JLG 642 Use and care manual

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

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,
birth defects and other
reproductive harm.

Revision Log
a31211031
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 & 9-8 thru 9-12.

Read This First
b31211031
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
Modifications to this machine may affect compliance with Industry Standards
and/or Governmental Regulations. Any modification must be approved by JLG.

Read This First
c31211031
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
In USA:
Toll Free: 1-877-JLG-SAFE (1-877-554-7233)
Outside USA:
Phone: [phone]
E-mail:
[e-mail]

Read This First
d31211031
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.
Machine Configuration
Two configurations of each machine are included in this manual. Determine if machine is
equipped with Ultra Low Sulfur Fuel Decal as indicated below.
• If equipped with Ultra Low Sulfur decal, all specific references to this machine
configuration will be referred to as Ultra Low Sulfur (
ULS ) from this point forward.
•If
not equipped with Ultra Low Sulfur decal, all specific references to this machine
configuration will be referred to as Low Sulfur (
LS ) from this point forward.
OD0840
ULTRA LOW
SULFUR DIESEL
FUEL ONLY
S < 15 mg/kg
1001125387 A

Table of Contents
i31211031
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
Electrical Hazards....................................................................................1-2
Tip Over Hazard.......................................................................................1-4
Travel Hazard............................................................................................1-7
Load Falling Hazard ...............................................................................1-8
Lifting Personnel .....................................................................................1-9
Driving Hazards on Slopes................................................................ 1-10
Pinch Points and Crush Hazards..................................................... 1-11
Fall Hazard .............................................................................................. 1-13
Chemical Hazards ................................................................................ 1-14
1.4 ClearSky (if equipped)............................................................................... 1-15
Federal Communications Commission (FCC) Information
for Users................................................................................................... 1-15
Section 2—Pre-Operation and Inspection
2.1 Preparation, Inspection and Maintenance...........................................2-1
2.2 Pre-Operation Check and Inspection.....................................................2-2
2.3 Safety Decals ...................................................................................................2-4
ANSI (if equipped)...................................................................................2-4
ISO (if equipped) .....................................................................................2-8
2.4 Walk-Around Inspection .......................................................................... 2-12
2.5 Warm-Up and Operational Checks ...................................................... 2-14
Warm-Up Check ................................................................................... 2-14
Operational Check............................................................................... 2-14
2.6 Cab................................................................................................................... 2-15
2.7 Enclosed Cab Windows (if equipped).................................................2-16
Cab Door Window ............................................................................... 2-16
Rear Window ......................................................................................... 2-17
Table of Contents

Table of Contents
ii 31211031
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) ....................................................... 3-15
Joystick .................................................................................................... 3-16
3.3 Multifunction Display (if equipped) .................................................... 3-18
Home Screen......................................................................................... 3-19
Main Menu Screen .............................................................................. 3-20
Attachment Selection Screen ......................................................... 3-22
Communication Error Screen.......................................................... 3-23
3.4 Anti Theft Functionality (if enabled) ................................................... 3-24
Instrument Panel Input ..................................................................... 3-24
Multifunction Display Input............................................................. 3-25
3.5 Steer Modes ................................................................................................. 3-26
Manual Steering Alignment Mode Change ............................... 3-26
3.6 Operator Seat .............................................................................................. 3-27
Adjustments .......................................................................................... 3-27
Seat Belt .................................................................................................. 3-28
3.7 Boom Angle and Extension Indicators ............................................... 3-29
3.8 Reverse Systems (if equipped) .............................................................. 3-30
Reverse Sensor System...................................................................... 3-30
Reversing Camera................................................................................ 3-31
3.9 Rear Axle Stabilization (RAS) System .................................................. 3-32
Free Pivot Mode ................................................................................... 3-32
Slow Pivot Mode .................................................................................. 3-32
Locked Mode......................................................................................... 3-32

Table of Contents
iii31211031
Section 4—Operation
4.1 Engine................................................................................................................4-1
Starting the Engine ................................................................................4-1
Extreme Cold Weather Starting (if equipped)..............................4-2
Battery Boosted Starting ......................................................................4-3
Normal Engine Operation....................................................................4-4
Shut-Down Procedure ..........................................................................4-5
4.2 After-Treatment System (ATS) (if equipped for ULS)........................4-6
Automatic Exhaust System Cleaning...............................................4-6
Stationary Exhaust System Cleaning ...............................................4-7
4.3 Operating with a Non-Suspended Load ...............................................4-8
Lift Load Safely.........................................................................................4-8
Picking Up a Load ...................................................................................4-8
Transporting a Load...............................................................................4-9
Leveling Procedure ................................................................................4-9
Placing a Load ....................................................................................... 4-10
Disengaging a Load ............................................................................ 4-10
4.4 Operating with a Suspended Load...................................................... 4-11
Lift Load Safely...................................................................................... 4-11
Picking Up a Suspended Load......................................................... 4-11
Transporting a Suspended Load.................................................... 4-12
Leveling Procedure ............................................................................. 4-12
Placing a Suspended Load ............................................................... 4-13
Disengaging a Suspended Load .................................................... 4-13
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
Coupler .......................................................................................................5-9
Hydraulic Operated Attachment.................................................... 5-12
5.7 Adjusting/Moving Forks .......................................................................... 5-13
5.8 Attachment Operation ............................................................................. 5-14
Carriage with Forks ............................................................................. 5-15
Side Shift Carriage ............................................................................... 5-16

