Operation & Safety Manual

Transcription

1 Operation & Safety Manual Original Instructions Keep this manual with machine at all times. Platforms for 3513PS, 4013PS, 4014PS, 4017PS Revised July 15, 2016 An Oshkosh Corporation Company

2

3 Revision Log Revision Log REVISION LOG December 12, A - Original Issue of Manual March 5, B - Revised pages 1-3, 9-1 and 9-2. November 16, C - Revised covers and page 9-2. March 22, D - Revised pages b, c, d, 1-1, 1-5, 2-1 thru 2-11, 3-2, 3-3, 3-4, 4-1, 4-3, 4-4, 5-1, 5-2, 5-3, 6-2, 6-3, 7-1 thru 7-6, 8-1 & 9-1. October 8, E - Revised covers and pages d, 2-4, 2-5, 5-3, 7-4 thru 7-7, 8-1, 9-1, 9-2 & 9-3. July 15, F - Revised rear cover and pages 2-4 thru 2-8, 2-11, 4-1, 4-3 & a

4 Read This First Read This First This manual is a very important tool! Keep it with the machine at all times. The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and operating procedures essential for the safe and proper machine operation for its intended purpose. Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without prior notification. Contact JLG Industries, Inc. for updated information. Operator Qualifications The operator of the machine must not operate the machine until this manual has been read, training is accomplished and operation of the machine has been completed under the supervision of an experienced and qualified operator. Operation within the U.S.A. requires training per OSHA 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

5 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 safety-related 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 Fountainhead Plaza Hagerstown, MD USA or Your Local JLG Office (Addresses on back cover) In USA: Toll Free: JLG-SAFE ( ) Outside USA: Phone: c

6 Read This First Other Publications Available For detailed machine operation procedures and safety information, please refer to the appropriate machine Operation & Safety Manual. d

7 Table of Contents Table of Contents TABLE OF CONTENTS Revision Log Read This First Operator Qualifications... b Modifications... b Other Publications Available... d Table of Contents Section 1 - General Safety Practices 1.1 Hazard Classification System Safety Alert System and Safety Signal Words General Precautions Operation Safety Electrical Hazards Tip Over Hazard Load Falling Hazard Lifting Personnel Pinch Points and Crush Hazards Fall Hazard Chemical Hazards Section 2 - Pre-Operation and Inspection 2.1 Pre-Operation Check and Inspection Safety Decals Console Fixed Platform Extendable Platform Walk-Around Inspection Operational Check Platform Gate Lanyard Anchorage Points Platform Extension (If Equipped) Section 3 - Controls and Indicators 3.1 General Controls Indicator Panel Boom Joystick i

8 Table of Contents Section 4 - Operation 4.1 Preparing Machine for Platform Operation Platform Operation Starting the Engine Normal Engine Operation Control Operation Shut-Down Procedure Loading and Securing for Transport Section 5 - Platform 5.1 Approved Platforms Unapproved Platforms Telehandler/Platform Capacity Platform Installation Section 6 - Emergency Procedures 6.1 Emergency Operation Operator Unable to Control Machine Platform or Boom Caught Overhead Emergency Lowering Of Boom Cab Auxiliary Power System Platform Auxiliary Power System Incident Notification Section 7 - Lubrication and Maintenance 7.1 Introduction Clothing and Safety Gear General Maintenance Instructions Service and Maintenance Schedules , 50 & 1000 Hour Maintenance Schedule Operator Maintenance Instructions Fuel System Tires Battery Section 8 - Additional Checks 8.1 General Auxiliary Power System ii

9 Table of Contents Section 9 - Specifications 9.1 Product Specifications Performance Dimensions Supplemental Information Index Inspection, Maintenance and Repair Log iii

10 Table of Contents iv

11 Section 1 - General Safety Practices SECTION 1 - GENERAL SAFETY PRACTICES 1.1 HAZARD CLASSIFICATION SYSTEM Safety Alert System and Safety Signal Words DANGER OW0010 DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING OW0021 WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION OW0031 CAUTION indicates a potentiality hazardous situation which, if not avoided, may result in minor or moderate injury. 1.2 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 or to support the structure. DO NOT assist a stuck or disabled machine by using boom functions. 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

12 Section 1 - General Safety Practices 1.3 OPERATION SAFETY Electrical Hazards OZ3020 This machine is not insulated and does not provide protection from contact or proximity to electrical current. Voltage Range (Phase to Phase) MINIMUM APPROACH DISTANCE (MAD) 0 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. Maintain distance from electrical lines, apparatus or any energized (exposed or insulated) parts according to the Minimum Approach Distance (MAD). Maintain a clearance of at least 3 m (10 ft) between any part of the machine and its occupants, their tools and their equipment from any electrical line or apparatus carrying up to 50,000 volts. One foot additional clearance is required for every additional 30,000 volts or less. Allow for machine movement and electrical line swaying

