operator & safety manual - jlg industries telehandlers... · operator & safety manual keep...

Operator & SafetyManual

Keep this manual with machine at all times.

Platformfor

3513, 4013& 4017

31200029

RevisedFebruary 27, 2006

Revision Log

Revision Log REVISION LOGOctober 3, 2005 - A - Original Issue of Manual

February 27, 2006 - B - Added 4017 information.

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Read This First

Read This FirstThis 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, andlessees with the precautions and operating procedures essential for the safe andproper machine operation for its intended purpose.

Due to continuous product improvements, JLG Industries, Inc. reserves the right tomake 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 hasbeen read, training is accomplished and operation of the machine has beencompleted under the supervision of an experienced and qualified operator.

Operators of this equipment must be in good physical and mental condition, havenormal reflexes and reaction time, good vision and depth perception and normalhearing. Operator must not be using medication which could impair abilities nor beunder the influence of alcohol or any other intoxicant during the work shift.

In addition, the operator must read, understand and comply with instructionscontained in the following material furnished with the telehandler:

• This Operator & Safety Manual

• Telehandler Safety Manual

• All instructional decals and plates

• Any optional equipment instructions furnished

The operator must also read, understand and comply with all applicable Employer,Industry and Governmental rules, standards and regulations.

Modifications

Any modification to this machine must be approved by JLG.

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This product must comply with all safety related bulletins. Contact JLG Industries,Inc. or the local authorized JLG representative for information regarding safety-related bulletins which may have been issued for this product.

JLG Industries, Inc. sends safety related bulletins to the owner of record of thismachine. Contact JLG Industries, Inc. to ensure that the current owner records areupdated and accurate.

JLG Industries, Inc. must be notified immediately in all instances where JLGproducts have been involved in an accident involving bodily injury or death ofpersonnel 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 DepartmentJLG Industries, Inc.1 JLG DriveMcConnellsburg, PA 17233USA

or Your Local JLG Office(Addresses on back cover)

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

Outside USA:Phone: 717-485-5161E-mail: [email protected]

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Table of ContentsTable of Contents

TABLE OF CONTENTSRevision Log

Read This FirstOperator Qualifications ......................................................bModifications ......................................................................b

Table of Contents

Section 1 - General Safety Practices1.1 General Precautions ............................................................1-11.2 Hazard Classification system...............................................1-1

Safety Alert System and Safety Signal Words................1-11.3 Operation Safety..................................................................1-2

Electrical Hazards ...........................................................1-2Tip Over Hazard..............................................................1-3Load Falling Hazard........................................................1-4Lifting Personnel .............................................................1-5Pinch Points and Crush Hazards ....................................1-6Fall Hazard......................................................................1-8Chemical Hazards...........................................................1-9

Section 2 - Pre-Operation and Controls2.1 Pre-Operation Checks & Inspection.....................................2-12.2 Safety Decals.......................................................................2-32.3 Controls ...............................................................................2-6

Ignition ............................................................................2-7Joystick ...........................................................................2-8Indicator Panels ............................................................2-10

2.4 Platform Gate.....................................................................2-122.5 Lanyard Anchorage Points ................................................2-13

Section 3 - Operation3.1 Warm-Up and Operational Checks......................................3-13.2 Engine..................................................................................3-2

Starting the Engine .........................................................3-2Normal Engine Operation ...............................................3-3Shut-Down Procedure.....................................................3-3

3.3 Platform Operation...............................................................3-43.4 Loading And Securing For Transport...................................3-5

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Table of Contents

Section 4 - Platform4.1 Approved Platforms............................................................. 4-14.2 Unapproved Platforms......................................................... 4-14.3 Telehandler/Platform Capacity ............................................ 4-24.4 Platform Installation............................................................. 4-3

Mechanical Quick-Switch Device ................................... 4-4Platform Attachment ....................................................... 4-4

Section 5 - Emergency Procedures5.1 Emergency Operation ......................................................... 5-1

Operator Unable to Control Machine.............................. 5-1Platform or Boom Caught Overhead .............................. 5-1

5.2 Emergency Lowering Of Boom ........................................... 5-2Ground ERS ................................................................... 5-2Platform ERS.................................................................. 5-2

5.3 Incident Notification ............................................................. 5-3

Section 6 - Lubrication & Maintenance6.1 Introduction.......................................................................... 6-1

Clothing and Safety Gear ............................................... 6-16.2 General Maintenance Instructions....................................... 6-16.3 Service & Maintenance Schedules...................................... 6-2

