Operation 31200354 09-19-11 ANSI English

Operation & Safety
Manual
Original Instructions
Keep this manual with machine at all times.
Models
644E-42
&
944E-42
S/N 0160037794 & After
31200354
Revised
September 19, 2011
An Oshkosh Corporation Company

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
Revision Log
REVISION LOG
March 18, 2009 - A - Original Issue of Manual
April 23, 2009 - B - Revised page 9-2.
December 21, 2010 - C - Revised pages 7-13, 9-2, 9-3 & 9-5.
September 19, 2011 - D - Revised covers and pages b, d, 1-5, 1-6, 1-9, 2-3, 2-6, 2-
7, 2-8, 2-11, 2-13, 3-1, 3-4, 3-5, 3-6, 3-7, 4-3, 4-6, 4-9, 4-10, 5-2, 5-15, 5-16, 5-18,
5-20, 5-21, 5-22, 5-24, 5-26, 5-28, 5-30, 5-32, 6-1, 7-3, 7-4, 7-5, 7-9, 7-10, 7-11,
7-12, 7-13, 7-17, 7-18, 7-19, 7-20, 7-22, 7-23, 9-1 & 9-2.
31200354 a
Read This First
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 telehandler:
• This Operation & Safety Manual
• Telehandler Safety Manual (ANSI only)
• All instructional decals and plates
• Any optional equipment instructions furnished
The operator must also read, understand and comply with all applicable Employer,
Industry and Governmental rules, standards and regulations.
Modifications
Any modification to this machine must be approved by JLG.
b 31200354
Read This First
This product must comply with all safety related bulletins. Contact JLG Industries,
Inc. or the local authorized JLG representative for information regarding safety-
related bulletins which may have been issued for this product.
JLG Industries, Inc. sends safety related bulletins to the owner of record of this
machine. Contact JLG Industries, Inc. to ensure that the current owner records are
updated and accurate.
JLG Industries, Inc. must be notified immediately in all instances where JLG
products have been involved in an accident involving bodily injury or death of
personnel or when damage has occurred to personal property or the JLG product.
FOR:
• Accident Reporting and Product Safety Publications
• Current Owner Updates
• Questions Regarding Product Applications and Safety
• Standards and Regulations Compliance Information
• Questions Regarding Product Modifications
CONTACT:
Product Safety and Reliability Department
JLG Industries, Inc.
13224 Fountainhead Plaza
Hagerstown, MD 21742
USA
or Your Local JLG Office

(Addresses on back cover)
In USA:
Toll Free: 1-877-JLG-SAFE (1-877-554-7233)
Outside USA:
Phone: +1-717-485-6591
E-mail:
ProductSafety@JLG.com
31200354 c
Read This First
Other Publications Available
Service Manual
Before S/N 0160041827 excluding 0160041630 ..................................8990461
S/N 0160041827 & After including 0160041630..................................31200355
Illustrated Parts Manual...............................................................................8990462
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.
d 31200354
Table of Contents
Table of Contents
TABLE OF CONTENTS
Revision Log
Read This First
Operator Qualifications ...................................................... b
Modifications ...................................................................... b
Other Publications Available .............................................. d
Table of Contents
Section 1 - General Safety Practices
1.1 Hazard Classification System ..............................................1-1
Safety Alert System and Safety Signal Words ................1-1
1.2 General Precautions ............................................................1-1
1.3 Operation Safety ..................................................................1-2
Electrical Hazards ...........................................................1-2
Tip Over Hazard..............................................................1-3
Travel Hazard .................................................................1-6
Load Falling Hazard........................................................1-7
Lifting Personnel .............................................................1-8
Driving Hazards on Slopes .............................................1-9
Pinch Points and Crush Hazards ..................................1-10
Fall Hazard....................................................................1-12
Chemical Hazards.........................................................1-13
Section 2 - Pre-Operation and Inspection
2.1 Pre-Operation Check and Inspection...................................2-1
2.2 Safety Decals.......................................................................2-3
Before S/N 0160041827 excluding 0160041630 ............2-3
S/N 0160041827 & After including 0160041630.............2-6
2.3 Walk-Around Inspection.....................................................2-10
2.4 Warm-Up and Operational Checks ....................................2-12
Warm-Up Check ...........................................................2-12
Operational Check ........................................................2-12
2.5 Operator Cab .....................................................................2-13
2.6 Windows ............................................................................2-14
Cab Door Window (if equipped) ....................................2-14
Section 3 - Controls and Indicators
3.1 General ................................................................................3-1
3.2 Controls ...............................................................................3-2
Instrument Panel.............................................................3-4
Dash Panel .....................................................................3-6
Ignition ............................................................................3-8
Park Brake ......................................................................3-9
31200354 i
Table of Contents
Parking Procedure.......................................................... 3-9
Transmission Control Lever.......................................... 3-10
Front Joystick ............................................................... 3-12
Middle Joystick ............................................................. 3-13
Single Joystick (if equipped)......................................... 3-14
Frame Level Joystick.................................................... 3-16
Accessory Control Lever (if equipped) ......................... 3-17
3.3 Steer Modes ...................................................................... 3-18
Steer Mode Change ..................................................... 3-18
3.4 Stabil-Trak™ System ...................................................... 3-19
3.5 Operator Seat.................................................................... 3-20
Adjustments.................................................................. 3-20
Seat Belt ....................................................................... 3-21
3.6 Indicators........................................................................... 3-22
Boom Angle and Extension .......................................... 3-22
Transfer Carriage Extension......................................... 3-22
Section 4 - Operation
4.1 Engine ................................................................................. 4-1
Starting the Engine ......................................................... 4-1
Cold Weather Starting Aids ............................................ 4-2
Battery Boosted Starting................................................. 4-3
Normal Engine Operation ............................................... 4-4
Shut-Down Procedure .................................................... 4-4
4.2 Operating with a Non-Suspended Load .............................. 4-5
Lift Load Safely............................................................... 4-5
Picking Up a Load .......................................................... 4-5
Transporting a Load ....................................................... 4-6
Leveling Procedure......................................................... 4-6
Placing a Load................................................................ 4-7
Disengaging a Load........................................................ 4-7
4.3 Operating with a Suspended Load ...................................... 4-8
Lift Load Safely............................................................... 4-8
Picking Up a Suspended Load ....................................... 4-8
Transporting a Suspended Load .................................... 4-9
Leveling Procedure......................................................... 4-9
Placing a Suspended Load........................................... 4-10
Disengaging a Suspended Load .................................. 4-10
4.4 Loading and Securing for Transport.................................. 4-11
Tiedown ........................................................................ 4-11
Lifting ............................................................................ 4-12
ii 31200354
Table of Contents
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 ..........................................................................5-8
5.6 Attachment Installation ......................................................5-10
Hydraulic Operated Attachment....................................5-12
5.7 Adjusting/Moving Forks......................................................5-13
5.8 Attachment Operation ........................................................5-14
Carriage w/Forks...........................................................5-15
Side Tilt Carriage ..........................................................5-16
Swing Carriage .............................................................5-18
Dual Fork Positioning Carriage .....................................5-20
Mast Carriage ...............................................................5-22
Fork Mounted Hook ......................................................5-24
Truss Boom...................................................................5-26
Bucket ...........................................................................5-28
Grapple Bucket .............................................................5-30
Personnel Work Platform ..............................................5-32
Section 6 - Emergency Procedures
6.1 Towing a Disabled Product ..................................................6-1
Moving Short Distances ..................................................6-1
Moving Longer Distances ...............................................6-1
6.2 Emergency Lowering of Boom.............................................6-2
6.3 Emergency Exit from Enclosed Cab ....................................6-2
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 Schedule ....................................7-3
10 & 50 Hour Maintenance Schedule .............................7-3
1st 100, 250 & 1st 500 Hour Maintenance Schedule......7-4
500, 1000 & 2000 Hour Maintenance Schedule .............7-5
7.4 Lubrication Schedules .........................................................7-6
50 Hour Lubrication Schedule.........................................7-6
31200354 iii
Table of Contents
7.5 Operator Maintenance Instructions ..................................... 7-8
Fuel System.................................................................... 7-8
Engine Oil ..................................................................... 7-10
Hydraulic Oil ................................................................. 7-11
Engine Cooling System ................................................ 7-12
Tires.............................................................................. 7-14
Transmission Oil........................................................... 7-17
Battery .......................................................................... 7-18
Air Intake System ......................................................... 7-20
Section 8 - Additional Checks
8.1 Stabil-Trak™ ....................................................................... 8-1
Section 9 - Specifications
9.1 Product Specifications......................................................... 9-1
Capacities....................................................................... 9-1
Tires................................................................................ 9-3
Performance ................................................................... 9-4
Dimensions..................................................................... 9-5
Index
Inspection, Maintenance and Repair Log
iv 31200354
SECTION 1 - GENERAL SAFETY PRACTICES
1.1 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.
CAUTION OW0031
CAUTION indicates a potentiality hazardous situation which, if not avoided, may

result in minor or moderate injury.
1.2 GENERAL PRECAUTIONS
WARNING
Before operation, read and understand this manual. Failure to comply with the
safety precautions listed in this manual could result in machine damage, property
damage, personal injury or death.
31200354 1-1
1.3 OPERATION SAFETY
Electrical Hazards
10 FT
(3 M)
OW0040
• This machine is not insulated and does not provide protection from contact or
being near electrical current.
• NEVER operate the telehandler in an area where overhead power lines,
overhead or underground cables, or other power sources may exist without
ensuring the appropriate power or utility company de-energizes the lines.
• Always check for power lines before raising the boom.
• Follow employer, local and governmental regulations for clearance from
powerlines.
1-2 31200354
Tip Over Hazard
General
• 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.
• DO NOT exceed rated lift capacity.
• Be sure that the ground conditions are able to support the machine.
OW0080
• DO NOT raise boom unless frame is level (0 degrees), unless otherwise noted on
capacity chart.
4 FT
(1,2 M)
OW0100
• 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.)
31200354 1-3
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
• Always wear the seat belt.

• Keep head, arms, hands, legs and all other body parts inside operator’s cab at all
times.
OH2221
If the telehandler starts to tip over:

• DO NOT JUMP
• BRACE YOURSELF and STAY WITH THE MACHINE
• KEEP YOUR SEAT BELT FASTENED
• HOLD ON FIRMLY
• LEAN AWAY FROM THE POINT OF IMPACT
1-4 31200354
Non-Suspended Load
OW0060
• 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.
• Beware of wind. Wind can cause a suspended load to swing and cause
dangerous side loads - even with tag lines.
• DO NOT attempt to use telehandler frame-leveling to compensate for load swing.
• Keep heavy part of load closest to attachment.
• Never drag the load; lift vertically.
When driving with a suspended load:
• Start, travel, turn and stop slowly to prevent load from swinging.
• DO NOT extend boom.
• DO NOT raise the load more than 11.8 in (300 mm) above ground surface or
the boom more than 45°.
• DO NOT exceed walking speed.
31200354 1-5
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.
• 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).
1-6 31200354
Load Falling Hazard
OW0130
• Never suspend load from forks or other parts of carriage.

• DO NOT burn or drill holes in fork(s).
• Forks must be centered under load and spaced apart as far as possible.
31200354 1-7
Lifting Personnel
OW0170
• When lifting personnel, USE ONLY a JLG approved personnel work platform,
with proper capacity chart displayed in the cab.
OW0190
• DO NOT drive machine from cab when personnel are in platform.
1-8 31200354
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.
• To avoid overspeeding the engine and drivetrain when driving down slopes,
downshift to a lower gear and use the service brake as necessary to maintain a
slow speed. DO NOT shift into neutral and coast downhill.
• Avoid excessively steep slopes or unstable surfaces. To avoid tip over DO NOT
drive across excessively steep slopes under any circumstances.
• Avoid turning on a slope. Never engage “inching” or shift to “Neutral” when going
downhill.
• DO NOT park on a slope.
31200354 1-9
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
• Keep clear from under boom.
1-10 31200354
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.
31200354 1-11
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.
OW0290
• DO NOT carry riders. Riders could fall off machine causing death or serious
injury.
1-12 31200354
Chemical Hazards
Exhaust Fumes
• 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.
• If spark arrestors are required, ensure they are in place and in good working
order.
Flammable Fuel
OW0300
• DO NOT fill the fuel tank or service the fuel system near an open flame, sparks
or smoking materials. Engine fuel is flammable and can cause a fire and/or
explosion.
Hydraulic Fluid
OW0950
• DO NOT attempt to repair or tighten any hydraulic hoses or fittings while the
engine is running or when the hydraulic system is under pressure.
• Stop engine and relieve trapped pressure. Fluid in the hydraulic system is under
enough pressure that it can penetrate the skin.
• DO NOT use your hand to check for leaks. Use a piece of cardboard or paper to
search for leaks. Wear gloves to protect hands from spraying fluid.
31200354 1-13
This Page Intentionally Left Blank
1-14 31200354
SECTION 2 - PRE-OPERATION AND INSPECTION
2.1 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. Cleanliness - Check all surfaces for leakage (oil, fuel or battery fluid) or foreign
objects. Report any leakage to the proper maintenance personnel.
2. Structure - Inspect the machine structure for dents, damage, weld or parent
metal cracks or other discrepancies.
OAH1000
PARENT METAL CRACK WELD CRACK
3. Safety Decals - Ensure all safety decals are legible and in place. Clean or
replace as required. See page 2-3 for details.
4. Operation and Safety Manuals - Operation & Safety Manual and AEM Safety
Manual (ANSI only) are located in cab manual holder.
5. Walk-Around Inspection - See page 2-10 for details.
6. Fluid Levels - Check fluids, including fuel, hydraulic oil, engine oil, transmission
fluid and coolant. When adding fluids, refer to Section 7 - Lubrication and
Maintenance and Section 9 - Specifications to determine proper type and
intervals. Before removing filler caps or fill plugs, wipe all dirt and grease away
from the ports. If dirt enters these ports, it can severely reduce component life.
7. Attachments/Accessories - Ensure correct capacity charts are installed on the
telehandler. If provided, reference the Operation & Safety Manual of each
attachment or accessory installed for specific inspection, operation and
maintenance instructions.
31200354 2-1
8. Operational Check - Once the walk-around inspection is complete, perform a
warm-up and operational check (see page 2-12) of all systems in an area free
of overhead and ground level obstructions. See Section 3 - Controls and
Indicators for more specific operating instructions.
WARNING
If telehandler does not operate properly, immediately bring machine to a stop,
lower boom and attachment to ground and stop the engine. Determine cause and
correct before continued use.
2-2 31200354
2.2 SAFETY DECALS