13 Tip Over Hazard Section 1 - General Safety Practices OZ1340 DO NOT exceed rated lift capacity. Distribute loads evenly on platform floor. Be sure that the ground conditions are able to support the machine. OW0080 DO NOT raise boom unless frame is level (0 degrees) m/s MAX OZ3030 DO NOT operate machine when wind conditions exceed 12.5 m/s (28 mph). DO NOT increase the surface area of platform or load. Increase of area exposed to wind will decrease stability. DO NOT increase the platform size with unauthorized deck extensions or attachments. OH2291 MAINTAIN proper tire pressure at all times. If proper tire pressures are not maintained, this machine could tip over

14 Section 1 - General Safety Practices Load Falling Hazard OZ1350 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 by their cord from the platform work area

15 Lifting Personnel Section 1 - General Safety Practices OW0170 USE ONLY a JLG approved personnel work platform. USE ONLY on machines configured for the platform attachment. OW0190 DO NOT drive machine from cab when personnel are in platform. DO NOT allow personnel to tamper with or operate the machine from the cab when personnel are in the platform except in an emergency. Never level the machine when the platform is occupied

16 Section 1 - General Safety Practices Pinch Points and Crush Hazards Stay clear of pinch points and rotating parts on the telehandler. OW0210 Stay clear of moving parts while engine is running. OW0220 Keep clear of steering tires and frame or other objects. OW0230 Keep clear from under boom. OW0240 Keep clear of boom holes

17 Section 1 - General Safety Practices OW0250 Keep arms and hands clear of attachment tilt cylinder. OZ1330 During operation, keep all body parts inside platform railing. OZ1320 Keep others away while operating. OZ1310 Approved head gear must be worn by all operating personnel. Check work area for clearances overhead, on sides and bottom of platform when lifting or lowering platform. Be sure that operators of other overhead and floor level machines are aware of the machine s presence. Disconnect power to overhead cranes

18 Section 1 - General Safety Practices Fall Hazard OZ1290 During operation, occupants in the platform must wear a full body harness with a lanyard attached to an authorized lanyard anchorage point. OZ1300 Before operating the machine, make sure all gates are closed and fastened in their proper position. Keep both feet firmly positioned on the platform floor at all times. Never use ladders, boxes, steps, planks or similar items on platform to provide additional reach. Never use the boom assembly to enter or leave the platform. Use extreme caution when entering or leaving platform. Be sure that the boom is fully 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 other slippery substances from footwear and platform deck

19 Chemical Hazards Section 1 - General Safety Practices Exhaust Fumes DO NOT operate machine in an enclosed area without proper ventilation. DO NOT operate the machine in hazardous environments unless approved for that purpose by JLG and site owner. Sparks from the electrical system and the engine exhaust can cause an explosion. Flammable Fuel OW0300 DO NOT fill the fuel tank or service the fuel system near an open flame, sparks or smoking materials. Engine fuel is flammable and can cause a fire and/or explosion. Hydraulic Fluid OW0950 DO NOT attempt to repair or tighten any hydraulic hoses or fittings while the engine is running or when the hydraulic system is under pressure. Stop engine and relieve trapped pressure. Fluid in the hydraulic system is under enough pressure that it can penetrate the skin. DO NOT use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks. Wear gloves to protect hands from spraying fluid. Welding DO NOT use machine as a ground for welding. When performing welding or metal cutting operations, precautions must be taken to protect the chassis from direct exposure to weld and metal cutting spatter

20 Section 1 - General Safety Practices This Page Intentionally Left Blank

21 Section 2 - Pre-Operation and Inspection 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. Note: Pre-operation check and inspection of the telehandler is to be completed first. Refer to the Operation & Safety Manual supplied with telehandler. The platform 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) or foreign objects. Report any leakage to the proper maintenance personnel. 2. Structure - Inspect the platform structure for dents, damage, weld or parent metal cracks or other discrepancies. PARENT METAL CRACK WELD CRACK OAH 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 manual holder. 5. Walk-Around Inspection - See page 2-8 for details

22 Section 2 - Pre-Operation and Inspection 6. Operational Check - Once the walk-around inspection is complete, perform an operational check (see page 2-9) 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

23 2.2 SAFETY DECALS Section 2 - Pre-Operation and Inspection Ensure all DANGER, WARNING, CAUTION and instructional decals are legible and in place. Clean and replace as required. Console F! ½ E C B B B A B C OZ

