(Operación I-31200352-2007.02-Sn0160029593 ) SKT 8042'10042'10054

Operation & Safety
Manual
Keep this manual with machine at all times.
Models
8042, 10042
& 10054
S/N 0160029593 & After
31200352
Original
February 21, 2007
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
February 21, 2007 - A - Original Issue of Manual
31200352 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 material handler:
• This Operation & Safety Manual
• Telehandler Safety Manual
• 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 31200352
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.
1 JLG Drive
McConnellsburg, PA 17233
USA
or Your Local JLG Office

(Addresses on back cover)
In USA:
Toll Free: 877-JLG-SAFE (877-554-7233)
Outside USA:
Phone: 717-485-5161 or 717-485-6591
E-mail: ProductSafety@JLG.com
Other Publications Available
Service Manual .............................................................31200353

Illustrated Parts Manual...................................................8990395
31200352 c
Read This First
This Page Intentionally Left Blank
d 31200352
Table of Contents
Table of Contents
TABLE OF CONTENTS
Revision Log
Read This First
Operator Qualifications ...................................................... b
Modifications ...................................................................... b
Other Publications Available .............................................. c
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
2.3 Walk-Around Inspection.......................................................2-6
2.4 Warm-Up and Operational Checks ......................................2-8
Warm-Up Check .............................................................2-8
Operational Check ..........................................................2-8
2.5 Operator Cab .......................................................................2-9
2.6 Windows ............................................................................2-10
Cab Door Window (if equipped) ....................................2-10
Section 3 - Controls and Indicators
3.1 General ................................................................................3-1
3.2 Controls ...............................................................................3-2
Dash Controls and Indicators..........................................3-3
Instrument Cluster...........................................................3-4
Engine Function Indicators .............................................3-5
Ignition ............................................................................3-6
Park Brake ......................................................................3-7
Parking Procedure ..........................................................3-7
Transmission Control Lever ............................................3-8
31200352 i
Table of Contents
Boom Joystick .............................................................. 3-10
Middle Joystick ............................................................. 3-11
Auxiliary Hydraulic Joystick .......................................... 3-12
Outrigger Control Switches (10042 & 10054 only) ....... 3-13
Accessory Control Lever (if equipped) ......................... 3-14
3.3 Steer Modes ...................................................................... 3-15
3.4 Stabil-TRAK™ System ...................................................... 3-16
Free Pivot Mode ........................................................... 3-16
Slow Pivot Mode........................................................... 3-16
Locked Mode ................................................................ 3-16
3.5 Boom/Outrigger Interlock System (10054 only) ................ 3-17
Extend Interlock Mode.................................................. 3-17
Outrigger Interlock Mode .............................................. 3-17
3.6 Operator Seat.................................................................... 3-18
Adjustments.................................................................. 3-18
Seat Belt ....................................................................... 3-19
3.7 Boom Angle and Extension Indicators .............................. 3-20
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 Load ......................................................... 4-5
Lift Load Safely............................................................... 4-5
Picking Up a Load .......................................................... 4-5
Transporting the Load .................................................... 4-6
Leveling Procedure......................................................... 4-6
Placing the Load............................................................. 4-7
Disengaging the Load..................................................... 4-7
4.3 Loading and Securing for Transport.................................... 4-8
Tiedown .......................................................................... 4-8
Lifting .............................................................................. 4-9
Section 5 - Attachments
5.1 Approved Attachments ........................................................ 5-1
5.2 Unapproved Attachments.................................................... 5-1
5.3 Telehandler/Attachment/Fork Capacity ............................... 5-2
5.4 Use of the Capacity Chart ................................................... 5-3
Capacity Indicator Locations .......................................... 5-3
Sample Capacity Chart................................................... 5-4
Example.......................................................................... 5-6
5.5 Attachment Installation ........................................................ 5-7
ii 31200352
Table of Contents
5.6 Adjusting/Moving Forks........................................................5-8
5.7 Attachment Operation ..........................................................5-8
Carriage w/Forks.............................................................5-9
Crane Hook...................................................................5-10
Bucket ...........................................................................5-12
Truss Boom...................................................................5-14
Swing Carriage .............................................................5-16
Auger ............................................................................5-18
Sweeper........................................................................5-20
Side Tilt Carriage ..........................................................5-22
Personnel Work Platform ..............................................5-24
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 Lower 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 Schedules...................................7-3
10 & 1st 50 Hour Maintenance Schedule .......................7-3
50, 250 & 500 Hour Maintenance Schedule ...................7-4
1000 & 2000 Hour Maintenance Schedule .....................7-5
7.4 Lubrication Schedules .........................................................7-6
50 Hour Lubrication Schedule for 8042 & 10042 ............7-6
50 Hour Lubrication Schedule for 10054 ........................7-7
250 Hour Lubrication Schedule.......................................7-8
1000 Hour Lubrication Schedule.....................................7-9
7.5 Operator Maintenance Instructions....................................7-10
Fuel System ..................................................................7-10
Air Intake System ..........................................................7-12
Engine Oil .....................................................................7-14
Hydraulic Oil..................................................................7-15
Tires ..............................................................................7-16
Engine Cooling System.................................................7-19
Transmission.................................................................7-20
Battery...........................................................................7-21
Section 8 - Additional Checks
8.1 Stabil-TRAK™ .....................................................................8-1
8.2 Boom/Outrigger Interlock .....................................................8-2
31200352 iii
Table of Contents
Section 9 - Specifications
9.1 Product Specifications......................................................... 9-1
Fluid and Lubrication Capacities .................................... 9-1
Tires................................................................................ 9-2
Performance ................................................................... 9-3
Dimensions..................................................................... 9-4
Index
Inspection, Maintenance and Repair Log
iv 31200352
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 OW0020
WARNING indicates a potentially hazardous situation which, if not avoided, could

