JLG 642 Operation & Safety Manual
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JLG 642 Operation & Safety Manual

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Operation & Safety
Manual
Original Instructions
Keep this manual with machine at all times.
Models
642, 943, 1043
1055, 1255
31211031
Revised
August 31, 2015
An Oshkosh Corporation Company

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  • Page 1 Operation & Safety Manual Original Instructions Keep this manual with machine at all times. Models 642, 943, 1043 1055, 1255 31211031 Revised August 31, 2015 An Oshkosh Corporation Company...
  • Page 2 CALIFORNIA PROPOSITION 65 BATTERY WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemical known to the State of California to cause cancer and reproductive harm. WASH HANDS AFTER HANDLING! CALIFORNIA PROPOSITION 65 EXHAUST WARNING Diesel Engine exhaust and some of its constituents are known to the State of California to cause cancer,...
  • Page 3 Revision Log Revision Log REVISION LOG April 17, 2015 - A - Original Issue of Manual August 31, 2015 - B - Revised cover and pages d, 2-1, 2-4 thru 2-13, 2-16, 3-3, 3-5, 3-8, 3-11, 3-16, 3-17, 4-5, 4-7, 5-2, 5-3, 5-37, 5-39, 5-40, 5-43, 7-6, 7-8 thru 7-13, 7-15, 7-16, 7-19, 7-23, 9-1 thru 9-6 &...

  • Page 4: Read This First

    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.
  • Page 5 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.

  • Page 6: Other Publications Available

    Read This First Other Publications Available Service Manual..........................31211033 642, 943 & 1043 Parts Manual....................31211111 1055 & 1255 Parts Manual......................31211032 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.

  • Page 7: Table Of Contents

    Table of Contents Table of Contents TABLE OF CONTENTS Revision Log Read This First Operator Qualifications ................b Modifications....................b Other Publications Available ..............d Machine Configuration................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...
  • Page 8 Table of Contents Section 3—Controls and Indicators 3.1 General......................3-1 3.2 Controls ......................3-2 Instrument Panel ..................3-4 LCD Display....................3-6 Left Dash Control Panel................3-8 Right Dash Control Panel..............3-9 Ignition ....................3-10 Park Brake....................3-11 Parking Procedure................3-11 Transmission Control Lever ............. 3-12 Accessory Control Lever (if equipped)......... 3-14 Outrigger Levers (if equipped) ............
  • Page 9 4.5 Loading and Securing for Transport ........... 4-14 Tie Down ....................4-14 Lifting ....................... 4-15 Section 5—Attachments 5.1 Approved Attachments................5-1 5.2 Unapproved Attachments .................5-1 5.3 JLG Supplied Attachments.................5-2 5.4 Telehandler/Attachment/Fork Capacity ..........5-4 5.5 Use of the Capacity Chart ................5-5 Capacity Indicator Locations ..............5-5 Sample Capacity Chart................5-6 Example......................5-7 5.6 Attachment Installation ................5-9...
  • Page 10 Table of Contents Side Tilt Carriage .................. 5-18 Swing Carriage ..................5-20 Dual Fork Positioning Carriage............5-22 Mast Carriage ..................5-24 Side Tilt Mast Carriage ............... 5-26 Pipe Grapple..................5-28 Fork Extension ..................5-30 Bucket ...................... 5-32 Grapple Bucket ..................5-34 Bucket—Fork Mounted..............
  • Page 11 Table of Contents 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 10 & 1st 50 Hour Maintenance Schedule ........7-3 50, 1st 250 & 250 Hour Maintenance Schedule ......7-4 500, 750 &...
  • Page 12 Table of Contents 31211031...

  • Page 13: Section 1-General Safety Practices

    Section 1—General Safety Practices SECTION 1—GENERAL SAFETY PRACTICES 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.

  • Page 14: Operation Safety

    Section 1—General Safety Practices OPERATION SAFETY Note: The manufacturer has no direct control over machine application and operation. Therefore, safety issues listed in this manual are non-exhaustive. The user and operator are responsible for conforming with good safety practices. Electrical Hazards 10 ft (3m) O 0891...
  • Page 15 Section 1—General Safety Practices • The minimum approach distance may be reduced if insulating barriers are installed to prevent contact, and the barriers are rated for the voltage of the line being guarded. These barriers shall not be part of (or attached to) the machine. The minimum approach distance shall be reduced to a distance within the designed working dimensions of the insulating barrier.

  • Page 16: Tip Over Hazard

    • For additional load requirements, refer to the appropriate capacity chart. OW0050 • 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.
  • Page 17 Section 1—General Safety Practices OH2291 • 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. OH20911 •...
  • Page 18 Section 1—General Safety Practices Non-Suspended Load O 0901 • DO NOT drive with boom raised. Suspended Load OW0150 • Tether suspended loads to restrict movement. • Weight of all rigging (slings, etc.) must be included as part of load. • DO NOT attempt to use telehandler frame-leveling to compensate for load swing. •...

  • Page 19: Travel Hazard

    Section 1—General Safety Practices Travel Hazard 2-WHEEL FRONT STEER 4-WHEEL CIRCLE STEER 4-WHEEL CRAB STEER OAL2030 • 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.

  • Page 20: Load Falling Hazard

    Section 1—General Safety Practices Load Falling Hazard OW0130 • Never suspend load from forks or other parts of carriage weldment. Use only approved lift points. • DO NOT burn or drill holes in fork(s). • Forks must be centered under load and spaced apart as far as possible. 31211031...

  • Page 21: Lifting Personnel

    Section 1—General Safety Practices Lifting Personnel O 0171 • When lifting personnel, USE ONLY an approved personnel work platform, with proper capacity chart displayed in the cab. O 0921 • DO NOT drive machine from cab when personnel are in platform. 31211031...

  • Page 22: Driving Hazards On Slopes

    Section 1—General Safety Practices Driving Hazards on Slopes OW0200 To maintain sufficient traction and braking capabilities, travel on slopes as follows: • When unloaded, drive with forks pointed downhill. • When loaded, drive with the forks pointed uphill. • For additional travel requirements, refer to the appropriate capacity chart. •...

  • Page 23: Pinch Points And Crush Hazards

    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 •...
  • Page 24 Section 1—General Safety Practices OW0240 • Keep clear of boom holes. OW0250 • Keep arms and hands clear of attachment tilt cylinder. OW0260 • Keep hands and fingers clear of carriage and forks. OW0960 • Keep others away while operating. 1-12 31211031...

  • Page 25: Fall Hazard

    Section 1—General Safety Practices Fall Hazard OW0280 • Enter using the proper hand holds and steps provided. Always maintain 3-point contact when mounting or dismounting. Never grab control levers or steering wheel when mounting or dismounting the machine. • DO NOT get off the machine until the shutdown procedure on page 4-5 has been performed.

  • Page 26: Chemical Hazards

    • 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.

  • Page 27: Clearsky (If Equipped)

    Section 1—General Safety Practices CLEARSKY (IF EQUIPPED) Federal Communications Commission (FCC) Information for Users FCC Statement Regarding Interference This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation.
  • Page 28 Section 1—General Safety Practices Notice Regarding Radio Frequency Radiation Exposure Do not operate your unit when a person is within eight inches (20 centimeters) of the antenna. A person or object within eight inches (20 centimeters) of the antenna could impair call quality and may cause the unit to operate at a higher power level than necessary, as well as expose that person to RF energy in excess of that established by the FCC RF Exposure Guidelines.

  • Page 29: Section 2-Pre-Operation And Inspection

    Section 2—Pre-Operation and Inspection SECTION 2—PRE-OPERATION AND INSPECTION PREPARATION, INSPECTION AND MAINTENANCE The following table covers the periodic machine inspections and maintenance required. Consult local regulations for further requirements for telehandlers. The frequency of inspections and maintenance must be increased as necessary when the machine is used in a harsh or hostile environment, if the machine is used with increased frequency, or if the machine is used in a severe manner.