24 A A 400NMAX 12.5 m/s MAX A G.V.W. DATE OF MANUFACTURE Section 2 - Pre-Operation and Inspection Fixed Platform Non-CE Platforms CE Platforms Prior to SN B MAX 3513PS / 5300 Kg 4013PS / 5300 Kg 4017PS / 6000 Kg = + = 450 kg MAX B (3513PS, 4013PS) (4017PS BEFORE S/N ) MAX 4014PS / 5200 Kg 4017PS / 6200 Kg (4014PS) (4017PS S/N & AFTER) C MODEL MAX MAX M/S M/S kg kg SERIAL NO. = + SAMPLE DESIGNATION : MEWP Producer: JLG Manufacturing Europe BVBA Industrieterrein Oude Bunders 1034, Breitwaterstraat Maasmechelen - Belgium MAX MAX kg SERIAL NUMBER PLATE kg kg N N B A OZ

25 A 400NMAX 12.5 m/s MAX A G.V.W. DATE OF MANUFACTURE CE Platforms SN to Present Section 2 - Pre-Operation and Inspection B = + = 450 kg MAX B MAX 4014PS / 5200 Kg 4017PS / 6200 Kg C MODEL MAX MAX M/S M/S kg kg SERIAL NO. = + SAMPLE DESIGNATION : MEWP Producer: JLG Manufacturing Europe BVBA Industrieterrein Oude Bunders 1034, Breitwaterstraat Maasmechelen - Belgium MAX MAX kg SERIAL NUMBER PLATE kg kg N N B A OZ

26 A A G.V.W. DATE OF MANUFACTURE 400NMAX 12.5 m/s MAX A Section 2 - Pre-Operation and Inspection Extendable Platform Non-CE Platforms CE Platforms Prior to SN MAX 3513PS / 5300 Kg 4013PS / 5300 Kg 4017PS / 6000 Kg B = + = 350 kg MAX (3513PS, 4013PS) (4017PS BEFORE S/N ) B MAX 4014PS / 5200 Kg 4017PS / 6200 Kg (4014PS) (4017PS S/N & AFTER) C A A OZ2763 MODEL MAX MAX M/S M/S kg kg SERIAL NO. = + SAMPLE DESIGNATION : MEWP Producer: JLG Manufacturing Europe BVBA Industrieterrein Oude Bunders 1034, Breitwaterstraat Maasmechelen - Belgium MAX MAX kg SERIAL NUMBER PLATE kg kg N N B

27 A G.V.W. DATE OF MANUFACTURE 400NMAX 12.5 m/s MAX A CE Platforms SN to Present Section 2 - Pre-Operation and Inspection = + = 350 kg MAX B B MAX 4014PS / 5200 Kg 4017PS / 6200 Kg C A A OZ4570 MODEL MAX MAX M/S M/S kg kg SERIAL NO. = + SAMPLE DESIGNATION : MEWP Producer: JLG Manufacturing Europe BVBA Industrieterrein Oude Bunders 1034, Breitwaterstraat Maasmechelen - Belgium MAX MAX kg SERIAL NUMBER PLATE kg kg N N B

28 Section 2 - Pre-Operation and Inspection 2.3 WALK-AROUND INSPECTION OZ2671 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 railing and lanyard anchorage points for cracks, excessive corrosion and other damage. 1. Platform - Properly installed, see Platform Installation on page 5-3. Rail Connections properly secure, undamaged and no missing hardware. 2. Rotate Coupler - Undamaged, bolts tight; hydraulic hoses undamaged, not leaking. 3. Platform Recognition Sensor Plate (AUS): See inspection note. 4. Cables and Hoses - Clean, undamaged, correctly connected and not kinked or twisted. 5. Platform Gates - Clean, undamaged and closes properly. 6. Control Console - Clean, undamaged; controls return to normal and control markings are legible

29 Section 2 - Pre-Operation and Inspection 2.4 OPERATIONAL CHECK After start-up from platform and when engine warms, perform an operational check: 1. Horn must be audible from platform. 2. All boom and platform functions operate smoothly and correctly. 3. Ensure all boom functions stop when function enable trigger is released. 4. Ensure all functions are disabled when power/emergency stop switch is depressed. 5. Perform any additional checks described in Section

30 Section 2 - Pre-Operation and Inspection 2.5 PLATFORM GATE Keep gates clean and unobstructed. Fixed and Extendable Platforms 1 2 OZ2701 Actuate gate handle (1) to open gate (2). During operation the gate must be latched closed. Extendable Platform 4 3 OZ2681 If extensions are in closed position, lift rail (3) and slide inner rail (4) left to access platform

31 2.6 LANYARD ANCHORAGE POINTS Section 2 - Pre-Operation and Inspection OZ1290 Attach lanyard to one of the lanyard anchorage points. Fixed Platform - Attach one lanyard per lanyard anchorage point. DO NOT attach more than one lanyard per lanyard anchorage point. Extendable Platform - Attach two lanyards per lanyard anchorage point. DO NOT attach more than two lanyards per lanyard anchorage point