Ensure all DANGER, WARNING, CAUTION and instructional decals and proper
capacity charts are legible and in place. Clean and replace as required.
Before S/N 0160041827 excluding 0160041630
4110361
1. Read operator's 2. Fasten 3. Allow 4. Use a compliant
SAFETY manual before seat no work platform to lift
INSTRUCTIONS operating. belt. riders. or lower personnel.
4110361
4108991 4110137
DANGER DANGER
CONTACTING NEVER operate VEHICLE DO NOT DO NOT raise MAINTAIN
ELECTRIC vehicle within TIPOVER travel boom while proper tire
POWER LINES 10 feet (3m) of can result with the on a slope pressure at
can result in electric power in death or boom unless load all times.
electrocution. lines.
4108991 serious injury. raised. is level. 4110137
4110359
4110359
CAPACITY
1705957 CHARTS
15
10 20
°F
1/2 176
RPM X 100
WARNING WARNING
E F 104 248
80
5 25 °C 120
r/min
30
0000000
VEHICLE AVOID
ROLLAWAY CRUSHING,
can cause falling off
death or vehicle can
serious cause death
injury or serious
injury.
ALWAYS
engage parking
brake before
dismounting
1705957
1705956
DANGER
AVOID CRUSHING
if vehicle tips.
Jumping can
result in death
or serious
injury.
DO NOT JUMP.
Brace yourself.
Stay in cab.
VIEW INSIDE CAB
Keep seat belt on.
1705956
4110366
4110366 4110423
4110360
4110423
4110360
4110367
4110367
4110367
4110367
OU1781
DUAL JOYSTICK SINGLE JOYSTICK
CONFIGURATION CONFIGURATION
31200354 2-3
4110130
4105262 1706300
70 80
7301380
50 60
40
20
-10 0 10 30
WARNING
FALLING OFF ATTACHMENT,
can result in death or
serious injury. 4 3
5
7301380 4109801
7301380 6 A
4109801
4109801 B 10 2
Pressure Tap Function Tested
4109801
Location
Refer to Hydraulic Test 10 2 Main Valve Pressure
Laminate or Service 3 Pilot Pressure
Manual for proper
testing procedures. 4 Park Brake
5 Pump #1
6 Accumulator Pressure
*Consult with OQT Technical
Service Department for A Load Sense (Steering)*
additional testing information.
B Load Sense (Implement)*
Lift or lower personnel DO NOT TRAVEL 4110392
only in a compliant with personnel in
4110392
work platform. a work platform.
4110389
4110389
91404299
ANGUS-PALM 005413
7301379 OU1791
2-4 31200354
1705883
7301380
4110356
200cm 190cm
6
Ft
180cm 170cm 160cm
5
Ft
150cm 140cm 130cm
4
Ft
120cm 110cm 100cm
3
Ft
90cm 80cm 70cm
2
Ft
60cm 50cm 40cm
1
30cm
Ft
20cm 10cm
0
4110356
4109801
7301380 4109801
7301380
4109801 4110405 4109801
1001103931
10
50
LB-FT
(Nm)
100
250
1000
2000
4110350
4110349
4110349
UNDERSIDE VIEW OF
ENGINE COVER
1706300
4110184
1707079
MOVING PARTS can cut.
Keep clear of fan and belts

while engine is running.
1707079
MOVING PARTS can entangle.
1707077
4110184
WARNING
1707114
-
EXPLOSIVE GASES can

cause serious injury.
Keep sparks, flames
OU1801 1707114
VIEW OF ENGINE COMPARTMENT

and lighted materials
away from batteries. 1707077
31200354 2-5
S/N 0160041827 & After including 0160041630
1706299
CONTACTING
POWER LINES
will result in death
or serious injury.
1706299A
1706306 1706850
WARNING
CRUSHING HAZARD Keep others
Lowering boom or falling load could away while
cause death or serious injury. operating.
1706306A 1706850A
CAPACITY
CHARTS
4110359 10
15
20
°F
1/2 176
E F RPM X 100 104 248

80
5 25 °C 120
r/min
30
0000000
4110359
VIEW INSIDE CAB
1706767
1706303
Operator must be trained and
1706303A
must read and understand Fasten

all capacity charts, operator seat
and safety manuals. belt.
1706767A
1706304
1706851
RUN-OVER
HAZARD
could cause
death or
serious
injury.
1706851A
1706304A
VIEW OF DECALS LOCATED INSIDE

4110366 CAB ON RIGHT HAND WALL
4110423
4110366
4110360
4110423
4110367
4110360
4110367
4110367
4110367
OU2440
DUAL JOYSTICK SINGLE JOYSTICK
CONFIGURATION CONFIGURATION
2-6 31200354
4110130
4105262 1706300 1706768
70 80
7301380
50 60
40
20
-10 0 10 30
4 3
5
7301380 4109801
7301380 6 A
4109801
4109801 B 10 2
Pressure Tap Function Tested
4109801
Location
Refer to Hydraulic Test 10 2 Main Valve Pressure
Laminate or Service 3 Pilot Pressure
Manual for proper
testing procedures. 4 Park Brake
5 Pump #1
6 Accumulator Pressure
*Consult with OQT Technical
Service Department for A Load Sense (Steering)*
additional testing information.
B Load Sense (Implement)* 4110392
1706298A
4110392
1706298
1706302 1706302 1706302 1706302
BOTTOM VIEW OF BOOM
91404299
ANGUS-PALM 005413
7301379
OU2450
31200354 2-7
1706296
(BETWEEN FRAME RAILS) 1705883
7301380
4110356
200cm 190cm
6
Ft
180cm 170cm 160cm
5
Ft
150cm 140cm 130cm
4
Ft
120cm 110cm 100cm
3
Ft
90cm 80cm 70cm
2
Ft
60cm 50cm 40cm
1
30cm
Ft
20cm 10cm
0
4110356
4109801
7301380 4109801
7301380
4109801 4110405 4109801
1001136373
10
50
LB-FT
(Nm)
100
250
1000
2000
4110350
4110349
UNDERSIDE VIEW OF 4110349

ENGINE COVER
1001125892
1706300
3.0 GPM MAX
11.4 lpm (BOTH SIDES OF ENGINE
COMPARTMENT WALL)
1001125892 REV A
1706301
1706301A
1707079 1707114
1707079
1707114
OU2530
VIEW OF ENGINE COMPARTMENT
2-8 31200354
31200354 2-9
2.3 WALK-AROUND INSPECTION
15
2 14
3 4
13
4
5
6 12
11
7
10
8 9
OU1811
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. Inspect all structural members including
attachment for cracks, excessive corrosion and other damage.
1. Boom Sections and Lift, Tilt, Extend/Retract, Compensating (Slave) Cylinders -
• Check front, top, side and rear slider pads for presence of grease.
• Pivot pins secure; hydraulic hoses undamaged, not leaking.
2. Front Axle - Steer cylinders undamaged, not leaking; pivot pins secure;
hydraulic hoses undamaged, not leaking.
3. Wheel/Tire Assembly - Properly inflated and secured; no loose or missing lug
nuts. Inspect for worn tread, cuts, tears or other discrepancies.
4. Mirrors - Clean and undamaged.
2-10 31200354
5. Cab and Electrical -
• General appearance; no visible damage.
• Frame level indicator and window glass undamaged and clean.
• Gauges, switches, joysticks, foot controls and horn operational.
• Check seat belt for damage, replace belt if frayed or cut webbing, damaged
buckles or loose mounting hardware.
6. Main Control Valve (under cab floor) - See Inspection Note.
8. Stabil-Trak Cylinder - Pins secure; hydraulic hoses undamaged, not leaking.
9. Rear Axle - Steer cylinders undamaged, not leaking; pivot pins secure;
11. Transfer Carriage - See inspection note. Transfer carriage cylinder pins secure;
12. Engine Compartment -
• Drive belts, check condition and replace as required.
• Engine mounts - See inspection note.
• (Before S/N 0160041827 including 0160041630) Battery cables tight, no
visible damage or corrosion.
• Engine cover closed and properly secured.
14. Frame Level Cylinder - Pins secure; hydraulic hoses undamaged, not leaking.
15. Attachment - Properly installed, see “Attachment Installation” on page 5-10.
31200354 2-11
2.4 WARM-UP AND OPERATIONAL CHECKS
Warm-Up Check
During warm-up period, check:

1. Heater, defroster and windshield wiper (if equipped).
2. Check all lighting systems (if equipped) for proper operation.
3. Adjust mirror(s) for maximum visibility.
WARNING
CUT/CRUSH/BURN HAZARD. Keep engine cover closed while engine is
running except when checking transmission oil level.
Operational Check
When engine warms, perform an operational check:

1. Service brake and parking brake operation.
2. Forward and reverse travel.
3. Each gear.
4. Steering in both directions with engine at low idle (steering lock to lock will not
be reached). Check in each steering mode.
5. Horn and back-up alarm. Must be audible from inside operators cab with engine
running.
6. All joystick functions - operate smoothly and correctly.
7. Perform any additional checks described in Section 8.
2-12 31200354
2.5 OPERATOR CAB

The telehandler is equipped with an open or enclosed ROPS/FOPS cab.
WARNING
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. It must be REPLACED.
31200354 2-13
2.6 WINDOWS
Keep all windows and mirrors clean and unobstructed.
Cab Door Window (if equipped)
3
2
4
1
OU1821
• Cab door (1) must be closed during operation.

• During operation the cab door window (2) must either be latched open or closed.
• Open the cab door window with the latch handle (3) and secure in place on
outside of cab.
• Turn either inside or outside knob (4) to unlatch the window.
2-14 31200354
SECTION 3 - CONTROLS AND INDICATORS
3.1 GENERAL
This section provides the necessary information needed to understand control
functions.
Note: The manufacturer has no direct control over machine application and
operation. The user and operator are responsible for conforming with good safety
practices.
NOTICE
EQUIPMENT DAMAGE. When a red indicator illuminates (except park brake and
engine air-intake heater), immediately bring machine to a stop, lower boom and
attachment to ground and stop the engine. Determine cause and correct before
continued use.
31200354 3-1
3.2 CONTROLS
9 10
8
14
7
13
6
11
5 12
13
SINGLE JOYSTICK
CONFIGURATION
3
2
1
OU1911
1. Accelerator Pedal: Pressing down the pedal increases engine and hydraulic
speed.
2. Ignition Switch: Key activated. See page 3-8.
3. Service Brake Pedal: The further the pedal is depressed, the slower the travel
speed.
With service brake pedal depressed and boom angles above 40°, the locked
mode of the Stabil-Trak system is activated. See page 3-19.
4. Transmission Control Lever: See page 3-10.
5. Dash Panel: See page 3-6.
6. Instrument Panel: See page 3-4.
7. 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 3-18.
8. Frame Level Indicator: Enables operator to determine the left to right level
condition of the telehandler.
9. Horn: Depress button to sound horn.
10. Accessory Control Lever (if equipped): See page 3-17.
3-2 31200354
11. Front Joystick: See page 3-12.
12. Middle Joystick: See page 3-13.
13. Frame Level Joystick: See page 3-16.
14. Single Joystick (if equipped): See page 3-14.
31200354 3-3
Instrument Panel
1 2 3 4 5 6 7 8
15
10 20
°F
1/2 176
140 212
E F RPM X 100 104 248
80
5 25 40
60
°C
100
120
r/min
30
0000000
OU1921 17 16 15 14 13 12 11 10 9
1. Fuel Gauge: Indicates amount of fuel in fuel tank.