8 Hour Maintenance Schedule ....................................... 6-26.4 Operator Maintenance Instructions ..................................... 6-3

Fuel System.................................................................... 6-3Tires................................................................................ 6-4Battery ............................................................................ 6-5

Section 7 - Additional Checks7.1 Emergency Recovery System Test ..................................... 7-17.2 Limited Boom Extension Switch Test .................................. 7-2

Section 8 - Specifications8.1 Product Specifications......................................................... 8-1

Performance................................................................... 8-1Dimensions..................................................................... 8-1Platform Vibration ........................................................... 8-1Platform Sound Level ..................................................... 8-1

Index

Inspection, Maintenance & Repair Log

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Section 1 - General Safety Practices

SECTION 1 - GENERAL SAFETY PRACTICES

1.1 GENERAL PRECAUTIONS• DO NOT use the machine with platform attached for any purpose other than

positioning personnel, their tools and equipment.

• DO NOT place boom or platform against any structure to steady the platform orto support the structure.

• DO NOT assist a stuck or disabled machine by using boom functions.

1.2 HAZARD CLASSIFICATION SYSTEM

Safety Alert System and Safety Signal Words

DANGER indicates an imminently hazardous situation which, if not avoided, willresult in death or serious injury.

WARNING indicates a potentially hazardous situation which, if not avoided, couldresult in death or serious injury.

CAUTION indicates a potentiality hazardous situation which, if not avoided, mayresult in minor or moderate injury.

WARNINGBefore operation, read & understand this manual. Failure to comply with thesafety precautions listed in this manual could result in machine damage, propertydamage, personal injury or death.

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1.3 OPERATION SAFETY

Electrical Hazards

• This machine is not insulated and does not provide protection from contact orproximity to electrical current.

• Maintain safe distance from electrical lines, apparatus or any energized (exposedor insulated) parts according to the Minimum Safe Approach Distance (MSAD).

• Allow for machine movement and electrical line swaying.

Voltage Range(Phase to Phase)

MINIMUM SAFE APPROACH DISTANCE (MSAD)

0 to 300 V AVOID CONTACT

Over 300 V to 50 KV 3 m (10 ft)

Over 50 KV to 200 KV 5 m (15 ft)

Over 200 KV to 350 KV 6 m (20 ft)

Over 350 KV to 500 KV 8 m (25 ft)

Over 500 KV to 750 KV 11 m (35 ft)

Over 750 KV to 1000 KV 14 m (45 ft)

Note: This requirement shall apply except where employer, local or governmental regulations are more stringent.

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Tip Over Hazard

• DO NOT exceed rated lift capacity. Distribute loads evenly on platform floor.

• Be sure that the ground conditions are able to support the machine.

• DO NOT raise boom unless frame is level (0 degrees).

• DO NOT operate machine when wind conditions exceed 12.5 m/s (28 mph).

• MAINTAIN proper tire pressure at all times. If proper tire pressures are notmaintained, this machine could tip over.

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Load Falling Hazard

• Never suspend load from platform or supports.

• DO NOT carry materials directly on platform railing unless approved by JLG.

• Always ensure that power tools are properly stowed and never left hanging bytheir cord from the platform work area.

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Lifting Personnel

• USE ONLY a JLG manufactured personnel work platform.

• DO NOT drive machine from cab when personnel are in platform.

• DO NOT allow personnel to tamper with or operate the machine from the cabwhen personnel are in the platform.

• Never sway the machine when the platform is occupied.

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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 tires and platform or other objects.

• Keep clear from under boom.

• Keep clear of boom holes.

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• Keep arms and hands clear of attachment tilt cylinder.

• During operation, keep all body parts inside platform railing.

• Keep others away while operating.

• Approved head gear must be worn by all operating personnel.

• Check work area for clearances overhead, on sides and bottom of platform whenlifting or lowering platform.

• Be sure that operators of other overhead and floor level machines are aware ofthe machine’s presence. Disconnect power to overhead cranes.

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Fall Hazard

• During operation, occupants in the platform must wear a full body harness with alanyard attached to an authorized lanyard anchorage point. Attach only onelanyard per lanyard anchorage point.

• Before operating the machine, make sure all gates are closed and fastened intheir proper position.

• Keep both feet firmly positioned on the platform floor at all times. Never useladders, boxes, steps, planks or similar items on platform to provide additionalreach.