result in death or serious injury.
CAUTION OW0030
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 & 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.
31200352 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.
1-2 31200352
Tip Over Hazard
OW0050
• Never use an attachment without the appropriate JLG supplied capacity chart
installed on the telehandler.
• DO NOT exceed rated lift capacity.
• Be sure that the ground conditions are able to support the machine.
OW0060
• DO NOT drive with boom raised.

• When driving in high speed, use only front wheel steer (if steering modes are
selectable).
OW0080
• DO NOT raise boom unless frame is level (0 degrees).
31200352 1-3
4 FT
(1,2 M)
OW0100
• DO NOT level machine with boom/attachment above 4 ft (1,2 m).
OW0150
• Carry load as low as possible. Tether suspended loads to restrict movement.

• Understand how to properly use the capacity charts located in cab (see
page 5-3).
• Weight of all rigging (slings, etc.) must be included as part of load.
• Start, travel, turn and stop slowly to prevent load from swinging.
• 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.
1-4 31200352
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
Trying to escape from a tipping machine could result in death or serious injury.
31200352 1-5
Travel Hazard
4-Wheel Steer Pivot Steer OW0120
• Steering characteristics differ between 4-Wheel Steer & Pivot Steer telehandlers
as shown above. Identify the telehandler you are operating & others on the
jobsite.
• Ensure that adequate clearance is provided between both rear tail swing and
front fork swing.
• Unlike a conventional 4-wheel steer telehandler the rear wheels of a pivot steer
telehandler turn a wider circle than the front wheels.
• 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.
1-6 31200352
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.
31200352 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 31200352
Driving Hazards on Slopes
OW0200
To maintain sufficient traction and braking capabilities, travel on slopes as follows:

• When unloaded, the rear of the machine is the “heavy end.” Drive with forks
pointed downhill.
• When loaded, the front of the machine is the “heavy end.” Drive with the forks
pointed uphill.
• 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.
31200352 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 31200352
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.
31200352 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 4-4 has been
performed.
OW0290
• DO NOT carry riders. Riders could fall off machine causing death or serious
injury.
1-12 31200352
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.
31200352 1-13
1-14 31200352
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. Failure to comply could result in death or serious
injury.
The pre-operation check & 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 and Safety Manual and AEM
Safety Manual are located in cab manual holder.
5. Walk-Around Inspection - See page 2-6 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 load charts are installed on the
telehandler. If provided, reference the Operation and Safety Manual of each
attachment or accessory installed for specific inspection, operation and
maintenance instructions.
31200352 2-1
8. Operational Check - Once the walk-around inspection is complete, perform a
warm-up and operational check (see page 2-8) 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 31200352
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.
4108991 4110137
4110188 4110187
DANGER
AVOID CRUSHING
4110188
1. Read operator's manual
before operating. 3. Allow no riders. if vehicle tips.
Jumping can
result in death
4. Use a compliant or serious
2. Fasten seat belt. work platform to lift injury.
or lower personnel.
DO NOT JUMP.
Brace yourself.
Stay in cab.
Keep seat belt on.
LOAD CHARTS
1
2
4110188 3
FOR SKYTRAK MANUFACTURED