2. Engine Air-Intake Heater Indicator: Illuminates with ignition key in the “RUN”
position. Indicator goes out when start temperature is reached. At temperatures
below 40° F (4° C), do not start until indicator turns off.
Note: Indicator may illuminate when engine is running and ambient
temperatures are below 40° F (4° C).
3. Stabil-Trak Indicator - Slow Pivot Mode: Illuminates when Stabil-Trak system is
in slow pivot mode. See page 3-19.
4. Engine Speed: Indicates engine speed in revolutions per minute (rpm).
5. High Beam Indicator (if equipped): Illuminates when high beam lights are on.
6. Stabil-Trak Indicator - Locked Mode: Illuminates when Stabil-Trak system is in
locked mode. See page 3-19.
7. Turn Signal Indicator (if equipped): Illuminates and flashes when turn signals or
hazard lights are activated.
8. Engine Temperature Gauge: Indicates engine operating temperature.
(Before S/N 0160041827 excluding 0160041630) If temperature is above 212°
F (100° C) bring machine to a stop, lower boom and attachment to ground and
idle engine. Shut-down engine. Determine cause and correct before continued
use.
(S/N 0160041827 & After including 0160041630) If temperature is above 224° F
(107° C) bring machine to a stop, lower boom and attachment to ground and
idle engine. Shut-down engine. Determine cause and correct before continued
use.
9. Hydraulic Oil Filter Restriction Indicator: Illuminates when hydraulic oil filter
requires maintenance.
10. Low Brake Pressure Indicator: Illuminates and buzzer sounds when hydraulic
brake pressure is too low.
3-4 31200354
11. Air Filter Restriction Indicator: Illuminates when air filter(s) require maintenance.
12. Hydraulic Oil Temperature Indicator: Illuminates when hydraulic oil temperature
is too high.
13. Hourmeter: Records and indicates engine operating hours.
14. Transmission Oil Temperature Indicator: Illuminates and buzzer sounds when
transmission oil temperature is too high.
15. Park Brake Indicator: Illuminates when park brake is applied. See page 3-9.
16. Battery Charge Indicator: Illuminates when battery is at low charge or charging
system is not functioning properly.
17. Engine Oil Pressure Indicator: Illuminates and buzzer sounds when engine oil
pressure is too low.
31200354 3-5
Dash Panel
5 6
7
1
b
8
9
13 10
2 12 11
3 4 OU1992
1. Steer Mode Selector: Three positions: 4-wheel circle steer, 4-wheel crab steer
and 2-wheel steer. See page 3-18.
2. Transmission Disconnect Switch: Depress bottom of switch to activate
transmission disconnect function and have transmission disconnect while
depressing service brake. Indicator illuminates to indicate transmission has
disconnected. Depress top of switch to deactivate transmission disconnect
function and keep transmission engaged while depressing service brake.
WARNING
UNEXPECTED MOVEMENT HAZARD. Always apply park brake or service
brake and return engine to idle before deactivating transmission disconnect
function. Deactivating transmission disconnect with engine above idle could
cause the machine to move abruptly.
3. Park Brake Switch: See page 3-9.

4. Engine Fault Indicators: Indicators illuminate when an engine fault occurs
during operation.
a. If red indicator illuminates during operation, stop the engine immediately and
diagnose the fault using the ECM diagnostic system. See Service Manual
for details.
b. If amber indicator illuminates during operation, the diagnostic system has
detected a fault. Stop the engine and diagnose the fault using the ECM
diagnostic system. See Service Manual for details.
Note: Indicators also flash fault codes. See Service Manual for details.
5. Beacon or Strobe Light Switch (if equipped): On/Off switch.
6. Hazard Lights Switch (if equipped): On/Off switch.
3-6 31200354
7. Work Lights Switch (if equipped): Three position switch. Move switch to middle
position to turn on front work lights. Push bottom of switch to turn on all work
lights. Push top of switch to turn all work lights off.
8. Roof Wiper/Washer Switch (if equipped): Three position switch. Move switch to
middle position to turn on wiper. Push and hold bottom of switch to activate
washer. Push top of switch to turn off wiper.
9. Front Washer Switch (if equipped): Push and hold bottom of switch to activate
washer.
10. Front Wiper Switch (if equipped): Three position switch. Move switch to middle
position to operate at low speed. Push bottom of switch to operate at high
speed. Push top of switch to turn off wiper.
Heater and Air Conditioning Controls (if equipped)

11. Temperature Control Switch: Adjustable rotary switch.
12. Air Conditioning Switch: On/Off switch.
13. Fan Speed Switch: Four position rotary switch.
31200354 3-7
Ignition
OFF
RUN
START
OU1891
• In the "RUN" position, voltage is available for all electrical functions.

• Full clockwise rotation to "START" engages starter motor.
• Counter-clockwise rotation to "OFF" stops engine and removes voltage from all
electrical functions.
3-8 31200354
Park Brake
1 2 OU1901
Park brake switch controls the application and release of the park brake. Indicator on
switch illuminates to indicate brake is applied.
• With the engine running and the park brake switch in "OFF" position (1), park
brakes are disengaged.
• With switch in "ON" position (2), park brake is engaged and transmission will not
engage forward or reverse.
• With switch in “ON” position and boom angles greater than 40°, locked mode of
Stabil-Trak system is activated. See page 3-19.
WARNING
MACHINE ROLL-AWAY HAZARD. Always move park brake switch to "ON"
position, lower boom to ground and stop engine before leaving cab.
WARNING
CRUSH HAZARD. Turning engine off applies the park brake. Applying park brake
or turning engine off while traveling will cause unit to stop abruptly and could
cause load loss. Either may be used in an emergency situation.
Parking Procedure
1. Using service brake, stop telehandler in an appropriate parking area.

2. Follow “Shut-Down Procedure” on page 4-4.
31200354 3-9
Transmission Control Lever
Direction of Travel Selection
R 1 OU1871
Transmission control lever (1) engages forward or reverse travel.

• Push lever forward for forward travel; pull lever rearward for reverse travel. Move
lever to centered position for neutral.
• Forward or reverse travel can be selected while in any gear.
• When traveling in reverse, the back-up alarm will automatically sound.
• Drive in reverse and turn only at slow rates of speed.
• If transmission disconnect function is not active (see page 3-6), do not increase
engine speed with the transmission in forward or reverse and the service brake
depressed in an attempt to get quicker hydraulic performances. This could cause
unexpected machine movement.
WARNING
TIP OVER/CRUSH HAZARD. Bring telehandler to a complete stop before
shifting transmission control lever. A sudden change in direction of travel could
reduce stability and/or cause load to shift or fall.
3-10 31200354
Gear Selection
1st 2nd
3rd
4th
2
OU1881
Gear selection is located on the twist grip handle (2) of transmission control lever.
• Twist hand grip to select gear.
• Select the appropriate gear for the task being performed. Use a lower gear
when transporting a load. Use a higher gear only when driving unloaded for
longer distances.
• Slow down prior to downshifting. Do not downshift more than one gear at a
time.
31200354 3-11
Front Joystick
2
1
OU1961
The front joystick (1) controls attachment tilt, transfer carriage and auxiliary hydraulic
functions.
Attachment Tilt Function
• Move the joystick forward to tilt down, move the joystick back to tilt up.
Transfer Carriage Function
• Move the joystick right to extend transfer carriage; move joystick left to retract
transfer carriage.
• For two simultaneous functions, move the joystick between quadrants. For
example; moving the joystick forward and to the left will tilt attachment down and
retract transfer carriage simultaneously.
Auxiliary Hydraulic Function
• For attachments that require hydraulic supply for operation, press button (2) to
activate auxiliary hydraulics control. The button must be held down while moving
the joystick left or right. See Section 5 - Attachments for approved attachments
and control instructions.
WARNING
TIP OVER/CRUSH HAZARD. Rapid, jerky operation of controls will cause rapid,
jerky movement of the load. Such movements could cause the load to shift or fall
or could cause the machine to tip over.
3-12 31200354
Middle Joystick
OU1951
The middle joystick (3) controls boom functions.

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. Increasing engine speed will also increase function
speed.
• For two simultaneous boom functions, move the joystick between quadrants. For
example; moving the joystick forward and to the left will lower and retract boom
simultaneously.
WARNING
31200354 3-13
Single Joystick (if equipped)
2 OU1971
The single joystick (1) controls boom, attachment tilt, transfer carriage and auxiliary
hydraulic functions.
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 functions depends upon the amount of joystick travel in
speed.
example; moving the joystick forward and to the left will lower and retract boom
simultaneously.
Transfer Carriage and Auxiliary Hydraulics
Transfer carriage and auxiliary hydraulic functions are enabled by the button (2).
Note: The button must be held during operation of the transfer carriage or auxiliary
hydraulics. Releasing the button will immediately change the controls back to boom
functions.
• While depressing button, move the joystick forward to extend transfer carriage;
move joystick back to retract transfer carriage.
• For attachments that require hydraulic supply for operation, the button must be
held down while moving the joystick left or right. See Section 5 - Attachments for
approved attachments and control instructions.
3-14 31200354
• The speed of functions depends upon the amount of joystick travel in
speed.
example; moving the joystick forward and to the left will extend transfer carriage
and activate auxiliary hydraulics simultaneously.
Attachment Tilt
• Slide the thumb control (3) forward to tilt down, slide the thumb control back to tilt
up.
WARNING
31200354 3-15
Frame Level Joystick
OU1941
The frame level joystick (1) controls the left to right frame level.
• Lift detent ring (2) and move the joystick left to rotate frame left; lift detent ring
and move the joystick right to rotate frame right.
• A level indicator is located above the front cab window to permit the operator to
determine whether the telehandler frame is level.
WARNING
TIP OVER HAZARD. Always move boom as low as possible while allowing for
best visibility of right hand mirror before leveling frame. Attempting to level
machine with boom raised could cause it to tip over.
3-16 31200354
Accessory Control Lever (if equipped)
The accessory control lever (3) operates the turn signals, parking lights and
headlights.
4 6
9
7
5
3 OU1931
Turn Signals
• Push lever forward (4) to activate the left turn signal.
• Pull lever back (5) to activate the right turn signal.
• The lever must be manually returned to the center position to deactivate either
turn signal. The lever will not cancel automatically after a turn.
Parking Lights and Headlights

• Turn the twist grip (6) of the lever counterclockwise to the first position (7) to turn
on the parking lights.
• Turn the twist grip to the second position (8) to turn on the headlights.
• Raise/lower the lever to switch between low and high beam.
• Turn the twist grip clockwise to the OFF position (9) to turn all lights off.
31200354 3-17
3.3 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.
Steer Mode Change
1 2 3 OU2380
1. Bring machine to a stop using service brake while either circle steer mode (1) or
crab steer mode (3) is selected.
4 5 OAM2400
2. Turn the steering wheel until the left rear wheel (4) is aligned with the side of the
machine.
3. Select front steer mode (2).
4. Turn the steering wheel until the left front wheel (5) is aligned with the side of
the machine.
5. Wheels are now aligned. Select desired steer mode.
3-18 31200354
3.4 STABIL-TRAK™ SYSTEM
2
3 4
15
10 20
1 E
1/2
F RPM X 100
140
104
°F
176
212
248
80
5 25 40
60
°C
100
120
r/min
30
0000000
OU2041
Free Pivot Mode

With boom below 40° (1), the Stabil-Trak system is in free pivot mode.
• The rear axle pivots freely and frame level functions normally.
• The Stabil-Trak slow pivot (3) and lock (4) indicators will not illuminate.
Slow Pivot Mode

With boom above 40° (2), the Stabil-Trak system is in slow pivot mode if the service
brake is not depressed and the transmission is in gear.
• The rear axle will respond slowly to changes in terrain and frame level functions
normally.
• The Stabil-Trak slow pivot indicator (3) will illuminate.
Locked Mode
With boom above 40° (2) and the park brake engaged, transmission control lever in
neutral or service brake depressed, the system is in locked mode.
• The rear axle is locked and the frame level functions slower than normal.
• The Stabil-Trak lock indicator (4) will illuminate.
31200354 3-19
3.5 OPERATOR SEAT
Adjustments
Prior to starting engine adjust seat for position and comfort.
OAL1270
1. Suspension: Use knob to adjust suspension to the appropriate setting. Turn

clockwise to increase stiffness. Turn counterclockwise to reduce stiffness.
2. Fore/Aft: Pull up on handle to move seat fore and aft.
3. Seat Belt: Always fasten seat belt during operation. If required, a 3 in (76 mm)
seat belt is available.
3-20 31200354
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.
3. With belt buckle positioned as low on the body as possible, pull the retractable
end of the belt away from the buckle until it is tight across the lap.
4. To release belt latch, depress red button on the buckle and pull free end from
buckle.
31200354 3-21
3.6 INDICATORS
Boom Angle and Extension
1
2
A B
80°
70°
°
60
°
50
°
40
°
30
-10° 20°
0° 10°
OU1831
• The boom angle indicator (1) is located on the left side of the boom. Use this
indicator to determine the boom angle when using the capacity chart (see “Use
of the Capacity Chart” on page 5-5).
• Boom extension indicators (2) 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” on page 5-5).
Transfer Carriage Extension
OU2020
• The transfer carriage extension indicator (3) is located on the right main frame
rail. Use this indicator to determine transfer carriage extension when using the
capacity chart (see “Use of the Capacity Chart” on page 5-5).
3-22 31200354
SECTION 4 - OPERATION
4.1 ENGINE
Starting the Engine
This machine can be operated under normal conditions in temperatures of 0°F to

