JLG 40xxPS SOperator Manual

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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

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

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

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

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)

50h

1001094858A

OPTIONAL 2999964 (40) 8009377 (35) 2603207 (20)

8009890 (22) 8009885 (12)

3700015

50h

1001094925A

1001094925

(17M)

8005869

8008657

OPTIONAL 2999964 (40) 8009377 (35) 2603207 (20) 8009890 (22) 8009885 (12)

8005675

8008657

8005616

37000163700016

8005670

3700016

1706227 (CE)

1001102513 (AUS)

8005616

8005617

VIEW 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

3700016

Optional 2999964 (40) 8009377 (35) 2603207 (20) 8009890 (22) 8009885 (12)

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

VIEW OF

OUTRIGGERS

2-4 31200205

OZ2145

1001098547

ON OFF

P P

1001098547A

10010991761001103421

1001103421 A

1705980

2447967

OIL

ATF

Dexron

2447 967

8005670

8008651

F01 7.5 A

F03 7.5 A

F02 15 A

F04 7.5 A

F05 7.5 A

F06 20 A

F07 20 A

F08 7.5 A

F09 15 A

F10 15 A

F11 10 A

F12 15 A

F13 15 A

F14 7.5 A

F15 15 A

F16 15 A

F17 15 A

F18 15 A

F19 7.5 A

F20 15 A

F21 15 A

F22 25 A

F23 10 A

F24 15 A

F25 15 A

F26 10 A

F28 15 A

F27 15 A

F29 15 A

F30 15 A

1001094778A

1001094778

1001094900

(LIFT PATTERN)

1001094900B

1001094901

(LOADER PATTERN)

1001094901B

1001094902

(12, 13 & 17M)

1001094902B

1001094713

1001094713A

1001102514

(AUS)

8008746 B

EN 1459 B (1998)

4017

P/N 4802111

P/N 8008014

P/N 1170001

P/N 2340029

4.000kg

3.500kg

3.000kg

2.500kg

2.000kg

1.500kg

1.000kg

500kg

750kg

400kg

0°

10°

20°

30°

40°

50°

60°

70°

876543210

2 0

0 0 k g

8005870

1001127546

1001127546 A

VIEW OF PARK

BRAKE LEVER (17M)

LOAD CHARTS

IF EQUIPPED FOR PLATFORM

VIEW OF

REAR WINDOW

VIEW C-C

(8 & 9M S/N 1160005993 & AFTER

INCLUDING 1160005949 & 1160005950)

Section 2 - Pre-Operation and Inspection

2-531200205

Section 2 - Pre-Operation and Inspection

OZ2152

2.3 WALK-AROUND INSPECTION

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

INSPECTION NOTE: On all components, make sure there are no loose or missing parts, that they are securely fastened and no visible leaks or excessive wear exists in addition to any other criteria mentioned. Inspect all structural members including attachment for cracks, excessive corrosion and other damage.

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

2. Front Axle

3. Left Outrigger

4. Boom Prop

5. Wheel/Tire Assembly

2-6 31200205

• Check front, top, side and rear wear pads for presence of grease.

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

equipped); hydraulic hoses undamaged, not leaking.

undamaged, not leaking.

nuts. Inspect for worn tread, cuts, tears or other discrepancies.

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

(if equipped) - Pins secure; hydraulic hoses and cylinder

(if equipped) - See inspection note.

- Properly inflated and secured; no loose or missing lug

Section 2 - Pre-Operation and Inspection

6. Work Lights (if equipped) - Clean and undamaged.

7. Mirrors

- Clean and undamaged.

8. Cab and Electrical

• General appearance; no visible damage.

• Frame level indicator(s) and window glass undamaged and clean.

• Gauges, switches, joystick, foot controls and horn operational.

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

9. Wheel Chock

10. Wheel/Tire Assembly

nuts. Inspect for worn tread, cuts, tears or other discrepancies.

11. Rear Axle hydraulic hoses undamaged, not leaking.

12. LSI Sensor

13. Wheel/Tire Assembly

nuts. Inspect for worn tread, cuts, tears or other discrepancies.

14. Boom Sensor

1160005950), (17M S/N 1160005937 & After excluding 1160005952, 1160005960, 1160005963, 1160005966 & 1160005978) - See inspection note.

15. Engine Compartment

• Drive belts, check condition and replace as required.

• Engine mounts - See inspection note.

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

element as required.

• Main control valve - See inspection note.

• Battery cables tight, no visible damage or corrosion.

• Engine cover closed and properly secured.

16. Air Precleaner

17. Wheel/Tire Assembly

nuts. Inspect for worn tread, cuts, tears or other discrepancies.

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

(if equipped) - See inspection note.

- Properly inflated and secured; no loose or missing lug

- See inspection note.

- Properly inflated and secured; no loose or missing lug

(8, 9, 12 & 13M S/N 1160005993 & After including 1160005949 &

- Check and clean as required.

- Properly inflated and secured; no loose or missing lug

18. Frame Level Cylinder not leaking.

19. Right Outrigger undamaged, not leaking.

20. Platform Recognition Sensor note.

21. Attachment

- Properly installed, see “Attachment Installation” on page 5-11.

(if equipped) - Pins secure; hydraulic hoses undamaged,

(if equipped) - Pins secure; hydraulic hoses and cylinder

(AUS - if equipped for platform): See inspection

2-731200205

Section 2 - Pre-Operation and Inspection

2.4 WARM-UP AND OPERATIONAL CHECKS

Warm-Up Check

During warm-up period, check:

1. Heater, defroster and windshield wiper (if equipped).

2. Check all lighting systems (if equipped) for proper operation.

3. Adjust mirror(s) for maximum visibility.

WARNING

CUT/CRUSH/BURN HAZARD. Keep covers closed while engine is running

except when checking transmission oil level.

Operational Check

When engine warms, perform an operational check:

1. Service brake and parking brake operation.

2. Forward and reverse travel.

3. Each gear.

4. Steering in both directions with engine at low idle (steering lock to lock will not be reached). Check in each steering mode

5. Horn and back-up alarm. Must be audible from inside operators cab with engine running.

6. All joystick functions - operate smoothly and correctly.

7. Perform any additional checks described in Section 8.

2-8 31200205

Section 2 - Pre-Operation and Inspection

2.5 OPERATOR CAB

The telehandler is equipped with an enclosed ROPS/FOPS cab.

WARNING

CRUSH HAZARD. 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 ROPS/FOPS certification for this cab/machine configuration. If damaged, the CAB CANNOT BE REPAIRED. It must be REPLACED.

2-931200205

Section 2 - Pre-Operation and Inspection

OZ0211

OAL1500

2.6 WINDOWS

Keep all windows clean and unobstructed.

Cab Door Window

• Cab door (1) must be closed during operation.

• During operation the cab door window (2) must either be latched open or closed.

• Open the cab door window and secure it in the latch.

• Press the release button (3) inside the cab to unlatch the window.

Rear Window

• Lift lever (4) and push to open the rear window (5).

• Lift lever and pull to close.

2-10 31200205

Section 3 - Controls and Indicators

SECTION 3 - CONTROLS AND INDICATORS

3.1 GENERAL

This section provides the necessary information needed to understand control functions.

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

3-131200205

Section 3 - Controls and Indicators

OZ2283

3.2 CONTROLS

1. Park Brake: See page 3-11.

2. Accelerator Pedal

speed.

3. Service Brake Pedal speed.

4. Ignition Switch

5. Hydraulic Quick Attach Switch

to hydraulically lock or unlock an attachment.

6. Power/Emergency Stop Switch power and stop engine.

7. Auxiliary Power Switch hold in place to engage auxiliary power. See “Emergency Lowering of Boom If Equipped for Platform” on page 6-3.

8. Transmission Control Lever

3-2 31200205

: Pressing down the pedal increases engine and hydraulic

: The further the pedal is depressed, the slower the travel

: Key Activated. See page 3-10.

(if equipped for platform): Depress back of switch and

(if equipped): Used in conjuction with the joystick

(if equipped for platform): Push down to shut off

: See page 3-12.

Section 3 - Controls and Indicators

9. Frame Level Indicator: Enables operator to determine the left to right level condition of the telehandler.

10. Steering Column Adjuster

11. Steering Wheel

machine in the corresponding direction. Three steering modes are available. See “Steer Modes” on page 3-26.