32 Section 2 - Pre-Operation and Inspection 2.7 PLATFORM EXTENSION (IF EQUIPPED) To extend an extendable platform perform the following procedure. 2 1 OZ2711 On extendable portion (1) of platform, lift gate (2) and latch closed. 3 OZ2781 Use gate and handles (3) to lift extension to extended position. CAUTION PINCH POINT. Keep hands on gate or extension handles while extending platform

33 Section 2 - Pre-Operation and Inspection OZ2791 Verify extension posts (4) are properly positioned as shown in figure. Remove safety latch (5) from stow position (6) and place through support bracket (7). To retract extension, reverse procedure

34 Section 2 - Pre-Operation and Inspection This Page Intentionally Left Blank

35 3.1 GENERAL Section 3 - Controls and Indicators SECTION 3 - CONTROLS AND INDICATORS 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

36 Section 3 - Controls and Indicators 3.2 CONTROLS OZ Boom Joystick: See page Platform Level Switch: Push switch forward to tilt platform up; pull switch back to tilt platform down. 3. Horn Button: Push button to sound horn. 4. Platform Rotate Switch: Push switch right to rotate platform right; push switch left to rotate platform left. 5. Indicator Panel: See page 3-3. WARNING FALL/CRUSH HAZARD. Only use platform tilt function for slight leveling of the platform. Incorrect use could cause the load/occupants to shift or fall. 6. Power/Emergency Stop Switch: Push down to shut off power to platform controls and stop engine. 7. Start Switch: Push switch forward and hold to start engine. Release switch after engine starts. 8. Function Enable Trigger: Squeeze trigger and hold to enable platform controls. In the event the engine does not start, squeeze trigger and hold to start the auxiliary power unit. See Platform Auxiliary Power System on page Engine Preheat Switch: At temperatures below 0 C (32 F), push switch forward and hold to activate engine preheat

37 Indicator Panel Section 3 - Controls and Indicators F! ½ E C OZ Outriggers Not Set Indicator: Illuminates and buzzer sounds when outriggers are not set. All functions are disabled until outriggers are set. 2. Platform Overload Indicator: Illuminates and buzzer sounds when platform capacity is exceeded. All functions are disabled until load is decreased. 3. Engine Fault Warning Indicator: Illuminates and buzzer sounds when engine is operating outside the normal range. 4. Engine Fault Critical Indicator: Illuminates and buzzer sounds when a critical engine fault exists. 5. Engine Preheat Indicator: Illuminates when engine preheat switch is activated. 6. Function Enable Indicator: Illuminates when function enable trigger is activated. If no valid function is operated within a seven second period, the indicator will go out and all functions are disabled. 7. Fuel Gauge: Indicates amount of fuel in fuel tank. 8. System Distress Indicator: Illuminates and buzzer sounds when machine faults exist. 9. Telehandler Not Level Indicator: Illuminates and buzzer sounds when telehandler is not level. All functions are disabled until telehandler is level. 10. Boom Control System Warning Indicator: Not used at present time. NOTICE EQUIPMENT DAMAGE. When the engine fault, system distress or a red indicator illuminates, immediately lower platform to ground and stop engine. Determine cause and correct before continued use

38 Section 3 - Controls and Indicators Boom Joystick 3 OZ2841 The boom joystick (3) controls the extend/retract and lift/lower boom functions. Move the joystick back to lower boom; move joystick forward to lift boom; move joystick right to retract boom; move joystick left to extend boom. The speed of boom functions depends upon the amount of joystick travel in corresponding direction. For two simultaneous boom functions, move the joystick between quadrants. For example; moving the joystick forward and to the left will raise and extend boom simultaneously. WARNING FALL/CRUSH HAZARD. Rapid, jerky operation of controls will cause rapid, jerky movement of the platform. Such movements could cause the load/occupants to shift or fall

39 SECTION 4 - OPERATION Section 4 - Operation 4.1 PREPARING MACHINE FOR PLATFORM OPERATION The following must be completed from the cab to transfer power to the platform. 1 N RPM OZ Verify platform is properly installed and quick attach lock pin is fully engaged. See Platform Installation on page 5-3. Platform (1) will be shown on display. 2. Apply park brake. 3. Shift transmission control lever to neutral. 4. Fully retract boom and lower boom below 10 degrees. 3 N RPM 2 OZ Fully lower outriggers, lifting front tires and ensure machine is level. Display indicates when outrigger (2) and level (3) requirements are satisfied. 4 N RPM OZ Shut off engine and rotate key to Platform position. Display indicates machine is in platform mode (4). 7. Remove key and verify the power/emergency stop switch is pulled up. 8. Exit cab