104°F (-20°C to 40°C). Consult JLG for operation outside this range or under
abnormal conditions.
1. Make sure all controls are in “Neutral” and all electrical components (lights,
heater, defroster, etc.) are turned off. Apply parking brake.
2. If equipped with engine air-intake heater and temperature is below 40° F (4° C),
turn the ignition switch to “RUN” position and wait for engine air-intake heater
indicator on instrument panel to turn off.
3. Turn ignition switch to “START” to engage starting motor. Release key
immediately when engine starts. If engine fails to start within 20 seconds,
release key and allow starting motor to cool for a few minutes before trying
again.
4. After engine starts, observe engine oil pressure gauge. If gauge remains on
zero for more than five seconds, stop engine and determine cause before
restarting engine.
5. Warm up engine at approximately 1/2 throttle.
Note: Engine will not start unless transmission control lever is in “Neutral” and park
brake switch is applied.
WARNING
UNEXPECTED MOVEMENT HAZARD. Always ensure that transmission control
lever is in neutral and the service brake is applied before releasing park brake.
Releasing park brake in either forward or reverse could cause the machine to
move abruptly, causing an accident.
31200354 4-1
Cold Weather Starting Aids
If the telehandler is equipped with an engine air-intake heater, the following applies:
• Air-intake heater is triggered by a temperature sensor on the engine.
• At start-up, temperature sensor will detect if air-intake heater is needed.
• A second battery is added for additional cold-cranking capacity.
WARNING
ENGINE EXPLOSION. If your telehandler is equipped with a cold start aid, do
not spray additional ether into air cleaner. If machine is not equipped with cold
start aid, follow instructions listed in the engine manual supplied with the
telehandler.
4-2 31200354
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.
• (Before S/N 0160041827 excluding 0160041630) Connect the positive (+)
jumper cable to positive (+) post of discharged battery.
(S/N 0160041827 & After including 0160041630) Connect the positive (+) jumper
cable to positive (+) jumper post of discharged machine.
• Connect the opposite end of positive (+) jumper cable to positive (+) post of
booster battery.
• Connect the negative (-) jumper cable to negative (-) post on booster battery.
• Connect opposite end of negative (-) jumper cable to ground point on machine
away from discharged battery.
• Follow standard starting procedures.
• Remove cables in reverse order after machine has started.
WARNING
BATTERY EXPLOSION HAZARD. Never jump start or charge a frozen battery
as it could explode. Keep sparks, flames and lighted smoking materials away
from the battery. Lead acid batteries generate explosive gases when charging.
Wear safety glasses.
31200354 4-3
Normal Engine Operation
• Observe gauges and indicators frequently to be sure all engine 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.
• Avoid prolonged idling. If the engine is not being used, turn it off.
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 the park brake.
2. Shift the transmission to “Neutral.”
3. Lower forks or attachment to the ground.
4. Operate engine at low idle for 3 to 5 minutes. DO NOT over rev engine.
5. Shut off engine and remove ignition key.
6. Exit telehandler properly.
7. Block wheels (if necessary).
4-4 31200354
4.2 OPERATING WITH A NON-SUSPENDED LOAD
Lift Load Safely
• You must know the weight and load center of every load you lift. If you are not
sure of the weight and load center, check with your supervisor or with the
supplier of the material.
WARNING
TIP OVER HAZARD. Exceeding lift capacity of the telehandler could damage the
equipment and/or cause tip over.
• Know the rated load capacities (see Section 5) of the telehandler to determine
the operating range in which you can safely lift, transport and place a load.
Picking Up a Load
• Note the conditions of the terrain. Adjust travel speed and reduce amount of load
if conditions warrant.
• Avoid lifting double-tiered loads.
• Make sure load is clear of any adjacent obstacles.
• Adjust spacing of forks so they engage the pallet or load at maximum width. See
“Adjusting/Moving Forks” on page 5-13.
• Approach load slowly and squarely with fork tips straight and level. NEVER
attempt to lift a load with just one fork.
• NEVER operate telehandler without a proper and legible capacity chart in the
operator cab for the telehandler/attachment combination you are using.
31200354 4-5
Transporting a Load
OW0540
After engaging the load and resting it against the backrest, tilt the load back to
position it for travel and fully retract transfer carriage. Travel in accordance with the
requirements set forth in Section 1 - General Safety Practices and Section
5 - Attachments.
Leveling Procedure
1. Position machine in best location to lift or place load.

2. Apply parking brake and move transmission control lever to NEUTRAL.
3. Observe level indicator to determine whether machine must be leveled prior to
lifting load. Level machine with frame level joystick (see page 3-16).
4. Move boom/attachment to 4 ft (1,2 m) off ground.
(AUS - Move boom so forks are no more than 11.8 in (300 mm) above ground
surface.)
Important things to remember:

• Never raise the boom/attachment more than 4 ft (1,2 m) above ground unless
telehandler is level.
(AUS - Never raise the forks more than 11.8 in (300 mm) above ground surface
unless telehandler is level.)
• The combination of frame leveling and load could cause the telehandler to tip
over.
4-6 31200354
Placing a Load
Before placing any load be sure that:

• The landing point can safely support the weight of the load.
• The landing point is level; front to back and side to side.
• Use the capacity chart to determine safe boom and transfer carriage extension
range. See “Use of the Capacity Chart” on page 5-5.
• Align forks at the level load is to be placed, then position boom slowly until load is
just above area where it is to be placed.
• Lower the boom until the load rests in position and the forks are free to retract.
• The transfer carriage can be used to place the load onto the landing point, being
certain the load is within the transfer limits.
Disengaging a Load
Once the load has been placed safely at the landing point, proceed as follows:
1. With the forks free from the weight of the load, the boom or transfer carriage can
be retracted.
2. Lower the carriage.
3. The telehandler can now be driven from the landing location to continue work.
31200354 4-7
4.3 OPERATING WITH A SUSPENDED LOAD
Lift Load Safely
• You must know the weight and load center of every load you lift. If you are not
sure of the weight and load center, check with your supervisor or with the
supplier of the material.
WARNING
TIP OVER HAZARD. Exceeding lift capacity of the telehandler could damage the
equipment and/or cause tip over.
• Know the rated load capacities (refer to Section 5) of the telehandler to

determine the operating range in which you can safely lift, transport and place a
load.
Picking Up a Suspended Load
• Note the conditions of the terrain. Adjust travel speed and reduce amount of load
if conditions warrant.
• Avoid lifting double-tiered loads.
• Make sure load is clear of any adjacent obstacles.
• NEVER operate telehandler without a proper and legible capacity chart in the
operator cab for the telehandler/attachment combination you are using.
• Only use approved lifting devices rated for the lifting of the load.
• Identify the proper lifting points of the load, taking into consideration the center of
gravity and load stability.
• Ensure to always properly tether loads to restrict movement.
• Refer to See “Use of the Capacity Chart” on page 5-5. for proper lifting guidelines
in addition to the appropriate capacity chart in the operator cab.
4-8 31200354
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 the appropriate capacity chart in the
operator cab.
Important things to remember:

• Ensure the boom and transfer carriage is fully retracted.
• Never raise the load more than 11.8 in (300 mm) above ground surface or the
boom more than 45°.
• The combination of frame leveling and load could cause the telehandler to tip
over.
• The guide persons and operator must remain in constant communication (verbal
or hand) and be in visual contact with the operator at all times.
• Never place the guide persons between the suspended load and the telehandler.
• Only transport the load at walking speed, 0.9 mph (0.4 m/s), or less.
Leveling Procedure
1. Position machine in best location to lift or place load.

2. Apply parking brake and move transmission control lever to NEUTRAL.
3. Observe level indicator to determine whether machine must be leveled prior to
lifting load. Level machine with frame level joystick (see page 3-16).
4. Move boom so load is no more than 11.8 in (300 mm) above ground surface
and boom/or boom is raised no more than 45°.
31200354 4-9
Placing a Suspended Load
Before placing any load be sure that:

• The landing point can safely support the weight of the load.
• The landing point is level; front to back and side to side.
• Use the capacity chart to determine safe boom and transfer carriage extension
range. See “Use of the Capacity Chart” on page 5-5.
• Align load at the level load is to be placed, then position boom slowly until load is
just above area where it is to be placed.
• Ensure that the guide persons and operator remain in constant communication
(verbal or hand) when placing the load.
• The transfer carriage can be used to place the load onto the landing point, being
certain the load is within the transfer limits.
Disengaging a Suspended Load
• Never place the guide men between the suspended load and the telehandler.
• Once at the destination of the load, ensure to bring the telehandler to a complete
stop and apply the park brake prior to disengagement of the lifting devices and
tethers.
4-10 31200354
4.4 LOADING AND SECURING FOR TRANSPORT
4109801 4109801
OU2031
Tiedown
1. Level the telehandler prior to loading.

2. Using a spotter, load the telehandler with boom as low as possible.
3. Once loaded, apply parking brake and lower boom until boom or attachment is
resting on deck. Move all controls to “Neutral,” stop engine and remove ignition
key.
4. Secure machine to deck by passing chains through the designated tie down
points as shown in the figure.
5. Do not tie down front of boom.
Note: The user assumes all responsibility for choosing the proper method of
transportation and tie-down devices, making sure the equipment used is capable of
supporting the weight of the vehicle being transported and that all manufacturer’s
instructions and warnings, regulations and safety rules of their employer, the
Department of Transportation and/or any other local, state or federal/provincial laws
are followed.
WARNING
TELEHANDLER SLIDE HAZARD. Before loading telehandler for transport,
make sure deck, ramps and telehandler wheels are free of mud, snow and ice.
Failure to do so could cause telehandler to slide.
31200354 4-11
Lifting
• When lifting machine, it is very important that the lifting device and equipment is
attached only to designated lifting points. If machine is not equipped with lifting
lugs contact JLG Product Safety for information.
• Make adjustments to the lifting device and equipment to ensure the machine will
be level when elevated. The machine must remain level at all times while being
lifted.
• Ensure that the lifting device and equipment is adequately rated and suitable for
the intended purpose. See Section 9 - Specifications for machine weight.
• Remove all loose items from machine prior to lifting.
• Lift machine with smooth, even motion. Set machine down gently. Avoid quick or
sudden motions that could cause shock loads to machine and/or lifting devices.
4-12 31200354
SECTION 5 - ATTACHMENTS
5.1 APPROVED ATTACHMENTS
To determine if an attachment is approved for use on the specific telehandler you are
using, perform the following prior to installation.
• The attachment type, weight, dimensions and load center must be equal to or
less than the data shown on a capacity chart located in the operator cab.
• The model on the capacity chart must match the model telehandler being used.
• Hydraulically powered attachments must only be used on machines equipped
with auxiliary hydraulics.
• Hydraulically powered attachments that require auxiliary electrics must only be
used on machines equipped with auxiliary hydraulics and electrics.
If any of the above conditions are not met, do not use the attachment. The
telehandler may not be equipped with the proper capacity chart or the attachment
may not be approved for the model telehandler being used. Contact JLG or a local
distributor for further information.
5.2 UNAPPROVED ATTACHMENTS

Do not use unapproved attachments for the following reasons:
• Range and capacity limitations for “will fit,” homemade, altered, or other
non-approved attachments cannot be established.
• An overextended or overloaded telehandler can tip over with little or no warning
and cause serious injury or death to the operator and/or those working nearby.
• The ability of a non-approved attachment to perform its intended function safely
cannot be assured.
WARNING
Use only approved attachments. Attachments which have not been approved for
use with your telehandler could cause machine damage or an accident.
31200354 5-1
5.3 JLG SUPPLIED ATTACHMENTS
Applicable Model
Attachment Part Number
644E-42 944E-42
Carriage, 50 in (1270 mm) 1170021 X X
Carriage, 60 in (1524 mm) 1170024 X X
Carriage, 72 in (1829 mm) 1170027 X X
Side Tilt Carriage, 50 in (1270 mm) 1170054 X X
90° Swing Carriage, 72 in (1829 mm) 1001095418 X X
180° Swing Carriage, 72 in (1829 mm) 1001104992 X X
Dual Fork Positioning Carriage, 50 in (1270 mm) 7301295 X X
8 ft Mast Carriage, 50 in (1270 mm) 1001108668 X X
Fork, Pallet 2.36x4x48 in (60x100x1220 mm) 2340045 X X
Fork, Pallet 2.36x5x48 in (60x127x1220 mm) 2340038 X X
Fork, Dual Taper 1.75x7x60 in (44x178x1524 mm) 2340046 X X
Fork, Dual Taper 2.36x6x60 in (60x152x1524 mm) 2340039 X X
Fork, Dual Taper 2x6x72 in (50x152x1830 mm) 1001092391 X X
Fork, Block 2x2x48 in (50x50x1220 mm) 2340037 X X
Bucket, 72 in - 1.0 yd3 1001100822 X X
Bucket, 96 in - 1.5 yd3 1001100823 X X
Bucket, 102 in - 2.0 yd3 1001100824 X X
Grapple Bucket, 96 in - 1.75 yd3 0930020 X X
Hook, Fork Mounted 91565094 X X
Truss Boom, 12 ft (3658 mm) 1001099902 X X
Truss Boom w/ Winch, 12 ft (3658 mm) 1001099351 X X
Truss Boom, 15 ft (4572 mm) 1001099901 X X
1001092280 X X
Platform, Fork Mounted (ASME)
1001103637 X X
1001097072 X X
Platform, Fork Mounted (ASME - French)
1001103736 X X
1001096306 X X
Platform, Fork Mounted (ISO)
1001103730 X X
5-2 31200354
31200354 5-3
5.4 TELEHANDLER/ATTACHMENT/FORK CAPACITY
OW0550
Prior to installing the attachment verify it is approved and the telehandler is equipped
with the proper capacity chart. See “Approved Attachments” on page 5-1.
To determine the maximum capacity of the telehandler and attachment, use the
smallest of the following capacities:
• Capacity stamped on the attachment identification plate (1).
• Fork capacities and load centers are stamped on the side of each fork (2)
(if equipped). This rating specifies the maximum load capacity that the individual
fork can safely carry at the maximum load center (3). Total attachment capacity is
multiplied by the number of forks on the attachment (if equipped), up to the
maximum capacity of the attachment.
• Maximum capacity as indicated on the proper capacity chart. See “Approved
Attachments” on page 5-1.
• When the load rating of the telehandler differs from the capacity of the forks or
attachment, the lower value becomes the overall load capacity.
Use the proper capacity chart to determine maximum capacity at various machine
configurations. 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.
5-4 31200354
5.5 USE OF THE CAPACITY CHART