• Never use the boom assembly to enter or leave the platform.

• Use extreme caution when entering or leaving platform. Be sure that the boom isfully lowered. Face the machine, maintain three point contact with the machine,using two hands and one foot or two feet and one hand during entry and exit.

• Avoid accumulation of debris on platform floor. Keep mud, oil, grease and otherslippery substances from footwear and platform deck.

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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 forthat purpose by JLG and site owner. Sparks from the electrical system and theengine exhaust can cause an explosion.

Flammable Fuel

• DO NOT fill the fuel tank or service the fuel system near an open flame, sparksor smoking materials. Engine fuel is flammable and can cause a fire and/orexplosion.

Hydraulic Fluid

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

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

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

Welding

• DO NOT use machine as a ground for welding.

• When performing welding or metal cutting operations, precautions must be takento protect the chassis from direct exposure to weld and metal cutting spatter.

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Section 2 - Pre-Operation and Controls

SECTION 2 - PRE-OPERATION AND CONTROLS

2.1 PRE-OPERATION CHECKS & INSPECTION

Note: Complete all required maintenance before operating unit.

A walk-around inspection of the telehandler is to be completed first. Refer to theOperator & Safety Manual supplied with telehandler.

Walk around inspection of the platform must be performed at beginning of each workshift or at each change of operator.

Ensure all Safety decals are legible and in place. Clean or replace as required. See“Safety Decals” on page 2-3.

WARNINGFALL HAZARD. Use extreme caution when checking items beyond your normalreach. Use an approved ladder. Failure to comply could result in death or seriousinjury.

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

INSPECTION NOTE: On all components, make sure there are no loose or missingparts, that they are securely fastened and no visible leaks or excessive wear existsin addition to any other criteria mentioned. Inspect all structural members includingattachment and railing for cracks, excessive corrosion and other damage.

1. Platform -

• Properly installed, see “Platform Installation” on page 4-3.

• Rail connections properly secure, undamaged and no missing hardware.

• Applicable Operator & Safety manual located in manual holder.

2. Platform Gate - Clean, undamaged and closes properly.

3. Footswitch - Clean, undamaged and work properly; not modified, disabled or blocked.

4. Control Console - Clean, undamaged; controls return to normal and control markings are legible.

5. Rotate Coupler - Undamaged, bolts tight; hydraulic hoses undamaged, not leaking.

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2.2 SAFETY DECALSEnsure all DANGER, WARNING, CAUTION and instructional decals and propercapacity charts are legible and in place. Clean and replace as required.

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2.3 CONTROLS

1. Emergency Stop Button: Push in to shut off power to platform controls and stop engine.

2. Indicator Panels: Indicator, caution and warning lights. See page 2-10 for details.

3. Fuel Gauge: Gauge for the diesel fuel tank.

4. Boom Joystick: See page 2-8 for details.

5. ERS Controller: See page 5-2 for details.

6. Horn: Push button to sound.

7. Ignition: Key activated. See page 2-7 for details.

8. Footswitch: Depress to enable platform controls.

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Ignition

• Position 0 - Engine off

• Position IGN - Voltage is available for all electrical functions.

• Position PHT - Engine preheat at temperature below 0°C.

• Position STR - Engine start.

• Position ERS - ERS controls are enabled.

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Joystick

The joystick (1) controls the boom and attachment functions.

Note: Buttons (5) & (6) are not used.

Boom Functions

• Boom functions are enabled by button (2). Press and hold the button; move thejoystick forward to lift boom; move joystick back to lower boom; move joystickright to extend boom; move joystick left to retract boom.

• The speed of boom functions depends upon the amount of joystick travel incorresponding direction.

• For two simultaneous boom functions, move the joystick between quadrants. Forexample; moving the joystick forward and to the left will lift and retract boomsimultaneously.

WARNINGCRUSH HAZARD. Rapid, jerky operation of controls will cause rapid, jerkymovement of the platform. Such movements could cause the load/occupants toshift or fall. Failure to comply could result in death or serious injury.

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Platform Functions

• Platform tilt is enabled by button (2) and controlled by the rocker switch (3). Pressand hold the button; push the rocker switch up to tilt platform back (up); push therocker switch down to tilt platform forward (down).

• Attachment rotate is enabled by button (4). Press and hold the button; move thejoystick left to rotate platform left; move the joystick right to rotate the platformright.

