Oshkosh Corporation JLG 3508PS Use and care manual

Operation & Safety
Manual
Original Instructions
Keep this manual with machine at all times.
An Oshkosh Corporation Company
Models
3508PS, 3509PS,
3512PS, 3513PS,
4008PS, 4009PS,
4012PS, 4013PS,
4017PS
31200205
Revised
March 31, 2017

Revision Log
a31200205
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.
March 31, 2017 - K - Revised pages 5-2, 5-3 & rear cover.

Read This First
b31200205
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.

Read This First
c31200205
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.
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: [phone]
E-mail:
[e-mail]

Read This First
d31200205
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.

Table of Contents
i31200205
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
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
Table of Contents

Table of Contents
ii 31200205
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
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

Table of Contents
iii31200205
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

Table of Contents
iv 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 ............................... 5-6
5.5 Use of the Capacity Chart ................................................... 5-7
Capacity Indicator Locations .......................................... 5-7
Sample Capacity Chart (CE) .......................................... 5-8
Sample Capacity Chart (AUS)...................................... 5-10
Example........................................................................ 5-12
5.6 Attachment Installation ...................................................... 5-13
JLG Quick Attach.......................................................... 5-13
Manitou Quick Attach ................................................... 5-18
Hydraulic Operated Attachment ................................... 5-20
Platform Attachment (If Equipped) ............................... 5-20
5.7 Adjusting/Moving Forks ..................................................... 5-21
5.8 Attachment Operation ....................................................... 5-22
Carriage w/Forks .......................................................... 5-23
Side Shift Carriage ....................................................... 5-24
Fork Positioning Carriage ............................................. 5-26
Fork Extension.............................................................. 5-28
Fork Mounted Hook ...................................................... 5-30
Quick Attach Mounted Hook......................................... 5-32
Truss Boom .................................................................. 5-33
Bucket........................................................................... 5-34
Multi-Purpose Bucket ................................................... 5-36
Grapple Bucket............................................................. 5-38
Concrete Bucket - Fork Mounted.................................. 5-40
Platform ........................................................................ 5-42
5.9 Hitches (3508PS, 4008PS, 3509PS & 4009PS) ............... 5-43
Pin Hitch - CUNA C (Italy) ............................................ 5-43
Pin Hitch - CUNA D2 (Italy) .......................................... 5-44
Pin Hitch ....................................................................... 5-45
Auto Hitch ..................................................................... 5-46
Piton Frame and Auto Hitch ......................................... 5-47
Hydraulic Hitch ............................................................. 5-48

Table of Contents
v31200205
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

Table of Contents
vi 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

Section 1 - General Safety Practices
1-131200205
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.
DANGER OW0010
WARNING OW0021
CAUTION
OW0031

Section 1 - General Safety Practices
1-2 31200205
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.
OW0040
10 FT
(3 M)

Section 1 - General Safety Practices
1-331200205
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.)
OW0050
OW0080
OW0100
4 FT
(1,2 M)

Section 1 - General Safety Practices
1-4 31200205
•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
OH2291
OH20911
OH2221

Section 1 - General Safety Practices
1-531200205
Non-Suspended Load
•DO NOT drive with boom raised.
Suspended Load
• 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.
OW0060
OW0150

Section 1 - General Safety Practices
1-6 31200205
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).
OAL2030
2-Wheel Front Steer 4-Wheel Circle Steer 4-Wheel Crab Steer

Section 1 - General Safety Practices
1-731200205
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.
OW0130

Section 1 - General Safety Practices
1-8 31200205
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.
OW0170
OW0190