12. Instrument Panel

13. Accessory Control Lever

14. LSI Indicator

15. Keypad

16. Joystick

17. Longitudinal Level Indicator

to back level condition of the telehandler.

18. Armrest and Right Hand Console

19. Hydraulic Hitch Safety Hook Release

safety hooks on hydraulic hitch. See page 5-46 for control instructions.

: See page 3-8.

: Turning the steering wheel to the left or right steers the

: See page 3-4.

: See page 3-14.

: See page 3-18.

: See page 3-17.

: See page 3-24.

(AUS): Enables the operator to determine the front

: See page 3-22.

(8 & 9M, if equipped): Pull to release

3-331200205

Section 3 - Controls and Indicators

OZ2061

1112131415161718192021

Instrument Panel

1. Low Fuel Indicator: Illuminates and buzzer sounds briefly when fuel level is low.

2. Fuel Gauge:

3. Left Turn Signal Indicator

4. Display Screen

5. Right Turn Signal Indicator

6. Engine Temperature Gauge

7. Engine Temperature Warning Indicator

engine temperature is too high.

8. Continuous Auxiliary Hydraulics Indicator auxiliary hydraulics are active.

9. Trailer Turn Signal Indicator

10. Clutch Lock Indicator

11. High Beam Indicator

12. Anti Theft Indicator

theft feature is active. Enter anti theft code, see page 3-25.

13. Maintenance Indicator

14. Engine Preheat Indicator

15. Park Brake Indicator

3-4 31200205

maintenance is required.

temperature is reached. At temperatures below 0° C (32° F), do not start until indicator goes out.

Indicates amount of fuel in fuel tank.

: Illuminates when left turn signal is active.

: See page 3-6.

: Illuminates when right turn signal is active.

: Indicates engine operating temperature.

: Illuminates and buzzer sounds when

: Illuminates when continuous

: Illuminates when trailer turn signal is activated.

: Illuminates when clutch lock feature is engaged.

: Illuminates when high beam lights are on.

: Illuminates and buzzer sounds briefly at start-up when anti

: Illuminates and buzzer sounds briefly when

: With ignition key in position II, illuminates until start

: Illuminates when park brake is applied. See page 3-11.

Section 3 - Controls and Indicators

16. System Distress Indicator: Illuminates and buzzer sounds when critical machine and engine faults exist.

17. Engine Fault Critical Indicator engine fault exists.

18. Engine Fault Warning Indicator operating outside the normal range.

19. Air Filter Restriction Indicator filter(s) require maintenance.

20. Engine Oil Pressure Indicator pressure is too low.

21. Battery Charge Indicator system is not functioning properly.

22. Transmission Oil Temperature Indicator transmission oil temperature is too high.

23. Steering Pressure Indicator pressure is too low.

24. Hydraulic Filter Restriction Indicator when hydraulic filter requires maintenance.

: Illuminates and buzzer sounds when a critical

: Illuminates and buzzer sounds when engine is

: Illuminates and buzzer sounds briefly when air

: Illuminates and buzzer sounds when engine oil

: Illuminates when battery is at low charge or charging

: Illuminates and buzzer sounds when

: Illuminates and buzzer sounds when steering

: Illuminates and buzzer sounds briefly

WARNING

EQUIPMENT DAMAGE. When the engine fault, system distress or a red

indicator illuminates (except park brake), immediately bring machine to a stop, lower boom and attachment to ground and stop the engine. Determine cause and correct before continued use.

Note: All indicators (except high beam and turn signals) perform a bulb check at system start up.

3-531200205

Section 3 - Controls and Indicators

OAH1270

0000

RPM

km/h

100

0000

RPM

km/h

DISPLAY SHOWN WITH CONTINUOUS

AUXILIARY HYDRAULICS ACTIVE

DISPLAY SHOWN WITH ANTI THEFT

ACTIVE AT SYSTEM START

Display Screen

1. Joystick Mode: Displays current joystick mode. Joystick mode can be changed

by the machine owner in Operator Tools Menu (level 2 password required). See Service Manual for information.

a. Loader Joystick Pattern - Displays loader joystick pattern icon on left when

active. See page 3-20.

b. Lift Joystick Pattern - Displays lift joystick pattern icon on right when active.

See page 3-18.

2. Speed and Power to Platform

c. Speed (if equipped) - Telehandler travel speed displayed in kilometers per

hour (km/h) or miles per hour (m/h).

d. Transfer Power to Platform (if equipped for platform) - Assists with

transferring power to platform. Refer to the Platform for 3513PS, 4013PS, 4017PS Operation & Safety Manual.

3. Driving Direction and Gear

a. Direction - Forward (F), Neutral (N) or Reverse (R).

b. Gear - First (1), Second (2), Third (3) or Fourth (4).

4. Engine Speed: Displays engine speed in revolutions per minute (rpm).

: Displays current driving condition.

5. Operating Hours

6. Boom Angle

7. Continuous Auxiliary Hydraulics, Steering Mode Change and Platform Status

a. Continuous Auxiliary Hydraulics - Displays flow value (-100% to +100%)

when continuous auxiliary hydraulics is activated. See Section

3-6 31200205

5 - Attachments and Hitches for details.

b. Steering Mode Change - Assists with steering mode change. See “Steer

Modes” on page 3-26 for details.

c. Platform Status (if equipped for platform) - Displays status when platform is

installed.

: Displays total hours of telehandler operation.

: Displays boom angle in degrees. 0 degrees indicates horizontal.

Section 3 - Controls and Indicators

OAH2000

MENU: HELP: PRESS ENTER

8. Anti Theft Code Entry: If active, the four digit code must be entered after system start. See “Anti Theft” on page 3-25 for details.

9. Menus

: Menus display fault codes and other machine information while allowing modification of some operating parameters. Depress and hold the C and OK buttons on the keypad to access menus.

a. Help - Displays active fault code. Depress OK button again and use keypad

arrows to cycle through the last 25 fault codes. Active faults are denoted with an asterisk.

b. Operator Tools - Speed, Temperature and Oil Pressure units and Steering

Alignment Mode can be modified by the operator. Customer or Service level access code required to modify additional items.

• Machine Speed - Select units (km/h or m/h) to be displayed.

• Engine Temperature - Select units (Celsius or Fahrenheit) to be displayed.

• Steering Alignment Mode - Select mode (manual or all wheel assisted) to be used when changing steering modes, see page 3-26.

c. Personalities - View performance parameters. Customer or Service level

access code required to modify parameters.

d. Access Level - Code entry determines access level.

• Operator (Level 3) - No code required.

• Customer (Level 2) - See Service Manual for information.

• Service (Level 1) - Manufacturer service representative only.

e. Diagnostics - View diagnostic information.

f. System Test - Performs test of all system inputs and outputs.

g. Machine Setup - View machine configurations. Service level access code

required to modify configurations.

h. Calibrations - Customer or Service level access code required.

3-731200205

Section 3 - Controls and Indicators

OZ2361

2 31

5 6 7

Keypad

1. C (Clear or escape): Use in conjuction with display screen. Returns user

interface one level during navigation. If at top level menu, depress and hold for one second to exit.

2. Up/Down Arrows selections and change adjustable values.

3. OK

(Enter): Use in conjuction with display screen. Confirms user interface

inputs.

4. Steer Mode Steer and 4-Wheel Crab Steer. Illuminated LED indicates current steer mode. See page 3-26.

: Use in conjuction with display screen. Navigate menu

: Three steer modes available: 4-Wheel Circle Steer, 2-Wheel Front

Note: If machine is shut-down during steer mode change, it must be completed at restart.

5. LSI Override: Momentarily disables the automatic function cut-out. LED flashes while activated. Depress and hold up to 30 seconds while operating joystick to momentarily disable the automatic function cut-out.

WARNING

TIP OVER HAZARD. Exceeding lift capacity of the telehandler could damage the

equipment and/or cause tip over.

6. Bucket Mode

7. Joystick Function

outrigger functions are enabled. Deactivate this function before traveling on public roads. See “Road Operation (CE)” on page 4-10.

Note: All LEDs perform a bulb check at system start up.

3-8 31200205

: LED lit while activated. Increases response to boom functions.

