st 50 Hour Maintenance Schedule .........................6-3

50, 250 & 500 Hour Maintenance Schedule ...................6-4

1000 & 1500 Hour Maintenance Schedule .....................6-5

6.4 Lubrication Schedules .........................................................6-6

8 Hour Lubrication Schedule - 3513 & 4013 ...................6-6

50 Hour Lubrication Schedule - 3513 & 4013 .................6-7

8 Hour Lubrication Schedule - 4017 ...............................6-8

50 Hour Lubrication Schedule - 4017 .............................6-9

6.5 Operator Maintenance Instructions.................................... 6-10

Fuel System .................................................................. 6-10

Air Intake System ..........................................................6-12

Engine Oil ..................................................................... 6-14

Battery...........................................................................6-15

Brake System................................................................6-16

Hydraulic Oil..................................................................6-17

Tires .............................................................................. 6-18

Transmission Oil ...........................................................6-19

Engine Cooling System.................................................6-20

Table of Contents

iii31200028

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 ................................................................... 8-2

Dimensions..................................................................... 8-4

Noise Emission Level ..................................................... 8-5

Telehandler Vibration ..................................................... 8-5

Index

Inspection, Maintenance & Repair Log

iv 31200028

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

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

OW0020

OW0030

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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.

1-2

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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).

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1-3

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. 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.

1-4

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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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1-5

Section 1 - General Safety Practices

Travel Hazard

4-Wheel Steer Pivot Steer

• 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.

• 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.

OW0120

1-6

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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.

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1-7

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.

1-8

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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. DO NOT lift or carry persons in the bucket or on forks.

Never tilt the platform forward, rearward, or sway the machine when the platform is occupied. Serious injury or death could result.

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1-9

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.

• 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

• Avoid turning on a slope. Never engage “inching” or shift to “Neutral” when going downhill.

• DO NOT park on a slope.

any

circumstances.

1-10

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Section 1 - General Safety Practices

Pinch Points and Crush Hazards

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

• Stay clear of moving parts while engine is running.

OW0220

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

OW0210

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OW0230

• Keep clear from under boom.

1-11

Section 1 - General Safety Practices

• Keep clear of boom holes.

• Keep arms and hands clear of attachment tilt cylinder.

OW0240

OW0250

1-12

OW0260

• Keep hands and fingers clear of carriage and forks.

OW0960

• Keep others away while operating.

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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.

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1-13

Section 1 - General Safety Practices

Chemical Hazards

Exhaust Fumes

• DO NOT operate machine in an enclosed area without proper ventilation.

• DO NOT operate the machine in hazardous environments unless approved for that purpose 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. Engine fuel is flammable and can cause a fire and/or explosion.

Hydraulic Fluid

OW0950

• DO NOT attempt to repair or tighten any hydraulic hoses or fittings while the engine is running or when the hydraulic system is under pressure.

• Stop engine and relieve trapped pressure. Fluid in the hydraulic system is under enough pressure that it can penetrate the skin.

• DO NOT use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks. Wear gloves to protect hands from spraying fluid.

1-14

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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.

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. Clean or replace as required. See

“Safety Decals”

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.

If spark arrestors are required, be sure they are in place and in good working order.

When adding fluids, refer to lubrication section of this manual to determine proper type and intervals.

on page 2-6.

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2-1

Section 2 - Pre-Operation and Controls

3513 & 4013

Begin your walk-around inspection at item 1. 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 & Lift, Tilt, Extend/Retract, Compensating (Slave) Cylinders

• Check front, top, side & rear slider pads for adequate grease.

• Pivot pins secure; hydraulic hoses undamaged, not leaking.

2. Left Outrigger leaking. Pressure switch and proximity switch undamaged and clean.

- Pins secure; hydraulic hoses & cylinder undamaged, not

2-2

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Section 2 - Pre-Operation and Controls

3. Front Work Lights - Clean, undamaged and work properly.

4. Front Axle

hydraulic hoses undamaged, not leaking.

5. Wheel/Tire Assembly

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.

• Check seat belt for damage, replace belt if frayed or cut webbing, damaged buckles or loose mounting hardware.

• Check brake fluid level, refill as required.