  • Page 30: Pre-Operation Check And Inspection

    Section 2—Pre-Operation and Inspection PRE-OPERATION CHECK AND INSPECTION Note: Complete all required maintenance before operating unit. WARNING FALL HAZARD. Use extreme caution when checking items beyond your normal reach. Use an approved ladder. The pre-operation check and inspection, performed at beginning of each work shift or at each change of operator, should include the following: 1.
  • Page 31 Section 2—Pre-Operation and Inspection 8. Operational Check—Once the walk-around inspection is complete, perform a warm-up and operational check (see page 2-14) of all systems in an area free of overhead and ground level obstructions. See Section 3—Controls and Indicators for more specific operating instructions.

  • Page 32: Safety Decals

    PINCH POINTS could crush or cut causing death or serious injury. 1706302B 1706301C Pre - 1706300C 150A 200A 1001191487 A 110hp (82kW) @ 2500 RPM 4109801 1001173422_B 1001173422 1001172037 1001195855 1001184632 4109801 (642, 943, 1043) (1055, 1255) O 0050 31211031...
  • Page 33 As released from factory this truck meets design specifications in ANSI \ ITSDF B56.6-2011 Keep clear of pinch points. 1001154575A Manufactured by PINCH POINTS could crush or cut JLG Industries Inc. McConnellsburg, PA causing death or serious injury. 1706302B 17233-9533 USA 4109801...
  • Page 34 ULTRA LOW SULFUR DIESEL FUEL ONLY S < 15 mg/kg 1001125387 A 1001094708B 1001094708 1001125387oENGLISH 1001163355oENGLISH/FRENCH 642, 943, 1043 - 1001205468 1055, 1255 - 1001180278 CHARTS NOT PRESENT IF EQUIPPED WITH MULTIFUNCTION DISPLAY CAPACITY CHARTS 91163028 XXXXX 1001180276 1001180276 A...
  • Page 35 Section 2—Pre-Operation and Inspection 1706303oENGLISH 1001163273oENGLISH/FRENCH Operator must be trained and Fasten must read and understand seat all capacity charts, operator belt. 1001181543 and safety manuals. 1706767oENGLISH 1001163291oENGLISH/FRENCH 1001188372 1001172035 1001172035_A 1001140322 (IF EQUIPPED) AVOID CRUSHING If machine tips. Jumping out 5A F20 could result in death or...

  • Page 36: Iso (If Equipped)

    2.5 GPM 9.5 lpm 1001109053 REV A 1001109053 1001139942 OD0980 1706285 1706098 1706292 1001191487 (INSIDE FRAME) 150A 200A 1001191487 A 110hp (82kW) @ 2500 RPM 4109801 1001173422_B 1001195855 1001184632 4109801 1001173422 1001172037 O 0070 (642, 943, 1043) (1055, 1255) 31211031...
  • Page 37 * Refer to load capacity chart for truck with attachment, and individual load ratings stamped on forks, if equipped. Use lowest capacity of all ratings. As released from factory this truck meets design specifications in ANSI \ ITSDF B56.6-2011 1001154575A Manufactured by JLG Industries Inc. McConnellsburg, PA 17233-9533 USA 4109801 1001143852...
  • Page 38 Section 2—Pre-Operation and Inspection 1706288 1001092877 8005870 (IF EQUIPPED WITH ENCLOSED CAB) 1706284 8005870C 1001130323 1001094708B 1001094708 642, 943, 1043 - 1001205468 1055, 1255 - 1001180278 CHARTS NOT PRESENT IF EQUIPPED WITH MULTIFUNCTION DISPLAY CAPACITY CHARTS 91163028 XXXXX 1001180276 1001180276 A O 0100...
  • Page 39 Section 2—Pre-Operation and Inspection 1706287 1001181543 1706289 1001188372 1001172035 1001172035_A 1001140322 (IF EQUIPPED) 5A F20 5A F10 1001200101A 1001200101 1706283 1001191229 B 1001191229 (INSIDE PANEL) 1001181537B 1001181537 (IF EQUIPPED) 1001092878 1706293 O 0963 31211031 2-11...

  • Page 40: Walk-Around Inspection

    Section 2—Pre-Operation and Inspection WALK-AROUND INSPECTION OD1040 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.
  • Page 41 Section 2—Pre-Operation and Inspection 1. Boom Sections and Lift, Tilt, Extend/Retract, Compensating Cylinders— • Check front, top, side and rear wear pads for presence of grease. • Pivot pins secure; hydraulic hoses undamaged, not leaking. 2. Left Outrigger (if equipped)—Pins secure; hydraulic hoses and cylinder undamaged, not leaking.

  • Page 42: Warm-Up And Operational Checks

    Section 2—Pre-Operation and Inspection WARM-UP AND OPERATIONAL CHECKS Warm-Up Check During warm-up period, check: 1. Heater, air conditioning and wipers (if equipped). 2. Check all lighting systems (if equipped) for proper operation. 3. Adjust mirrors for maximum visibility. WARNING CUT/CRUSH/BURN HAZARD. Keep engine cover closed while engine is running except when checking transmission oil level.

  • Page 43: Cab

    Never operate telehandler unless the overhead guard, cab structure and right side glass or screen are in good condition. Any modification to this machine must be approved by JLG to assure compliance with ROPS/FOPS certification for this cab/ machine configuration. If the overhead guard or cab structure is damaged, the CAB CANNOT BE REPAIRED.

  • Page 44: Enclosed Cab Windows (If Equipped)

    Section 2—Pre-Operation and Inspection ENCLOSED CAB WINDOWS (IF EQUIPPED) Keep all windows clean and unobstructed. Cab Door Window O 0190 • Cab door (1) must be closed during operation • During operation the cab door window (2) must either be latched open or closed •...

  • Page 45: Rear Window

    Section 2—Pre-Operation and Inspection Rear Window OD0030 • Lift lever (6) and push to open the rear window (7) • Lift lever and pull to close 31211031 2-17...
  • Page 46 Section 2—Pre-Operation and Inspection This Page Intentionally Left Blank 2-18 31211031...

  • Page 47: Section 3-Controls And Indicators

    Section 3—Controls and Indicators SECTION 3—CONTROLS AND INDICATORS GENERAL This section provides the necessary information needed to understand control functions. 31211031...

  • Page 48: Controls

    Section 3—Controls and Indicators CONTROLS OD1050 OD0100 31211031...
  • Page 49 Section 3—Controls and Indicators 1. Transmission Control Lever: See page 3-12. 2. Instrument Panel: See page 3-4. 3. Steering Wheel: Turning the steering wheel to the left or right steers the machine in the corresponding direction. Three steering modes are available. See “Steer Modes” on page 3-26.

  • Page 50: Instrument Panel

    Section 3—Controls and Indicators Instrument Panel The instrument panel uses different colors to alert the operator to different types of operational situations that could arise. • When an indicator illuminates RED (except park brake) or if a gauge enters a red zone, immediately bring machine to a stop, lower boom and attachment to the ground and stop the engine.
  • Page 51 Section 3—Controls and Indicators 4. Left Turn (if equipped): Illuminates and flashes when left turn signal or hazard lights are active. 5. Low Engine Oil Pressure: Illuminates when oil pressure is low. 6. Low Fuel Level: Illuminates when fuel level is low. 7.