: LED lit while activated. Boom, auxiliary hydraulics and

Section 3 - Controls and Indicators

This Page Intentionally Left Blank

3-931200205

Section 3 - Controls and Indicators

OZ2300

III

Ignition

• Position 0 - Engine off.

• Position I - Voltage available for all electrical functions.

• Position II - Engine preheat at temperatures below 0° C (32° F). Wait to start engine until preheat indicator on instrument panel goes out.

• Position III - Engine start. In the event the engine does not start, rotate key to position 0 then back to position III to re-engage the starter.

• Position P (if equipped for platform) - Power transferred to platform.

Note: Key is removable in the 0 and P positions.

3-10 31200205

Section 3 - Controls and Indicators

OZ2290

8, 9, 12 & 13M 17M

Park Brake

The park brake lever (1) controls the application and release of the park brake.

• Pull lever back to apply park brake.

• Squeeze release (2) or lift detent ring (3) and push lever forward to release park brake.

WARNING

MACHINE ROLL-AWAY HAZARD. Always move park brake switch to "ON"

position, lower boom to ground and stop engine before leaving cab.

WARNING

CRUSH HAZARD. Applying park brake while traveling will cause unit to stop

abruptly and could cause load loss. To stop the machine in an emergency, apply the park brake. 17M Only - Turning engine off also applies the park brake.

Parking Procedure

1. Using service brake, stop telehandler in an appropriate parking area.

2. Follow “Shut-Down Procedure” on page 4-3.

3-1131200205

Section 3 - Controls and Indicators

OZ2310

Transmission Control Lever

Direction of Travel Selection

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

• Push lever forward for forward travel; pull lever rearward for reverse travel. Move lever to centered position for Neutral.

• Forward or reverse travel can be selected while in any gear.

• When traveling in reverse, the back-up alarm will automatically sound.

• Drive in reverse and turn only at slow rates of speed.

• If clutch lock switch is activated (see page 3-22), do not increase engine speed with the transmission in forward or reverse and the service brake depressed in an attempt to get quicker hydraulic performances. This could cause unexpected machine movement.

WARNING

TIP OVER/CRUSH HAZARD. Bring telehandler to a complete stop before

shifting transmission control lever. A sudden change in direction of travel could reduce stability and/or cause load to shift or fall.

3-12 31200205

Section 3 - Controls and Indicators

OZ2320

1st

2nd

3rd

4th

Gear Selection

Gear selection is located on the twist grip handle (2) of transmission control lever.

• Twist hand grip to select gear.

• Select the appropriate gear for the task being performed. Use a lower gear when transporting a load. Use a higher gear only when driving unloaded for longer distances.

• Slow down prior to downshifting. Do not downshift more than one gear at a

time.

3-1331200205

Section 3 - Controls and Indicators

OZ2340

POWER TEST

Load Stability Indicator (LSI)

WARNING

TIP OVER HAZARD. The LSI considers only longitudinal stability limitations,

observe all operating parameters. Failure to follow operating parameters of the telehandler could damage the equipment and/or cause tip over.

8, 9, 12 & 13M Before S/N 1160005993 excluding 1160005949 & 1160005950 17M Before S/N 1160005937 including 1160005952, 1160005960, 1160005963, 1160005966 & 1160005978

The LSI (1) provides visual and audible indication of forward stability limitations when machine is static on firm, level surface.

• Green LED (2) will illuminate when LSI power is on.

• When approaching forward stability limitations LEDs progressively illuminate, green (3), then yellow (4) and finally red (5).

• The warning buzzer sounds as the first red LED illuminates.

• As the telehandler reaches forward stability limitations and the second red LED illuminates, the automatic function cut-out is activated. Certain functions are disabled (i.e. boom lift, extend, etc). Retract boom to re-enable functions.

• Press button (6) to disable the warning buzzer. When disabled, yellow LED (7) will illuminate. If last red LED illuminates, disable button is overridden and warning buzzer sounds.

• Test LSI (8) at the beginning of each work shift. See Section 8 - Additional Checks.

3-14 31200205

Section 3 - Controls and Indicators

OZ3711

8, 9, 12 & 13M S/N 1160005993 & After including 1160005949 & 1160005950 17M S/N 1160005937 & After excluding 1160005952, 1160005960, 1160005963, 1160005966 & 1160005978

The LSI (9) provides visual and audible indication of forward stability limitations when machine is static on firm, level surface.

• Green LED (10) will illuminate when LSI power is on.

• When approaching forward stability limitations LEDs progressively illuminate, green (11), then orange (12) and finally red (13).

• If the red LED illuminates the warning buzzer also sounds.

The LSI has two modes:

Active Mode (8, 9, 12, 13 & 17M)

• As the telehandler reaches forward stability limitations and the red LED (13) illuminates, the automatic function cut-out is activated. All boom, frame level and outrigger functions are disabled except for boom retract (CE & AUS) and boom lift (CE). Retract boom to re-enable functions.

• In some instances the LSI system may slow down or stop boom functions if operated close to forward stability limitations. When LEDs begin to flash, certain functions can not be operated. Retract boom and/or return the joystick to neutral position for a short period to allow system to reset and LEDs to stop flashing before proceeding with operation.

Passive Mode (8 & 9M)

• The orange LED (15) illuminates when either of the following occurs:

• The boom is fully retracted.

• The park brake is not applied and transmission control lever is in the forward or reverse position.

• When approaching forward stability limitations, visual and audible indication is provided and the automatic function cut-out and/or slow down feature is disabled.

3-1531200205

Section 3 - Controls and Indicators

• Travel in accordance with the requirements set forth in Section 1 - General Safety Practices.

• Test LSI (14) at the beginning of each work shift. See Section 8 - Additional Checks.

• When placing a load, ensure axles are not fully steered in either direction.

WARNING

TIP OVER HAZARD. If the green, orange and red LEDs flash and warning

buzzer sounds, retract and lower boom immediately. Determine cause and correct before continued use.

3-16 31200205

Section 3 - Controls and Indicators

OZ2330

Steering Column Adjuster

•Follow “Shut-Down Procedure” on page 4-3.

• Turn lever (1) counterclockwise to unlock.

• Place steering column in desired position.

• Turn lever clockwise to lock.

WARNING

TIP OVER/CRUSH HAZARD. Bring telehandler to a complete stop before

shifting transmission control lever. A sudden change in direction of travel could reduce stability and/or cause load to shift or fall.

3-1731200205

Section 3 - Controls and Indicators

OAH1351

OZ2490

12, 13 & 17M

Joystick

Lift Joystick Pattern

Verify the lift joystick pattern icon (2) is active on the display (1) and the joystick decal located inside the cab matches the machine controls.

The joystick (1) controls the boom, attachment, auxiliary hydraulics 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.

• For two simultaneous boom functions, move the joystick between quadrants. For example; moving the joystick forward and to the left will lower and retract boom simultaneously.

3-18 31200205

Section 3 - Controls and Indicators

WARNING

TIP OVER/CRUSH HAZARD. Rapid, jerky operation of controls will cause rapid,

jerky movement of the load. Such movements could cause the load to shift or fall or could cause the machine to tip over.

Attachment Functions

Attachment tilt is controlled by the roller switch (2).

• Push the roller switch up to tilt attachment down; push the roller switch down to tilt attachment up.

Auxiliary Hydraulic Functions

Auxiliary Hydraulics buttons (3 & 4) control functions of attachments that require hydraulic supply for operation. Buttons (3) can be used simultaneously with normal boom attachment functions. Button (4) must be used independently of boom lift/ lower functions. See Section 5 - Attachments and Hitches for approved attachments and control instructions.

Outrigger Functions (12, 13 & 17M)

Button (5) controls both outriggers.

• Press and hold the button; move the joystick forward to lower both outriggers; move the joystick back to raise both outriggers.

• Press and hold the button; move the joystick left then forward to lower the left outrigger; move the joystick left then back to raise the left outrigger.

• Press and hold the button; move the joystick right then forward to lower the right outrigger; move the joystick right then back to raise the right outrigger.

• Outriggers operable with boom below 20 degrees. If equipped with boom retracted switch, outriggers operable with boom below 20 degrees or with boom fully retracted and between 20 and 55 degrees.