Table of Contents
iv 31211031
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..................................................................... 5-36
Trash Hopper—Fork Mounted ....................................................... 5-38
Coupler Mounted Hook .................................................................... 5-40
Fork Mounted Hook............................................................................ 5-42
Truss Boom ............................................................................................ 5-44
Material Handling Arm ...................................................................... 5-46
Personnel Work Platform—Fork Mounted................................. 5-48
Section 6—Emergency Procedures
6.1 Towing a Disabled Product .......................................................................6-1
Moving Short Distances .......................................................................6-1
Moving Longer Distance......................................................................6-1
6.2 Emergency Lowering of Boom.................................................................6-2
6.3 Emergency Exit from Enclosed Cab........................................................6-3
Inside Cab..................................................................................................6-3
Outside Cab (if equipped) ...................................................................6-3

Table of Contents
v31211031
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 & 1000 Hour Maintenance Schedule .............................7-5
1500, 2000, 4000 & 5000 Hour Maintenance Schedule ............7-6
7.4 Lubrication Schedules .................................................................................7-8
50 Hour Lubrication Schedule............................................................7-8
250 Hour Lubrication Schedule...................................................... 7-10
1000 Hour Lubrication Schedule.................................................... 7-12
7.5 Operator Maintenance Instructions .................................................... 7-15
Engine Maintenance Components................................................7-15
Fuel System............................................................................................ 7-18
Emission System (if equipped for ULS) ........................................ 7-20
Engine Oil................................................................................................ 7-21
Air Intake System ................................................................................. 7-22
Tires........................................................................................................... 7-24
Hydraulic Oil .......................................................................................... 7-26
Transmission Oil ................................................................................... 7-27
Brake Fluid.............................................................................................. 7-28
Engine Cooling System...................................................................... 7-29
Windshield Washer System (if equipped)................................... 7-30
Section 8—Additional Checks
8.1 General..............................................................................................................8-1
8.2 Reverse Sensor System (if equipped).....................................................8-1
Section 9—Specifications
9.1 Product Specifications.................................................................................9-1
Fluids ...........................................................................................................9-1
Capacities...................................................................................................9-4
Tires..............................................................................................................9-6
Performance .............................................................................................9-8
Dimensions ............................................................................................ 9-10
Index
Inspection, Maintenance and Repair Log

Table of Contents
vi 31211031

Section 1—General Safety Practices
1-131211031
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
• Hydraulic cylinders are subject to thermal expansion and contraction. This may result
in changes to the boom and/or attachment position while the machine is stationary.
Factors affecting thermal movement can include the length of time machine is
stationary, hydraulic oil temperature, ambient air temperature and boom and/or
attachment position.
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 31211031
1.3 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
• This machine is not insulated and does not provide protection from contact or being
near electrical current.
• Always check for power lines before raising the boom.
• Maintain distance from electrical lines, apparatus, or any energized (exposed or
insulated) parts according to the Minimum Approach Distance (MAD).
• Allow for machine movement and electrical line swaying.
• Maintain a clearance of at least 10 ft (3m) 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.
Voltage Range
(Phase to Phase)
Minimum Approach Distance
(MAD)
0 to 50 KV 10 ft (3 m)
Over 50KV to 200 KV 15 ft (5 m)
Over 200 KV to 350 KV 20 ft (6 m)
Over 350 KV to 500 KV 25 ft (8 m)
Over 500 KV to 750 KV 35 ft (11 m)
Over 750 KV to 1000 KV 45 ft (14 m)
O 0891D
10 ft
(3m)

Section 1—General Safety Practices
1-331211031
• 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. This determination shall be made by a qualified
person in accordance with the employer, local, or governmental requirements for
work practices near energized equipment.
DANGER
Do not maneuver machine or personnel inside prohibited zone (MAD). Assume all
electrical parts and wiring are energized unless known otherwise.

Section 1—General Safety Practices
1-4 31211031
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.
• Be aware of wind conditions. Wind may cause load swing and dangerous side loads.
•DO NOT raise boom unless frame is level (0 degrees), unless otherwise noted on
capacity chart.
•DO NOT level machine with boom/attachment above 4 ft (1,2 m).
(AUS—DO NOT level machine with load more than 11.8 in (300 mm) above
ground surface.)
OW0050
OW0080
OW0100
4 FT
(1,2 M)

Section 1—General Safety Practices
1-531211031
•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 seat belt.
• Keep head, arms, hands, legs and all other body parts inside operator’s cab at all times.
If 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
1-6 31211031
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.
•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.
O 0901D
OW0150

Section 1—General Safety Practices
1-731211031
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).
• Telehandlers equipped with solid or foam filled tires should not be used in
applications requiring excessive roading or driving extended distances. In the event
an application requires excessive roading or driving expanded distances, it is
recommended to use telehandlers not equipped with solid or foam filled tires.
OAL2030
2-WHEEL FRONT STEER 4-WHEEL CIRCLE STEER 4-WHEEL CRAB STEER

Section 1—General Safety Practices
1-8 31211031
Load Falling Hazard
• 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.
OW0130