WARNINGCRUSH HAZARD. Only use platform tilt function for slight leveling of the platform.Incorrect use could cause the load/occupants to shift or fall. Failure to complycould result in death or serious injury.

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Indicator Panels

1. Engine Temperature: Illuminates red when engine temperature is high.

2. Battery Charge: Illuminates red when battery charge is low.

3. Engine Oil Pressure: Illuminates red when engine oil pressure is low.

4. Glow Indicator: Illuminates yellow when ignition key is at position PHT; engine preheat.

5. Wait Indicator: Illuminates yellow when system diagnostics are in process. Do not operate joystick or footswitch while lit.

6. Controls Enable Indicator: Illuminates green when engine is running and footswitch is activated; joystick is enabled.

7. Platform Ready Indicator: Illuminates green when necessary conditions are met for operation.

• Outriggers are lowered and front tires are lifted off the ground.

• Machine is level.

8. ERS Indicator: Illuminates green when ERS is enabled. See “Platform ERS” on page 5-2.

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9. System Distress Indicator:

a. Flashes yellow and buzzer sounds intermittently when pressure is low ineither outrigger.

b. Illuminates yellow and buzzer sounds when one of the following items is outof range.

• Engine Oil Pressure

• Engine Temperature

• Transmission Temperature

• Air Filter

• Hydraulic Oil Filter

• CAN Bus

• Engine Speed Sensor

• Hydraulic Pump Pressure

• Short Circuit Main Control Valve

• Boom Angle Sensor

c. Illuminates for three seconds then flashes for three seconds whenconditions a and b occur simultaneously.

10. Platform Overload: Illuminates red and buzzer sounds when platform capacity is exceeded. All functions are inoperable until load is decreased.

CAUTIONEQUIPMENT DAMAGE. When a red light or the system distress indicatorilluminates and a warning tone is heard, immediately lower platform to groundand stop engine. Determine cause before continued use.

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2.4 PLATFORM GATEKeep gate clean and unobstructed.

• Pull the black hook (1) away from the gate and push/pull the gate to open.

• During operation the gate must be latched closed.

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2.5 LANYARD ANCHORAGE POINTS

• Attach lanyard to one of the lanyard anchorage points (2).

• Only attach one lanyard per lanyard anchorage point.

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Section 3 - Operation

SECTION 3 - OPERATION

3.1 WARM-UP AND OPERATIONAL CHECKSThis section outlines the checks to be performed at the beginning of each work shiftor at each change of operator.

Warm-up and operational checks of the telehandler are to be completed beforeentering the platform. Refer to the Operator & Safety Manual supplied withtelehandler.

After start-up from platform and engine warms, check:

1. Horn must be audible with engine running.

2. All boom and platform functions - operate smoothly and correctly.

3. Perform any additional checks described in Section 7.

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3.2 ENGINE

Starting the Engine

This machine can be operated in temperatures of -20°C to 40°C (0°F to 104°F).Consult JLG for operation outside this range.

Note: Initial starting of engine should be performed from the cab. Refer to the Operator & Safety Manual supplied with telehandler.

1. In the cab make sure transmission control lever is in neutral and locked, emergency stop button is pulled out, outriggers are lowered, machine is level and ignition is turned to position P.

2. Remove ignition key and enter the platform. Ensure the emergency stop button is pulled out and platform ready indicator is illuminated.

3. Insert key into ignition and turn to position “IGN”. The wait indicator on the indicator panel will illuminate for four seconds as diagnostics are performed.

4. After the indicator light goes out, turn ignition switch to preheat position “PHT” if temperature is below 0°C.

5. Turn ignition switch to start position “STR” 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.

Note: After engine starts, all controls are inoperable for four seconds while diagnostics are run again. If the footswitch is activated during diagnostics, the engine will shut-down after completion.

6. After diagnostics are complete and wait indicator is no longer lit, the platform controls are ready for operation.

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Normal Engine Operation

• Observe indicator panels frequently to be sure all engine systems are functioningproperly.

• Be alert for unusual noises or vibration. When an unusual condition isnoticed, perform shut-down procedure. See “Shut-Down Procedure”. Reportcondition to your supervisor or maintenance personnel.

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

Shut-Down Procedure

1. Lower platform to ground.

2. Release footswitch.

3. Shut-off engine and remove ignition key.

4. Exit platform properly.

5. Insert key into cab ignition and turn to OFF position. Remove key.

6. Depress emergency stop button.

7. Turn off electrical master switch in engine compartment (if equipped).

8. Block wheels (if necessary).

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3.3 PLATFORM OPERATION• After engine start-up from the platform is successful, activate the footswitch to

enable the platform controls. The controls enable indicator will illuminate.