WARNING

TIP OVER HAZARD. Outriggers increase stability and load capacity only if they

are used properly. Using outriggers on soft surfaces could cause telehandler to tip over. Always ensure surface can support telehandler and load.

3-1931200205

Section 3 - Controls and Indicators

OAH1381

OZ2500

12, 13 & 17M

Loader Joystick Pattern

Verify the loader joystick pattern icon (3) is active on the display (1) and the joystick decal located inside the cab matches the machine controls.

The joystick (1) controls the boom, attachment, auxiliary hydraulics and outrigger functions.

Boom Functions

• Move the joystick back to lift boom; move joystick forward to lower boom.

• Extend/retract is controlled by the roller switch (2). Push roller switch up to extend boom; push roller switch down to retract boom.

• The speed of boom functions depends upon the amount of joystick travel in corresponding direction. Increasing engine speed will also increase function speed.

• For two simultaneous boom functions, move the joystick between quadrants. For example; moving the joystick forward and to the left will lower boom and tilt attachment up simultaneously.

3-20 31200205

Section 3 - Controls and Indicators

WARNING

TIP OVER/CRUSH HAZARD. Rapid, jerky operation of controls will cause rapid,

jerky movement of the load. Such movements could cause the load to shift or fall or could cause the machine to tip over.

Attachment Functions

Attachment tilt is controlled by the joystick.

• Move joystick right to tilt down; move joystick left to tilt up.

Auxiliary Hydraulic Functions

Outrigger Functions (12, 13 & 17M)

Button (5) controls both outriggers.

• Press and hold the button; move the joystick forward to lower both outriggers; move the joystick back to raise both outriggers.

• Press and hold the button; move the joystick left then forward to lower the left outrigger; move the joystick left then back to raise the left outrigger.

• Press and hold the button; move the joystick right then forward to lower the right outrigger; move the joystick right then back to raise the right outrigger.

• Outriggers operable with boom below 20 degrees. If equipped with boom retracted switch, outriggers operable with boom below 20 degrees or with boom fully retracted and between 20 and 55 degrees.

WARNING

TIP OVER HAZARD. Outriggers increase stability and load capacity only if they

are used properly. Using outriggers on soft surfaces could cause telehandler to tip over. Always ensure surface can support telehandler and load.

3-2131200205

Section 3 - Controls and Indicators

OZ2420

Armrest and Right Hand Console

1. Frame Level Switch (if equipped): Controls the left to right frame level. Depress

right side of switch to rotate frame right; depress left side of switch to rotate frame left. Frame level operable with boom below 20 degrees. If equipped with boom retracted switch, frame level operable with boom below 20 degrees or with boom fully retracted and between 20 and 55 degrees.

2. Hazard Light Switch: On/Off switch.

3. Beacon Light Switch

beacon on cab roof. Power supplied by 12V receptacle at rear left of cab roof.

4. Clutch Lock Switch engaged while depressing service brake. Depress back of switch to deactivate system and have transmission disengage while depressing service brake.

5. Boom Work Lights Switch

6. Front/Rear Auxiliary Hydraulics Switch

auxiliary hydraulics. Depress back of switch to activate rear auxiliary hydraulics.

7. Rear Wiper Switch

8. Driving Lights Switch

(if equipped): On/Off switch. Place magnetic base of

: Depress front of switch to activate and keep transmission

(if equipped): On/Off switch.

: Depress front of switch to activate front

: On/Off switch.

(if equipped): On/Off switch.

9. Rear Work Lights Switch

10. Front Work Lights Switch

11. Power Outlet

12. Auxiliary Electrics

auxiliary electric feature. See Section 5 - Attachments and Hitches for approved attachments and control instructions.

: 12V receptacle.

3-22 31200205

(if equipped): On/Off switch.

(if equipped): On/Off switch. Depress button to activate

Section 3 - Controls and Indicators

13. Continuous Auxiliary Hydraulics Switch:

a. Depress and release front of switch for continuous operation of hydraulic

powered attachments. Set continuous auxiliary hydraulic level (-100% to 100%) within 10 seconds using the keypad up/down arrow buttons (see page 3-8). See Section 5 - Attachments and Hitches for approved attachments and control instructions.

b. Relieves auxiliary hydraulic circuit pressure. See page 5-18.

Heater and Air Conditioning Controls

14. Fan Speed Switch

15. Recycle/Fresh Air Switch

: Adjustable rotary switch.

(if equipped): Adjustable rotary switch.

16. Temperature Control Switch

17. Air Conditioning Switch

(if equipped): On/Off switch.

: Adjustable rotary switch.

3-2331200205

Section 3 - Controls and Indicators

OZ3450

OZ3460

Accessory Control Lever

Turn Signals and Low/High Beam Headlights

• Push accessory control lever (1) forward (2) to activate left turn signal.

• Pull lever backward (3) to activate right turn signal.

• The lever must be manually returned to the center position to deactivate either turn signal. The lever will not cancel automatically after a turn.

• Pull lever up (4) to switch between low and high beam headlights.

Front Windshield Wiper and Horn

• Rotate hand grip (5) to activate front windshield wiper, O - Off, J - Continuous or I - Fast

• Depress end of lever (6) to activate windshield wiper fluid.

• Depress button (7) to sound horn.

3-24 31200205

Section 3 - Controls and Indicators

OAH1430

2 3

0000

RPM

km/h

3.3 ANTI THEFT

Machines with the anti theft feature active require entering a numeric code before operation to prevent unauthorized use. Code entry is accomplished using the display and keypad.

1. Turn ignition switch to position I. If anti theft is active, the display (1) will prompt the operator for a numeric code.

2. Use the up/down arrow buttons (2) to select the first digit.

3. Depress OK button (3) to confirm and move to the next digit.

4. Continue until the code is complete.

5. If an incorrect code is entered, the buzzer will sound briefly and the display will prompt the operator again for the numeric code.

Note: If the anti theft feature is active and the current access code is not known, it may be viewed or changed by the machine owner in Operator Tools Menu (level 2 password required). See Service Manual for information.

6. If the correct code is entered, normal start up can continue.

3-2531200205

Section 3 - Controls and Indicators

OAL2030

2-Wheel Front Steer 4-Wheel Circle Steer 4-Wheel Crab Steer

OAM2381

1 2 3

OAM2400

4 5

3.4 STEER MODES

Three steer modes are available for operator use.

Note: 2-Wheel Front Steer mode is required for travel on public roads.

Manual Steering Alignment Mode Change

If manual steering alignment mode is active under the Operator Tools menu (see page 3-7), use the following procedure for steer mode change.

Note: Steer mode will change immediately after selection.

1. Bring machine to a stop using service brake. If front steer mode (2) is active and rear wheels are aligned, go directly to step 4.

2. With circle steer (1) or crab steer (3) mode active, turn the steering wheel until the left rear wheel (4) is aligned with the side of the machine.

3. Select front steer mode (2).

4. Turn the steering wheel until the left front wheel (5) is aligned with the side of the machine.

5. Wheels are now aligned. Select desired steer mode.

3-26 31200205

Section 3 - Controls and Indicators

OAM2381

1 2 3

OAM2391

6 7 8

0000

RPM

km/h

0000

RPM

km/h

0000

RPM

km/h

All Wheel Assisted Steering Alignment Mode Change

If all wheel assisted steering alignment mode is active under the Operator Tools menu (see page 3-7), use the following procedure for steer mode change.

1. Bring machine to a stop using service brake.

2. Select desired steer mode: circle steer (1), front steer (2) or crab steer (3).

Note: Selected steer mode LED will flash and display will show steering alignment screens until the change is complete. After steering alignment is complete, steer mode LED will illuminate solid.

3. Turn the steering wheel until the rear wheels are centered (6). This step will be skipped if changing from front steer mode and rear wheels are already centered.

4. Turn the steering wheel until the front wheels are centered (7). This step will be skipped if changing to front steer mode.

5. Wheels are now aligned and steer mode change is complete (8).

3-2731200205

Section 3 - Controls and Indicators

OAH1471

3.5 OPERATOR SEAT

Adjustments

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

Mechanical Suspension Seat

1. Backrest: Use handle to adjust backrest angle.

2. Fore/Aft

3. Suspension

4. Weight

5. Lumbar Support

6. Seat Belt

7. Height

: Use handle to move seat fore and aft.

: Use handle to adjust suspension to the appropriate weight setting.