To properly use the capacity chart (see page 5-6), the operator must first determine
and/or have the following:
1. An approved attachment. See “Approved Attachments” on page 5-1.
2. The proper Capacity Chart(s).
3. Weight of the load being lifted.
4. Load placement information:
a. HEIGHT where the load is to be placed.
b. DISTANCE from the front tires of the telehandler where the load is to be
placed.
5. On the Capacity Chart, find the line for the height and follow it over to the
distance.
6. The number in the load zone where the two cross is the maximum capacity for
this lift. If the two cross at a division between zones, the smaller number must
be used.
The number in the load zone must be equal to or greater than the weight of the load
to be lifted. Determine the limits of the load zone on the capacity chart and keep
within these limits.
Capacity Indicator Locations
BOOM BOOM ANGLE TRANSFER CARRIAGE

EXTENSION INDICATOR EXTENSION INDICATOR
INDICATOR
ATTACHMENT
IDENTIFICATION
PLATE
80°
70°
60°
B
50°
A
40°
30°
20°
10°
-10° 0°
FORK
WEIGHT
STAMP
OU2051
31200354 5-5
Sample Capacity Chart
Load zones indicate the maximum

weight that may be safely lifted.
XXXXXXXXXX X
XX
XX
XX XX
XX Boom Extension
XX XX
XX Indicator (arc)
XX XX
XX
XX
XX
X X
XX
XX
Boom XX
XX
Angle XX XX
XXXX XX
XXXX XX
XX
XXXX XX
XX
XX
XX Load center
XX
XX must be equal to
XX XX XX XX XX XX XX XX XX XX
or less than
X XX MAX value shown.
XXXXXX XXXX XX MAX =XXXX XX MAX
OU2390
This Capacity Chart may be used with this model ONLY. Attachment type, weight and
The telehandler model is indicated on the boom or chassis. dimensions must be equal to or
Model XXXXX is used for demonstration purposes only. less than the data shown.
Note: This is a sample capacity chart only! DO NOT use this chart, use the one
located in your operator cab.
WARNING
TIP OVER HAZARD. All loads shown on rated capacity chart are based on
machine being on firm ground with frame level (see page 4-6); the forks being
positioned evenly on carriage; the load being centered on forks; proper size tires
being properly inflated; and the telehandler being in good operating condition.
5-6 31200354
To identify the proper capacity chart on telehandlers equipped with transfer carriage,
refer to the following icons which may be located on the load chart.
80" 1"
• Use for any forward movement (1 to 80 in) of the transfer

carriage.
OW0910
0"
• Use for no forward movement (0 in) of the transfer carriage.

Fully retracted position only.
OW0920
31200354 5-7
Example
A contractor owns a model xxxxx telehandler with a fork carriage. He knows this
attachment may be used with his model since:
• The attachment style, weight, dimensions and load center match the attachment
data on the capacity chart.
• The capacity chart is clearly marked for model xxxxx and corresponds with
machine configuration being used.
Below are examples with various conditions the contractor may encounter and
whether or not the load may be lifted.
Load Weight Distance Height OK to Lift

1 6000 lb (2722 kg) 18 ft (5,5 m) 12 ft (3,7 m) Yes
2 4000 lb (1814 kg) 30 ft (9,1 m) 26 ft (7,9 m) NO
3 7500 lb (3402 kg) 8 ft (2,4 m) 24 ft (7,3 m) Yes
4 5750 lb (2608 kg) 12 ft (3,7 m) 44 ft (13,4 m) NO
60'
56' 71°
10
52' 60°
9
48' Example 4
8
50°
44' 7
40' 6
40° 5
36'
4
32' 3
30°
28' 2 Example 3
1
24'
S
S
LB
B
BS
0 L
BS
Example 2 20' 20°

00
0 L
0 L
600
50
LBS
400
800
16'
3000 LBS
00
12'
100
10°
8'
Example 1 4'
0°
0'
-4° XX
-4'
48 44' 40' 36' 32' 28' 24' 20' 16' 12' 8' 4' 0' OY1710
Note: This is a sample capacity chart only! DO NOT use this chart, use the one
located in your operator cab.
5-8 31200354
31200354 5-9
5.6 ATTACHMENT INSTALLATION
1 2
3
6
4 5 OH4430
1. Attachment
2. Attachment Pin Recess
3. Attachment Pin
4. Lock Pin
5. Lock Lever
6. Quick Attach (attachment tilt control in cab, see page 3-12)
WARNING
CRUSH HAZARD. Always be certain that carriage or attachment is properly
positioned on boom and is secured by lock pin and lock lever. Failure to ensure
proper installation could permit carriage/attachment/load to disengage.
5-10 31200354
This installation procedure is designed for one-person operation. Prior to exiting cab,
perform “Shut-Down Procedure” on page 4-4.
1. Tilt quick attach back to provide clearance.

Check to be sure lock pin is removed.
OH4440
2. Align attachment pin with recess in attachment.

Raise boom slightly to engage attachment pin in
recess.
OH4450
3. Tilt quick attach forward to engage attachment.
OH4460
4. Lift lock lever and insert lock pin completely

through quick attach. Release lock lever and
ensure lock pin is secured.
OH4470
5. If equipped, connect auxiliary hydraulic hoses. See “Hydraulic Operated

Attachment” on page 5-12.
31200354 5-11
Hydraulic Operated Attachment
1. Install attachment (see page 5-10).

2. Lower attachment to ground and perform “Shut-Down Procedure” on page 4-4.
OH4480
3. Connect attachment hoses to both auxiliary fittings (1).
5-12 31200354
5.7 ADJUSTING/MOVING FORKS

Carriages may have different locations where forks can be positioned. Two different
methods can be used for repositioning, depending upon the carriage structure.
Note: Apply a light coating of appropriate lubricant to ease sliding of forks or fork
bar.
To slide forks:
1. Ensure attachment is properly installed. See “Attachment Installation” on
page 5-10.
2. Elevate attachment to approximately 5 ft (1,5 m) and tilt carriage forward until
fork heel is free from attachment.
3. Stand at the side of the carriage. To slide fork toward the center of the carriage,
push the fork near the fork eye. To slide fork toward the edge of the carriage,
pull the fork near the fork eye. To avoid pinching, do not place fingers or thumb
between the fork and carriage structure.
If removing fork bar is necessary:
1. Rest forks on ground.
2. Remove fork bar.
3. Reposition forks.
4. Reinstall the fork bar and fork bar retaining mechanism(s).
31200354 5-13
5.8 ATTACHMENT OPERATION

• Capacities and range limits for the telehandler change depending on the
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 the attachment
if it is equipped with a manual holder.
• Operations described within this section reference a dual joystick configuration.
Refer to page 3-14 if equipped with a single joystick configuration.
NOTICE
EQUIPMENT DAMAGE. Some attachments may contact the front tires or
machine structure when the boom is retracted and the attachment is rotated.
Improper use of attachment may result in attachment or machine structural
damage.
NOTICE
EQUIPMENT DAMAGE. Avoid contact with any structure or object when lifting a
load. Maintain clearance around boom structure and load. Failure to maintain
clearance may result in attachment or machine structural damage.
5-14 31200354
Carriage w/Forks
Use Carriage Attachment Capacity Chart

To determine maximum capacity, refer to “Telehandler/
Attachment/Fork Capacity” on page 5-4.
OY0690
OU2181
The middle joystick (1) controls lift/lower and extend/retract movement of the boom.
The front joystick (2) controls fork tilt.
• Move joystick back to tilt up.
• Move joystick forward to tilt down.
Installation Procedure:
Refer to “Attachment Installation” on page 5-10.
Equipment Damage Precautions:

• Do not use forks as a lever to pry material. Excessive prying forces could
damage forks or machine structure.
• Do not attempt to lift loads that are attached or connected to another object.
31200354 5-15
Side Tilt Carriage
Use Side Tilt Carriage Attachment Capacity Chart

OAL1550
OU2181
To Side Tilt:
The button (3) on the front joystick enables carriage side tilt.
• While depressing button move joystick left to (side) tilt left.
• While depressing button move joystick right to (side) tilt right.
• Refer to “Attachment Installation” on page 5-10.
5-16 31200354
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.
• Level telehandler before side tilting carriage to engage load.
• Side tilt carriage to left or right to align forks with load and engage load.
• Raise load slightly and level carriage side to side.
Safety Practices.

31200354 5-17
Swing Carriage
Use Swing Carriage Attachment Capacity Chart

OU2150
OU2161
To Swing:
The button (3) on the front joystick enables the swing function.
• While depressing button move joystick left to swing left.
• While depressing button move joystick right to swing right.
5-18 31200354
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.
WARNING
CRUSH HAZARD. Use retaining pin (if equipped) for locking swing frame to fixed
frame when carrying loads greater than 5000 lb. Failure to comply could cause
object or load to fall.
Operation:
• To drive with a load, keep forks pointed forward and travel in accordance with the
requirements set forth in Section 1 - General Safety Practices.

31200354 5-19
Dual Fork Positioning Carriage
Use Carriage Attachment Capacity Chart

OZ3670
OU2460
To Fork Position:
The button (3) on the front joystick enables fork positioning.
• While depressing button move joystick left to shift forks out.
• While depressing button move joystick right to shift forks in.
5-20 31200354
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:
Safety Practices.

31200354 5-21
Mast Carriage
Use Mast Carriage Attachment Capacity Chart

OY0580
OU2400
To Raise/Lower Mast:
The button (3) on the front joystick enables the raise/lower movement of the mast.
• While depressing button move joystick left to lower.
• While depressing button move joystick right to raise.
Refer to “Attachment Installation” on page 5-10.
5-22 31200354
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.
• To drive with a load, lower forks fully in mast and travel in accordance with the
requirements set forth in Section 1 - General Safety Practices.
• Use a signal person to assist in positioning of load if necessary.