40 Section 4 - Operation 4.2 PLATFORM OPERATION 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. Enter platform. 2. Pull up power/emergency stop switch and verify platform ready indicator is illuminated. 3. If the temperature is below 0 C (32 F), push engine pre-heat switch forward and wait for preheat indicator on instrument panel to go out. 4. Push start switch forward to start engine. If engine fails to start within 20 seconds, release switch and allow starting motor to cool for a few minutes before trying again. 5. After diagnostics are complete, the platform controls are ready for operation. Normal Engine Operation Observe indicator panel frequently to be sure all engine systems are functioning properly. Be alert for unusual noises or vibration. When an unusual condition is noticed, 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

41 Control Operation Section 4 - Operation After engine start-up from the platform is successful, activate the function enable trigger. Platform controls are activated and the function enable indicator will illuminate. If a control function is not operated within a seven second period, the function enable indicator will go out and controls are disabled. Release the function enable trigger and activate again to re-enable controls. With the function enable trigger activated, operate the boom joystick and other switches to control boom and platform functions. If platform is overloaded, the platform overload indicator will illuminate and buzzer will sound. All platform function controls are disabled. The load in platform must be decreased below the platform s maximum capacity in order to allow continued operation. WARNING TIP OVER HAZARD. Exceeding lift capacity of the telehandler/platform could damage the equipment and/or cause tip over. If needed, push the power/emergency stop switch to shut off power to platform controls and shut off engine. Shut-Down Procedure 1. Lower platform to ground. 2. Release function enable trigger. 3. Depress power/emergency stop switch to shut-off engine. 4. Exit platform properly. 5. Open cab door. 6. Turn cab ignition to OFF position. Remove key. 7. Depress power/emergency stop switch in cab. 8. Turn off electrical master switch in engine compartment (if equipped). 9. Block wheels (if necessary)

42 Section 4 - Operation 4.3 LOADING AND SECURING FOR TRANSPORT C OZ To move/load platform when detached from telehandler, position forks under extendable platform support structure or use fork slots located under fixed platform. OZ Secure platform to deck with strap. 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

43 5.1 APPROVED PLATFORMS SECTION 5 - PLATFORM Section 5 - Platform To determine if platform is approved for use on the specific telehandler you are using, perform the following prior to installation. The platform model/option number on the platform identification plate must match the platform number on a capacity chart located in the operator cab. The telehandler model on the capacity chart must match the model telehandler being used. If the above condition is not met, do not use the platform attachment. The telehandler may not be equipped for the attachment 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 PLATFORMS Do not use unapproved platforms for the following reasons: Range and capacity limitations for will fit, homemade, altered, or other non-approved platforms 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 platform 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

44 Section 5 - Platform 5.3 TELEHANDLER/PLATFORM CAPACITY Prior to installing the platform verify it is approved and the telehandler is equipped with the proper capacity chart. See Approved Platforms on page 5-1. To determine the maximum capacity of the telehandler and platform, use the capacity shown on the capacity decal. See Safety Decals on page 2-3. WARNING Never use an attachment without the appropriate JLG approved capacity chart installed on the telehandler

45 Section 5 - Platform 5.4 PLATFORM INSTALLATION PS & 4013PS 4017PS BEFORE S/N PS PS S/N &AFTER OZ HYDRAULIC QUICK ATTACH 3 MECHANICAL QUICK ATTACH Verify the platform is properly installed. Refer to the Operation & Safety Manual supplied with telehandler for complete installation instructions. Hydraulic Quick Attach - Attachment pin (2) engaged in platform pin recess (1) and lock pin (3) fully engaged. Mechanical Quick Attach - Attachment pin (2) engaged in platform pin recess (1) and lock pin (3) fully inserted and secured with retainer pin (4). WARNING FALL/CRUSH HAZARD. Always be certain that platform is properly positioned on boom and secured. Failure to ensure proper installation could permit platform to disengage. Platform hydraulic hoses (5) securely connected at boom. Platform electric cable (6) securely connected at boom. WARNING Never use platform without the hydraulic hoses and electrical cable properly installed

46 Section 5 - Platform This Page Intentionally Left Blank

47 Section 6 - Emergency Procedures SECTION 6 - EMERGENCY PROCEDURES 6.1 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 cab 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 or equipment, rescue platform occupants prior to freeing the machine

48 F ½ E C Section 6 - Emergency Procedures 6.2 EMERGENCY LOWERING OF BOOM In case of an emergency or engine failure an auxiliary power system is available. Cab Auxiliary Power System Refer to the Operation & Safety Manual supplied with telehandler. Platform Auxiliary Power System OZ With the engine shut-down verify the power/emergency stop switch (1) is pulled up. 2. Squeeze and hold the function enable trigger (2) to activate the auxiliary power system. If platform is overloaded, the platform overload indicator (3) will illuminate and alarm will sound until the load is below maximum capacity. 3. While holding the function enable trigger, move boom joystick (4) back to lower boom; move forward to raise boom; move right to retract boom; move left 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 due to limited battery life. 4. Release the function enable trigger and depress the power/emergency stop switch