: Displays current weight setting.

: Use knob to adjust lumbar support.

: Always fasten seat belt during operation.

: Pull up on both sides of seat to adjust height.

3-28 31200205

Pneumatic Suspension Seat

OAH1481

Section 3 - Controls and Indicators

1. Backrest Angle

2. Fore/Aft

3. Suspension

4. Height

: Use handle to move seat fore and aft.

: Use knob to adjust suspension to the appropriate weight setting.

: Use knob to adjust height to the appropriate setting.

5. Lumbar Support

6. Seat Belt

: Always fasten seat belt during operation.

7. Fore/Aft Isolator

: Use handle to adjust backrest angle.

: Use knob to adjust lumbar support.

: Use handle to lock or unlock.

3-2931200205

Section 3 - Controls and Indicators

OH20912

Seat Belt

Fasten seat belt as follows:

1. Grasp both free ends of the belt making certain that belt webbing is not twisted or entangled.

2. With back straight in the seat, couple the retractable end (male end) of the belt into the receptacle (buckle) end of the belt.

3. With belt buckle positioned as low on the body as possible, pull the retractable end of the belt away from the buckle until it is tight across the lap.

4. To release belt latch, depress red button on the buckle and pull free end from buckle.

3-30 31200205

Section 3 - Controls and Indicators

OZ2411

3.6 BOOM INDICATORS

Boom Extension

• The boom extension indicators (1) are located on the left side of the boom. Use these indicators to determine boom extension when using the capacity chart (see “Use of the Capacity Chart” on page 5-5).

Boom Angle (AUS)

• The boom angle indicator (2) is located on the left side of the boom. Use this indicator to determine boom angle when using the capacity chart (see “Use of the Capacity Chart” on page 5-5).

3-3131200205

Section 3 - Controls and Indicators

This Page Intentionally Left Blank

3-32 31200205

Section 4 - Operation

SECTION 4 - OPERATION

4.1 ENGINE

Starting the Engine

This machine can be operated under normal conditions in temperatures of -18°C to 45°C (0°F to 113°F). Consult JLG for operation outside this range or under abnormal conditions.

1. Make sure all controls are in “Neutral” and all electrical components (lights, heater, defroster, etc.) are turned off. Set parking brake.

2. If equipped for platform, pull the power/emergency stop switch up.

3. Turn ignition switch to position I. If active, enter anti theft code.

4. Turn ignition switch to position II. If the temperature is below 0° C (32° F), wait for preheat indicator on instrument panel to go out.

5. Turn ignition switch to position III to engage starting motor. Release key immediately when engine starts. If engine fails to start within 20 seconds, release key and allow starting motor to cool for a few minutes before trying again.

6. After engine starts, observe engine oil pressure indicator. If indicator remains on for more than five seconds, stop engine and determine cause before restarting engine.

7. Warm up engine at approximately 1/2 throttle.

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

WARNING

UNEXPECTED MOVEMENT HAZARD. Always ensure that transmission control

lever is in neutral and the service brake is applied before releasing park brake. Releasing park brake in either forward or reverse could cause the machine to move abruptly.

WARNING

ENGINE EXPLOSION. Do not spray ether into air intake for cold weather

starting.

4-131200205

Section 4 - Operation

OW0530

Battery Boosted Starting

If battery-boost starting (jump-start) is necessary, proceed as follows:

• Never allow vehicles to touch.

• Ensure boosting vehicle engine is running.

• Connect the positive (+) jumper cable to positive (+) post of discharged battery.

• Connect the opposite end of positive (+) jumper cable to positive (+) post of booster battery.

• Connect the negative (-) jumper cable to negative (-) post on booster battery.

• Connect opposite end of negative (-) jumper cable to ground point on machine away from discharged battery.

• Follow standard starting procedures.

• Remove cables in reverse order after machine has started.

WARNING

BATTERY EXPLOSION HAZARD. Never jump start or charge a frozen battery

as it could explode. Keep sparks, flames and lighted smoking materials away from the battery. Lead acid batteries generate explosive gases when charging. Wear safety glasses.

4-2 31200205

Section 4 - Operation

Normal Engine Operation

• Observe instrument panel and display frequently to be sure all systems are functioning properly.

• Be alert for unusual noises or vibration. When an unusual condition is noticed, park machine in safe position and perform shut-down procedure. Report condition to your supervisor or maintenance personnel.

• Avoid prolonged idling. If the engine is not being used, turn it off.

Shut-Down Procedure

When parking the telehandler, park in a safe location on flat level ground and away from other equipment and/or traffic lanes.

1. Apply the park brake.

2. Shift the transmission to “Neutral.”

3. Lower forks or attachment to the ground.

4. Operate engine at low idle for 3 to 5 minutes. DO NOT over rev engine.

5. Shut off engine and remove ignition key.

6. Push power/emergency stop switch down (if equipped for platform).

7. Exit telehandler properly.

8. Turn off electrical master switch (if equipped).

9. Block wheels (if necessary).

4-331200205

Section 4 - Operation

4.2 OPERATING WITH A NON-SUSPENDED LOAD

Lift Load Safely

• You must know the weight and load center of every load you lift. If you are not sure of the weight and load center, check with your supervisor or with the supplier of the material.

WARNING

TIP OVER HAZARD. Exceeding lift capacity of the telehandler could damage the

equipment and/or cause tip over.

• Know the rated load capacities (refer to Section 5 - Attachments and Hitches) of the telehandler to determine the operating range in which you can safely lift, transport and place a load.

Picking Up a Load

• Note the conditions of the terrain. Adjust travel speed and reduce amount of load if conditions warrant.

• Avoid lifting double-tiered loads.

• Make sure load is clear of any adjacent obstacles.

• Adjust spacing of forks so they engage the pallet or load at maximum width. See “Adjusting/Moving Forks” on page 5-19.

• Approach load slowly and squarely with fork tips straight and level. NEVER attempt to lift a load with just one fork.

• NEVER operate telehandler without a proper and legible capacity chart in the operator cab for the telehandler/attachment combination you are using.

4-4 31200205

Section 4 - Operation

OW0540

Transporting a Load

• After engaging the load and resting it against the backrest, tilt the load back to position it for travel. Travel in accordance with the requirements set forth in Section 1 - General Safety Practices and Section 5 - Attachments and Hitches.

Leveling Procedure

1. Position machine in best location to lift or place load.

2. Apply parking brake and move transmission control lever to NEUTRAL.

3. Observe level indicator(s) to determine whether machine must be leveled prior to lifting load.

4. Move boom/attachment to 1,2 m (4 ft) off ground. (AUS - Move boom so forks are no more than 300 mm (11.8 in) above ground surface.)

Important things to remember:

• Never raise the boom/attachment more than 1,2 m (4 ft) above ground unless telehandler is level. (AUS - Never raise the forks more than 300 mm (11.8 in) above ground surface unless telehandler is level.)

• The combination of frame leveling and load could cause the telehandler to tip over.

4-531200205

Section 4 - Operation

Placing a Load

Before placing any load be sure that:

• The landing point can safely support the weight of the load.

• The landing point is level; front to back and side to side.

• Use the capacity chart to determine safe boom extension range. See “Use of the Capacity Chart” on page 5-5.

• Align forks at the level load is to be placed, then extend boom slowly until load is just above area where it is to be placed.

• Lower the boom until the load rests in position and the forks are free to retract.

Disengaging a Load

Once the load has been placed safely at the landing point, proceed as follows:

1. With the forks free from the weight of the load, the boom can be retracted and/or the telehandler can be backed away from under the load if surface will not change level condition of telehandler.

2. Lower the carriage.

3. The telehandler can now be driven from the landing location to continue work.

4-6 31200205

Section 4 - Operation

4.3 OPERATING WITH A SUSPENDED LOAD

Lift Load Safely

• You must know the weight and load center of every load you lift. If you are not sure of the weight and load center, check with your supervisor or with the supplier of the material.

WARNING

TIP OVER HAZARD. Exceeding lift capacity of the telehandler could damage the

equipment and/or cause tip.

• Know the rated load capacities (refer to Section 5 - Attachments and Hitches) of the telehandler to determine the operating range in which you can safely lift, transport and place a load.

Picking Up a Suspended Load

• Note the conditions of the terrain. Adjust travel speed and reduce amount of load if conditions warrant.