  • Page 52: Lcd Display

    Section 3—Controls and Indicators LCD Display STOP O 1441 54321 VIEW WITH ACTIVE DIAGNOSTICS SHOWN 1. Indicators: Indicator will display when active. a. Continuous Auxiliary Hydraulics—Illuminates when continuous auxiliary hydraulics are active. b. Transmission Disconnect—Illuminates when transmission disconnect function is enabled.
  • Page 53 Section 3—Controls and Indicators TRANSMISSION OIL AIR CLEANER LOW BATTERY TEMPERATURE RESTRICTION INDICATOR INDICATOR O 0301 SYSTEM DISTRESS MAINTENANCE INDICATOR REQUIRED INDICATOR 4. Active Diagnostics: Displays icon and applicable diagnostic code. Display cycles through each active warning or diagnostic if multiple are present. See Service Manual for details.

  • Page 54: Left Dash Control Panel

    Section 3—Controls and Indicators Left Dash Control Panel O 0170 1. Air Conditioning Switch (if equipped): On/Off switch. 2. HVAC Recirculation Switch (if equipped): On/Off switch. Push to activate and recirculate air inside the cab. While deactivated, air is circulated from outside the cab. 3.

  • Page 55: Right Dash Control Panel

    Section 3—Controls and Indicators Right Dash Control Panel OD0130 1. Front Work Lights Switch (if equipped): On/Off switch. 2. Boom Work Lights Switch (if equipped): On/Off switch. 3. Rear Work Lights Switch (if equipped): On/Off switch. 4. Beacon Light Switch (if equipped): On/Off switch. 5.

  • Page 56: Ignition

    Section 3—Controls and Indicators Ignition OD0160 • Position 0—Engine off, no voltage available. • Position 1—Voltage available for all electrical functions. Wait to start engine until preheat indicator on instrument panel goes out. • Position 1—Engine run. • Position 2—Engine start. In the event the engine does not start, rotate key to position 0 then back to position 2 to re-engage the starter.

  • Page 57: Park Brake

    Section 3—Controls and Indicators Park Brake OD0141 Park brake switch controls the application and release of the park brake. • With the engine running and the park brake switch in OFF position, park brakes are disengaged. • With switch in ON position, park brake is engaged and transmission will not engage forward or reverse.

  • Page 58: Transmission Control Lever

    Section 3—Controls and Indicators Transmission Control Lever Direction of Travel Selection OD0170 Transmission control lever engages forward or reverse travel. • Push lever forward for forward travel; pull lever rearward for reverse travel. Move lever to centered position for neutral. •...
  • Page 59 Section 3—Controls and Indicators Gear Selection OD0180 Gear selection is located on the twist grip handle of transmission control lever. • Twist hand grip to select gear. • The Transmission is equipped with four forward and three reverse gears • Select appropriate gear for task being performed. Use a lower gear for transporting a load.

  • Page 60: Accessory Control Lever (If Equipped)

    Section 3—Controls and Indicators Accessory Control Lever (if equipped) Turn Signals and Low/High Beam Headlights OD0200 • Push accessory control lever forward (1) to activate left turn signal. • Pull lever backward (2) to activate right turn signal. • The lever must be manually returned to the center position to deactivate either turn signal.

  • Page 61: Outrigger Levers (If Equipped)

    Section 3—Controls and Indicators Outrigger Levers (if equipped) OD0230 Levers (1 & 2) control the outriggers. • Left lever (1) controls left outrigger and right lever (2) controls right outrigger. • Press lever down to lower outriggers. • Lift lever up to raise outriggers. •...

  • Page 62: Joystick

    Section 3—Controls and Indicators Joystick Verify the joystick decal located inside the cab matches the machine controls. O 1231 The joystick controls the boom, attachment tilt, auxiliary hydraulic and transmission disconnect functions. 3-16 31211031...
  • Page 63 Section 3—Controls and Indicators Boom Functions • Move the joystick back to lift boom; move joystick forward to lower boom; move joystick right to extend boom; move joystick left to retract boom. • The speed of boom functions depends upon the amount of joystick travel in corresponding direction.

  • Page 64: Multifunction Display (If Equipped)

    Section 3—Controls and Indicators MULTIFUNCTION DISPLAY (IF EQUIPPED) OD1860 1. Display: The display shows the following depending on selection: • Anti theft. See page 3-24. • Home Screen. See page 3-19. • Capacity information. • Rear camera. See page 3-31. •...

  • Page 65: Home Screen

    Section 3—Controls and Indicators Home Screen The home screen displays upon successful startup or when selected using the home button. OD1930 1. Capacity chart and attachment selection area. Note: If capacity chart or attachment programming is not compatible with your machine configuration, a large gray question mark (?) displays.

  • Page 66: Main Menu Screen

    Section 3—Controls and Indicators Main Menu Screen Press the Main Menu button to access the menu. OD1940 Note: Telehandler must be stopped and park brake applied before menu can be accessed. Operator Tools OD1950 Note: Scroll down or up to view all items. Machine Set-Up.
  • Page 67 Section 3—Controls and Indicators Display Settings. Display settings allows the operator to set up Language, Maintenance Icon, Real Time Clock (RTC), and screen brightness. Some options may not be available depending on machine programming. See Service Manual. Maintenance. Maintenance menu provides the operator with maintenance intervals and lubrication requirements to properly maintain the telehandler.

  • Page 68: Attachment Selection Screen

    Section 3—Controls and Indicators Attachment Selection Screen The attachment select screen allows the operator to select the attachment in order to display the applicable capacity chart. 1. Press the Attachment Select button to access the types of attachments. OD2050 2. Select the type of attachment. Note: Scroll down or up to view all items.

  • Page 69: Communication Error Screen

    Section 3—Controls and Indicators Communication Error Screen OD1900 Screen displays if the multifunction display cannot communicate with the machine. Wait a few moments and restart the machine. If the communication error continues to display, contact the local dealer. 31211031 3-23...

  • Page 70: Anti Theft Functionality (If Enabled)

    Section 3—Controls and Indicators ANTI THEFT FUNCTIONALITY (IF ENABLED) Machines with anti theft feature active require entering a numeric code before operation to prevent unauthorized use. If multifunction display is installed, ant-theft feature is accessed from that display only. Note: If the anti theft feature is active and the current access code is not known, it may be viewed or changed by the machine owner (level 2 password may be required).

  • Page 71: Multifunction Display Input

    Section 3—Controls and Indicators Multifunction Display Input Code entry is accomplished using information provided in the multifunction display. OD1920 1. Turn ignition switch to position 1. If anti theft is active, the display will prompt the operator for a numeric code. 2.

  • Page 72: Steer Modes

    Section 3—Controls and Indicators STEER MODES Three steer modes are available for operator use. 2-Wheel Front Steer 4-Wheel Circle Steer 4-Wheel Crab Steer OAL2030 Note: 2-Wheel Front Steer mode is required for travel on public roads. Manual Steering Alignment Mode Change Note: Steer mode will change immediately after selection.

  • Page 73: Operator Seat

    Section 3—Controls and Indicators OPERATOR SEAT Adjustments Prior to starting the engine adjust seat for position and comfort. O 2040 1. Suspension: Use the knob (6) to adjust the suspension to appropriate weight setting. 2. Fore/Aft: Use lever (7) to move seat fore and aft. 3.

  • Page 74: Seat Belt

    Section 3—Controls and Indicators Seat Belt OH20912 Fasten seat belt as follows: 1. Grasp both free ends of the belt making certain that belt webbing is not twisted or entangled. 2. With back straight in the seat, couple the retractable end (male end) of the belt into the receptacle (buckle) end of the belt.

  • Page 75: Boom Angle And Extension Indicators

    Section 3—Controls and Indicators BOOM ANGLE AND EXTENSION INDICATORS OD0660 • The boom extension indicators (1) are located on the left side of the boom. Use these indicators to determine boom extension when using the capacity chart (see “Use of the Capacity Chart”...

