JLG 40xxPS SOperator Manual
Operation & Safety
An Oshkosh Corporation Company
Manual
Original Instructions
Keep this manual with machine at all times.
Models
3508PS, 3509PS,
3512PS, 3513PS,
4008PS, 4009PS,
4012PS, 4013PS,
4017PS
31200205
Revised
August 28, 2012
Revision Log
Revision Log
REVISION LOG
August 10, 2007 - A - Original Issue of Manual
December 12, 2007 - B - Added platform information. Revised pages c, 2-5, 3-2,
3-3, 3-5, 3-8, 3-9, 3-14, 3-16, 3-22, 4-1, 4-3, 5-10, 5-11, 5-30, 6-2, 6-3, 7-18, 7-19,
8-5, 9-1 & 9-4.
March 5, 2008 - C - Revised pages 2-5 & 9-7.
May 16, 2008 - D - Revised pages c, d, 1-4, 1-9, 2-3, 3-2, 3-3, 3-7, 4-4 thru 4-9, 5-4,
5-6, 5-15 & 9-3.
November 16, 2009 - E - Revised covers and page 9-7.
February 26, 2010 - F - Revised pages d, 1-2 thru 1-6, 1-9, 2-1, 2-4 thru 2-9, 3-2 thru
3-8, 3-11, 3-12, 3-14 thru 3-27, 3-29, 4-1 thru 4-12, 5-1 thru 5-46, 6-1, 6-3, 7-1 thru
7-4, 7-10, 7-11, 7-12, 7-14 thru 7-17, 7-19 thru 7-22, 8-2, 8-3 & 9-2 thru 9-5.
August 30, 2010 - G - Revised pages 2-6, 2-7, 3-14, 3-15, 7-4 & 8-1.
November 11, 2010 - H - Revised pages 2-5, 3-14, 3-15 & 3-16.
December 23, 2010 - I - Revised pages 5-2 & 5-3.
August 28, 2012 - J - Revised pages 5-2 & 5-3.
a31200205
Read This First
Read This First
This manual is a very important tool! Keep it with the machine at all times.
The purpose of this manual is to provide owners, users, operators, lessors, and
lessees with the precautions and operating procedures essential for the safe and
proper machine operation for its intended purpose.
Due to continuous product improvements, JLG Industries, Inc. reserves the right to
make specification changes without prior notification. Contact JLG Industries, Inc.
for updated information.
Operator Qualifications
The operator of the machine must not operate the machine until this manual has
been read, training is accomplished and operation of the machine has been
completed under the supervision of an experienced and qualified operator.
Operation within the U.S.A. requires training per OSHA 1910.178.
Operators of this equipment must possess a valid, applicable driver’s license, be in
good physical and mental condition, have normal reflexes and reaction time, good
vision and depth perception and normal hearing. Operator must not be using
medication which could impair abilities nor be under the influence of alcohol or any
other intoxicant during the work shift.
In addition, the operator must read, understand and comply with instructions
contained in the following material furnished with the material handler:
• This Operation & Safety Manual
• Telehandler Safety Manual (ANSI only)
• All instructional decals and plates
• Any optional equipment instructions furnished
The operator must also read, understand and comply with all applicable Employer,
Industry and Governmental rules, standards and regulations.
Modifications
Any modification to this machine must be approved by JLG.
b 31200205
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.
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
c31200205
Read This First
Other Publications Available
Service Manual............................................................................................31200206
Illustrated Parts Manual...............................................................................31200204
Load Management Indicator System Operation & Safety
Manual (if equipped)................................................................................Contact JLG
Platform for 3513PS, 4013PS & 4017PS Operation &
Safety Manual (if equipped for platform) .................................................Contact JLG
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.