• Avoid lifting double-tiered loads.

• Make sure load is clear of any adjacent obstacles.

• NEVER operate telehandler without a proper and legible capacity chart in the operator cab for the telehandler/attachment combination you are using.

• Only use approved lifting devices rated for the lifting of the load.

• Identify the proper lifting points of the load, taking into consideration the center of gravity and load stability.

• Ensure to always properly tether loads to restrict movement.

• Refer to “Use of the Capacity Chart” on page 5-5 for proper lifting guidelines in addition to the appropriate capacity chart in the operator cab.

4-731200205

Section 4 - Operation

OW0130

OZ3160

Transporting a Suspended Load

• Travel in accordance with the requirements set forth in Section 1 - General Safety Practices and Section 5 - Attachments and Hitches.

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

Important things to remember:

• Ensure the boom is fully retracted.

• Never raise the load more than 300 mm (11.8 in) above ground surface or the boom more than 45°.

• The combination of frame leveling and load could cause the telehandler to tip over.

• The guide persons and operator must remain in constant communication (verbal or hand) and be in visual contact with the operator at all times.

• Never place the guide persons between the suspended load and the telehandler.

• Only transport the load at walking speed (0.4 m/s) or less.

Leveling Procedure

1. Position machine in best location to lift or place load.

2. Apply parking brake and move transmission control lever to NEUTRAL.

3. Observe level indicator(s) to determine whether machine must be leveled prior to lifting load.

4. Move boom so load is no more than 300 mm (11.8 in) above ground surface and/or boom is raised no more than 45°.

4-8 31200205

Section 4 - Operation

Placing a Suspended Load

Before placing any load be sure that:

• The landing point can safely support the weight of the load.

• The landing point is level; front to back and side to side.

• Use the capacity chart to determine safe boom extension range. See “Use of the Capacity Chart” on page 5-5.

• Align load at the level load is to be placed, then position boom slowly until load is just above area where it is to be placed.

• Ensure that the guide persons and operator remain in constant communication (verbal or hand) when placing the load.

Disengaging a Suspended Load

• Never place the guide persons between the suspended load and the telehandler.

• Once at the destination of the load, ensure to bring the telehandler to a complete stop and apply the park brake prior to disengagement of the lifting devices and the tethers.

4-931200205

Section 4 - Operation

OZ2171

1 2

4.4 ROAD OPERATION (CE)

1. Preparation

a. Remove load from attachment.

b. Remove any large amounts of dirt from machine.

c. Check lights and mirrors and adjust if necessary.

Note: Be sure to follow all local and federal/provincial traffic regulations.

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. Place protective shield over front bucket edge: remove or reposition carriage forks toward the machine and secure to the carriage.

5. Depress button (2) to deactivate joystick function and disable all joystick controlled functions. Joystick function LED will go out.

6. Deactivating the joystick function automatically changes steer mode to front wheel steering (1). See “Steer Modes” on page 3-26 for details.

7. Machine is now ready for road operation.

4-10 31200205

Section 4 - Operation

OZ2180

4.5 LOADING AND SECURING FOR TRANSPORT

Tiedown

1. If equipped, 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 tiedown points as shown in the figure.

5. Do not tiedown front of boom.

Note: The user assumes all responsibility for choosing the proper method of transportation and tie-down devices, making sure the equipment used is capable of supporting the weight of the vehicle being transported and that all manufacturer’s instructions and warnings, regulations and safety rules of their employer and all local and federal/provincial laws are followed.

WARNING

TELEHANDLER SLIDE HAZARD. Before loading telehandler for transport,

make sure deck, ramps and telehandler wheels are free of mud, snow and ice. Failure to do so could cause telehandler to slide.

4-1131200205

Section 4 - Operation

Lifting

• When lifting machine, it is very important that the lifting device and equipment is attached only to designated lifting points. If machine is not equipped with lifting lugs contact JLG Product Safety for information.

• Make adjustments to the lifting device and equipment to ensure the machine will be level when elevated. The machine must remain level at all times while being lifted.

• Ensure that the lifting device and equipment is adequately rated and suitable for the intended purpose. See Section 9 - Specifications for machine weight or weigh machine.

• Remove all loose items from machine prior to lifting.

• Lift machine with smooth, even motion. Set machine down gently. Avoid quick or sudden motions that could cause shock loads to machine and/or lifting devices.

4-12 31200205

Section 5 - Attachments and Hitches

SECTION 5 - ATTACHMENTS AND HITCHES

5.1 APPROVED ATTACHMENTS

To determine if an attachment is approved for use on the specific telehandler you are using, perform the following prior to installation.

• The attachment 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.

• The load center of the fork (if equipped) must match the load center as indicated on the capacity chart.

• Hydraulically powered attachments must only be used on machines equipped with auxiliary hydraulics.

If any of the above conditions are not met, do not use the attachment. The telehandler may not be equipped with the proper capacity chart or the attachment may not be approved for the model telehandler being used. Contact JLG or the local distributor for further information.

5.2 UNAPPROVED ATTACHMENTS

Do not use unapproved attachments for the following reasons:

• Range and capacity limitations for “will fit,” homemade, altered, or other non-approved attachments cannot be established.

• An overextended or overloaded telehandler can tip over with little or no warning and cause serious injury or death to the operator and/or those working nearby.

• The ability of a non-approved attachment to perform its intended function safely cannot be assured.

WARNING

Use only approved attachments. Attachments which have not been approved for use with your telehandler could cause machine damage or an accident.