49 6.3 INCIDENT NOTIFICATION Section 6 - Emergency Procedures JLG Industries, Inc. must be notified immediately of any incident involving a JLG product. Even if no injury or property damage is evident, the factory should be contacted by telephone and provided with all necessary details. In USA: Toll Free: JLG-SAFE ( ) 8:00am to 4:45pm EST Outside USA: Phone: ProductSafety@JLG.com Failure to notify the manufacturer of an incident involving a JLG Industries product within 48 hours of such an occurrence may void any warranty consideration on that particular machine. Note: Following any accident, thoroughly inspect the machine and test all functions first from cab controls, then from the platform controls. Do not lift above 3 m (10 ft) until all damage has been repaired, if required, and all controls are operating correctly

50 Section 6 - Emergency Procedures This Page Intentionally Left Blank

51 Section 7 - Lubrication and Maintenance SECTION 7 - LUBRICATION AND MAINTENANCE 7.1 INTRODUCTION Service the product in accordance with the Operation & Safety Manual supplied with telehandler and the maintenance schedule on the following pages. Clothing and Safety Gear Wear all the protective clothing and personal safety devices issued to you or called for by job conditions. DO NOT wear loose clothing or jewelry that can get caught on controls or moving parts. 7.2 GENERAL MAINTENANCE INSTRUCTIONS Prior to performing any service or maintenance on the telehandler, follow the shut-down procedure on page 4-3 unless otherwise instructed. Ensure telehandler 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 for abnormal usage and conditions. WARNING CUT/CRUSH/BURN HAZARD. Do not perform service or maintenance on the machine with the engine running, with the exception of the transmission oil level check

52 Section 7 - Lubrication and Maintenance 7.3 SERVICE AND MAINTENANCE SCHEDULES 10, 50 & 1000 Hour Maintenance Schedule EVERY 10 Check Fuel Level Check Tire Condition & Pressure Check Battery Additional Checks - Section 8 EVERY 50 Check Rotator Check Platform Controls EVERY 1000 Check Load Sensing System (LSS) Check Platform Structure Check Lanyard Anchorage Points Check Platform Gate Operation Check Rotator Bolt Torque OZ

53 Section 7 - Lubrication and Maintenance This Page Intentionally Left Blank

54 Section 7 - Lubrication and Maintenance 7.4 OPERATOR MAINTENANCE INSTRUCTIONS Fuel System A. Fuel Level Check 8 OW1150 OW PS, 4013PS 4017PS Before S/N OZ2081 OZ 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 Open rear access door (2). 4. Turn fuel tank cap (3) to remove from filler neck (4). 5. Add diesel fuel as needed. 6. Replace fuel tank cap. 7. Close and secure rear access door. Note: Replenish diesel fuel at end of each work shift to minimize condensation. NOTICE EQUIPMENT DAMAGE. Do not allow machine to run out of fuel during operation. See Engine Operation & Maintenance Manual for details prior to servicing

55 4014PS 4017PS S/N & After Section 7 - Lubrication and Maintenance 1 2 OZ2081 OAM 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 Turn fuel tank cap (2) to remove from filler neck. 4. Add diesel fuel as needed. 5. Replace fuel tank cap. Note: Replenish diesel fuel at end of each work shift to minimize condensation. NOTICE EQUIPMENT DAMAGE. Do not allow machine to run out of fuel during operation. See Engine Operation & Maintenance Manual for details prior to servicing

56 Section 7 - Lubrication and Maintenance Tires A. Tire Air Pressure Check 8 OW1150 OW Perform Shut-Down Procedure on page Remove valve stem cap. 3. Check tire pressure. 4. Add air if required. Refer to the Operation & Safety Manual supplied with telehandler for tire pressures. 5. Replace valve stem cap. B. Tire Damage For pneumatic tires, when any cut, rip or tear is discovered that exposes sidewall or tread area cords in the tire, measures be taken to remove the product from service immediately. Arrangements must be made for replacement of the tire or tire assembly. C. Tire and Wheel Replacement It is recommended that a replacement tire to be the same size, ply and brand as originally installed. Refer to the appropriate parts manual for ordering information. If not using an approved replacement tire, the replacement tires must have the following characteristics: Equal or greater ply/load rating and size of original. Tire tread contact width equal or greater than original. Wheel diameter, width and offset dimensions equal to the original. Approved for the application by the tire manufacturer (including inflation pressure and maximum tire load). Unless specifically approved by JLG, do not replace a foam filled or ballast filled tire assembly with a pneumatic tire. Due to size variations between tire brands, when selecting and installing a replacement tire ensure both tires on the axle are the same. The rims installed have been designed for stability requirements which consist of track width, tire pressure and load capacity. Size changes such as rim width, center piece location, larger or smaller diameter, etc., without written factory recommendations, may result in unsafe condition regarding stability