d 31200205
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 - Pre-Operation and Inspection
2.1 Pre-Operation Check and Inspection...................................2-1
2.2 Safety Decals.......................................................................2-3
2.3 Walk-Around Inspection.......................................................2-6
2.4 Warm-Up and Operational Checks ......................................2-8
Warm-Up Check ............................................................. 2-8
Operational Check .......................................................... 2-8
2.5 Operator Cab .......................................................................2-9
2.6 Windows ............................................................................2-10
Cab Door Window .........................................................2-10
Rear Window ................................................................2-10
Section 3 - Controls and Indicators
3.1 General ................................................................................ 3-1
3.2 Controls ...............................................................................3-2
Instrument Panel ............................................................. 3-4
Display Screen................................................................3-6
Keypad............................................................................3-8
Ignition ..........................................................................3-10
Park Brake ....................................................................3-11
i31200205
Table of Contents
Parking Procedure........................................................ 3-11
Transmission Control Lever.......................................... 3-12
Load Stability Indicator (LSI) ........................................ 3-14
Steering Column Adjuster............................................. 3-17
Joystick......................................................................... 3-18
Armrest and Right Hand Console................................. 3-22
Accessory Control Lever .............................................. 3-24
3.3 Anti Theft ........................................................................... 3-25
3.4 Steer Modes ...................................................................... 3-26
Manual Steering Alignment Mode Change................... 3-26
All Wheel Assisted Steering Alignment Mode
Change ......................................................................... 3-27
3.5 Operator Seat.................................................................... 3-28
Adjustments.................................................................. 3-28
Seat Belt ....................................................................... 3-30
3.6 Boom Indicators ................................................................ 3-31
Boom Extension ........................................................... 3-31
Boom Angle (AUS) ....................................................... 3-31
Section 4 - Operation
4.1 Engine ................................................................................. 4-1
Starting the Engine ......................................................... 4-1
Battery Boosted Starting................................................. 4-2
Normal Engine Operation ............................................... 4-3
Shut-Down Procedure .................................................... 4-3
4.2 Operating with a Non-Suspended Load .............................. 4-4
Lift Load Safely............................................................... 4-4
Picking Up a Load .......................................................... 4-4
Transporting a Load ....................................................... 4-5
Leveling Procedure......................................................... 4-5
Placing a Load................................................................ 4-6
Disengaging a Load........................................................ 4-6
4.3 Operating with a Suspended Load ...................................... 4-7
Lift Load Safely............................................................... 4-7
Picking Up a Suspended Load ....................................... 4-7
Transporting a Suspended Load .................................... 4-8
Leveling Procedure......................................................... 4-8
Placing a Suspended Load............................................. 4-9
Disengaging a Suspended Load .................................... 4-9
4.4 Road Operation (CE)......................................................... 4-10
4.5 Loading and Securing for Transport .................................. 4-11
Tiedown ........................................................................ 4-11
Lifting ............................................................................ 4-12
ii 31200205
Section 5 - Attachments and Hitches
5.1 Approved Attachments ........................................................ 5-1
5.2 Unapproved Attachments ....................................................5-1
5.3 JLG Supplied Attachments .................................................. 5-2
3508PS, 3509PS, 3512PS, 4008PS, 4009PS
& 4012PS........................................................................5-2
3513PS, 4013PS & 4017PS ...........................................5-3
5.4 Telehandler/Attachment/Fork Capacity................................ 5-4
5.5 Use of the Capacity Chart....................................................5-5
Capacity Indicator Locations ...........................................5-5
Sample Capacity Chart (CE)...........................................5-6
Sample Capacity Chart (AUS) ........................................ 5-8
Example ........................................................................5-10
5.6 Attachment Installation ......................................................5-11
JLG Quick Attach ..........................................................5-11
Manitou Quick Attach ....................................................5-16
Hydraulic Operated Attachment ....................................5-18
Platform Attachment (If Equipped) ................................5-18
5.7 Adjusting/Moving Forks......................................................5-19
5.8 Attachment Operation ........................................................ 5-20
Carriage w/Forks...........................................................5-21
Side Shift Carriage ........................................................5-22
Fork Positioning Carriage .............................................5-24