CAPACITY CHARTS
WARNING
ATTACHMENTS ONLY
4
AVOID
CRUSHING,
falling off
vehicle can
cause death
or serious
injury
4110437R
Allow no riders
4107462
91404299
ANGUS-PALM 005413
OH3760
VIEW INSIDE CAB
31200352 2-3
4110389
4105262
4107442
B B
1706300 4110226
VIEW A-A
A
C
4110184 4110226
1706300
VIEW C-C
VIEW B-B
1705884
4110172 4110226 OH3770
2-4 31200352
D
E E
F
D
Sky Trak
8042
Sky Trak
10
2/
1706300
LB-FT
(Nm)
50
2
50
2
2 2
250
2
500
1000
4110217
4110217 (8042)
2000
4110339
4110186 (10042) 4110339

4110218 (10054)
VIEW D-D
4100181 4105171
4108302
4100181 4105171
4108302
VIEW E-E
OH4370
VIEW F-F
31200352 2-5
2.3 WALK-AROUND INSPECTION
17
2
16
1
3 15
4 14
5
13
7 12
8 11
10
9
OH3780
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 & Lift, Tilt, Extend/Retract, Compensating (Slave) Cylinders -
• Check front, top, side & rear slider pads for adequate grease.
• Pivot pins secure; hydraulic hoses undamaged, not leaking.
• Check extend/retract chains and adjustment blocks for adequate tension.
2. Left Outrigger (if equipped) - Pins secure; hydraulic hoses and cylinder
undamaged, not leaking.
2-6 31200352
3. Front Axle - Steer cylinders undamaged, not leaking; pivot pins secure;
hydraulic hoses undamaged, not leaking.
4. Wheel/Tire Assembly - Properly inflated and secured; no loose or missing lug
nuts. Inspect for worn tread, cuts, tears or other discrepancies.
5. Mirrors - Clean and undamaged.
6. Cab & 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.
8. Stabil-TRAK Cylinder - Pins secure; hydraulic hoses undamaged, not leaking.
9. Engine Compartment -
• Drive belts, check condition and replace as required.
• Battery cables tight, no visible damage or corrosion.
• Engine cover properly secured.
10. Air Cleaner - Air cleaner element condition indicator, check for clogged
condition. Replace element as required.
11. Rear Axle - Steer cylinders undamaged, not leaking; pivot pins secure;
hydraulic hoses undamaged, not leaking.
13. Main Control Valve - See Inspection Note.
15. Sway Cylinder - Pins secure; hydraulic hoses undamaged, not leaking.
16. Right Outrigger (if equipped) - Pins secure; hydraulic hoses and cylinder
undamaged, not leaking.
17. Attachment - Properly installed, see “Attachment Installation” on page 5-7.
31200352 2-7
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 covers closed while engine is running
except when checking transmission oil level. Failure to comply could result in
death or serious injury.
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.
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.
2-8 31200352
2.5 OPERATOR CAB

The telehandler is equipped with a standard open ROPS/FOPS cab. An optional
enclosed ROPS/FOPS cab is available.
WARNING
CRUSH HAZARD. Never operate telehandler unless the overhead guard and cab
structure 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 damaged, the CAB CANNOT BE REPAIRED. It
must be REPLACED. Failure to comply could result in death or serious injury.
31200352 2-9
2.6 WINDOWS
Keep all windows and mirrors clean and unobstructed.
Cab Door Window (if equipped)
OH4280
• During operation the window must either be latched open or closed.

• Open the cab door window (1) and secure it in the latch.
• Press the release button (2) inside the cab or pull on the lever (3) outside the cab
to unlatch the window.
2-10 31200352
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.
CAUTION
EQUIPMENT DAMAGE. When a red light illuminates, immediately bring machine
to a stop, lower boom and attachment to ground and stop the engine. Determine
cause and correct before continued use.
31200352 3-1
3.2 CONTROLS
3 4
5
2
6 7
1 8
9 10
13
12 11
OH3790
1. Transmission Control Lever: See page 3-8.