7. Hydraulic Reservoir be cool); filler/breather cap secure and working.

8. Wheel/Tire Assembly - No loose or missing lug nuts; proper inflation.

9. Rear Axle - Steer cylinders undamaged, not leaking; pivot pins secure;

hydraulic hoses undamaged, not leaking.

10. Rear Work Lights - Clean, undamaged and work properly.

11. Fuel Tank - Check fluid level, refill as required; filler cap is securely fastened.

12. Wheel/Tire Assembly

13. Engine Compartment

• Engine Crankcase and Radiator, check levels & refill as required.

• Drive belts, check condition & replace as required.

• Air cleaner element condition indicator, check for clogged condition. Replace

element as required.

• Main control valve, see inspection note.

• Battery charged, indicator must be green. Cables tight, no visible damage or

corrosion.

• Engine cover properly secured and latched.

14. Mirrors - Clean, undamaged and work properly.

15. Wheel/Tire Assembly

- Steer cylinders undamaged, not leaking; pivot pins secure;

- No loose or missing lug nuts; proper inflation.

- Recommended fluid level on sight gauge (lubricant must

- No loose or missing lug nuts; proper inflation.

16. Sway Cylinder

17. Right Outrigger

leaking. Pressure switch and proximity switch undamaged and clean.

18. Attachment

- Pins secure; hydraulic hoses undamaged, not leaking.

- Pins secure; hydraulic hoses & cylinder undamaged, not

- Properly installed, see

“Attachment Installation”

31200028

on page 4-7.

2-3

Section 2 - Pre-Operation and Controls

4017

Begin your walk-around inspection at item 1. Continue to your right (counterclockwise when viewed from top) checking each item in sequence.

16 15

OZ0400

1. Boom Sections & Lift, Tilt, Extend/Retract, Compensating (Slave) Cylinders

• Check front, top, side & rear slider pads for adequate grease.

• Pivot pins secure; hydraulic hoses undamaged, not leaking.

• Check extend/retract chains and adjustment blocks for adequate tension.

2. Front Work Lights

3. Left Outrigger - Pins secure; hydraulic hoses & cylinder undamaged, not

leaking. Pressure switch and proximity switch undamaged and clean.

2-4

- Clean, undamaged and work properly.

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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.

• Check seat belt for damage, replace belt if frayed or cut webbing, damaged

buckles or loose mounting hardware.

• Check brake fluid level, refill as required.

7. Hydraulic Reservoir be cool); filler/breather cap secure and working.

8. Wheel/Tire Assembly

9. Rear Axle

hydraulic hoses undamaged, not leaking.

10. Rear Worklights

11. Fuel Tank

12. Wheel/Tire Assembly - No loose or missing lug nuts; proper inflation.

13. Engine Compartment

• Engine Crankcase and Radiator, check levels & refill as required.

• Drive belts, check condition & replace as required.

• Air cleaner element condition indicator, check for clogged condition. Replace

element as required.

• Main control valve, see inspection note.

• Battery charged, light must be green. Cables tight, no visible damage or

corrosion.

• Engine cover properly secured and latched.

14. Mirrors

- Clean, undamaged and work properly.

- Recommended fluid level on sight gauge (lubricant must

- No loose or missing lug nuts; proper inflation.

- Steer cylinders undamaged, not leaking; pivot pins secure;

- Clean, undamaged and work properly.

- Check fluid level, refill as required; filler cap is securely fastened.

15. Wheel/Tire Assembly

16. Sway Cylinder

17. Right Outrigger

leaking. Pressure switch and proximity switch undamaged and clean.

18. Attachment

- Properly installed, see

- No loose or missing lug nuts; proper inflation.

- Pins secure; hydraulic hoses undamaged, not leaking.

- Pins secure; hydraulic hoses & cylinder undamaged, not

“Attachment Installation”

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on page 4-7.

2-5

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

Optional 8009377 (35) 2603207 (20) 8009890 (22) 8009885 (12)

8005616

8006612

8008657

8005617

8005670

8008657

80031988003198

8005616

AERIAL PLATFORM APPLICATION

PLATE S/N

TRUCK S/N

This truck can be combined with the aerial platform:

MODEL

P/N

HOMOLOGATION No.

1706628

8005675

8003198

1706227

8008793

2-6

8009815

8005869

3931579

VIEW A-A

Optional 8009377 (35) 2603207 (20) 8009890 (22) 8009885 (12)

OZ0960

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