Fork Extension ..............................................................5-26
Fork Mounted Hook ......................................................5-28
Quick Attach Mounted Hook ......................................... 5-30
Truss Boom...................................................................5-31
Bucket ...........................................................................5-32
Multi-Purpose Bucket ....................................................5-34
Grapple Bucket .............................................................5-36
Concrete Bucket - Fork Mounted ..................................5-38
Platform.........................................................................5-40
5.9 Hitches (3508PS, 4008PS, 3509PS & 4009PS) ................5-41
Pin Hitch - CUNA C (Italy).............................................5-41
Pin Hitch - CUNA D2 (Italy)...........................................5-42
Pin Hitch........................................................................5-43
Auto Hitch .....................................................................5-44
Piton Frame and Auto Hitch ..........................................5-45
Hydraulic Hitch..............................................................5-46
Table of Contents
iii31200205
Table of Contents
Section 6 - Emergency Procedures
6.1 Towing a Disabled Product ................................................. 6-1
Moving Short Distances.................................................. 6-1
Moving Longer Distances ............................................... 6-1
6.2 Emergency Lowering of Boom ............................................ 6-2
6.3 Emergency Lowering of Boom If Equipped for Platform ..... 6-3
Auxiliary Power System.................................................. 6-3
6.4 Cab Emergency Exit............................................................ 6-4
Section 7 - Lubrication and Maintenance
7.1 Introduction.......................................................................... 7-1
Clothing and Safety Gear ............................................... 7-1
7.2 General Maintenance Instructions....................................... 7-2
7.3 Service and Maintenance Schedules .................................. 7-3
8 & 1st 50 Hour Maintenance Schedule ......................... 7-3
50, 250 & 500 Hour Maintenance Schedule................... 7-4
1000 & 1500 Hour Maintenance Schedule..................... 7-5
7.4 Lubrication Schedules ......................................................... 7-6
8 Hour Lubrication Schedule .......................................... 7-6
50 Hour Lubrication Schedule ........................................ 7-8
7.5 Operator Maintenance Instructions ................................... 7-10
Fuel System.................................................................. 7-10
Air Intake System ......................................................... 7-12
Engine Oil ..................................................................... 7-14
Hydraulic Oil ................................................................. 7-15
Tires.............................................................................. 7-16
Brake System ............................................................... 7-18
Transmission ................................................................ 7-19
Engine Cooling System ................................................ 7-20
Battery .......................................................................... 7-21
Windshield Washer System.......................................... 7-22
Section 8 - Additional Checks
8.1 General................................................................................ 8-1
8.2 Load Stability Indicator Test................................................ 8-1
8.3 Boom Interlock .................................................................... 8-2
8.4 Outrigger Interlock (4017PS Only) ...................................... 8-4
8.5 Auxiliary Power (If Equipped for Platform) .......................... 8-5
iv 31200205
Section 9 - Specifications
9.1 Product Specifications ......................................................... 9-1
Fluid and Lubrication Capacities .....................................9-1
Tires ................................................................................9-2
Performance ................................................................... 9-3
Dimensions .....................................................................9-6
Declaration of Vibration (CE) ..........................................9-8
Noise Emission Level (CE) ............................................. 9-8
Index
Inspection, Maintenance and Repair Log
Table of Contents
v31200205
Table of Contents
vi 31200205
Section 1 - General Safety Practices
DANGER
OW0010
WARNING
OW0021
CAUTION
OW0031
SECTION 1 - GENERAL SAFETY PRACTICES
1.1 HAZARD CLASSIFICATION SYSTEM
Safety Alert System and Safety Signal Words
DANGER indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION indicates a potentiality hazardous situation which, if not avoided, may
result in minor or moderate injury.
1.2 GENERAL PRECAUTIONS
WARNING
Before operation, read and understand this manual. Failure to comply with the
safety precautions listed in this manual could result in machine damage, property
damage, personal injury or death.
1-131200205
Section 1 - General Safety Practices
OW0040
10 FT
(3 M)
1.3 OPERATION SAFETY
Electrical Hazards
• This machine is not insulated and does not provide protection from contact or
being near electrical current.
• NEVER operate the telehandler in an area where overhead power lines,
overhead or underground cables, or other power sources may exist without
ensuring the appropriate power or utility company de-energizes the lines.
• Always check for power lines before raising the boom.
• Follow employer, local and governmental regulations for clearance from
powerlines.
1-2 31200205
Section 1 - General Safety Practices
OW0050
OW0080
OW0100
4 FT
(1,2 M)
Tip Over Hazard
General
• For additional load requirements, refer to the appropriate capacity chart.
• 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.
• DO NOT raise boom unless frame is level (0 degrees), unless otherwise noted on
capacity chart.
• DO NOT level machine with boom/attachment above 1,2 m (4 ft).
(AUS - DO NOT level machine with load more than 300 mm (11.8 in) above
ground surface.)
1-331200205
Section 1 - General Safety Practices
OH2291
OH
20911
OH2221
• 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.
• Always wear the seat belt.