31200354 5-23
Fork Mounted Hook
Use Appropriate Carriage Attachment Capacity Chart

OY0640
Suspend loads in accordance with requirements set forth in Section

1 - General Safety Practices.
OU2091
• Ensure carriage is properly installed. Refer to “Attachment Installation” on
page 5-10.
• 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.
5-24 31200354
Operation:
• Pallet or lumber forks of an appropriate load rating must be used. Do not use with
cubing or block forks.
• Weight of rigging must be included as part of total load being lifted.
• Do not use with mast carriage attachment.
• Do not use fork mounted hook with attachments capable of rotating (i.e. side tilt
and swing carriages) without disabling the rotation feature(s).
31200354 5-25
Truss Boom
Use Appropriate Truss Boom Attachment Capacity Chart

OY0570
Suspend loads in accordance with requirements set forth in Section

1 - General Safety Practices.
OU2141
The front joystick (2) controls truss boom tilt.
Winch Control (if equipped):
The button (3) on the front joystick enables the truss boom mounted winch.
• While depressing button move joystick left to lower cable.
• While depressing button move joystick right to raise cable.
5-26 31200354
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:
• Weight of rigging must be included as part of total load being lifted.
31200354 5-27
Bucket
Use Appropriate Bucket Capacity Chart

OZ0730
OU2111
The front joystick (2) controls bucket tilt.
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.
• Tilt bucket up far enough to retain load and back away from pile.
• Travel in accordance with requirements set forth in Section 1 - General Safety
Practices.
• Tilt bucket down to dump load.
5-28 31200354
Equipment Damage Precautions
• Except for lifting or dumping a load, the boom must be fully retracted for all
bucket operations.
• Do not corner-load bucket. Distribute material evenly within the bucket. Bucket
capacity charts are for evenly distributed loads only.
• Do not use bucket as a lever to pry material. Excessive prying forces could
damage bucket or machine structure.
• Do not attempt to load material which is hard or frozen. This could cause severe
damage to quick attach or machine structure.
• Do not use bucket for "back dragging." This could cause severe damage to quick
attach and retraction cables/chains.
31200354 5-29
Grapple Bucket
Use Grapple Bucket Capacity Chart

OZ1450
OU2410
The front joystick (2) controls grapple bucket tilt.
To open/close grapple:
The button (3) on the front joystick enables the open/close movement of the grapple.
• While depressing button move joystick left to close grapple.
• While depressing button move joystick right to open grapple.
5-30 31200354
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.
• Tilt bucket up far enough to retain load, close grapple and back away from pile.
• Travel in accordance with requirements set forth in Section 1 - General Safety
Practices.
• Open grapple and tilt bucket down to dump load.
Equipment Damage Precautions

• Except for lifting or dumping a load, the boom must be fully retracted for all
bucket operations.
• Do not corner-load bucket. Distribute material evenly within the bucket. Bucket
capacity charts are for evenly distributed loads only.
• Do not use bucket as a lever to pry material. Excessive prying forces could
damage bucket or machine structure.
• Do not attempt to load material which is hard or frozen. This could cause severe
damage to quick attach or machine structure.
• Do not use bucket for "back dragging." This could cause severe damage to quick
attach and retraction cables/chains.
31200354 5-31
Personnel Work Platform
Use Appropriate Carriage Attachment Capacity Chart

OY1610
The operator and personnel in platform must read and understand the
separate personnel work platform manual prior to installing and using a
platform.
OU2420
The front joystick (2) controls platform tilt.
• Ensure carriage is properly installed. Refer to “Attachment Installation” on
page 5-10.
• Secure the personnel work platform to the forks by sliding the personnel work
platform onto the parent forks and install the retaining pin behind the vertical
shank of the fork.
5-32 31200354
Preparation and Setup:
1. Ensure the telehandler is on a firm surface and is level.
2. Engage the park brake. Blocking the wheels is also recommended.
3. Level the platform, both side to side (frame level) and front to back (attachment
tilt).
4. Keep area under platform free from personnel.
5. When personnel are on platform, the operator must remain seated in cab with
personnel in direct line of sight.
6. DO NOT lift or carry persons in a bucket or on forks.
WARNING
FALL HAZARD. Never tilt the platform forward, rearward, or level the machine
when the platform is occupied.
31200354 5-33
5-34 31200354
SECTION 6 - EMERGENCY PROCEDURES
6.1 TOWING A DISABLED PRODUCT
The following information assumes the 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.
• Machine mounted retrieval devices provide suitable means to attach a tow rope,
chain or tow bar only in the event the telehandler becomes stuck or disabled.
Retrieval devices are not intended for trailer towing devices.
• The steering system permits manual steering if engine or power assist feature
fails; however, steering will be slow and will require much greater force.
• DO NOT attempt to tow a telehandler that is loaded or the boom/attachment is
raised above 4 ft (1,2 m).
Moving Short Distances
• If it is only necessary to move telehandler a short distance, less than 100 ft

(30 m), it is permissible to use a vehicle of sufficient capacity to tow the unit with
no previous preparation. Drive wheels will not roll.
Moving Longer Distances
• See Service Manual for information.
Contact a local Authorized Distributor for specific instructions if neither of

these methods are applicable.
31200354 6-1
6.2 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 a local Authorized Distributor for specific instructions.
Secure the telehandler using the following procedures:
1. Clear the area around telehandler of all personnel.
2. Engage the parking brake. Place the transmission control lever in “NEUTRAL”.
3. Block all four wheels.
4. Section off a large area under the boom with string or tape to restrict any
personnel from entering this area.
6.3 EMERGENCY EXIT FROM ENCLOSED CAB
ANGUS-PALM 005413
OWO740
• In an emergency, an escape hammer located directly below the rear window in

an enclosed cab can be used to exit the telehandler.
6-2 31200354
SECTION 7 - LUBRICATION AND MAINTENANCE
7.1 INTRODUCTION
Service the product in accordance with the maintenance schedule on the following
pages.
2
OU2221 1
The Maintenance (1) and Lubrication (2) decals contain instructions that must be
followed to keep this product in good operating condition. The Operation & Safety
Manual and Service Manual contain more detailed service information with specific
instructions.
Clothing and Safety Gear
• Wear all the protective clothing and personal safety devices issued to you or
called for by job conditions.
• DO NOT wear loose clothing or jewelry that can get caught on controls or moving
parts.
31200354 7-1
7.2 GENERAL MAINTENANCE INSTRUCTIONS

Prior to performing any service or maintenance on the telehandler, follow the
shut-down procedure on page 4-4 unless otherwise instructed. Ensure
telehandler is level, for proper fluid readings.
• Clean lubrication fittings before lubricating.
• After greasing telehandler, cycle all functions several times to distribute
lubricants. Perform this maintenance procedure without attachment installed.
• Apply a light coating of engine oil to all linkage pivot points.
• Intervals shown are for normal usage and conditions. Adjust intervals for
abnormal usage and conditions.
• Check all lubricant levels when lubricant is cool, with the exception of the
transmission fluid. For ease of filling hydraulic reservoir, use a funnel with a hose
or flexible tube for best results.
Note: Be certain to check boom extend chain adjustment every 250 hours, boom
retract chain adjustment every 1000 hours and adjust chains as required. Chain
damage can occur if chain is not adjusted properly.
WARNING
CUT/CRUSH/BURN HAZARD. Do not perform service or maintenance on the
machine with the engine running, with the exception of the transmission oil level
check.
7-2 31200354
7.3 SERVICE AND MAINTENANCE SCHEDULE
10 & 50 Hour Maintenance Schedule
EVERY
10
Check Fuel Drain Fuel/ Check Engine Check Hydraulic Check Engine
Level Water Seprator Oil Level Oil Level Coolant Level
Check Tire Check Check Air Additional

Condition & Transmission Intake System Checks -
Pressure Oil Level Section 8
EVERY
50
Check Check Boom Check Transfer Check Transfer Check Transfer

Battery Wear Pads Carriage Rear Carriage Carriage Roll
Wear Pads Roller Gap Back Hoses
Check Washer Lubrication

Fluid Level Schedule
(if equipped)
OU2232
31200354 7-3
1st 100, 250 & 1st 500 Hour Maintenance Schedule
1st
100
LB/F
T (N
m)
Change Change Change Check Wheel

Transmission Transfer Hydraulic Lug Nut
Oil and Filter Case Oil Filters Torque
EVERY
250
LB/F
T (N
m)
Change Engine Oil Change Air Change Fuel Filter Check Wheel Lubricate
and Filter* (Before Filter Elements and Strainer (Before Lug Nut Boom Extend
S/N 0160041827) S/N 0160041827) Torque Chains
Check Axle Check Wheel Check Boom Check Transfer Check Transfer
Oil Level End Oil Levels Extend Chains Case Oil Level Carriage Front
and Tension Upstop Wear Pads
1st
500
Change Change Wheel

Axle Oil End Oil
OU2243
Note: Engine oil and filter service interval can be extended, see page 7-10 for
details.
7-4 31200354
500, 1000 & 2000 Hour Maintenance Schedule
EVERY
500
Change Engine Change Fuel

Oil and Filter Filters
(S/N 0160041827 & After)
EVERY
1000
Change Change Change Change Change Wheel

Transmission Transfer Hydraulic Axle Oil End Oil
Oil and Filter Case Oil Fluid and Filters
Lubricate Check Boom Check Axle Check

Boom Retract Retract Chains Brake Discs Fan Belt
Chains and Tension
EVERY
2000
Change
Engine Coolant
OU2253
31200354 7-5
7.4 LUBRICATION SCHEDULES
50 Hour Lubrication Schedule
EVERY
50
OU2430
7-6 31200354
31200354 7-7
7.5 OPERATOR MAINTENANCE INSTRUCTIONS
Fuel System
A. Fuel Level Check 10

OW0970 OW0990
1
15
10 20
°F
1/2 176
140 212
E F RPM X 100 104 248
80
5 25 40
60
°C
100
120
r/min
30
0000000
3
2
OU2271
1. Check fuel gauge (1) located on instrument panel in cab.

2. If fuel is low, proceed to fuel source and perform “Shut-Down Procedure” on
page 4-4.
3. Locate fuel tank (3), turn fuel tank cap (2) and remove from filler neck.
4. Add diesel fuel as needed.
5. Replace and secure fuel tank cap.
Note: Replenish diesel fuel at end of each work shift to minimize condensation.
NOTICE
EQUIPMENT DAMAGE. Do not allow machine to run out of fuel during
operation. See Engine Operation & Maintenance Manual for details prior to
servicing.
7-8 31200354
B. Drain Fuel/Water Separator

10OW0970
OW1000
BEFORE S/N 0160041827 EXCLUDING 0160041630
OU2281
S/N 0160041827 & AFTER INCLUDING 0160041630
5
OU2480 4
1. Perform “Shut-Down Procedure” on page 4-4.

2. Open the engine cover.
3. Loosen drain cock (4) on underside of fuel filter (5) and allow all water to drain
into a glass until clear fuel is visible.
4. Tighten drain cock.
5. Close and secure the engine cover.
31200354 7-9
Engine Oil
A. Engine Oil Level Check 10 OW0970

OW1020
BEFORE S/N 0160041827 S/N 0160041827 & AFTER

EXCLUDING 0160041630 INCLUDING 0160041630
3
1
1
OU2312

3. Remove dipstick (1) and check oil mark. The oil should be between the full (2)
and add (3) marks within the crosshatched area of the dipstick.
4. If oil is low, remove oil fill cap (4) and add motor oil to bring oil up to the full mark
in the crosshatch area.
5. Replace oil fill cap and dipstick.
Note: The standard service interval for engine oil and filter is 250 hours maximum.
If an extended service interval is desired, see your engine manual for specific
guidelines for optimizing oil change intervals.
7-10 31200354
Hydraulic Oil
A. Hydraulic Oil Level Check 10 OW0970 OW1030
BEFORE S/N 0160041827 EXCLUDING 0160041630
4108302
5
6 OU2322
S/N 0160041827 & AFTER INCLUDING 0160041630
5
OU2470
1. Be sure all cylinders and transfer carriage are fully retracted and machine is
level.
4. Check level of hydraulic oil at the sight gauge (6) on the hydraulic tank (5). The
oil level should be visible in the gauge window.
5. If hydraulic oil is low remove oil fill cap (7).
6. Add hydraulic fluid to bring oil up to the upper mark on the sight gauge.
7. Replace hydraulic oil fill cap.
31200354 7-11
Engine Cooling System
A. Engine Coolant Level Check 10 OW0970 OW1070
1
OU2301

3. Check coolant level in overflow bottle (1). When coolant is hot, bottle should be
1/2 to 3/4 full. When coolant is cool, bottle should be 1/4 to 1/2 full.
4. If coolant is low, remove overflow bottle cap (2) and add coolant as required.
5. Replace overflow bottle cap.
7-12 31200354
3 4
OU2490

3. Coolant should be visible in the sight gauge (3).
4. If coolant is low, allow system to cool. Remove radiator cap (4) and add coolant
as required.
5. Replace radiator cap.
Note: When filling coolant, the maximum fill rate is 3.0 gallon per minute (11,4 liter
per minute).
31200354 7-13
Tires
A. Tire Air Pressure Check 10 OW0970

OW1040

2. Remove valve stem cap.
3. Check tire pressure.
644E-42
13.00 x 24, G-2/L-2 Bias-Ply Traction - 12 Ply .........................65 psi (4,5 bar)
13.00 x 24, G-3/L-3 Bias Ply Rock - 12 Ply..............................65 psi (4,5 bar)
13.00 x 24, G-2/L-2 Radial - 1 Star ..........................................65 psi (4,5 bar)
370/75-28, 14 Ply.....................................................................76 psi (5,2 bar)
944E-42
15.50 x 24, G-2/L-2 Bias-Ply Traction - 12 Ply .........................65 psi (4,5 bar)
15.50 x 24, G-3/L-3 Bias Ply Rock - 12 Ply..............................65 psi (4,5 bar)
15.50 x 24, G-2/L-2 Radial - 1 Star ..........................................65 psi (4,5 bar)
370/75-28, 14 Ply.....................................................................76 psi (5,2 bar)
4. Replace valve stem cap.
B. Tire Damage
For pneumatic tires, when any cut, rip or tear is discovered that exposes sidewall or
tread area cords in the tire, measures be taken to remove the product from service
immediately. Arrangements must be made for replacement of the tire or tire
assembly.
For polyurethane foam filled tires, when any of the following are discovered,
measures must be taken to remove the product from service immediately.
Arrangements must be made for replacement of the tire or tire assembly.
• a smooth even cut through the cord piles which exceeds 3 in (7,5 cm) in total
length.
• any tears or rips (ragged edges) in the cord plies which exceeds 1 in (2,5 cm) in
any direction
• any punctures which exceed 1 in (2,5 cm) in diameter.
If a tire is damaged but within the above noted criteria, the tire must be inspected
daily to ensure the damage has not propagated beyond the allowable criteria.
7-14 31200354
C. Tire and Wheel Replacement
It is recommended that a replacement tire to be the same size, ply and brand as
originally installed. Refer to the appropriate parts manual for ordering information. If
not using an approved replacement tire, the replacement tires must have the
following characteristics:
• Equal or greater ply/load rating and size of original.
• Tire tread contact width equal or greater than original.
• Wheel diameter, width and offset dimensions equal to the original.
• Approved for the application by the tire manufacturer (including inflation pressure
and maximum tire load).
Unless specifically approved by JLG, do not replace a foam filled or ballast filled tire
assembly with a pneumatic tire. 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. Size changes such as rim width, center
piece location, larger or smaller diameter, etc., without written factory
recommendations, may result in unsafe condition regarding stability.
31200354 7-15
E. Wheel Installation
Torque lug nuts before first use and after each wheel removal.
Note: If machine is equipped with directional tire assemblies, the wheel and tire
assemblies must be installed with the directional tread pattern “arrows” facing in the
direction of forward travel.
1. Install wheel lug washers.
2. Start all nuts by hand to prevent cross threading. DO NOT use a lubricant on
threads or nuts.
3. Tighten lug nuts in an alternating pattern as indicated in figure. Torque to
430-470 lb-ft (583-637 Nm).
3
1 5
8 7
6 2
4
OAH0990
WARNING
TIP OVER HAZARD. Lug nuts must be installed and maintained at the proper
torque to prevent loose wheels, broken studs and possible separation of wheel
from the axle.
7-16 31200354
Transmission Oil
A. Transmission Oil Level Check 10 OW0970 OW1050
BEFORE S/N 0160041827 S/N 0160041827 & AFTER