  • Page 76: Reverse Systems (If Equipped)

    Section 3—Controls and Indicators REVERSE SYSTEMS (IF EQUIPPED) WARNING CRUSH HAZARD. Running into persons or objects can cause death, serious injury, or damage to property and equipment. Always check mirrors and area behind vehicle before and when backing up. Reverse systems are for supplementary use only. Reverse Sensor System The reverse sensor system provides audible indication of objects to rear of unit while in reverse gear.

  • Page 77: Reversing Camera

    Section 3—Controls and Indicators Reversing Camera The reversing camera provides an additional view of the area directly behind the telehandler. The view displays on the multifunction display home screen when the telehandler is running and transmission is in reverse. The display automatically returns to the standard home screen when transmission is shifted out of reverse.

  • Page 78: Rear Axle Stabilization (Ras) System

    Section 3—Controls and Indicators REAR AXLE STABILIZATION (RAS) SYSTEM OD1420 OD1430 Free Pivot Mode With boom below 40° (1), RAS system is in Free Pivot Mode. Rear axle pivots freely and frame level functions normally. RAS indicator (2) will be off. Slow Pivot Mode With boom above 40°...

  • Page 79: Section 4-Operation

    This machine can be operated under normal conditions in temperatures of 0°F to 114°F (-20°C to 45°C). Consult JLG for operation outside this range or under abnormal conditions. If equipped for extreme cold weather, -40°F to 0°F (-40°C to -20°C), see page 4-2 for starting procedure.

  • Page 80: Extreme Cold Weather Starting (If Equipped)

    Section 4—Operation Extreme Cold Weather Starting (if equipped) If equipped with extreme cold weather components, machine can be operated in temperatures of -40°F to 0°F (-40° C to -20° C). 1. Machine must be equipped with heating components and extreme cold weather fluids.

  • Page 81: Battery Boosted Starting

    Section 4—Operation Battery Boosted Starting OW0530 If battery-boost starting (jump-start) is necessary, proceed as follows: • Never allow vehicles to touch. • Ensure boosting vehicle engine is running. OD1700 • Remote battery post is located on right side of engine compartment for jump-starting.

  • Page 82: Normal Engine Operation

    Section 4—Operation Normal Engine Operation • Observe instrument panel and display frequently to be sure all systems are functioning properly. • Be alert for unusual noises or vibration. When an unusual condition is noticed, park machine in safe position and perform shut-down procedure. Report condition to your supervisor or maintenance personnel.

  • Page 83: Shut-Down Procedure

    Section 4—Operation Shut-Down Procedure When parking the telehandler, park in a safe location on flat level ground and away from other equipment and/or traffic lanes. 1. Apply park brake. 2. Shift transmission to “Neutral”. 3. Lower forks or attachment to ground. 4.

  • Page 84: After-Treatment System (Ats) (If Equipped For Uls)

    Section 4—Operation AFTER-TREATMENT SYSTEM (ATS) (IF EQUIPPED FOR ULS) This machine is equipped with an exhaust After-Treatment System. O 1031 Automatic Exhaust System Cleaning ATS is an automatic exhaust cleaning system and will perform as required without any operator interaction. •...

  • Page 85: Stationary Exhaust System Cleaning

    Section 4—Operation Stationary Exhaust System Cleaning STOP OD1160 OD1220 Selective Catalytic Reduction (SCR) Indicator (2) will illuminate when stationary exhaust system cleaning is required. 1. Move telehandler to an area free of flammables and people that could be exposed to hot exhaust.

  • Page 86: Operating With A Non-Suspended Load

    Section 4—Operation OPERATING WITH A NON-SUSPENDED LOAD Lift Load Safely • You must know weight and load center of every load you lift. If you are not sure of weight and load center, check with your supervisor or with supplier of the material. WARNING TIP OVER HAZARD.

  • Page 87: Transporting A Load

    Section 4—Operation Transporting a Load OW0540 • After engaging the load and resting it against the backrest, tilt the load back to position it for travel. Travel in accordance with the requirements set forth in Section 1—General Safety Practices and Section 5—Attachments. Leveling Procedure 1.

  • Page 88: Placing A Load

    Section 4—Operation Placing a Load Before placing any load be sure that: • Landing point can safely support weight of the load. • Landing point is level; front to back and side to side. • Use capacity chart to determine safe boom extension range. See “Use of the Capacity Chart”...

  • Page 89: Operating With A Suspended Load

    Section 4—Operation OPERATING WITH A SUSPENDED LOAD Lift Load Safely • You must know weight and load center of every load you lift. If you are not sure of weight and load center, check with your supervisor or with supplier of the material. WARNING TIP OVER HAZARD.

  • Page 90: Transporting A Suspended Load

    Section 4—Operation Transporting a Suspended Load OZ3160 OW0130 • Travel in accordance with the requirements set forth in Section 1—General Safety Practices and Section 5—Attachments. • For additional requirements, refer to appropriate capacity chart in operator cab. Important things to remember: •...

  • Page 91: Placing A Suspended Load

    Section 4—Operation Placing a Suspended Load Before placing any load be sure that: • Landing point can safely support weight of load. • Landing point is level; front to back and side to side. • Use capacity chart to determine safe boom extension range. See “Use of the Capacity Chart”...

  • Page 92: Loading And Securing For Transport

    Section 4—Operation LOADING AND SECURING FOR TRANSPORT Tie Down OD0650 4109801 4109801 1. Level telehandler prior to loading. 2. Using a spotter, load telehandler with boom as low as possible. 3. Once loaded, apply parking brake and lower boom until boom or attachment is resting on deck.

  • Page 93: Lifting

    Section 4—Operation Lifting The weight of the machine is listed on the serial number plate located at the front of the frame. Actual machine weight and center of gravity will vary depending on attachment, fluid levels and machine options. Actual weight and center of gravity should be verified prior to lifting.
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  • Page 95: Section 5-Attachments

    If any of the above conditions are not met, do not use attachment. Telehandler may not be equipped with proper capacity chart or attachment may not be approved for the model telehandler being used. Contact JLG or a local distributor for further information. UNAPPROVED ATTACHMENTS Do not use unapproved attachments for the following reasons: •...

  • Page 96: Jlg Supplied Attachments

    Section 5—Attachments JLG SUPPLIED ATTACHMENTS Applicable Model Attachment Part Number 1043 1055 1255 Carriage, 50 in (1270 mm) 1001146084 Carriage, 60 in (1524 mm) 1001146086 Carriage, 72 in (1829 mm) 1001146088 Carriage, 72 in (1829 mm) 1001193794 Side Shift Carriage, 50 in (1270 mm)
  • Page 97 Section 5—Attachments Applicable Model Attachment Part Number 1043 1055 1255 Bucket, 96 in–1.5 yd 1001100823 (2438 mm–1,15 m Bucket, 102 in–2.0 yd 1001100824 (2590 mm–1,5 m Grapple Bucket, 96 in–1.75 yd 0930020 (2438 mm–1,34 m Hook, Fork Mounted 1001097205 Hook, Coupler Mounted 1001207606 Trash Hopper, Fork Mounted 1001195082...

  • Page 98: Telehandler/Attachment/Fork Capacity

    Lifting and placing a load may require use of more than one capacity chart based on machine configuration. Other than block forks, all forks should be used in matched pairs, block forks used in matched sets. WARNING Never use an attachment without the appropriate JLG approved capacity chart installed on the telehandler. 31211031...

  • Page 99: Use Of The Capacity Chart

    Section 5—Attachments USE OF THE CAPACITY CHART To properly use capacity chart (see page 5-6), operator must first determine and/or have the following: 1. An approved attachment. See “Approved Attachments” on page 5-1. 2. Proper Capacity Chart(s). 3. Weight of load being lifted. 4.