• Keep head, arms, hands, legs and all other body parts inside operator’s cab at all
times.
If the telehandler starts to tip over:
• DO NOT JUMP
• BRACE YOURSELF and STAY WITH THE MACHINE
• KEEP YOUR SEAT BELT FASTENED
• HOLD ON FIRMLY
• LEAN AWAY FROM THE POINT OF IMPACT
1-4 31200205
Non-Suspended Load
OW0060
OW0150
• DO NOT drive with boom raised.
Suspended Load
Section 1 - General Safety Practices
• Tether suspended loads to restrict movement.
• Weight of all rigging (slings, etc.) must be included as part of load.
• Beware of wind. Wind can cause a suspended load to swing and cause
dangerous side loads - even with tag lines.
• DO NOT attempt to use telehandler frame-leveling to compensate for load swing.
• Keep heavy part of load closest to attachment.
• Never drag the load; lift vertically.
When driving with a suspended load:
• Start, travel, turn and stop slowly to prevent load from swinging.
• DO NOT extend boom.
• DO NOT raise the load more than 300 mm (11.8 in) above ground surface or
the boom more than 45°.
• DO NOT exceed walking speed.
1-531200205
Section 1 - General Safety Practices
OAL2030
2-Wheel Front Steer 4-Wheel Circle Steer 4-Wheel Crab Steer
Travel Hazard
• Steering characteristics differ between steer modes. Identify the steer mode
settings of the telehandler being operated.
• DO NOT change steer modes while traveling. Steer modes must be changed
while telehandler is stationary.
• Visually verify proper wheel alignment after each steer mode change.
• Ensure that adequate clearance is provided for both rear tail swing and front fork
swing.
• Look out for and avoid other personnel, machinery and vehicles in the area. Use
a spotter if you DO NOT have a clear view.
• Before moving be sure of a clear path and sound horn.
• When driving, retract boom and keep boom/attachment as low as possible while
maintaining visibility of mirrors and maximum visibility of path of travel.
• Always look in the direction of travel.
• Always check boom clearances carefully before driving underneath overhead
obstructions. Position attachment/load to clear obstacles.
• When driving in high speed, use only front wheel steer (if steering modes are
selectable).
1-6 31200205
Section 1 - General Safety Practices
OW0130
Load Falling Hazard
• 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.
1-731200205
Section 1 - General Safety Practices
OW0170
OW0190
Lifting Personnel
• When lifting personnel, USE ONLY a JLG approved personnel work platform,
with proper capacity chart displayed in the cab.
• DO NOT drive machine from cab when personnel are in platform.
1-8 31200205
Section 1 - General Safety Practices
OW0200
Driving Hazards on Slopes
To maintain sufficient traction and braking capabilities, travel on slopes as follows:
• When unloaded, the rear of the machine is the “heavy end.” Drive with forks
pointed downhill.
• When loaded, the front of the machine is the “heavy end.” Drive with the forks
pointed uphill.
• For additional travel requirements, refer to the appropriate capacity chart.
• To avoid overspeeding the engine and drivetrain when driving down slopes,
downshift to a lower gear and use the service brake as necessary to maintain a
slow speed. DO NOT shift into neutral and coast downhill.
• Avoid excessively steep slopes or unstable surfaces. To avoid tip over DO NOT
drive across excessively steep slopes under any circumstances.
• Avoid turning on a slope. Never engage “inching” or shift to “Neutral” when going
downhill.
• DO NOT park on a slope.
1-931200205
Section 1 - General Safety Practices
OW0210
OW0220
OW0
230
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.
• Keep clear of steering tires and frame or other objects.
• Keep clear from under boom.
1-10 31200205
Section 1 - General Safety Practices
OW0240
OW0250
OW0260
OW0960
• Keep clear of boom holes.
• Keep arms and hands clear of attachment tilt cylinder.
• Keep hands and fingers clear of carriage and forks.
• Keep others away while operating.
1-1131200205
Section 1 - General Safety Practices
OW0280
OW0290
Fall Hazard
• Enter using the proper hand holds and steps provided. Always maintain 3-point
contact when mounting or dismounting. Never grab control levers or steering
wheel when mounting or dismounting the machine.
• DO NOT get off the machine until the shutdown procedure on page 4-3 has been
performed.