5-131200205

Section 5 - Attachments and Hitches

5.3 JLG SUPPLIED ATTACHMENTS

3508PS, 3509PS, 3512PS, 4008PS, 4009PS & 4012PS

Applicable Standard

3508PS 4008PS

CE CE AUS CE

Attachment

Part

Number

Carriage, 1185 mm 1170028 XXXX

Carriage, 1185 mm 1001107333 X X X

Carriage, 1185 mm 1001107581 X

Side Shift Carriage, 1200 mm 1170002 X X X

Fork, 50x100x1200 mm 2340030 XXXX

Fork, Narrow 50x100x1200 mm 2340041 XXXX

Fork, 50x100x1200 mm 1001100911 X X X

Fork, 60x100x1200 mm 1001107586 X

Fork Extension, 50x100 mm 1001112559 XXXX

Fork Extension, 60x100 mm 1001112560 X

Bucket, 0,51 m

Bucket, 0,9 m

Bucket, 1,0 m

Bucket, 1,8 m

Bucket, 2,0 m

Bucket with Teeth, 0,8 m

Bucket with Teeth, 1,0 m

Bucket, Multi-Purpose, 1,0 m

Bucket, Multi-Purpose

Bucket, Grapple, 0,8 m

Fork Mounted Concrete Bucket,

500L

1001145722 X

0930015 XXXX

1001145724 X

0930016 XXXX

1001145725 X

4805670 X

4802100 XXXX

0930003 XXXX

1001128891 X

1001145723 X

0930004 X X X

0240158 X X X

Concrete Bucket Mixer, 500 L 1001106930 X X

Truss Boom, 3,4 m 0240063 X X X

Truss Boom, 3,6 m 0240110 X X X

Truss Boom, 2,0 m 1001101442 X

Fork Mounted Hook 2700118 X X X

3509PS 4009PS

3512PS 4012PS

5-2 31200205

3513PS, 4013PS & 4017PS

Section 5 - Attachments and Hitches

Applicable Standard

Attachment

Part

Number

3513PS 4013PS

CE AUS CE AUS JLG Manitou

4017PS

Carriage, 1185 mm 1170028 XXXX X

Carriage, 1185 mm 1001107333 X X X

Carriage, 1185 mm 1001107581 X X X

Carriage, 1200 mm 1001102553 X X X

Side Shift Carriage, 1200 mm 1170002 X X X

Fork Positioning Carriage, 1225 mm 1001091313 X X X

Fork, 50x100x1200 mm 2340030 XXXX X

Fork, Narrow 50x100x1200 mm 2340041 XXXX X

Fork, 50x100x1200 mm 1001100911 X X X

Fork, 60x100x1200 mm 1001107586 X X X

Fork Extension, 50x100 mm 1001112559 XXXX X

Fork Extension, 60x100 mm 1001112560 X X X

Bucket, 0.51 m

Bucket, 0,9 m

Bucket, 1,0 m

Bucket, 1,8 m

Bucket, 2,0 m

Bucket with Teeth, 0,8 m

Bucket with Teeth, 1,0 m

Bucket, Multi-Purpose, 1,0 m

Bucket, Multi-Purpose

Fork Mounted Concrete Bucket,

500L

1001145722 X X X

0930015 XXXX X

1001145724 X X X

0930016 XXXX X

1001145725 X X X

4805670 X X X

4802100 XXXX X

0930003 XXXX X

1001128891 X X X

1001145723 X X X

0240158 X X X

Concrete Bucket Mixer, 500 L 1001106930 X X X

Truss Boom, 3,4 m 0240063 X X X

Truss Boom, 3,6 m 0240110 X X X

Truss Boom, 2,0 m 1001101442 X X X

Fork Mounted Hook 2700118 X X X

Quick Attach Mounted Hook 1170058 X X X

1001097353 X X X

Platform, 1,8 m

1001112107 X X X

1001114460 X X X

1001097355 X X X

Platform, 4,5 m

1001112108 X X X

1001114462 X X X

Quick

Attach

5-331200205

Section 5 - Attachments and Hitches

OZ0810

5.4 TELEHANDLER/ATTACHMENT/FORK CAPACITY

Prior to installing the attachment verify it is approved and the telehandler is equipped with the proper capacity chart. See “Approved Attachments” on page 5-1.

To determine the maximum capacity of the telehandler and attachment, use the smallest of the following capacities:

• Capacity stamped on the attachment identification plate (1).

• Fork capacities and load centers are stamped on the side of each fork (2) (if equipped). This rating specifies the maximum load capacity that the individual fork can safely carry at the maximum load center (3). Total attachment capacity is multiplied by the number of forks on the attachment (if equipped), up to the maximum capacity of the attachment.

• Maximum capacity as indicated on the proper capacity chart. See “Approved Attachments” on page 5-1.

• When the load rating of the telehandler differs from the capacity of the forks or attachment, the lower value becomes the overall load capacity.

Use the proper capacity chart to determine maximum capacity at various machine configurations. Lifting and placing a load may require use of more than one capacity chart based on machine configuration.

Other than block forks, all forks should be used in matched pairs, block forks used in matched sets.

WARNING

Never use an attachment without the appropriate JLG approved capacity chart installed on the telehandler.

5-4 31200205

Section 5 - Attachments and Hitches

OZ1702

BOOM

EXTENSION

INDICATOR

FORK

WEIGHT

STAMP

BOOM ANGLE

INDICATOR

(inside cab)

ATTACHMENT

IDENTIFICATION

PLATE

BOOM ANGLE

INDICATOR

(AUS)

5.5 USE OF THE CAPACITY CHART

To properly use the capacity chart (see page 5-6), the operator must first determine and/or have the following:

1. An approved attachment. See “Approved Attachments” on page 5-1.

2. The proper 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. On the capacity chart, find the line for the height and follow it over to the distance.

6. The number in the load zone where the two cross is the maximum capacity for this lift. If the two cross at a division between zones, the smaller number must be used.

The number in the load zone must be equal to or greater than the weight of the load to be lifted. Determine the limits of the load zone on the capacity chart and keep within these limits.

Capacity Indicator Locations

5-531200205

Section 5 - Attachments and Hitches

XXXXXXX

EN 1459 B (1998)

XXXX

P/N 1122334

P/N 9988776

P/N 1234567

P/N 9876543

4.000kg

3.500kg

3.000kg

2.500kg

2.000kg

1.500kg

1.000kg

500kg

750kg

400kg

0°

10°

20°

30°

40°

50°

60°

70°

876543210

2000kg

OZ0640

Boom Extension

Indicator (arc)

Load zones indicate

the maximum weight

that may be safely lifted.

These numbers must match the

model/option number stamped

on the attachment ID Plate.

Boom Angle

This Capacity Chart may be used with this model ONLY.

The telehandler model is indicated on the boom or chassis.

Model XXXX is used for demonstration purposes only.

Sample Capacity Chart (CE)

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

TIP OVER HAZARD. All loads shown on rated capacity chart are based on machine being on firm ground with frame level (see page 4-5); the forks being positioned evenly on carriage; the load being centered on forks; proper size tires being properly inflated; and the telehandler being in good operating condition.

5-6 31200205

WARNING

Section 5 - Attachments and Hitches

OW0930

OW0940

To identify the proper capacity chart on telehandlers equipped with outriggers, refer to the following icons which may be located on the capacity chart.

• Use when lifting a load with outriggers up.

• Use when lifting a load with outriggers down.

5-731200205

Section 5 - Attachments and Hitches

OAH1072

REQUIRES FIRM SURFACE WITH LOAD ON FORKS.

LIFTING (STATIONARY)

LEVEL CHASSIS BEFORE LIFTING.

XXXXXXXXXX

TRAVELLING (PICK & CARRY)

REQUIRES LOAD ON FORKS. MAX TRAVEL WITH RATED LOAD 10 KM/H. BOOM FULLY RETRACTED.

1. TYRE SIZES:

SPECIFICATIONS FOR SAFE USE

- XXXXX XXPLY XX PSI / X BAR.

2. IN-SERVICE WIND SPEED:

- XXM/S (XXKM/H).

3. GROUND CONDITIONS:

- FIRM SURFACES FOR LIFTING.

- SLOPE AND LOAD LISTED ABOVE FOR BOTH CONFIGURATIONS.

4. STANDARD USED: (AS 1418.19-2007).

XXX MM LOAD CENTER.

X° MAX

XXXMM MAX

X° MAX

XXXMM

MAX

X° MAX

JLG XXXXXX

P/N XXXXXXX

0123456789

XXXX kg

0°

10°

20°

30°

40°

50°

60°

70°

X° MAX

XXXMM MAX

Boom

Extension

Indicator

(arc)

Load zones indicate

the maximum weight

that may be safely lifted.

Boom Angle

This Capacity Chart may be

used with this model ONLY.

The telehandler model is

indicated on the boom or chassis.

Model XXXX is used for

demonstration purposes only.

These numbers must match the

model/option number stamped

on the attachment ID Plate.

Lifting

Information

Traveling

Information

Specifications

For Safe Use

Sample Capacity Chart (AUS)

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

TIP OVER HAZARD. All loads shown on rated capacity chart are based on machine being operated within the parameters indicated on the appropriate load chart; proper size tires being properly inflated; and the telehandler being in good operating condition.

WARNING

5-8 31200205

Section 5 - Attachments and Hitches

OW0930

OW0940

To identify the proper capacity chart on telehandlers equipped with outriggers, refer to the following icons which may be located on the capacity chart.

• Use when lifting a load with outriggers up.

• Use when lifting a load with outriggers down.

5-931200205

Section 5 - Attachments and Hitches

XXXXXXX

EN 1459 B (1998)

XXXX

P/N 1122334

P/N 9988776

P/N 1234567

P/N 9876543

4.000kg

3.500kg

3.000kg

2.500kg

2.000kg

1.500kg

1.000kg

500kg

750kg

400kg

0°

10°

20°

30°

40°

50°

60°

70°

876543210

2000kg

OZ0650

Example 1

Example 2

Example 3

Example 4

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.

Load Weight Distance Height OK to Lift

1 3.000 kg (6,614 lbs) 3 m (9.8 ft) 3 m (9.8 ft) Yes

2 900 kg (1,984 lbs) 7 m (23 ft) 7,5 m (24.6 ft) NO

3 3.750 kg (8,267 lbs) 1,5 m (4.9 ft) 6,75 m (22.1 ft) Yes

4 2.500 kg (5,512 lbs) 4 m (13.1 ft) 10 m (32.8 ft) NO

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

5-10 31200205

Section 5 - Attachments and Hitches

OZ3470

4 5

MECHANICAL HYDRAULIC

5.6 ATTACHMENT INSTALLATION

JLG Quick Attach

1. Attachment

2. Attachment Pin Recess

3. Attachment Pin

4. Lock Pin

5. Retainer Pin

6. Quick Attach

(mechanical quick attach)

(attachment tilt control in cab, see page 3-18 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.