2. Left Hand Instrument Panel: See page 3-3.
3. Steering Wheel: Turning the steering wheel to the left or right steers the
machine in the corresponding direction. Three steering modes are available.
See “Steer Modes” on page 3-15.
4. Horn: Depress button to sound horn.
5. Right Hand Instrument Panel: See page 3-3.
6. Accessory Control Lever (if equipped): See page 3-14.
7. Boom Joystick: See page 3-10.
8. Middle Joystick: See page 3-11.
9. Outrigger Control Switches (10042 & 10054 only): See page 3-13.
10. Auxiliary Control Joystick: See page 3-12.
11. Accelerator Pedal: Pressing down the pedal increases engine and hydraulic
speed.
Accelerator pedal also used to activate Cummins ECM diagnostic system. See
Service manual for details.
12. 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.
13. Ignition Switch: Key Activated. See page 3-6.
3-2 31200352
Dash Controls and Indicators
3 4 5 6
7 8 9 10 11
13 12
14 OH3800
1. Park Brake Switch: See page 3-7 for details.

2. Frame Level Indicator: Enables the operator to determine the left to right level
condition of the telehandler.
3. Emergency Flasher Switch: On/Off switch.
4. Worklight Switch (if equipped): Three position switch. Push top of switch to turn
all worklights on. Move switch to middle position to turn on front and boom
worklights. Push bottom of switch to off all worklights.
5. Engine Air-Intake Heater Indicator (if equipped): Illuminates with ignition key in
the “RUN” position. Light goes out when start temperature is reached. At
temperatures below 40° F (4° C), do not start until light goes out.
6. Engine Function Indicator Lights: See page 3-5 for details.
7. Windshield Wiper Switch (if equipped): Three position switch. Push bottom of
switch to operate wiper at high speed. Move switch to middle position to operate
wiper at low speed. Push top of switch to turn wiper off.
8. Skylight Wiper Switch (if equipped): On/Off switch.
9. Windshield & Skylight Washer Switch (if equipped): Push and hold bottom of
switch to activate windshield & skylight washer.
10. Steer Select Switch: Three positions: 4-wheel circle steer, 4-wheel crab steer
and 2-wheel steer. See page 3-15 for details.
11. Beacon Light Switch (if equipped): On/Off switch.
12. Temperature Control Switch (if equipped): Adjustable rotary switch.
13. Fan Speed Switch (if equipped): Four-position rotary switch.
14. Instrument Cluster: See page 3-4 for details.
31200352 3-3
Instrument Cluster
6
5 7
4 P 8
3 9
2 0000 00
10
1 11 OH3910
1. Hourmeter: Records and indicates engine operating hours.

2. Stabil-TRAK Indicator: Illuminates when Stabil-TRAK system has been
activated.
3. Transmission Temperature Indicator: Illuminates when transmission oil
temperature is too high. Stop and idle engine with transmission in neutral,
allowing time for cooling. If light remains on, shut-down engine.
4. Engine Coolant Temperature Indicator: Illuminates when engine coolant
temperature is too high. Stop and idle engine, allowing time to cool and shut-
down.
5. Park Brake Indicator: Illuminates when park brake is applied. See page 3-7
6. Battery Charge Indicator: Illuminates to indicate batteries at low charge or a
weak or improperly functioning charging system.
7. Engine Oil Pressure Indicator: Illuminates when engine oil pressure is too low.
Shut-down engine immediately.
8. Hydraulic Oil Temperature Indicator: Illuminates when hydraulic oil temperature
is too high. Stop and idle engine, allowing time for cooling. If light remains on,
shut-down engine.
9. High Beam Indicator (if equipped): Illuminates while high beam lights are
activated.
10. Turn Signal Indicator (if equipped): Illuminates and flashes while turn signals
are activated in either direction or the hazard lights have been activated.
11. Fuel Gauge: Indicates amount of fuel in fuel tank.
3-4 31200352
Engine Function Indicators
1
2
OH3900
The engine function indicators (1) illuminate when any engine faults occur during
operation.
• If red indicator (2) illuminates during operation, stop the engine immediately and
diagnose the fault using the ECM diagnostic system. See Service manual for
details.
• If amber indicator (3) illuminates during operation, the diagnostic system has
detected a fault within the engine. Stop the engine and diagnose the fault using
the ECM diagnostic system. See Service manual for details.
• The indicators also flash engine fault codes. See service manual for details.
31200352 3-5
Ignition
OFF
RUN
START
OH3810
• 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.
3-6 31200352
Park Brake
1 2
OH3820
This switch controls the application and release of the park brake. Indicator light on
button 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°, switch also
activates the locked mode of the Stabil-TRAK system.
WARNING
MACHINE ROLL-AWAY HAZARD. Always move park brake switch to "ON"
position, lower boom to ground and stop engine before leaving cab. Machine
roll-away could cause death or serious injury.
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, resulting in death or serious injury. 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.
31200352 3-7
Transmission Control Lever
Direction of Travel Selection
1
OH3830
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.
• 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.
• With boom angles greater than 40°, shifting to neutral activates the locked mode
of the Stabil-TRAK system.
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. Failure to comply could result in
3-8 31200352
Gear Selection
1st
2nd
3rd
4th
2 OH3840
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.
Neutral Lock Lever
5 4
ND ND
OH4350
Neutral lock lever (3) locks transmission control lever.