• If a control function is not operated within a seven second period, the controlsenable indicator will go out and the controls are disabled. Release the footswitchand activate again to re-enable the controls.

• With the footswitch activated, operate the joystick (see page 2-8) to control theboom and platform functions.

• If the platform is overloaded, the platform overload indicator will illuminate andbuzzer will sound. All platform functions are cut out. The load in the platformmust be decreased below the platform’s maximum capacity in order to allowcontinued operation.

• The platform ready indicator will remain illuminated while the machine is inplatform mode. If a condition would exist to cause this light to go out all platformfunctions are cut out and engine may shut off. Other personnel on the groundshould operate the telehandler ERS only as required to lower boom andpersonnel. Refer to Section 5 of the Operator & Safety Manual supplied withtelehandler.

• If needed, push the emergency stop switch down to shut off power to platformcontrols and shut off engine.

WARNINGTIP OVER HAZARD. Exceeding lift capacity of the telehandler/platform coulddamage the equipment and/or cause tip over resulting in death or serious injury.

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3.4 LOADING AND SECURING FOR TRANSPORT

1. To move/load the platform when detached from telehandler, use fork slots located under the platform.

2. Secure platform to deck with strap as shown in the figure.

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 platform 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.

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Section 4 - Platform

SECTION 4 - PLATFORM

4.1 APPROVED PLATFORMS

To determine if platform is approved for use on the specific telehandler you areusing, perform the following prior to installation.

• The platform model (1) and part number (2) on the platform identification platemust match the platform model (4) and part number (5) on the telehandleridentification plate.

If the above condition is not met, do not use the platform attachment. Thetelehandler may not be equipped for the attachment or the attachment may not beapproved for the model telehandler being used. Contact JLG or your local distributorfor further information.

4.2 UNAPPROVED PLATFORMSDo not use unapproved platforms for the following reasons:

• JLG cannot establish range and capacity limitations for “will fit,” homemade,altered, or other non-approved platforms.

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

• JLG cannot assure the ability of a non-approved platform to perform its intendedfunction safely.

WARNINGUse only approved attachments. Attachments which have not been approved foruse with your telehandler could cause machine damage or an accident resultingin death or serious injury.

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TELEHANDLER IDENTIFICATION PLATEPLATFORM IDENTIFICATION PLATE

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4.3 TELEHANDLER/PLATFORM CAPACITYPrior to installing the platform verify it is approved (see page 4-1) and thetelehandler is equipped with the proper capacity chart.

To determine the maximum capacity of the telehandler and platform, use thecapacity shown on the capacity decals (see page 2-3).

WARNINGNever use an attachment without the appropriate JLG supplied capacity chartinstalled on the telehandler. Failure to install the proper JLG supplied capacitychart could cause an accident resulting in death or serious injury.

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4.4 PLATFORM INSTALLATIONVerify the platform is properly installed.

Refer to the Operator & Safety Manual supplied with telehandler for completeinstallation instructions.

1. Platform

2. Platform Pin Recess

3. Attachment Pin

4. Lock Pin

5. Retainer Pin

6. Quick-Switch Device

WARNINGFALL/CRUSH HAZARD. Always be certain that platform is properly positionedon boom and secured. Failure to ensure proper installation could permit platformto disengage causing death or serious injury.

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Mechanical Quick-Switch Device

Attachment pin engaged in platform pin recess andlock pin inserted and secured with retainer pin.

Platform Attachment

Platform hydraulic hoses securely connected at boom.

Electric cable from the platform securely connectedto electrical box on boom.

WARNINGNever use the platform without the hydraulic hoses and electric cable properlyinstalled. Failure to ensure proper installation could cause an accident resulting indeath or serious injury.

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Section 5 - Emergency Procedures

SECTION 5 - EMERGENCY PROCEDURES

5.1 EMERGENCY OPERATION

Operator Unable to Control Machine

If the platform operator is pinned, trapped or unable to operate or control machine:

1. Other personnel should operate the machine from ground ERS controls only as required.

2. Other qualified personnel on the platform may use the platform controls. DO NOT CONTINUE OPERATION IF CONTROLS DO NOT FUNCTION PROPERLY.