57 E. Wheel Installation Section 7 - Lubrication and Maintenance Torque lug nuts after first 50 hours and after each wheel installation. Note: If machine is equipped with directional tire assemblies, the wheel and tire assemblies must be installed with the directional tread pattern arrows facing in the direction of forward travel. 1. Start all nuts by hand to prevent cross threading. DO NOT use a lubricant on threads or nuts. 2. Tighten lug nuts in an alternating pattern as indicated in figure. Refer to the Operation & Safety Manual supplied with telehandler for torque values OY1220 WARNING TIP OVER HAZARD. Lug nuts must be installed and maintained at the proper torque to prevent loose wheels, broken studs and possible separation of wheel from the axle

58 Section 7 - Lubrication and Maintenance Battery A. Battery Check 8 OW1150 OW OZ Perform Shut-Down Procedure on page Open engine cover. 3. Wearing eye protection, visually inspect the battery (3). Check terminals for corrosion. Replace battery if it has a cracked, melted or damaged case. 4. Close and secure engine cover

59 8.1 GENERAL Section 8 - Additional Checks SECTION 8 - ADDITIONAL CHECKS If any of the following test results cannot be achieved, the system is not functioning properly and the machine must be removed from service and repaired before continued operation. 8.2 AUXILIARY POWER SYSTEM A. Auxiliary Power System Test 8 OW1150 OZ2770 The auxiliary power system is available on the platform in case of emergency or engine failure. To check this feature, perform the following: 1. Test system with machine on a level surface. 2. Lower platform to ground and shut-off engine. 3. Verify the power/emergency stop switch is pulled up. 4. Squeeze and hold function enable trigger to start auxiliary power system. 5. While holding function enable trigger operate each boom joystick function briefly to ensure proper operation. 6. While holding function enable trigger operate the platform rotate switch to ensure proper operation. 7. Release function enable trigger and depress the power/emergency stop switch

60 Section 8 - Additional Checks This Page Intentionally Left Blank

61 SECTION 9 - SPECIFICATIONS 9.1 PRODUCT SPECIFICATIONS Section 9 - Specifications For telehandler specifications refer to the Operation & Safety Manual supplied with telehandler. Performance Maximum Capacity Fixed Platform kg (992 lb) Extendable Platform kg (772 lb) Maximum Lift Height 3513PS & 4013PS CE... 10,6 m (34.8 ft) AUS... 10,9 m (35.8 ft) 4014PS... 12,0 m (39.4 ft) 4017PS Before S/N ,1 m (46.3 ft) S/N & After... 15,0 m (49.2 ft) Maximum Forward Reach Fixed Platform 3513PS & 4013PS... 10,3 m (33.8 ft) 4014PS... 10,0 m (32.8 ft) 4017PS Before S/N ,6 m (44.6 ft) S/N & After... 12,2 m (40.4 ft) Extendable Platform 3513PS & 4013PS CE... 10,6 m (34.8 ft) AUS...8,4 m (27.6 ft) 4014PS... 10,3 m (33.8 ft) 4017PS Before S/N ,9 m (45.6 ft) S/N & After... 12,5 m (41.0 ft) Maximum Ground Bearing Load 3513PS & 4013PS kg ( lb) 4014PS kg ( lb) 4017PS Before S/N kg ( lb) S/N & After kg ( lb) Platform Rotation degrees

62 Section 9 - Specifications Dimensions Platform Overall Height Fixed Platform mm (64.2 in) Extendable Platform mm (64.0 in) Platform Overall Length Fixed Platform mm (75.1 in) Extendable Platform mm (90.2 in) Platform Overall Width Fixed Platform mm (72.0 in) Extendable Platform Retracted mm (96.1 in) Extended mm (178.1 in) Overall Length of Machine with Platform Attached 3513PS & 4013PS Fixed Platform...7,59 m (24.9 ft) Extendable Platform...7,97 m (26.1 ft) 4014PS Fixed Platform...8,06 m (26.5 ft) Extendable Platform...8,46 m (27.8 ft) 4017PS Before S/N Fixed Platform...7,70 m (25.3 ft) Extendable Platform...8,09 m (26.5 ft) S/N & After Fixed Platform...8,33 m (27.3 ft) Extendable Platform...8,71 m (28.6 ft) Platform Working Area Width Fixed Platform...1,8 m (5.9 ft) Extendable Platform... 4,5 m (14.8 ft) Length Fixed Platform... 0,76 m (2.5 ft) Extendable Platform... 1,04 m (3.4 ft)