  • Page 100: Sample Capacity Chart

    Section 5—Attachments Sample Capacity Chart This Capacity Chart may be used with this xxxxx model ONLY. Attachment JLG Supplied P/N: The telehandler model XXXXXXXXXX–xx in. Attachments XXXXXXXXXX–xx in. is indicated on the XXXXXXXXXX–xx in. boom or chassis. Model XXXX is used for...

  • Page 101: Example

    Section 5—Attachments Example A contractor owns a model xxxx telehandler with a fork carriage. The contractor knows this attachment may be used with his model since: • The part number on the attachment identification plate matches the attachment part number on a capacity chart located in the operator cab. •...
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  • Page 103: Attachment Installation

    Section 5—Attachments ATTACHMENT INSTALLATION Coupler HYDRAULIC MECHANICAL OD0540 1. Attachment 2. Attachment Pin Recess 3. Attachment Pin 4. Retainer Pin (mechanical coupler) 5. Lock Pin 6. Coupler (attachment tilt control in cab, see page 3-16) WARNING CRUSH HAZARD. Always be certain that carriage or attachment is properly positioned on boom and is secured by lock pin and retainer pin.
  • Page 104 Section 5—Attachments Mechanical Coupler This installation procedure is designed for one-person operation. Prior to exiting cab, perform “Shut-Down Procedure” on page 4-5. OD0550 OD0560 OD0570 1. Tilt coupler back to provide clearance. Check to be sure lock pin is removed. 2.
  • Page 105 Section 5—Attachments Hydraulic Coupler This installation procedure is designed for one-person operation. OD0600 OD0610 OD0620 1. Tilt coupler back to provide clearance. 2. Align attachment pin with recess in attachment. Raise boom slightly to engage attachment pin in recess. 3. Check to be sure lock pin is disengaged. Tilt coupler forward to engage attachment. OD0630 OD0340 4.

  • Page 106: Hydraulic Operated Attachment

    Section 5—Attachments Hydraulic Operated Attachment OY1720 OD0860 1. Install attachment (see page 5-9). 2. Lower attachment to ground. 3. Press and hold auxiliary decompression switch (1) on right control panel for three seconds to relieve pressure at both auxiliary fittings (2). 4.

  • Page 107: Adjusting/Moving Forks

    Section 5—Attachments ADJUSTING/MOVING FORKS Carriages may have different locations where forks can be positioned. Two different methods can be used for repositioning, depending upon carriage structure. Note: Apply a light coating of appropriate lubricant to ease sliding of forks or fork bar. To slide forks: 1.

  • Page 108: Attachment Operation

    Section 5—Attachments ATTACHMENT OPERATION • Capacities and range limits for telehandler change depending on attachment in use. • Separate attachment instructions must be kept in manual holder in cab with this Operation & Safety Manual. An additional copy must be kept with attachment if it is equipped with a manual holder.

  • Page 109: Carriage With Forks

    Section 5—Attachments Carriage with Forks Use Carriage Attachment Capacity Chart To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-4. OY0690 OD0390 OD0870 OD0370 Joystick (1) controls movement of the boom. Roller switch (2) controls carriage tilt. • Press roller switch down to tilt up. •...

  • Page 110: Side Shift Carriage

    Section 5—Attachments Side Shift Carriage Use Side Shift Carriage Capacity Chart To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-4. OAL1540 OD0390 OD0880 OD0380 OD0370 Joystick (1) controls movement of the boom Roller switch (2) controls carriage tilt. •...
  • Page 111 Section 5—Attachments Installation Procedure: • Refer to “Attachment Installation” on page 5-9. WARNING CRUSH HAZARD. Do not use side shift to push or pull objects or load. Failure to comply could cause object or load to fall. Equipment Damage Precautions: •...

  • Page 112: Side Tilt Carriage

    Section 5—Attachments Side Tilt Carriage Use Side Tilt Carriage Attachment Capacity Chart To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-4. OAL1550 OD0390 OD0880 OD0370 OD0400 Joystick (1) controls movement of the boom Roller switch (2) controls carriage tilt. •...
  • Page 113 Section 5—Attachments Installation Procedure: • Refer to “Attachment Installation” on page 5-9. WARNING CRUSH HAZARD. Do not use side tilt to push or pull objects or load. Failure to comply could cause object or load to fall. Operation: • Approach load with forks centered on load and stop telehandler. •...

  • Page 114: Swing Carriage

    Section 5—Attachments Swing Carriage Use Swing Carriage Attachment Capacity Chart To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-4. OU2150 OD0390 OD0880 OD0410 OD0370 Joystick (1) controls movement of the boom Roller switch (2) controls carriage tilt. •...
  • Page 115 Section 5—Attachments Installation Procedure: • Refer to “Attachment Installation” on page 5-9. WARNING CRUSH HAZARD. Always level forks (horizontally) and telehandler frame before swinging load to side. Swinging unlevel forks could cause load to slide off forks. WARNING CRUSH HAZARD. Do not use swing carriage to push or pull objects or load. Failure to comply could cause object or load to fall.

  • Page 116: Dual Fork Positioning Carriage

    Section 5—Attachments Dual Fork Positioning Carriage Use Dual Fork Positioning Carriage Capacity Chart To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-4. OZ3670 OD0390 OD0880 OD0370 OD0420 Joystick (1) controls movement of the boom Roller switch (2) controls carriage tilt. •...
  • Page 117 Section 5—Attachments Installation Procedure: • Refer to “Attachment Installation” on page 5-9. WARNING CRUSH HAZARD. Do not use fork positioning to push or pull objects or load. Failure to comply could cause object or load to fall. Operation: • Travel in accordance with requirements set forth in Section 1—General Safety Practices.

  • Page 118: Mast Carriage

    Section 5—Attachments Mast Carriage Use Mast Carriage Attachment Capacity Chart To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-4. OY0580 OD0390 OD0880 OD0430 OD0370 Joystick (1) controls movement of the boom Roller switch (2) controls carriage tilt. •...
  • Page 119 Section 5—Attachments Installation Procedure: • Refer to “Attachment Installation” on page 5-9. WARNING CRUSH HAZARD. Do not use mast to push or pull objects or load. Failure to comply could cause object or load to fall. Operation: • Always lower forks fully in mast before engaging load. •...

  • Page 120: Side Tilt Mast Carriage

    Section 5—Attachments Side Tilt Mast Carriage Use Mast Carriage Attachment Capacity Chart To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-4. OY0580 OD0390 OD0880 OD0430 OD0370 Joystick (1) controls movement of the boom Roller switch (2) controls carriage tilt. •...
  • Page 121 Section 5—Attachments OD0390 OD0530 OD0880 OD0370 OD0400 To Side Tilt: Press Auxiliary Electric Switch (4) on Right Control Panel to activate side tilt function. Roller switch (3) controls carriage side tilt. • Press roller switch down to (side) tilt right. •...

  • Page 122: Pipe Grapple

    Section 5—Attachments Pipe Grapple Use Pipe Grapple Attachment Capacity Chart To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-4. OH5660 OD0390 OD0880 OD0370 O 1650 Joystick (1) controls movement of the boom. Roller switch (2) controls pipe grapple tilt. •...
  • Page 123 Section 5—Attachments Installation Procedure: • Refer to “Attachment Installation” on page 5-9. Operation: • Raise or lower boom to appropriate height and open pipe grapple for loading material. • Align and center telehandler with face of material. • Drive slowly and smoothly into material for loading. Boom extension may be required for loading material.

  • Page 124: Fork Extension

    5-4. The maximum capacity of the carriage when equipped with fork extensions may be reduced to the capacity indicated on the fork extensions. If the load exceeds the capacity of the fork extension, contact JLG to obtain forks and/or fork extensions of the proper load rating and length.
  • Page 125 Section 5—Attachments Installation Procedure: • Ensure carriage is properly installed. Refer to “Attachment Installation” on page 5-9. • Ensure length and cross section of the parent fork arm is equal to or exceeds the parent fork arm blade length stamped into the fork extension. •...