Platform or Boom Caught Overhead

If the platform or boom becomes jammed or snagged in overhead structures orequipment, rescue platform occupants prior to freeing the machine.

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5.2 EMERGENCY LOWERING OF BOOMIn case of an emergency, engine or hydraulic failure an emergency recovery system(ERS) is available.

Ground ERS

Refer to the Operator & Safety Manual supplied with telehandler.

Platform ERS

1. Verify the emergency stop switch (1) is not depressed.

2. Turn ignition switch (2) to position “ERS”. The ERS indicator (3) should illuminate. If platform is overloaded, the platform overload indicator (4) will illuminate and alarm will sound until the load is below maximum capacity.

3. Activate the foot switch (5) to enable the ERS joystick (6).

4. While depressing the footswitch; move joystick back to lower boom; move joystick forward to raise boom; move joystick left to retract boom; move joystick right to extend boom. Operate until the platform is at ground level.

Note: It is recommended to only use the extend or lift functions if necessary and to limit their duration.

5. Release the footswitch and turn ignition switch off.

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5.3 INCIDENT NOTIFICATIONJLG Industries, Inc. must be notified immediately of any incident involving a JLGproduct. Even if no injury or property damage is evident, the factory should becontacted by telephone and provided with all necessary details.

In USA:Toll Free: 877-JLG-SAFE (877-554-7233)8:00am to 4:45pm EST

Outside USA:Phone: 717-485-5161

E-mail:[email protected]

Failure to notify the manufacturer of an incident involving a JLG Industries productwithin 48 hours of such an occurrence may void any warranty consideration on thatparticular machine.

Important:Following any accident, thoroughly inspect the machine and test all functions firstfrom cab controls, then from the platform controls. Do not lift above 3 m (10 ft) untilall damage has been repaired, if required, and that all controls are operatingcorrectly.

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Section 6 - Lubrication & Maintenance

SECTION 6 - LUBRICATION & MAINTENANCE

6.1 INTRODUCTIONService the product in accordance with Section 6 of the Operator & Safety Manualsupplied with telehandler and the maintenance schedule on the following pages.

Service intervals are based on machine usage of 1500 hours annually. Use of yourproduct may vary significantly and you must adjust service frequency for your usageto obtain maximum service life.

Note: Failure To Use JLG Hydraulic Filter Elements Could Void Warranty.

Clothing and Safety Gear

• Wear all the protective clothing and personal safety devices issued to you orcalled for by job conditions.

• DO NOT wear loose clothing or jewelry that can get caught on controls or movingparts.

6.2 GENERAL MAINTENANCE INSTRUCTIONSPrior to performing any service or maintenance on the telehandler, follow the“Shut-Down Procedure” on page 3-3 unless otherwise instructed. Ensuretelehandler is level for proper fluid readings.

• Clean lubrication fittings before lubricating.

• Apply a light coating of engine oil to all linkage pivot points.

• Intervals shown are for normal usage and conditions. Adjust intervals forabnormal usage and conditions.

WARNINGCUT/CRUSH/BURN HAZARD. Do not perform service or maintenance on themachine with the engine running, with the exception of the transmission fluid levelcheck. Failure to comply could cause death or serious injury.

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6.3 SERVICE & MAINTENANCE SCHEDULES

8 Hour Maintenance Schedule

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6.4 OPERATOR MAINTENANCE INSTRUCTIONS

Fuel System

A. Fuel Level Check

1. Check fuel gauge (1) located on instrument panel in cab.

2. If fuel is low, proceed to fuel source and perform “Shut-Down Procedure” on page 3-3.

3. Open the rear access door (2).

4. Turn fuel tank cap (3) and remove from filler neck (4). Add diesel fuel as needed. Replace fuel tank cap.

5. Close and secure the rear access door.

Note: Replenish diesel fuel at end of each work shift to minimize condensation.

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Tires

A. Tire Air Pressure Check

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

2. Remove valve stem cap.

3. Check tire pressure using a good quality gauge.

4. Add air if required.405/70-24 ...........................................................................4.5 bar (65 psi)

5. Replace valve stem cap.

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Battery

A. Battery Check

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

2. Open the engine cover.

3. Wearing eye protection, visually inspect the battery (5). Charge indicator (6) must be green. Check terminals for corrosion. Replace battery if it has a cracked, melted or damaged case.

