Oshkosh JLG 742 Use and care manual

Operation & Safety
Manual
Original Instructions
Keep this manual with machine at all times.
An Oshkosh Corporation Company
Models
742, 943, 1043,
1055, 1255
PVC 1911, 2005
31211368
May 5, 2020 - Rev B
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WARNING
Operating, servicing and maintaining this vehicle or equipment
can expose you to chemicals including engine exhaust, carbon
monoxide, phthalates, and lead, which are known to the State of
California to cause cancer and birth defects or other
reproductive harm. To minimize exposure, avoid breathing
exhaust, do not idle the engine except as necessary, service your
vehicle or equipment in a well-ventilated area and wear gloves
or wash your hands frequently when servicing. For more
information go to www.P65Warnings.ca.gov.
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Revision Log
a31211368
Revision Log REVISION LOG
November 11, 2019 - A - Original Issue of Manual.
May 5, 2020 - B - Revised front cover and pages 2-16, 2-17, 3-2 thru 3-5, 3-10, 3-20, 3-21,
5-9, 7-4, 7-6, 7-7, 7-23, 7-32, 7-33, 9-1, 9-3, 9-6, 9-7, 9-12 & 9-13.
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Read This First
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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.
Refer to www.JLG.com for Warranty, Product Registration, and other machine-related
documentation.
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.
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This product must comply with all safety related bulletins. Contact JLG Industries, Inc. or
the local authorized JLG representative for information regarding safety-related bulletins
which may have been issued for this product.
JLG Industries, Inc. sends safety related bulletins to the owner of record of 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]
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Read This First
d31211368
Other Publications Available
Service Manual.............................................................................................................................31211369
Parts Manual
742 ............................................................................................................................................31211370
943 ............................................................................................................................................31211371
1043..........................................................................................................................................31211372
1055 & 1255...........................................................................................................................31211373
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 (1) 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.
Maximum engine power can be found on the decal (2) located on the side of the radiator.
O 0841D
XXXhp (XXkW) @ XXXX RPM
XXXXXXXXXX_A
2
1
ULTRA LOW
SULFUR DIESEL
FUEL ONLY
S < 15 mg/kg
1001125387 A
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Table of Contents
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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) .................................................................................. 2-10
2.4 Walk-Around Inspection..........................................................................2-16
2.5 Warm-Up and Operational Checks ......................................................2-19
Warm-Up Check ...................................................................................2-19
Operational Check...............................................................................2-19
2.6 Cab................................................................................................................... 2-20
2.7 Enclosed Cab Windows (if equipped).................................................2-21
Cab Door Window ...............................................................................2-21
Rear Window.........................................................................................2-22
Table of Contents
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Section 3 - Controls and Indicators
3.1 General..............................................................................................................3-1
3.2 Controls ............................................................................................................3-2
Instrument Panel ....................................................................................3-4
LCD Display...............................................................................................3-8
Left Dash Control Panel..................................................................... 3-10
Right Dash Control Panel.................................................................. 3-12
Ignition.................................................................................................... 3-14
Park Brake............................................................................................... 3-15
Parking Procedure............................................................................... 3-15
Transmission Control Lever ............................................................. 3-16
Accessory Control Lever (if equipped)......................................... 3-18
Outrigger Levers (if equipped) ....................................................... 3-19
Load Stability Indicator - LSI (if equipped) ................................. 3-20
Joystick.................................................................................................... 3-22
3.3 Anti Theft Functionality (if enabled) ................................................... 3-24
Instrument Panel Input ..................................................................... 3-24
Multifunction Display Input............................................................. 3-24
3.4 Steer Modes ................................................................................................. 3-25
Manual Steering Alignment Mode Change ............................... 3-25
3.5 Operator Seat .............................................................................................. 3-26
Adjustments.......................................................................................... 3-26
Seat Belt .................................................................................................. 3-27
3.6 Boom Angle and Extension Indicators............................................... 3-28
3.7 Reverse Systems (if equipped) .............................................................. 3-29
Reverse Sensing System.................................................................... 3-29
Reversing Camera................................................................................ 3-30
3.8 Rear Axle Stabilization (RAS) System .................................................. 3-31
Free Pivot Mode................................................................................... 3-31
Slow Pivot Mode.................................................................................. 3-31
Locked Mode......................................................................................... 3-31
3.9 Multifunction Display (if equipped) .................................................... 3-32
General Information ........................................................................... 3-32
Multifunction Display and Buttons............................................... 3-33
Home Screen......................................................................................... 3-35
Main Menu............................................................................................. 3-38
Operation and Maintenance ........................................................... 3-47
Troubleshooting .................................................................................. 3-62
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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/110 OR 130HP)......................................................4-6
Automatic Exhaust System Cleaning (In-Mission) ......................4-6
Stationary Exhaust System Cleaning (Non-Mission)..................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
Coupler Mounted Attachments ........................................................5-1
JLG Supplied Fork Mounted Attachments ....................................5-1
Non-OEM Fork Mounted Attachments...........................................5-1
5.2 Unapproved Attachments .........................................................................5-2
5.3 Fork Mounted Attachments ......................................................................5-4
General Requirements ..........................................................................5-4
Non-OEM Attachments.........................................................................5-5
5.4 Equivalent Load .............................................................................................5-6
Load Centers Beyond 24 Inches ........................................................5-6
Fork Mounted Attachments Equivalent Load ..............................5-7
5.5 JLG Supplied Attachments.........................................................................5-8
5.6 Telehandler/Attachment/Fork Capacity............................................ 5-10
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5.7 Use of the Capacity Chart........................................................................ 5-11
Capacity Indicator Locations........................................................... 5-11
Sample Capacity Chart ...................................................................... 5-12
Example................................................................................................... 5-13
5.8 Attachment Installation........................................................................... 5-15
Coupler.................................................................................................... 5-15
Auxiliary Hydraulic Decompression.............................................. 5-18
5.9 Adjusting/Moving Forks.......................................................................... 5-19
5.10 Attachment Operation............................................................................. 5-20
Carriage with Forks ............................................................................. 5-21
Side Shift Carriage............................................................................... 5-22
Side Tilt Carriage.................................................................................. 5-24
Swing Carriage ..................................................................................... 5-26
Drywall Swing Carriage ..................................................................... 5-28
Dual Fork Positioning Carriage....................................................... 5-32
Mast Carriage ........................................................................................ 5-34
Side Tilt Mast Carriage ....................................................................... 5-36
Pipe Grapple.......................................................................................... 5-38
Fork Extension ...................................................................................... 5-40
Bucket...................................................................................................... 5-42
Grapple Bucket..................................................................................... 5-44
Bucket - Fork Mounted...................................................................... 5-46
Trash Hopper - Fork Mounted......................................................... 5-48
Coupler Mounted Hook .................................................................... 5-50
Fork Mounted Hook............................................................................ 5-52
Truss Boom ............................................................................................ 5-54
Adjustable Truss Boom - Fork Mounted...................................... 5-56
Material Handling Arm ...................................................................... 5-58
Personnel Work Platform - Fork Mounted.................................. 5-60
Sweeper .................................................................................................. 5-62
Boom Mounted Lifting Lug.............................................................. 5-64
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) ...................................................................6-4
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