  • Page 126: Bucket

    Section 5—Attachments Bucket Use Appropriate Bucket Capacity Chart To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-4. OZ0730 OD0390 OD0870 OD0460 Joystick (1) controls movement of the boom Roller switch (2) controls bucket tilt. • Press roller switch down to tilt up. •...
  • Page 127 Section 5—Attachments Installation Procedure: • Refer to “Attachment Installation” on page 5-9. Operation: • Raise or lower boom to appropriate height for loading material from stockpile. • Align telehandler with face of stockpile and drive slowly and smoothly into pile to load bucket.

  • Page 128: Grapple Bucket

    Section 5—Attachments Grapple Bucket Use Grapple Bucket Capacity Chart To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-4. OZ1450 OD0390 OD0880 OD0460 OD0480 Joystick (1) controls movement of the boom Roller switch (2) controls grapple bucket tilt. •...
  • Page 129 Section 5—Attachments Installation Procedure: • Refer to “Attachment Installation” on page 5-9. Operation: • Raise or lower boom to appropriate height and open grapple for loading material from stockpile. • Align telehandler with face of stockpile and drive slowly and smoothly into pile to load bucket.

  • Page 130: Bucket-Fork Mounted

    Section 5—Attachments Bucket—Fork Mounted Use Appropriate Carriage Attachment Capacity Chart To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-4. O 2070 OD0390 OD0870 OD0460 Joystick (1) controls movement of the boom Roller switch (2) controls bucket tilt. •...
  • Page 131 Section 5—Attachments Installation Procedure: • Ensure carriage is properly installed. Refer to “Attachment Installation” on page 5-9. • Secure the fork mounted bucket to the forks by sliding the fork mounted bucket onto the parent forks and install the retaining pin behind the vertical shank of the fork. Operation: •...

  • Page 132: Trash Hopper-Fork Mounted

    Section 5—Attachments Trash Hopper—Fork Mounted Use Appropriate Trash Hopper Capacity Chart To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-4. OD1630 OD0390 OD0870 OD1640 Joystick (1) controls movement of the boom Roller switch (2) controls trash hopper tilt. •...
  • Page 133 Section 5—Attachments Installation Procedure: • Ensure carriage is properly installed. Refer to “Attachment Installation” on page 5-9. • Secure the fork mounted trash hopper to the forks by sliding the fork mounted trash hopper onto the parent forks and install the retaining pin behind the vertical shank of the fork.

  • Page 134: Coupler Mounted Hook

    Section 5—Attachments Coupler Mounted Hook Use Appropriate Coupler Mounted Hook Capacity Chart To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-4. OC0130 Suspend loads in accordance with requirements set forth in Section 1—General Safety Practices. OD0390 OD0870 OC0140 Joystick (1) controls movement of the boom Roller switch (2) controls coupler mounted hook tilt.
  • Page 135 Section 5—Attachments Installation Procedure: • Refer to “Attachment Installation” on page 5-9. Operation: • Weight of rigging must be included as part of total load being lifted. 31211031 5-41...

  • Page 136: Fork Mounted Hook

    Section 5—Attachments Fork Mounted Hook Use Appropriate Carriage Attachment Capacity Chart To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-4. OY0640 Suspend loads in accordance with requirements set forth in Section 1—General Safety Practices. OD0390 OD0870 OD0450 Joystick (1) controls movement of the boom Roller switch (2) controls carriage tilt.
  • Page 137 Section 5—Attachments Installation Procedure: • Ensure carriage is properly installed. Refer to “Attachment Installation” on page 5-9. • Secure the fork mounted hook to the forks by sliding the fork mounted hook onto the parent forks and install the retaining pin behind the vertical shank of the fork. Operation: •...

  • Page 138: Truss Boom

    Section 5—Attachments Truss Boom Use Appropriate Truss Boom Attachment Capacity Chart To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-4. OY0570 Suspend loads in accordance with requirements set forth in Section 1—General Safety Practices. OD0390 OD0880 OD0520 OD0440 Joystick (1) controls movement of the boom Roller switch (2) controls truss boom tilt.
  • Page 139 Section 5—Attachments Installation Procedures • Refer to “Attachment Installation” on page 5-9. WARNING CRUSH HAZARD. Maintain a minimum of three wraps of wire rope on the cable drum at all times. Failure to comply could cause object or load to fall. Operation: •...

  • Page 140: Material Handling Arm

    Section 5—Attachments Material Handling Arm Use Appropriate Material Handling Arm Attachment Capacity Chart To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-4. OH5670 Suspend loads in accordance with requirements set forth in Section 1—General Safety Practices. OD0390 OD0870 OD1660 Joystick (1) controls movement of the boom.
  • Page 141 Section 5—Attachments Installation Procedures • Refer to “Attachment Installation” on page 5-9. • Secure adjustable arm in desired position using the retaining pin. WARNING CRUSH HAZARD. Ensure adjustable arm is properly secured using the retaining pin prior to lifting load. Failure to comply could cause object or load to fall. Operation: •...

  • Page 142: Personnel Work Platform-Fork Mounted

    Section 5—Attachments Personnel Work Platform—Fork Mounted Use Appropriate Carriage Attachment Capacity Chart To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-4. OY1610 The operator and personnel in platform must read and understand the separate personnel work platform manual prior to installing and using a platform. OD0390 OD0340 OD0470...
  • Page 143 Section 5—Attachments Installation Procedure: • Ensure carriage is properly installed. Refer to “Attachment Installation” on page 5-9. • Secure the fork mounted platform to the forks by sliding the fork mounted platform onto the parent forks and install the retaining pin behind the vertical shank of the fork. Preparation and Setup: 1.
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  • Page 145: Section 6-Emergency Procedures

    Section 6—Emergency Procedures SECTION 6—EMERGENCY PROCEDURES TOWING A DISABLED PRODUCT The following information assumes telehandler cannot be moved under its own power. • Before moving the telehandler, read all of the following information to understand options available. Then select the appropriate method. •...

  • Page 146: Emergency Lowering Of Boom

    Section 6—Emergency Procedures EMERGENCY LOWERING OF BOOM In the event of total loss of engine power or hydraulic pump failure with an elevated load, the situation must be properly evaluated and dealt with on an individual basis. Contact the local dealer for specific instructions. Secure the telehandler using the following procedures: 1.

  • Page 147: Emergency Exit From Enclosed Cab

    Section 6—Emergency Procedures EMERGENCY EXIT FROM ENCLOSED CAB In an emergency the rear window can be used to exit the telehandler. Inside Cab OZ0240 • Remove the latch pin (1). The window is then free to swing open. Outside Cab (if equipped) OD1250 •...
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  • Page 149: Section 7-Lubrication And Maintenance

    Section 7—Lubrication and Maintenance SECTION 7—LUBRICATION AND MAINTENANCE INTRODUCTION This section is intended as information to assist the operator to perform maintenance tasks only. Service product in accordance with maintenance schedule on the following pages. IF EQUIPPED WITH MULTIFUNCTION DISPLAY, REFER TO PAGE 3-18 FOR NAVIGATION INFORMATION.

  • Page 150: General Maintenance Instructions

    Section 7—Lubrication and Maintenance GENERAL MAINTENANCE INSTRUCTIONS Prior to performing any service or maintenance on the telehandler, follow the shut-down procedure on page 4-5 unless otherwise instructed. Ensure telehandler is level, for proper fluid readings. • Clean lubrication fittings before lubricating. •...