4. Close and secure the engine cover.

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6-6 31200029

Section 7 - Additional Checks

SECTION 7 - ADDITIONAL CHECKS

7.1 EMERGENCY RECOVERY SYSTEM TEST

The Emergency Recovery System (ERS) is available on the platform in case ofemergency, engine or hydraulic failure. To check this feature, perform the following:

1. Lower platform to ground and shut-off engine.

2. Make sure the emergency stop switch is not depressed.

3. Turn ignition switch to position “ERS”. The ERS indicator should illuminate.

4. Activate the foot switch to enable the ERS joystick.

5. While depressing the footswitch operate each boom function briefly to ensure proper operation.

6. Release the footswitch and turn ignition switch off.

If any function does not operate properly, the machine must be removed fromservice and repaired before continued operation.

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Section 7 - Additional Checks

7.2 LIMITED BOOM EXTENSION SWITCH TEST

Australian machines are equipped with a switch (1) on the boom to limit extensionwhile being operated from platform.

Perform the following to check for proper operation:

1. With platform just above ground level, extend unloaded platform to full extension.

2. Lower platform to ground, release footswitch and shut-off engine.

3. Exit platform properly.

4. View the boom extension indicators on the side of the boom. The left edge (2) of the indicator “E” should be visible. If the entire indicator “E” is visible, the system is not functioning properly.

If the feature does not operate properly, the machine must be removed from serviceand repaired before continued operation.

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7-2 31200029

Section 8 - Specifications

SECTION 8 - SPECIFICATIONS

8.1 PRODUCT SPECIFICATIONSFor telehandler specifications refer to the Operator & Safety Manual supplied withtelehandler.

Performance

Maximum Lift Capacity ........................................................................ 450 kg (992 lb)

Maximum Lift Height3513 & 4013 ..............................................................................13,07 m (42.88 ft)3513 & 4013 (Australian) ...........................................................10,90 m (35.76 ft)4017...........................................................................................16,70 m (54.79 ft)

Capacity at Maximum Height .............................................................. 450 kg (992 lb)

Capacity at Maximum Forward Reach ................................................ 450 kg (992 lb)

Platform Rotation..................................................................................... 180 degrees

Dimensions

Platform Overall Height .................................................................1.700 mm (66.9 in)

Platform Overall Width ..................................................................2.240 mm (88.2 in)

Platform Overall Depth ..................................................................2.015 mm (79.3 in)

Overall Length of Machine with Platform Attached3513 & 4013..............................................................................7.666 mm (302 in)4017 ..........................................................................................7.808 mm (307 in)

Platform Vibration

Vibrations emitted by this machine are not hazardous to the operator in the platform.

Platform Sound Level

The equivalent continuous A-Weighted sound pressure level at the work platform isless than 70dB.

8-131200029

Section 8 - Specifications


8-2 31200029

IndexIndex

AAdditional Checks............................. 7-1

Approved Platforms.......................... 4-1

BBattery Check................................... 6-5

CCapacity ........................................... 4-2

Chemical Hazards ............................ 1-9

Controls ............................................ 2-6

DDecals .............................................. 2-3

Dimensions....................................... 8-1

EElectrical Hazards ............................ 1-2

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

Emergency Operation ...................... 5-1

Emergency Procedures.................... 5-1

Emergency Stop Button ................... 2-6

Engine .............................................. 3-2Normal Operation........................ 3-3Shut-Down .................................. 3-3Starting........................................ 3-2

ERS.................................................. 5-2Test ............................................. 7-1

FFall Hazard ....................................... 1-8

Fuel Level......................................... 6-3

GGate................................................ 2-12

General Maintenance ....................... 6-1

HHazard Classification System........... 1-1

IIgnition ..............................................2-7

Incident Notification...........................5-3

Indicator Panels ..............................2-10

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

LLanyard Anchorage Points..............2-13

Lifting Personnel ...............................1-5

Limited Boom Extension SwitchTest............................................7-2

Load Falling Hazard..........................1-4

Lubrication & Maintenance ...............6-1

MMinimum Safe Approach Distance....1-2

OOperational Checks ..........................3-1

Operator MaintenanceInstructions ................................6-3

PPerformance .....................................8-1

Pinch Points and Crush Hazards ......1-6

Platform Installation ..........................4-3

Platform Operation............................3-4

Pre-Operation and Controls ..............2-1

Pre-Operation Checks ......................2-1

SSafety Decals....................................2-3

Safety Practices ................................1-1

Safety Signal Words .........................1-1

Service & MaintenanceSchedules ..................................6-2

8 Hour..........................................6-2

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

Sound Level ......................................8-1

Specifications....................................8-1

131200029

Index

TTip Over Hazard ............................... 1-3

Tire Pressure.................................... 6-4

VVibration ........................................... 8-1

WWarm-Up .......................................... 3-1

2 31200029

Inspection, Maintenance & Repair LogInspection, Maintenance & Repair Log

Serial Number ______________________________

Date Comments

131200129

Inspection, Maintenance & Repair Log

Date Comments

2 31200129

JLG Industries, Inc.