EXCLUDING 0160041630 INCLUDING 0160041630
2
T
HO
1 LD
MIN
CO
OU2510
1. Apply park brake, shift transmission to "Neutral" and lower forks or attachment
to the ground.
2. Check transmission oil level with engine at idle and oil at normal operating
temperature.
4. Remove the transmission dipstick (3) and check oil level. The oil level should be
within the "HOT" zone (4).
5. If oil is low, add hydraulic fluid to bring oil up to the "HOT" zone.
6. Replace transmission dipstick.
31200354 7-17
Battery
A. Battery Check 50 OW0980 OW1080
OU2340

3. Rotate upper battery to inspect both batteries (1).
4. Wearing eye protection, visually inspect the batteries. Check terminals for
corrosion. Replace battery if it has a cracked, melted or damaged case.
5. Rotate upper battery back.
7-18 31200354
3 1
OU2520

2. Remove the battery compartment cover (2).
3. Wearing eye protection, visually inspect the batteries (1). Check terminals for
corrosion. Replace battery if it has a cracked, melted or damaged case.
4. Replace and secure the battery compartment cover.
6. Check battery jumper post (3) for corrosion.
31200354 7-19
Air Intake System
A. Air Filter Check 50 OW0980

OW1010
4
1
6
OU2291 2

3. Locate air cleaner (1).
4. Remove dust from vacuator valve (2) by squeezing bottom of valve to allow
loose particles to fall out.
Note: Only remove canister cover to service the elements as restriction indicator
indicates. Excessive access to check an element can lead to premature element
failure.
7-20 31200354
B. Element Change (as restriction indicator indicates)
If air filter restriction indicator remains on after start up or illuminates during
operation, perform the following:
1. Unlock air cleaner cover (3), turn counterclockwise and remove from air cleaner
canister (4).
2. Remove outer primary element (5) and inspect for damage. Damaged elements
should not be reused.
3. Thoroughly clean the interior of the air cleaner canister and vacuator valve.
4. Replace inner safety element (6) after every third primary element change. If
replacing the inner safety element at this time, carefully slide the element out
and replace with new element.
5. Slide the new primary element over the inner element making sure the sealing
edge is flush with the base of the air cleaner.
6. Position air cleaner cover in place, turn clockwise and lock into position.
Note: An inner safety element should never be washed or reused. Always install a
new element.
31200354 7-21
1 4
6
5
3
OU2500 2

3. Locate air cleaner (1).
4. Remove dust from vacuator valve (2) by squeezing bottom of valve to allow
loose particles to fall out.
Note: Only remove canister cover to service the elements as restriction indicator
indicates. Excessive access to check an element can lead to premature element
failure.
7-22 31200354
B. Element Change (as restriction indicator indicates)
If air filter restriction indicator remains on after start up or illuminates during
operation, perform the following:
1. Unlock air cleaner cover (3) and remove from air cleaner canister (4).
2. Remove outer primary element (5) and inspect for damage. Damaged elements
should not be reused.
3. Thoroughly clean the interior of the air cleaner canister and vacuator valve.
4. Replace inner safety element (6) after every third primary element change. If
replacing the inner safety element at this time, carefully slide the element out
and replace with new element.
5. Slide the new primary element over the inner element making sure the sealing
edge is flush with the base of the air cleaner.
6. Position air cleaner cover in place and lock into position.
Note: An inner safety element should never be washed or reused. Always install a
new element.
31200354 7-23
7-24 31200354
SECTION 8 - ADDITIONAL CHECKS
8.1 STABIL-TRAK™
A. Stabil-Trak Indicator Test 10 OW0970 OH4340
Stabil-Trak system operates in three modes. In slow pivot mode the Stabil-Trak slow
pivot indicator illuminates. In locked mode the Stabil-Trak lock indicator illuminates. If
indicator does not illuminate the test was not performed properly or Stabil-Trak
system is not functioning correctly and the test should be stopped immediately. To
check the indicator, perform the following:
2 4 7
15
6 10 20
1
°F
1/2 176
140 212
E F RPM X 100 104 248
80
3
5 25 40
60
°C
100
120
r/min
30
0000000
5
OU2351
A. Slow Pivot Mode

1. Test Stabil-Trak system with vehicle on a level surface and boom fully retracted,
no load.
2. Depress service brake pedal (5) and shift transmission into forward (6).
3. Raise the boom above 40° (2). Release service brake pedal.
4. Stabil-Trak system slow pivot mode will be activated and indicator (4) will
illuminate.
5. Depress service brake pedal and lower boom below 40° (1).
B. Locked Mode
1. Test Stabil-Trak system with vehicle on a level surface and boom fully retracted,
no load.
2. Depress service brake pedal and shift transmission to neutral.
3. Raise boom above 40°. Release service brake pedal.
4. Stabil-Trak system locked mode will be activated and indicator (7) will illuminate.
31200354 8-1
5. Depress service brake pedal and lower boom below 40°.
6. Depress service brake pedal (5) and shift transmission into forward.
7. Raise the boom above 40°.
9. Lower boom below 40°.
10. Engage park brake switch (3).
11. Release service brake pedal.
12. Raise the boom above 40°.
14. Lower boom below 40°.
8-2 31200354
SECTION 9 - SPECIFICATIONS
9.1 PRODUCT SPECIFICATIONS
Capacities
Engine Crankcase Oil

Capacity with Filter Change
Before S/N 0160041827 excluding 0160041630 .................... 10.6 quart (10 liter)
S/N 0160041827 & After including 0160041630 ................. 13.5 quart (12.8 liter)
Type of Oil ................................................................................................ 15W-40 CH
Fuel Tank
Capacity ....................................................................................... 45 gallon (171 liter)
Type of Fuel.................................................................................................. #2 Diesel
Cooling System
System Capacity
Before S/N 0160041827 excluding 0160041630 .................. 3.6 gallon (13,8 liter)
S/N 0160041827 & After including 0160041630 .................. 7.7 gallon (29.1 liter)
Overflow Bottle Capacity

(Before S/N 0160041827 excluding 0160041630) ........................... 3.2 quart (3 liter)
Type of Coolant ............................................................ 50/50 ethylene glycol & water
Hydraulic System
System Capacity .......................................................................... 50 gallon (190 liter)
Reservoir Capacity to Full Mark ................................................... 34 gallon (127 liter)
Type of Oil ...................................................... Mobilfluid® 424 Tractor Hydraulic Fluid
Transmission
Capacity with Filter Change
Before S/N 0160041827 excluding 0160041630 ..................... 4.0 gallon (15 liter)
S/N 0160041827 & After including 0160041630 ..................... 4.2 gallon (16 liter)
Type of Fluid ................................................... Mobilfluid® 424 Tractor Hydraulic Fluid
31200354 9-1
Axles
Differential Housing Capacity
644E-42
Before S/N 0160039830 excluding S/N 0160036724, 0160036811,
0160036907 & 0160037012............................................... 9.5 quart (9,0 liter)
S/N 0160039830 & After including S/N 0160036724, 0160036811,
0160036907 & 0160037012
Front Axle ................................................................. 12.5 quart (11,8 liter)
Rear Axle ................................................................. 12.7 quart (12,0 liter)
944E-42
Before S/N 0160040124 excluding 0160034634, 0160036710,
0160036722, 0160036735 & 0160036738
Front Axle .................................................................... 10.6 quart (10 liter)
Rear Axle ..................................................................... 9.5 quart (9,0 liter)
S/N 0160040124 & After including 0160034634, 0160036710,
0160036722, 0160036735 & 0160036738
Front ......................................................................... 12.7 quart (12,0 liter)
Rear Axle ................................................................. 12.5 quart (11,8 liter)
Wheel End Capacity

644E-42
Before S/N 0160039830 excluding S/N 0160036724, 0160036811,
0160036907 & 0160037012............................................... 1.7 quart (1,6 liter)
S/N 0160039830 & After including S/N 0160036724, 0160036811,
0160036907 & 0160037012............................................... 2.3 quart (2,2 liter)
944E-42
Before S/N 0160040124 excluding 0160034634, 0160036710,
0160036722, 0160036735 & 0160036738
Front Axle ..................................................................... 1.3 quart (1,2 liter)
S/N 0160040124 thru 0160041826 including 0160034634, 0160036710,
0160036722, 0160036735 & 0160036738, excluding 0160041630
Type of Fluid ................................................... Mobilfluid® 424 Tractor Hydraulic Fluid
9-2 31200354
Tires
644E-42
13.00 x 24, G-2/L-2 Bias Ply Traction - 12 ply
Pneumatic......................................................................................65 psi (4,5 bar)
Foam .................................................................................Approx 542 lb (246 kg)
13.00 x 24, G-3/L-3 Bias Ply Rock - 12 Ply
Foam .................................................................................Approx 542 lb (246 kg)
13.00 x 24, G-2/L-2 Radial - 1 Star
Foam .................................................................................Approx 542 lb (246 kg)
370/75-28, 14 Ply
Foam .................................................................................Approx 464 lb (210 kg)
944E-42
15.50 x 25, G-2/L-2 Bias Ply Traction - 12 Ply
Foam .................................................................................Approx 600 lb (272 kg)
15.50 x 25, G-3/L-3 Bias Ply Rock - 12 Ply
Foam .................................................................................Approx 600 lb (272 kg)
15.50 x 25, G-2/L-2 Radial - 1 Star
Foam .................................................................................Approx 600 lb (272 kg)
370/75-28, 14 Ply
Foam .................................................................................Approx 464 lb (210 kg)
Wheel Lug Nut

Torque ..............................................................................430-470 lb-ft (583-637 Nm)
31200354 9-3
Performance
Maximum Lift Capacity

644E-42
Transfer Carriage Fully Retracted .......................................6,000 lb (2722 kg)
Transfer Carriage Extended ................................................4,000 lb (1814 kg)
944E-42
Maximum Lift Height.............................................................................. 42 ft (12,8 m)
Capacity at Maximum Height

644E-42
944E-42
Maximum Forward Reach

Transfer Carriage Fully Retracted ...................................................... 29 ft (8,8 m)
Transfer Carriage Extended .......................................................... 35.6 ft (10,9 m)
Capacity at Maximum Forward Reach

644E-42
Transfer Carriage Fully Retracted .........................................1,500 lb (680 kg)
Transfer Carriage Extended .....................................................300 lb (136 kg)
944E-42
Transfer Carriage Fully Retracted .........................................2,000 lb (907 kg)
Transfer Carriage Extended .....................................................500 lb (227 kg)
Reach at Maximum Height

Transfer Carriage Fully Retracted ..................................................... 6.6 ft (2,0 m)
Transfer Carriage Extended ............................................................ 13.2 ft (4,0 m)
Horizontal Load Placement Distance ....................................................80 in (2.03 m)
Maximum Travel Speed .....................................................................20 mph (32 kph)
Towing Capacity
644E-42 ....................................................................................6,000 lb (2722 kg)
944E-42 ....................................................................................9,000 lb (4082 kg)
Frame Leveling ..........................................................................................12 degrees
Maximum Travel Grade

Gradeability.....................................................................................................45%
Side Slope ...................................................................................................8.75%
9-4 31200354
Dimensions
Overall Height.................................................................................95.5 in (2426 mm)
Overall Width.....................................................................................99 in (2489 mm)
Track Width........................................................................................84 in (2134 mm)
Wheelbase ......................................................................................131 in (3327 mm)
Overall Length (less Forks) .............................................................253 in (6426 mm)
Ground Clearance ...............................................................................16 in (406 mm)
Outside Turning Radius

644E-42 .....................................................................................147 in (3734 mm)
944E-42 .....................................................................................150 in (3810 mm)
Maximum Gross Vehicle Weight (no attachment)