• To lock the transmission control lever in the neutral position, place the
transmission control lever in the neutral position and move the neutral lock
lever to the “N” position (4).
• To unlock, move the neutral lock lever to the “D” position (5).
31200352 3-9
Boom Joystick
OH3850
The boom joystick (1) controls the 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
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. Failure to comply could result in death or
serious injury.
3-10 31200352
Middle Joystick
OH3860
The middle joystick (2) controls the attachment tilt and frame sway functions.
Attachment Tilt Functions
• Move the joystick forward to tilt down, move the joystick back to tilt up.
Frame Sway Functions

• Move the joystick left to sway frame left, move the joystick right to sway frame
right.
• A level indicator is located above the front cab window to permit 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 resulting in death or serious
injury.
31200352 3-11
Auxiliary Hydraulic Joystick
OH3870
Auxiliary Control Joystick (1) controls function of attachments that require hydraulic
supply for operation. See Section 5 - Attachments for approved attachments and
control instructions.
3-12 31200352
Outrigger Control Switches (10042 & 10054 only)
3 4
OH3880
The rear switches (2) control the outriggers.

• Use outriggers to increase stability and/or load capacity and in leveling the
telehandler. Study load charts to determine maximum load capacities, with and
without outriggers.
• The left switch controls left outrigger and the right switch controls right outrigger.
Push top of switches (4) to raise outriggers; push bottom of switches (3) to lower
outriggers.
WARNING
TIP OVER HAZARD. Outriggers increase stability and load capacity only if they
are used properly. Using outriggers on soft surfaces could cause telehandler to
tip over and result in death or serious injury. Always ensure surface can support
telehandler and load.
31200352 3-13
Accessory Control Lever (if equipped)
The accessory control lever (1) operates the turn signals, parking lights and
headlights.
5 7
4 6
3
1 OH3840
Turn Signals
• Raise the lever (2) to activate the left turn signal.
• Lower the lever (3) 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 (4) of the lever counterclockwise to the first position (5) to turn
on the parking lights.
• Turn the twist grip to the second position (6) to turn on the headlights.
• Pull lever forward to switch between low and high beam.
• Turn the twist grip clockwise to the OFF position (7) to turn all lights off.
3-14 31200352
3.3 STEER MODES

4 Wheel Crab Steer
OH3920
2-Wheel Front Steer
OH3930
4-Wheel Circle Steer
OH3940
31200352 3-15
3.4 STABIL-TRAK™ SYSTEM
1 3
0000 00
OH4290
Free Pivot Mode
With boom below 40° (1), the Stabil-TRAK system is in Free Pivot Mode. The rear
axle pivots freely and frame sway functions normally. The Stabil-TRAK indicator (3)
will be off.
Slow Pivot Mode
With boom above 40° (2), the Stabil-TRAK system is in Slow Pivot Mode when the
service brake is not applied and the transmission is in gear. The rear axle will
respond slowly to changes in terrain and frame sway functions normally. The
Stabil-TRAK indicator (3) will be off.
Locked Mode
With boom above 40° (2), and activating one or more of the following functions, the
Stabil-TRAK system is in Locked Mode.
• Park brake switch engaged.
• Transmission control lever in Neutral.
• Service brake pedal depressed.
The rear axle is locked and the frame sway functions slower than normal. The
Stabil-TRAK indicator (3) will illuminate.
3-16 31200352
3.5 BOOM/OUTRIGGER INTERLOCK SYSTEM (10054 ONLY)