  • Page 151: Service And Maintenance Schedules

    Section 7—Lubrication and Maintenance SERVICE AND MAINTENANCE SCHEDULES 10 & 1st 50 Hour Maintenance Schedule EVERY Check Fuel Check Tire Check Brake Check Engine Check Hydraulic Level Condition Fluid Level Oil Level Oil Level & Pressure Check Check DEF Level Drain Fuel/ Check Engine Check Air...

  • Page 152: 50, 1St 250 & 250 Hour Maintenance Schedule

    Section 7—Lubrication and Maintenance 50, 1st 250 & 250 Hour Maintenance Schedule EVERY Lubrication Check Schedule Washer Fluid Change Change Wheel Change Change Axle Oil End Oil Transfer Transmission Case Fluid Fluid and Filter EVERY Lubrication Check Boom Check Boom Check Check Axle Schedule...

  • Page 153: 500, 750 & 1000 Hour Maintenance Schedule

    Section 7—Lubrication and Maintenance 500, 750 & 1000 Hour Maintenance Schedule EVERY Check Check Check Wheel Change Change Engine Battery Fan Belt Lug Nut Torque Fuel Filters Oil and Filter EVERY Change Change Hydraulic Hydraulic Filters Tank Breather EVERY 1000 Lubrication Check Boom Check Air...
  • Page 154 Section 7—Lubrication and Maintenance 1500, 2000, 4000 & 5000 Hour Maintenance Schedule EVERY 1500 Change Hydraulic Fluid and Filters EVERY 2000 Change Change DEF Tank Filter (if equipped Engine Coolant EVERY 4000 Change DEF Pump Filter equipped for EVERY 5000 Engine Valve Lash Adjustment...
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  • Page 156: Lubrication Schedules

    Section 7—Lubrication and Maintenance LUBRICATION SCHEDULES 50 Hour Lubrication Schedule 642, 943 & 1043 EVERY O 0010 31211031...
  • Page 157 Section 7—Lubrication and Maintenance 1055 & 1255 EVERY OD1300 31211031...
  • Page 158 Section 7—Lubrication and Maintenance 250 Hour Lubrication Schedule 642, 943 & 1043 EVERY O 0020 7-10 31211031...
  • Page 159 Section 7—Lubrication and Maintenance 1055 & 1255 EVERY OD1310 31211031 7-11...

  • Page 160: 1000 Hour Lubrication Schedule

    Section 7—Lubrication and Maintenance 1000 Hour Lubrication Schedule 642, 943 & 1043 EVERY 1000 O 0030 7-12 31211031...
  • Page 161 Section 7—Lubrication and Maintenance 1055 & 1255 EVERY 1000 OD1320 31211031 7-13...
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  • Page 163: Operator Maintenance Instructions

    Section 7—Lubrication and Maintenance OPERATOR MAINTENANCE INSTRUCTIONS Engine Maintenance Components If Equipped for ULS O 0681 1. Surge Tank: See page 7-29. 2. Transmission Fluid Dipstick: See page 7-27. 3. Primary Fuel Filter: See page 7-18. 4. Engine Oil Cap: See page 7-21. 5.
  • Page 164 Section 7—Lubrication and Maintenance If Equipped for LS OC0120 1. Surge Tank: See page 7-29. 2. Transmission Oil Dipstick: See page 7-27. 3. Primary Fuel Filter: See page 7-18. 4. Engine Oil Cap: See page 7-21. 5. Engine Oil Dipstick: See page 7-21. 6.
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  • Page 166: Fuel System

    Section 7—Lubrication and Maintenance Fuel System A. Fuel Level Check OW0970 OW0990 OD0690 OD0710 1. Check Fuel Gauge (7) located in right side of Instrument Panel in cab. 2. If fuel is low, proceed to fuel source and perform “Shut-Down Procedure” on page 4-5. 3.
  • Page 167 Section 7—Lubrication and Maintenance B. Drain Fuel/Water Separator OW0970 OW1000 IF EQUIPPED FOR LS IF EQUIPPED FOR ULS OD0730 OC0110 1. Perform “Shut-Down Procedure” on page 4-5. 2. Open engine cover. 3. Loosen drain cock (2) on underside of fuel filter (1) and allow all water to drain into a glass until clear fuel is visible.

  • Page 168: Emission System (If Equipped For Uls)

    Section 7—Lubrication and Maintenance Emission System (if equipped for ULS) A. Diesel Emission Fluid (DEF) Level Check OW0970 OD1350 OD1330 OD1340 1. Check Diesel Emission Fluid (DEF) Gauge (1) located in right side of Instrument Panel in cab. 2. If DEF is low, proceed to DEF source and perform “Shut-Down Procedure” on page 4-5. 3.

  • Page 169: Engine Oil

    Section 7—Lubrication and Maintenance Engine Oil A. Engine Oil Level Check OW0970 OW1020 O 0751 OD0740 1. Perform “Shut-Down Procedure” on page 4-5. 2. Open engine cover. 3. Remove dipstick (3) and check oil mark. Oil should be between full (4) and add (5) marks of dipstick.

  • Page 170: Air Intake System

    Section 7—Lubrication and Maintenance Air Intake System A. Air Cleaner Check OW0970 OW1010 OD0780 1. Perform “Shut-Down Procedure” on page 4-3. 2. Open engine cover. 3. Remove dust from vacuator valve (1) by squeezing bottom of valve to allow loose particles to fall out.
  • Page 171 Section 7—Lubrication and Maintenance B. Element Change Note: Change elements as air cleaner restriction indicator indicates or every two years. Use the interval that occurs first. 1. Perform “Shut-Down Procedure” on page 4-3. 2. Open engine cover. 3. Unlock air cleaner cover (2) and remove from air cleaner. 4.

  • Page 172: Tires

    Section 7—Lubrication and Maintenance Tires A. Tire Air Pressure Check OW0970 OW1040 1. Perform “Shut-Down Procedure” on page 4-5. 2. Remove valve stem cap. 3. Check tire pressure. 4. Add air if required. See page 9-6 for tire pressures. 5. Replace valve stem cap. B.
  • Page 173 Section 7—Lubrication and Maintenance 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.

  • Page 174: Hydraulic Oil

    Section 7—Lubrication and Maintenance Hydraulic Oil A. Hydraulic Oil Level Check OW0970 OW1030 OD0720 1. Be sure all cylinders are fully retracted, outriggers (if equipped) are fully raised and machine is level. 2. Perform “Shut-Down Procedure” on page 4-5. 3. Allow hydraulic oil to cool. Check fluid level at sight gauge (4). Oil level should be visible in gauge window.

  • Page 175: Transmission Oil

    Section 7—Lubrication and Maintenance Transmission Oil A. Transmission Oil Level Check OW0970 OW1050 OD0750 OD0770 1. Check transmission oil level with engine at idle and transmission oil at normal operating temperature. 2. Apply park brake, shift transmission to Neutral and lower attachment to ground. 3.

  • Page 176: Brake Fluid

    Section 7—Lubrication and Maintenance Brake Fluid A. Brake Fluid Level Check OW0970 OD1380 OD1360 OD1370 1. Perform “Shut-Down Procedure” on page 4-5. 2. Check the brake fluid level (1). Fluid should be between Max and Min (2) marks on brake reservoir. 3.

  • Page 177: Engine Cooling System

    Section 7—Lubrication and Maintenance Engine Cooling System A. Engine Coolant Level Check OW0970 OW1070 OD0760 1. Perform “Shut-Down Procedure” on page 4-5. 2. Open engine cover. 3. Check coolant level in surge tank (3). Coolant should be between Full and Add (4) marks on surge tank.

  • Page 178: Windshield Washer System (If Equipped)

    Section 7—Lubrication and Maintenance Windshield Washer System (if equipped) A. Windshield Washer Fluid Level Check OW0980 OAL2040 OD0820 1. Perform “Shut-Down Procedure” on page 4-5. 2. Remove reservoir cap (3). 3. Windshield washer fluid should be visible in the reservoir. 4.