• DO NOT carry riders. Riders could fall off machine causing death or serious
injury.
1-12 31200205
Section 1 - General Safety Practices
OW0300
OW0950
Chemical Hazards
Exhaust Fumes
• DO NOT operate machine in an enclosed area without proper ventilation.
• DO NOT operate the machine in hazardous environments unless approved for
that purpose by JLG and site owner. Sparks from the electrical system and the
engine exhaust can cause an explosion.
• If spark arrestors are required, ensure they are in place and in good working
order.
Flammable Fuel
• 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
• 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.
1-1331200205
Section 1 - General Safety Practices
This Page Intentionally Left Blank
1-14 31200205
Section 2 - Pre-Operation and Inspection
OAH1000
PARENT METAL CRACK WELD CRACK
SECTION 2 - PRE-OPERATION AND INSPECTION
2.1 PRE-OPERATION CHECK AND INSPECTION
Note: Complete all required maintenance before operating unit.
WARNING
FALL HAZARD. Use extreme caution when checking items beyond your normal
reach. Use an approved ladder.
The pre-operation check and inspection, performed at beginning of each work shift
or at each change of operator, should include the following:
1. Cleanliness - Check all surfaces for leakage (oil, fuel or battery fluid) or foreign
objects. Report any leakage to the proper maintenance personnel.
2. Structure - Inspect the machine structure for dents, damage, weld or parent
metal cracks or other discrepancies.
3. Safety Decals - Ensure all safety decals are legible and in place. Clean or
replace as required. See page 2-3 for details.
4. Operation and Safety Manuals - Operation & Safety Manual located in cab
manual holder.
5. Walk-Around Inspection - See page 2-6 for details.
6. Fluid Levels - Check fluids, including fuel, brake fluid, hydraulic oil, engine oil,
transmission fluid and coolant. When adding fluids, refer to Section
7 - Lubrication and Maintenance and Section 9 - Specifications to determine
proper type and intervals. Before removing filler caps or fill plugs, wipe all dirt
and grease away from the ports. If dirt enters these ports, it can severely reduce
component life.
7. Attachments/Accessories - Ensure correct capacity charts are installed on
the telehandler. If provided, reference the Operation & Safety Manual of each
attachment or accessory installed for specific inspection, operation and
maintenance instructions.
2-131200205
Section 2 - Pre-Operation and Inspection
8. Operational Check - Once the walk-around inspection is complete, perform a
warm-up and operational check (see page 2-8) of all systems in an area free of
overhead and ground level obstructions. See Section 3 - Controls and
Indicators for more specific operating instructions.
WARNING
If telehandler does not operate properly, immediately bring machine to a stop,
lower boom and attachment to ground and stop the engine. Determine cause and
correct before continued use.
2-2 31200205
Section 2 - Pre-Operation and Inspection
OZ2122
8006612
8009815
1001094858
(8, 9, 12 & 13M)
8h
2x
50h
1001094858A
OPTIONAL
2999964 (40)
8009377 (35)
2603207 (20)
8009890 (22)
8009885 (12)
35
3700015
50h
1001094925A
2X
8h
8h
1001094925
(17M)
8005869
8008657
OPTIONAL
2999964 (40)
8009377 (35)
2603207 (20)
8009890 (22)
8009885 (12)
8005675
8008657
8005616
37000163700016
8005670
3700016
35
1706227 (CE)
1001102513 (AUS)
8005616
8005617
VIEW A-A
A
A
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.
2-331200205
Section 2 - Pre-Operation and Inspection
OZ2131
8006038
8008195
17M12 & 13M
8005617
17M
8, 9, 12 & 13M
8005671
8005671
3700016
Optional
2999964 (40)
8009377 (35)
2603207 (20)
8009890 (22)
8009885 (12)
35
8008657
8005616
8008657
1001094708
1001094708B
3700016
A - 1706753
B - 1706754
C - 1706755
D - 1706756 (12, 13 & 17M)
E - 1706757 (12, 13 & 17M)
F - 1706758 (12, 13 & 17M)
G - 1706759 (13 & 17M)
8005675
8005617
ABC
3700016
ABCDEFG
8005616
1001094171
(AUS)
VIEW B-B
VIEW OF FRONT
TIEDOWN POINTS
B
B
VIEW OF
OUTRIGGERS
2-4 31200205
Loading...