644E-42 ............................................................................... 26,655 lb (12.091 kg)
944E-42 ............................................................................... 29,665 lb (13.456 kg)
Maximum Front Axle Weight (no attachment) (boom level and fully retracted)
644E-42 .................................................................................. 10,129 lb (4594 kg)
944E-42 .................................................................................. 10,976 lb (4979 kg)
Maximum Rear Axle Weight (no attachment) (boom level and fully retracted)
644E-42 .................................................................................. 16,526 lb (7496 kg)
944E-42 .................................................................................. 18,689 lb (8477 kg)
Maximum Ground Bearing Pressure

644E-42
13.00 x 24
Air Filled ................................................................ 144 lb/in² (10,1 kg/cm²)
Foam Filled ........................................................... 183 lb/in² (12,9 kg/cm²)
370/75-28
Air Filled .................................................................... 92 lb/in² (6,5 kg/cm²)
Foam Filled ............................................................. 118 lb/in² (8,3 kg/cm²)
944E-42
15.50 x 25
Air Filled ................................................................ 157 lb/in² (11,0 kg/cm²)
Foam Filled ........................................................... 200 lb/in² (14,1 kg/cm²)
370/75-28
Air Filled .................................................................... 94 lb/in² (6,6 kg/cm²)
Foam Filled ............................................................. 122 lb/in² (8,6 kg/cm²)
31200354 9-5
9-6 31200354
Index
Index
A Disengaging a Suspended Load.....4-10
Accessory Control Lever ................ 3-17 Driving Hazards on Slopes ...............1-9
Additional Checks............................. 8-1 Dual Fork Positioning Carriage .......5-20
Adjusting/Moving Forks .................. 5-13
E
Air Filter .......................................... 7-20
Electrical Hazards .............................1-2
Attachment Tilt Function................. 3-12
Emergency Exit from
Attachments Enclosed Cab....................................6-2
Approved..................................... 5-1
Emergency Lowering of Boom..........6-2
Installation................................. 5-10
JLG Supplied .............................. 5-2 Emergency Procedures ....................6-1
Operation .................................. 5-14 Engine
Unapproved ................................ 5-1 Normal Operation ........................4-4
Auxiliary Hydraulic Function ........... 3-12 Starting ........................................4-1
Engine Coolant Level......................7-12
B
Engine Oil Level..............................7-10
Battery ............................................ 7-18
Bucket ............................................ 5-28 F
Fall Hazard......................................1-12
C
Fork Mounted Hook ........................5-24
Capacities
Frame Level Joystick ......................3-16
Axles ........................................... 9-2
Cooling System........................... 9-1 Front Joystick..................................3-12
Engine Oil ................................... 9-1 Fuel Level .........................................7-8
Fuel Tank .................................... 9-1 Fuel/Water Separator........................7-9
Hydraulic System ........................ 9-1
Transmission............................... 9-1 G
Capacity ........................................... 5-4 General Maintenance........................7-2
Capacity Chart Grapple Bucket ...............................5-30
Example ...................................... 5-8
Sample........................................ 5-6 H
Capacity Indicator Locations ............ 5-5 Hazard Classification System ...........1-1
Carriage w/Forks ............................ 5-15 Hydraulic Oil Level ..........................7-11
Chemical Hazards .......................... 1-13 Hydraulic Operated Attachment......5-12
Cold Weather Starting Aids .............. 4-2
I
Controls ............................................ 3-2
Ignition ..............................................3-8
D Indicator
Dash Panel....................................... 3-6 Boom Angle ...............................3-22
Boom Extension ........................3-22
Decals .............................................. 2-3
Transfer Carriage Extension......3-22
Dimensions....................................... 9-5
Instrument Panel...............................3-4
Disengaging a Load ......................... 4-7
31200354 1
Index
L Service and Maintenance Schedule
Leveling Procedure.................... 4-6, 4-9 10 Hour ........................................7-3
1000 Hour ....................................7-5
Lifting Personnel............................... 1-8 1st 100 Hour ................................7-4
Load Falling Hazard ......................... 1-7 1st 500 Hour ................................7-4
Lubrication and Maintenance ........... 7-1 2000 Hour ....................................7-5
250 Hour ......................................7-4
Lubrication Schedule
50 Hour ........................................7-3
50 Hour ....................................... 7-6
500 Hour ......................................7-5
M Shut-Down Procedure.......................4-4
Mast Carriage ................................. 5-22 Side Tilt Carriage ............................5-16
Middle Joystick ............................... 3-13 Single Joystick ................................3-14
Specifications ....................................9-1
O
Stabil-Trak System..........................3-19
Operating with a Non-Suspended Test..............................................8-1
Load.................................................. 4-5
Steer Modes....................................3-18
Operating with a Suspended Load ... 4-8
Swing Carriage................................5-18
Operation.......................................... 4-1
Operational Check.......................... 2-12 T
Operator Cab.................................. 2-13 Tip Over Hazard................................1-3
Operator Maintenance Instructions .. 7-8 Tires ........................................ 7-14, 9-3
Operator Seat ................................. 3-20 Air Pressure ...............................7-14
Damage .....................................7-14
P Replacement..............................7-15
Park Brake........................................ 3-9 Towing...............................................6-1
Parking Procedure............................ 3-9 Transfer Carriage Function .............3-12
Performance ..................................... 9-4 Transmission Control Lever
Direction of Travel......................3-10
Personnel Work Platform................ 5-32
Gear Selection ...........................3-11
Picking Up a Load ............................ 4-5
Transmission Oil Level....................7-17
Picking Up a Suspended Load ......... 4-8
Transport
Pinch Points and Crush Hazards.... 1-10 Lifting .........................................4-12
Placing a Load.................................. 4-7 Tiedown .....................................4-11
Placing a Suspended Load............. 4-10 Transporting a Load ..........................4-6
Pre-Operation Check and Transporting a Suspended Load.......4-9
Inspection ......................................... 2-1 Travel Hazard....................................1-6
Truss Boom.....................................5-26
S
Safety Decals ................................... 2-3
Safety Practices................................ 1-1
Safety Signal Words ......................... 1-1
Seat Belt ......................................... 3-21
2 31200354
Index
W
Walk-Around Inspection ................. 2-10
Warm-Up Check............................. 2-12
Wheel Installation ........................... 7-16
Wheel Lug Nut.................................. 9-3
Wheel Replacement ....................... 7-15
Windows......................................... 2-14
31200354 3
Index
4 31200354
Serial Number ______________________________
Date Comments
Date Comments
TRANSFER OF OWNERSHIP
To Product Owner:
If you now own but ARE NOT the original purchaser of the product covered by this
manual, we would like to know who you are. 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.
Please use this form to provide JLG with updated information with regard to the
current ownership of JLG products. Please return completed form to the JLG Product
Safety & Reliability Department via facsimile or mail to address as specified below.
Thank You,
Product Safety & Reliability Department
13224 Fountainhead Plaza
Hagerstown, MD 21742
USA
Telephone: +1-717-485-6591
Fax: +1-301-745-3713
NOTE: Leased or rented units should not be included on this form.
Mfg. Model: _______________________________________________________________
Serial Number: ____________________________________________________________
Previous Owner: ___________________________________________________________
Address: _________________________________________________________________
_________________________________________________________________________
Country: _________________________ Telephone: (_______) ____________________
Date of Transfer: _________________________________
Current Owner: ____________________________________________________________
Address: _________________________________________________________________
_________________________________________________________________________
Country: _________________________ Telephone: (_______) ____________________
Who in your organization should we notify?
Name: ___________________________________________________________________
Title: _____________________________________________________________________
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.
OY1120 OY1130 OY1140
RAISE BOOM - With either arm LOWER BOOM - With either arm MOVE SLOWLY - Place one hand
extended horizontally, fingers extended horizontally, fingers motionless in front of hand giving
closed, point thumb upward. closed, point thumb downward. motion signal. (Raise load slowly
shown)
OY1150 OY1160 OY1170
EXTEND BOOM - With both RETRACT BOOM - With both THIS FAR TO GO - With hands
hands clenched, point thumbs hands clenched, point thumbs raised and open inward, move
outward. inward. hands laterally, indicating distance
to go.
OY1180 OY1190
TILT FORKS UP - With one arm TILT FORKS DOWN - With one
held at side, extend other arm arm held at side, extend other arm
upward at about 45 degrees. downward at about 45 degrees.
Special Signals - When signals for auxiliary equipment functions or conditions not
covered are required, they shall be agreed upon in advance by the operator and
signalman.
31200354

1 JLG Drive
McConnellsburg PA. 17233-9533
USA
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 Bentley Avenue
Port Macquarie 13347-404 Indaiatuba - SP Middleton
N.S.W. 2444 Brazil Greater Manchester
Australia Phone: +55 19 3936 8870 M24 2GP - England
Phone: +61 265 811 111 Fax: +55 19 3935 2312 Phone: +44 (0)161 654 1000
Fax: +61 265 810 122 Fax: +44 (0)161 654 1001
JLG France SAS JLG Deutschland GmbH JLG Equipment Services Ltd.
Z.I. de Baulieu Max-Planck-Str. 21 Rm 1107 Landmark North
47400 Fauillet D - 27721 Ritterhude-lhlpohl 39 Lung Sum Avenue
France Germany Sheung Shui N.T.
Phone: +33 (0)5 53 88 31 70 Phone: +49 (0)421 69 350 20 Hong Kong
Fax: +33 (0)5 53 88 31 79 Fax: +49 (0)421 69 350 45 Phone: +852 2639 5783
Fax: +852 2639 5797
JLG Industries (Italia) s.r.l. JLG Europe B.V. JLG Polska

Via Po. 22 Polaris Avenue 63 UI. Krolewska
20010 Pregnana Milanese - MI 2132 JH Hoofddorp 00-060 Warsawa
Italy The Netherlands Poland
Phone: +39 029 359 5210 Phone: +31 (0)23 565 5665 Phone: +48 (0)914 320 245
Fax: +39 029 359 5845 Fax: +31 (0)23 557 2493 Fax: +48 (0)914 358 200
Plataformas Elevadoras JLG Sverige AB

JLG Iberica, S.L. Enkopingsvagen 150
Trapadella, 2 Box 704
P.I. Castellbisbal Sur SE - 176 27 Jarfalla
08755Castellbisbal, Barcelona Sweden
Spain Phone: +46 (0)850 659 500
Phone: +34 93 772 4 700 Fax: +46 (0)850 659 534
Fax: +34 93 771 1762
www.jlg.com

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Operation & Safety

An Oshkosh Corporation Company

Read This First

Any modification to this machine must be approved by JLG.

or Your Local JLG Office

Other Publications Available

Note: The following standards may be referenced in this manual:

Safety Alert System and Safety Signal Words

DANGER indicates an imminently hazardous situation which, if not avoided, will

WARNING indicates a potentially hazardous situation which, if not avoided, could

CAUTION indicates a potentiality hazardous situation which, if not avoided, may

1.2 GENERAL PRECAUTIONS

1.3 OPERATION SAFETY

• DO NOT level machine with boom/attachment above 4 ft (1,2 m).

• Always wear the seat belt.

If the telehandler starts to tip over:

• DO NOT drive with boom raised.

• Tether suspended loads to restrict movement.

2-Wheel Front Steer 4-Wheel Circle Steer 4-Wheel Crab Steer

• Never suspend load from forks or other parts of carriage.

• DO NOT drive machine from cab when personnel are in platform.

To maintain sufficient traction and braking capabilities, travel on slopes as follows:

Stay clear of pinch points and rotating parts on the telehandler.

• Stay clear of moving parts while engine is running.

• Keep clear of steering tires and frame or other objects.

• Keep clear from under boom.

• Keep clear of boom holes.

• Keep arms and hands clear of attachment tilt cylinder.

• Keep hands and fingers clear of carriage and forks.

• Keep others away while operating.

This Page Intentionally Left Blank

2.2 SAFETY DECALS

Before S/N 0160041827 excluding 0160041630

only in a compliant with personnel in

Keep clear of fan and belts

MOVING PARTS can entangle.

EXPLOSIVE GASES can

Keep sparks, flames

VIEW OF ENGINE COMPARTMENT

E F RPM X 100 104 248

VIEW INSIDE CAB

must read and understand Fasten

VIEW OF DECALS LOCATED INSIDE

4105262 1706300 1706768

1706302 1706302 1706302 1706302

BOTTOM VIEW OF BOOM

UNDERSIDE VIEW OF 4110349

This Page Intentionally Left Blank

2.3 WALK-AROUND INSPECTION

2.4 WARM-UP AND OPERATIONAL CHECKS

During warm-up period, check:

When engine warms, perform an operational check:

2.5 OPERATOR CAB

Cab Door Window (if equipped)

• Cab door (1) must be closed during operation.

1. Fuel Gauge: Indicates amount of fuel in fuel tank.

3. Park Brake Switch: See page 3-9.

Heater and Air Conditioning Controls (if equipped)

• In the "RUN" position, voltage is available for all electrical functions.

1. Using service brake, stop telehandler in an appropriate parking area.

Direction of Travel Selection

Transmission control lever (1) engages forward or reverse travel.

The middle joystick (3) controls boom functions.