  • Page 179: Section 8-Additional Checks

    Section 8—Additional Checks SECTION 8—ADDITIONAL CHECKS GENERAL 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. REVERSE SENSOR SYSTEM (IF EQUIPPED) A.
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  • Page 181: Section 9-Specifications

    Section 9—Specifications SECTION 9—SPECIFICATIONS PRODUCT SPECIFICATIONS Fluids If Equipped for ULS Ambient Temperature Range Compartment or Type and Classification Viscosities System °F °C SAE 5W-40 SAE 15W-40 API CJ-4 Engine Crankcase SAE 10W-30 CES-20081 SAE 5W-30 SAE 0W-30 Mobilfluid 424 10W-30 Transmission and Transfer Case...
  • Page 182 Section 9—Specifications Ambient Temperature Range Compartment or Type and Classification Viscosities System °F °C #2 Diesel Standard B5 Biodiesel Blend of #1 diesel and Ultra Low Sulfur Fuel #2 diesel fuels (S ≤ 15 mg/kg) ("winterized" #2) Cold Weather B5 Biodiesel with Winter Conditioner Diesel Exhaust ISO22241-1...
  • Page 183 Section 9—Specifications If Equipped for LS Ambient Temperature Range Compartment or Type and Classification Viscosities System °F °C SAE 5W-40 SAE 15W-40 API CI-4 Engine Crankcase SAE 10W-30 CES-20078 SAE 5W-30 SAE 0W-30 Mobilfluid 424 10W-30 Transmission and Transfer Case Mobilfluid LT 75W-80 Mobilfluid 424*...

  • Page 184: Capacities

    1055..........................48.6 gal (184 L) 1255..........................49.9 gal (189 L) Reservoir Capacity to Full Mark..................23.8 gal (90 L) Transmission System Capacity with Filter Change ....................17 qt (16,1L) Transfer Case Capacity 642, 943, 1043........................1.5 qt (1,4 L) 1055, 1255..........................1.6 qt (1,5 L) 31211031...
  • Page 185 Section 9—Specifications Axles Differential Housing Capacity 642 ............................7.2 qt (6,8 L) 943, 1043..........................15 qt (14,2 L) 1055, 1255 Front..........................15 qt (14,2 L) Rear ..........................14 qt (13,3 L) Friction Modifier—May be added to axle differentials (Must be premixed with axle fluid) ........... Not to Exceed 24 oz (709 mL) Wheel End Capacity 642 ............................2.1 qt (2,0 L)

  • Page 186: Tires

    Section 9—Specifications Tires 370/75-28, 14 Ply Pneumatic ....................... 76 psi (5,2 bar) Foam......................Approx 464 lb (210 kg) 13.00–24 16PR Pneumatic ......................80 psi (5,52 bar) 13.00–24 12PR Foam......................Approx 542 lb (246 kg) 370/75-28, 14 Ply Pneumatic ....................... 76 psi (5,2 bar) Foam......................
  • Page 187 Section 9—Specifications Wheel Lug Nut Torque......................375 ±25 lb-ft (508 ±34 Nm) 31211031...

  • Page 188: Performance

    Section 9—Specifications Performance Maximum Lift Capacity 642 ..........................6,600 lb (2994 kg) 943 ..........................9,000 lb (4082 kg) 1043, 1055.......................10,000 lb (4536 kg) 1255...........................12,000 lb (5443 kg) Maximum Lift Height 642 ............................42 ft (12,8 m) 943, 1043 ..........................43 ft (13,1 m) 1055, 1255..........................
  • Page 189 Outriggers Engaged..................3,500 lb (1588 kg) Outriggers Not Engaged ....................0 lb (0 kg) Reach at Maximum Height 642 ..........................54.1 in (1375 mm) 943 ..........................64.3 in (1633 mm) 1043 ..........................63.7 in (1618 mm) 1055, 1255 ........................ 99.5 in (2527 mm) Auxiliary Hydraulic Circuit Max Flow 642 ..........................

  • Page 190: Dimensions

    Section 9—Specifications Dimensions Note: Values will vary depending on machine configuration. Maximum Overall Height 642 ..........................96 in (2438 mm) 943 ..........................98 in (2489 mm) 1043..........................99 in (2513 mm) 1055, 1255........................100 in (2540 mm) Maximum Overall Width 642, 943 No Outriggers .....................
  • Page 191 Section 9—Specifications Outside Turning Radius 642, 943, 1043 ......................144 in (3658 mm) 1055, 1255 ......................... 168 in (4267 mm) Maximum Operating Weight (no attachment) No Outriggers.....................23,593 lb (10 702 kg) With Outriggers ..................24,784 lb (11 242 kg) 943 .........................27,620 lb (12 528 kg) 1043 ........................28,735 lb (13 034 kg)
  • Page 192 Section 9—Specifications Maximum Ground Bearing Pressure 370/75-28, 14 Ply Pneumatic................Not Available at Publication Foam..................Not Available at Publication 13.00–24 16PR Pneumatic................Not Available at Publication 13.00–24 12PR Foam..................Not Available at Publication 370/75-28, 14 Ply Pneumatic................Not Available at Publication Foam..................

  • Page 193: Index

    Emergency Lowering of Boom....6-2 Mechanical Coupler......5-10 Emergency Procedures ........6-1 Attachment Operation ......5-14 Engine Attachments.............5-1 Extreme Cold Weather Starting ..4-2 JLG Supplied ..........5-2 Normal Operation........4-4 Automatic Exhaust System Cleaning ..4-6 Starting ............4-1 Axles ..............9-5 Engine Crankcase Oil........9-4 Engine Oil Level ........... 7-21 Battery Boosted Starting......4-3...
  • Page 194 Index Ignition.............3-10 Park Brake ............3-11 Instrument Panel..........3-4 Parking Procedure ........3-11 Performance ............ 9-8 Personnel Work Platform—Fork Joystick.............3-16 Mounted............5-48 Picking Up a Load .......... 4-8 Picking Up a Suspended Load....4-11 Leveling Procedure......4-9, 4-12 Pinch Points and Crush Hazards.....1-11 Lifting Personnel ..........1-9 Pipe Grapple ..........5-28 Load Falling Hazard........
  • Page 195 Index Safety Practices ..........1-1 Tip Over Hazard ..........1-4 Safety Signal Words........1-1 Tires ............7-24, 9-6 Air Pressure..........7-24 Seat Belt ............3-28 Damage ........... 7-24 Service and Maintenance Schedule Replacement.......... 7-24 10 Hour ............7-3 Towing..............6-1 1000 Hour...........7-5 1500 Hour...........7-6 Transfer Case............9-4 1st 250 Hour..........7-4 Transmission Control 1st 50 Hour ..........7-3...
  • Page 196 Index 31211031...

  • Page 197: Inspection, Maintenance And Repair Log

    Inspection, Maintenance and Repair Log Inspection, Maintenance and Repair Log Serial Number ___________________________________ Date Comments...
  • Page 198 Inspection, Maintenance and Repair Log Date Comments...
  • Page 199 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.
  • Page 201 Hand Signals OY1090 OY1100 OY1110 EMERGENCY STOP - With both STOP - With either arm extended STOP ENGINE - Draw thumb or arms extended laterally, hands laterally, hand open downward, forefinger across throat. open downward, move arms back move arm back and forth. and forth.
  • Page 202 McConnellsburg PA. 17233-9533 Phone: +1-717-485-5161 Customer Support Toll Free: 1-877-554-5438 Fax: +1-717-485-6417 JLG Worldwide Locations JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) Ltd P.O. Box 5119 Rua Antonia Martins Luiz, 580 Bentley House 11 Bolwarra Road Distrito Industrial João Narezzi...

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