63 Section 9 - Specifications Supplemental Information The following information is provided in accordance with the requirements of the European Machinery Directive 2006/42/EC and is only applicable to CE machines. For combustion engine powered machines, guaranteed Sound Power Level (LWA) per European Directive 2000/14/EC (Noise Emission in the Environment by Equipment for Use Outdoors) based on test methods in accordance with Annex III, Part B, Method 36 of the directive, is 106 db. The vibration total value to which the hand-arm system is subjected does not exceed 2,5 m/s 2. The highest root mean square value of weighted acceleration to which the whole body is subjected does not exceed 0,5 m/s

64 Section 9 - Specifications This Page Intentionally Left Blank

65 Index A Additional Checks Approved Platforms Auxiliary Power System Test B Battery Boom Joystick C Capacity Chemical Hazards Control Operation Controls D Decals Dimensions E Electrical Hazards Emergency Lowering of Boom Emergency Operation Emergency Procedures F Fall Hazard Fuel Level G Gate General Maintenance H Hazard Classification System I Incident Notification Indicator Panel Installation L Index Lanyard Anchorage Points Lifting Personnel Load Falling Hazard Lubrication and Maintenance M Minimum Approach Distance N Normal Engine Operation O Operational Check Operator Maintenance Instructions P Performance Pinch Points and Crush Hazards Platform Platform Extension Platform Operation Power/Emergency Stop Switch Pre-Operation Check and Inspection Preparing Machine for Platform Operation S Safety Decals Safety Practices Safety Signal Words Service and Maintenance Schedule 10 Hour Hour Hour Shut-Down Procedure Specifications Starting the Engine Supplemental Information

66 Index T Tip Over Hazard Tires Air Pressure Damage Replacement Transport W Walk-Around Inspection Wheel Installation Wheel Replacement

67 Inspection, Maintenance and Repair Log Inspection, Maintenance and Repair Log Serial Number Date Comments

68 Inspection, Maintenance and Repair Log Date Comments

69

70 An Oshkosh Corporation Company JLG Industries, Inc. 1 JLG Drive McConnellsburg PA USA (717) (Corporate) (800) (Service) (717) JLG Worldwide Locations JLG Industries 358 Park Road Regents Park NSW 2143 Sydney 2143 Australia +6 (12) (12) techservicesauc@jlg.com JLG Ground Support Oude Bunders 1034 Breitwaterstraat 12A 3630 Maasmechelen Belgium +32 (0) emeaservice@jlg.com JLG Latino Americana LTDA Rua Antonia Martins Luiz, 580 Distrito Industrial Joao Narezzi Indaiatuba-SP Brasil +55 (19) (Parts) +55(19) (Service) comercialpecas@jlg.com servicos@jlg.com Oshkosh-JLG (Tianjin) Equipment Technology LTD Shanghai Branch No 465 Xiao Nan Road Feng Xian District Shanghai China +86 (21) JLG Deutschland GmbH Max Planck Str Ritterhude - Ihlpohl Germany +49 (0) (0) german-parts@jlg.com JLG Industries Dubai Jafza View PO Box , LB 19 20th Floor, Office 05 Jebel Ali, Dubai +971 (0) (0) emeaservice@jlg.com JLG Equipment Services Ltd. Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N. T. Hong Kong +(852) (852) JLG France SAS Z.I. Guillaume Mon Amy Fauillet Tonniens France +33 (0) (0) pieces@jlg.com JLG Industries (Italia) S.R.L. Via Po Pregnana Milanese (MI) Italy +39 (0) (0) ricambi@jlg.com JLG EMEA B.V. Polaris Avenue JH Hoofdorf The Netherlands +31 (0) emeaservice@jlg.com Oshkosh-JLG Singapore Technology Equipment Pte Ltd. 35 Tuas Avenue 2 Jurong Industrial Estate Singapore SEA@jlg.com JLG NZ Access Equipment & Services 2B Fisher Cresent Mt Wellington 1060 Auckland, New Zealand +6 (12) (12) techservicesaus@jlg.com JLG Iberica S.L. Trapadella, 2 Pol. Ind. Castellbisbal Sur Castellbisbal Barcelona Spain +34 (0) (0) parts_iberica@jlg.com JLG Industries Vahutinskoe shosse 24b. Khimki Moscow Region Russia Federation +7 (499) (499) JLG Sverige AB Enkopingsvagen Jarfalla Sweden +46 (0) (0) nordicsupport@jlg.com JLG Industries (UK) Ltd. Bentley House Bentley Avenue Middleton, Greater Manchester M24 2GP United Kingdom +44 (0) (0) ukparts@jlg.com