5-1131200205

Section 5 - Attachments and Hitches

OZ3480

Z3490

OZ3500

OZ3510

Mechanical Quick Attach

This installation procedure is designed for one-person operation. Prior to exiting cab, perform “Shut-Down Procedure” on page 4-3.

1. Tilt quick attach forward to provide clearance. Check to be sure lock pin is out.

2. Align attachment pin with recess in attachment. Raise boom slightly to engage attachment pin in recess.

3. Tilt quick attach back to engage attachment.

4. Insert lock pin and secure with retainer pin.

5. If attachment is equipped, connect auxiliary hydraulic hoses. See “Hydraulic Operated Attachment” on page 5-18.

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Section 5 - Attachments and Hitches

OZ3520

OZ3530

OZ3540

OZ3550

Z3570

Manual Hydraulic Quick Attach

This installation procedure is designed for one-person operation. Prior to exiting cab, perform “Shut-Down Procedure” on page 4-3.

1. Turn auxiliary hydraulic valve handle (1) back, toward the operator cab, to enable hydraulic quick attach function.

2. Tilt quick attach forward to provide clearance. Check to be sure lock pin is disengaged.

3. Align attachment pin with recess in attachment. Raise boom slightly to engage attachment pin in recess.

4. Tilt quick attach back to engage attachment.

5. Press and hold switch (2) and button (3), at the same time move joystick forward to engage lock pin or move joystick back to disengage lock pin.

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Section 5 - Attachments and Hitches

OAL1930

DISENGAGED

ENGAGED

OZ3560

6. Raise boom to eye level and visually check that the lock pin protrudes through the hole. If the pin does not protrude through the hole, place the attachment on the ground and return to step 2.

7. Turn auxiliary hydraulic valve handle (1) forward, away from the operator cab, to enable attachment auxiliary hydraulics function.

8. If attachment is equipped, connect auxiliary hydraulic hoses. See “Hydraulic Operated Attachment” on page 5-18.

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Section 5 - Attachments and Hitches

OZ3580

Z3590

OZ3600

Z3570

OAL1930

DISENGAGED

ENGAGED

Hydraulic Quick Attach

This installation procedure is designed for one-person operation.

1. Tilt quick attach forward to provide clearance. Check to be sure lock pin is disengaged.

2. Align attachment pin with recess in attachment. Raise boom slightly to engage attachment pin in recess.

3. Tilt quick attach back to engage attachment.

4. Press and hold switch (2) and button (3), at the same time move joystick forward to engage lock pin or move joystick back to disengage lock pin.

5. Raise boom to eye level and visually check that the lock pin protrudes through the hole. If the pin does not protrude through the hole, place the attachment on the ground and return to step 2.

6. If attachment is equipped, connect auxiliary hydraulic hoses. See “Hydraulic Operated Attachment” on page 5-18.

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Section 5 - Attachments and Hitches

OZ3610

Manitou Quick Attach

1. Attachment

2. Attachment Pin

3. Attachment Pin Recess

4. Lock Pin

5. Retainer Pin

6. Manitou Quick Attach

(mechanical quick attach)

(attachment tilt control in cab, see page 3-18 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.

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Section 5 - Attachments and Hitches

OZ3620

Z3630

Z3640

OZ3650

This installation procedure is designed for one-person operation. Prior to exiting cab, perform “Shut-Down Procedure” on page 4-3.

1. Tilt quick attach forward to provide clearance. Check to be sure lock pin is out.

2. Align attachment pin recess with attachment pin. Raise boom slightly to engage attachment pin in recess.

3. Tilt quick attach back to engage attachment.

4. Insert lock pin and secure with retainer pin.

5. If attachment is equipped, connect auxiliary hydraulic hoses. See “Hydraulic Operated Attachment” on page 5-18.

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Section 5 - Attachments and Hitches

OZ2220

OZ0632

OZ2861

Hydraulic Operated Attachment

1. Install attachment (see page 5-11 or 5-16).

2. Lower attachment to ground.

3. Quickly depress and release continuous auxiliary hydraulics switch (1) twice. Depress again and hold to relieve pressure at both auxiliary fittings (2).

Note: Depressing of auxiliary hydraulics switch three times must be accomplished within two seconds. If buzzer sounds or continuous auxiliary hydraulics indicator illuminates, repeat step 3.

4. Perform “Shut-Down Procedure” on page 4-3.

5. Connect attachment hoses to both auxiliary fittings.

Platform Attachment (If Equipped)

1. Install platform (see page 5-11) and connect hydraulic lines (see above).

2. With the park brake applied and engine off, remove connector cover (3) and connect electric cable (4) from the platform.

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Section 5 - Attachments and Hitches

5.7 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. Refer to “Attachment Installation” page 5-11.

2. Elevate attachment to approximately 1,5 m (5 ft) and tilt carriage forward until fork heel is free from attachment.

3. Stand at the side of the carriage. To slide fork toward the center of the carriage, push the fork near the fork eye. To slide fork toward the edge of the carriage, pull the fork near the fork eye. To avoid pinching, do not place fingers or thumb between the fork and carriage structure.

If removing fork bar is necessary:

1. Rest forks on ground.

2. Remove fork bar.

3. Reposition forks.

4. Reinstall the fork bar and fork bar retaining mechanism(s).

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Section 5 - Attachments and Hitches

5.8 ATTACHMENT OPERATION

• Capacities and range limits for the telehandler change depending on the attachment in use.

• Separate attachment instructions must be kept in Manual Holder in cab with this Operation & Safety Manual. An additional copy must be kept with the attachment if it is equipped with a manual holder.

Note: Operations described within this section reference the Lift joystick pattern. Refer to page 3-20 if utilizing the Loader joystick pattern.

NOTICE

EQUIPMENT DAMAGE. Some attachments may contact the front tires or machine structure when the boom is retracted and the attachment is rotated. Improper use of attachment may result in attachment or machine structural damage.

NOTICE

EQUIPMENT DAMAGE. Avoid contact with any structure or object when lifting a load. Maintain clearance around boom structure and load. Failure to maintain clearance may result in attachment or machine structural damage.

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JLG 40xxPS SOperator Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Revision Log

Read This First

Table of Contents

Section 1 - General Safety Practices

1.1 HAZARD CLASSIFICATION SYSTEM

Safety Alert System and Safety Signal Words

1.2 GENERAL PRECAUTIONS

1.3 OPERATION SAFETY

Electrical Hazards

Tip Over Hazard

Travel Hazard

Load Falling Hazard

Lifting Personnel

Driving Hazards on Slopes

Pinch Points and Crush Hazards

Fall Hazard

Chemical Hazards

Section 2 - Pre-Operation and Inspection

2.1 PRE-OPERATION CHECK AND INSPECTION

2.2 SAFETY DECALS

2.3 WALK-AROUND INSPECTION

2.4 WARM-UP AND OPERATIONAL CHECKS

Warm-Up Check

Operational Check

2.5 OPERATOR CAB

2.6 WINDOWS

Cab Door Window

Rear Window

Section 3 - Controls and Indicators

3.1 GENERAL

3.2 CONTROLS

Instrument Panel

Display Screen

Keypad

Ignition

Park Brake

Parking Procedure

Transmission Control Lever

Load Stability Indicator (LSI)

Steering Column Adjuster

Joystick

Armrest and Right Hand Console

Accessory Control Lever

3.3 ANTI THEFT

3.4 STEER MODES

Manual Steering Alignment Mode Change

All Wheel Assisted Steering Alignment Mode Change

3.5 OPERATOR SEAT

Adjustments

Seat Belt

3.6 BOOM INDICATORS

Boom Extension

Boom Angle (AUS)

Section 4 - Operation

4.1 ENGINE

Starting the Engine

Battery Boosted Starting

Normal Engine Operation

Shut-Down Procedure

4.2 OPERATING WITH A NON-SUSPENDED LOAD

Lift Load Safely

Picking Up a Load

Transporting a Load

Leveling Procedure

Placing a Load

Disengaging a Load

4.3 OPERATING WITH A SUSPENDED LOAD

Lift Load Safely

Picking Up a Suspended Load

Transporting a Suspended Load

Leveling Procedure

Placing a Suspended Load

Disengaging a Suspended Load

4.4 ROAD OPERATION (CE)

4.5 LOADING AND SECURING FOR TRANSPORT

Tiedown