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JLG 642 User Manual

JLG 642
202 pages
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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

Table of Contents

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JLG 642 Specifications

General IconGeneral
BrandJLG
Model642
CategoryBoom Lifts
LanguageEnglish

Summary

Read This First

Operator Qualifications

Details the required skills, physical, and mental condition for machine operators.

Modifications

States that modifications must be approved by JLG to ensure compliance with standards.

Other Publications Available

Lists related manuals and their part numbers for additional information.

Machine Configuration

Explains how machine configurations are referred to based on fuel decals.

General Safety Practices

Hazard Classification System

Defines DANGER, WARNING, and CAUTION signal words for hazard communication.

General Precautions

Provides essential safety precautions before operating the telehandler.

Electrical Hazards

Details safe operating distances and procedures when working near electrical lines.

Tip Over Hazard

Explains factors contributing to tip-over and how to avoid them, including load capacity.

Pinch Points and Crush Hazards

Identifies hazardous areas on the machine to avoid to prevent crushing or cutting injuries.

Fall Hazard

Details safety procedures for mounting, dismounting, and preventing falls from the machine.

Chemical Hazards

Covers hazards associated with exhaust fumes, flammable fuels, and hydraulic fluids.

Pre-Operation and Inspection

Preparation, Inspection and Maintenance

Outlines the table for periodic machine inspections and required maintenance.

Pre-Operation Check and Inspection

Lists the essential checks to perform before each work shift or operator change.

Safety Decals

Ensures all safety decals are legible and in place, providing visual examples.

Walk-Around Inspection

Guides the operator through a systematic visual inspection of the machine's components.

Warm-Up and Operational Checks

Describes the procedures for warming up the engine and checking operational systems.

Cab

Provides warnings and requirements regarding the condition and modification of the telehandler's cab.

Controls and Indicators

Controls

Provides an overview of the machine's primary controls with numbered callouts.

Instrument Panel

Explains the function of various indicators and gauges on the instrument panel.

LCD Display

Describes the indicators, driving direction, gear display, and operating hours shown on the LCD.

Left Dash Control Panel

Details the switches and functions located on the left side of the operator's dash.

Right Dash Control Panel

Details the switches and functions located on the right side of the operator's dash.

Ignition

Explains the different positions of the ignition switch and their functions.

Park Brake

Describes the park brake switch operation and the parking procedure.

Transmission Control Lever

Explains how to select the direction of travel and gear using the transmission control lever.

Joystick

Describes the joystick functions for controlling boom, tilt, hydraulics, and transmission disconnect.

Multifunction Display (if equipped)

Outlines the features and navigation of the multifunction display, including home and menu screens.

Anti Theft Functionality (if enabled)

Explains the process of entering a numeric code for anti-theft activation and operation.

Steer Modes

Describes the available steer modes (2-wheel, 4-wheel, crab) and how to change them.

Operator Seat

Details the adjustments for suspension and fore/aft position, and seat belt usage.

Reverse Systems (if equipped)

Covers the reverse sensor system and reversing camera for enhanced rearward visibility.

Operation

Engine

Covers engine starting procedures, including normal and cold weather conditions.

After-Treatment System (ATS) (if equipped for ULS)

Explains the automatic and stationary exhaust system cleaning processes.

Operating with a Non-Suspended Load

Provides detailed instructions on safely lifting, transporting, and placing non-suspended loads.

Operating with a Suspended Load

Details safe practices for picking up, transporting, and placing suspended loads.

Loading and Securing for Transport

Outlines the procedure for properly loading and securing the telehandler for transportation.

Attachments

Approved Attachments

Lists criteria for determining if an attachment is approved for use with the telehandler.

JLG Supplied Attachments

Provides a table listing JLG supplied attachments and their applicable models.

Telehandler/Attachment/Fork Capacity

Explains how to determine maximum capacity by using the smallest of available ratings.

Use of the Capacity Chart

Guides the operator on how to properly read and interpret capacity charts for safe lifting.

Attachment Installation

Details the procedures for installing mechanical and hydraulic couplers.

Carriage with Forks

Explains the operation of the joystick and roller switch for boom movement and carriage tilt.

Side Shift Carriage

Details the joystick and roller switch operations for boom movement, carriage tilt, and side shift.

Mast Carriage

Explains controls for boom movement, carriage tilt, and mast raise/lower functions.

Bucket

Details controls for boom movement and bucket tilt.

Personnel Work Platform—Fork Mounted

Outlines installation and preparation for fork-mounted personnel work platforms.

Emergency Procedures

Towing a Disabled Product

Provides information and methods for moving a telehandler that cannot move under its own power.

EMERGENCY LOWERING OF BOOM

Outlines procedures for safely lowering the boom in the event of power loss.

EMERGENCY EXIT FROM ENCLOSED CAB

Explains how to exit the cab through the rear window in an emergency situation.

Lubrication and Maintenance

General Maintenance Instructions

Provides general guidelines and safety warnings before performing any service or maintenance.

Service and Maintenance Schedules

Presents maintenance schedules based on operating hours (10, 50, 250, 500, etc.).

Lubrication Schedules

Provides visual lubrication schedules for different operating hour intervals.

Operator Maintenance Instructions

Details maintenance components and procedures for engine systems.

Fuel System

Covers fuel level checks and procedures for draining the fuel/water separator.

Engine Oil

Details the engine oil level check and procedures for adding oil.

Air Intake System

Covers air cleaner checks, dust removal, and element replacement procedures.

Tires

Details tire air pressure checks, damage identification, and replacement guidelines.

Hydraulic Oil

Explains how to check and maintain the hydraulic oil level.

Transmission Oil

Details the procedure for checking and maintaining the transmission oil level.

Brake Fluid

Explains how to check the brake fluid level and when to remove the product from service.

Engine Cooling System

Details the procedure for checking and maintaining the engine coolant level.

Additional Checks

Reverse Sensor System (if equipped)

Details the procedure for checking the functionality of the reverse sensor system.

Specifications

Fluids

Lists recommended fluids and their classifications for various systems and temperature ranges.

Capacities

Provides a detailed list of fluid capacities for different machine components and models.

Tires

Lists tire specifications, including ply, type, and load ratings for various models.

Performance

Details key performance metrics like lift capacity, height, reach, and travel speed.

Dimensions

Provides overall height, width, wheelbase, length, ground clearance, and turning radius.

Hand Signals

Standard Hand Signals

Illustrates and defines common hand signals used for machine operation and movement.

Special Signals

Explains the need for pre-agreed signals for auxiliary equipment or non-standard conditions.

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