TRANSFER OF OWNERSHIPTo: JLG, Gradall, Lull and SkyTrak product owner:

If you now own but ARE NOT the original purchaser of the product covered by this manual, we would like to know who you are. For the purpose of receiving safety-related bulletins, it is very important to keep JLG Industries, Inc. updated with the current ownership of all JLG products. JLG maintains owner information for each JLG product and uses this information in cases where owner notification is necessary.

Please use this form to provide JLG with updated information with regard to the current ownership of JLG products. Please return completed form to the JLG Product Safety & Reliability Department via facsimile or mail to address as specified below.

Thank You,Product Safety & Reliability DepartmentJLG Industries, Inc.1 JLG DriveMcConnellsburg, PA 17233-9533U.S.ATelephone: (717) 485-5161Fax: (717) 485-6573

NOTE: Leased or rented units should not be included on this form.

Mfg. Model: _______________________________________________________________

Serial Number: ____________________________________________________________

Previous Owner: ___________________________________________________________

Address: _________________________________________________________________

_________________________________________________________________________

Country: _________________________ Telephone: (_______) ____________________

Date of Transfer: _________________________________

Current Owner: ____________________________________________________________

Address: _________________________________________________________________

_________________________________________________________________________

Country: _________________________ Telephone: (_______) ____________________

Who in your organization should we notify?

Name: ___________________________________________________________________

Title: _____________________________________________________________________

JLG Worldwide Locations

Corporate Office

JLG Industries, Inc.

1 JLG Drive

McConnellsburg PA. 17233-9533

USA

Phone: (717) 485-5161

Customer Support Toll Free: (877) 554-5438

Fax: (717) 485-6417

JLG Industries (Australia)P.O. Box 511911 Bolwarra RoadPort MacquarieN.S.W. 2444AustraliaPhone: (61) 2 65 811111Fax: (61) 2 65 810122

JLG Industries (UK)Unit 12, SouthsideBredbury Park Industrial EstateBredburyStockportSK6 2sPEnglandPhone: (44) 870 200 7700Fax: (44) 870 200 7711

JLG Deutschland GmbHMax Planck Strasse 21D-27721 Ritterhude/lhlpohlBei BremenGermanyPhone: (49) 421 693 500Fax: (49) 421 693 5035

JLG Industries (Italia)Via Po. 2220010 Pregnana Milanese - MIItalyPhone: (39) 02 9359 5210Fax: (39) 02 9359 5845

JLG Latino Americana Ltda.Rua Eng. Carlos Stevenson,80-Suite 7113092-310 Campinas-SPBrazilPhone: (55) 19 3295 0407Fax: (55) 19 3295 1025

JLG Europe B.V.Jupiterstraat 2342132 HJ FoofddorpThe NetherlandsPhone: (31) 23 565 5665Fax: (31) 23 557 2493

JLG Industries (Norge AS)Sofeimyrveien 12N-1412 SofienyrNorwayPhone: (47) 6682 2000Fax: (47) 6682 2001

JLG PolskaUI. Krolewska00-060 WarsawaPolandPhone: (48) 91 4320 245Fax: (48) 91 4358 200

JLG Industries (Europe)Kilmartin Place, Tannochside ParkUddingston G71 5PHScotlandPhone: (44) 1 698 811005Fax: (44) 1 698 811055

JLG Industries (Pty) Ltd.Unit 1, 24 Industrial ComplexHerman StreetMeadowdaleGermistonSouth AfricaPhone: (27) 11 453 1334Fax: (27) 11 453 1342

Plataformas Elevadoras JLG Iberica, S.L.Trapadella, 2P.I. Castellbisbal Sur08755CastellbisbalSpainPhone: (34) 93 77 24700Fax: (34) 93 77 11762

JLG Industries (Sweden)Enkopingsvagen 150Box 704SE - 175 27 JarfallaSwedenPhone: (46) 8 506 59500Fax: (46) 8 506 59534

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