The interlock system allows the boom to be extended to its maximum limits.
4 8
0000 00
OH4360
7 6
Extend Interlock Mode
With outriggers raised (6), telehandler is in extend interlock mode which limits boom
extension (5).
• The boom is limited from extending beyond a point between the “E” and “F” boom
extension indicators.
• Vehicle and Stabil-TRAK will function normally.
Outrigger Interlock Mode
With outriggers lowered (7) on firm terrain, telehandler is in outrigger interlock mode
which allows for full boom extension (4).
When outriggers are lowered shift travel select lever into neutral, move neutral lock
lever to neutral lock position and engage the parking brake.
With the outrigger interlock engaged additional systems are automatically activated.
• Stabil-TRAK is in locked mode and indicator (8) will illuminate.
• Frame sway will be slower than normal.
• Outriggers can be lowered to adjust for any changes in outrigger footing.
Boom must be retracted past the extension limit for any of these conditions to
change.
31200352 3-17
3.6 OPERATOR SEAT
Adjustments
OX0520
Prior to starting engine adjust seat for position and comfort as follows:
1. Turn the knob (1) on the front of seat to adjust the suspension. Turn the knob
clockwise to increase stiffness. Turn the knob counterclockwise to reduce
stiffness.
2. Pull up on handle (2) to move seat fore and aft.
3. Arm rest (3) can be moved up or down for comfort.
4. A two inch seat belt (4) is standard equipment. If required, an optional three
inch belt is available.
3-18 31200352
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.
31200352 3-19
3.7 BOOM ANGLE AND EXTENSION INDICATORS
2 1
OH3950
• 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 5-3).
• The 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 5-3).
3-20 31200352
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. Set parking brake.
2. If the temperature is below 40° F (4° C), turn the ignition switch to “RUN”. Wait
until the air intake heater light goes out.
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 indicator. If indicator remains
on 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 resulting in death or serious injury.
31200352 4-1
Cold Weather Starting Aids
If your telehandler is equipped with a block heater, the following applies:

• Grid heater is located inside the induction manifold.
• Grid heater is triggered by temperature sensor located on engine.
• At start-up, temperature sensor on engine will detect if grid heater is needed.
Follow normal start-up procedure.
• A second battery is added for additional cold-cranking capacity.
CAUTION
ENGINE EXPLOSION. If your telehandler is equipped with cold start aid, do not
use ether or any high energy fuels to assist starting. If machine is not equipped
with cold start aid, follow instructions listed in the engine manual supplied with the
telehandler. Failure to comply could result in death or serious injury.
4-2 31200352
Battery Boosted Starting
OW0530
If battery-boost starting (jump-start) is necessary, proceed as follows:

• Never allow vehicles to touch.
• Connect the positive (+) jumper cable to positive (+) post of discharged battery.
• 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. Failure to comply could result in death or serious injury.
31200352 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 31200352
4.2 OPERATING WITH A 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 resulting in death or serious injury.
• 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 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 5-8.
• 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’s cab for the telehandler/attachment combination you are using.
31200352 4-5
Transporting the Load
OW0540
After engaging the load and resting it against the backrest, tilt the load back to
position it for travel. Travel in accordance with the requirements set forth in Section
1 - General Safety Practices and Section 5 - Attachments.
Leveling Procedure
1. Position machine in best location to lift or place load.

2. Apply parking brake and move transmission control lever to NEUTRAL.
3. Move boom/attachment to 4 ft (1,2 m) off ground.
4. Observe level indicator to determine whether machine must be leveled prior to
lifting load.
Important things to remember:

• Never raise the boom/attachment more than 4 ft (1,2 m) above ground unless
telehandler is level.
• The combination of sway and load could cause the telehandler to tip over.
The telehandler is designed to permit swaying the main frame 10° to left or right to
compensate for uneven ground conditions.
4-6 31200352
Placing the 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 extension range. See “Use of the
Capacity Chart” on page 5-3.
• 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.
Disengaging the 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 can be retracted
and/or the telehandler can be backed away from under the load if surface will
not change level condition of telehandler.
2. Lower the carriage.
3. The telehandler can now be driven from the landing location to continue work.
31200352 4-7
4.3 LOADING AND SECURING FOR TRANSPORT
4110226 4110226
OH3970
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 tiedown
points as shown in the figure.
5. Do not tiedown 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 state or federal 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, resulting in an accident causing
4-8 31200352
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.
31200352 4-9
4-10 31200352
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 your
local distributor for further information.
5.2 UNAPPROVED ATTACHMENTS

Do not use unapproved attachments for the following reasons:
• JLG cannot establish range and capacity limitations for “will fit,” homemade,
altered, or other non-approved attachments.
• 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.
• JLG cannot assure the ability of a non-approved attachment to perform its
intended function safely.
WARNING
Use only approved attachments. Attachments which have not been approved for
use with your telehandler could cause machine damage or an accident resulting
in death or serious injury.
31200352 5-1
5.3 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 supplied capacity chart
installed on the telehandler. Failure to install the proper JLG supplied capacity
chart could cause an accident resulting in death or serious injury.
5-2 31200352
5.4 USE OF THE CAPACITY CHART

To properly use the capacity chart (see page 5-4), the operator must first determine
and/or have the following:
1. A JLG 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 EXTENSION BOOM ANGLE

INDICATOR INDICATOR
FORK
WEIGHT
STAMP
ATTACHMENT
IDENTIFICATION
PLATE
OH3960
31200352 5-3
Sample Capacity Chart
This Capacity Chart may be used with this model

ONLY. The model of your telehandler is indicated on
the boom or chassis. Model XXXXX is used for
demonstration purposes only.
xxxxx
WITH SKY TRAK MANUFACTURED
Attachment Type
STANDARD CARRIAGES ONLY
28 24 20 16 12 8 4 0 ft
44 68°
40 60° E
D Boom Extension
36 50°
32 C Indicator (arc)
8000
40° lbs
28 6 B
0 A
24 30° 4 0
0 0 10,000
20 3 0 lbs Load zones indicate the
0 0 l maximum weight that
20° 2 0 b
16
Boom Angle 5 0 l s may be safely lifted.
2 0 b
12 0 0 l s
10° 0 b
8 0 l s 24"
b
4 l s
0° b
0 ft s
-4 -8°
20 13 8 ASME B56.6 - 2002 PART lll

4110443L 22 17 10 4110443R
OH3980
These numbers must match the
model/option number stamped
on the attachment ID Plate.
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.
Failure to comply could result in death or serious injury.
5-4 31200352
To identify the proper capacity chart on telehandlers equipped with outriggers and/or
transfer carriage, refer to the following icons which may be located on the capacity
chart.
• Use when lifting a load with outriggers up.
OW0930
• Use when lifting a load with outriggers down.
OW0940
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
31200352 5-5
Example
A contractor owns a model xxxxx telehandler with a 48" Carriage. He knows this
attachment may be used with his model since:
• The attachment style 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 2500 lbs (1134 kg) 20 ft (6,1 m) 12 ft (3,6 m) Yes
2 3000 lbs (1361 kg) 22 ft (6,7 m) 20 ft (6,1 m) NO
3 6000 lbs (2722 kg) 10 ft (3,0 m) 18 ft (5,5 m) Yes
4 8500 lbs (3856 kg) 8 ft (2,4 m) 28 ft (8,5 m) NO
xxxxx
WITH SKY TRAK MANUFACTURED
STANDARD CARRIAGES ONLY
28 24 20 16 12 8 4 0 ft
44 68°
40 60° E
D
36 50°
32 C
8000
40° lbs
28 6 B
0 A
24 30° 4 0 EXAMPLE 4
0 0 10,000
20 3 0 lbs
0 0 l
EXAMPLE 2 20° 2 0 b
16
5 l s EXAMPLE 3
2 0 0 b
12 0 0 l s
10° 0 b
EXAMPLE 1 8 0 l s 24"
b
4 l s
0° b
0 ft s
-4 -8°
20 13 8 ASME B56.6 - 2002 PART lll

4110443L 22 17 10 4110443R
OH3990
Note: This is a sample capacity chart only! DO NOT use this chart, use the one
located in your operator cab.
5-6 31200352
5.5 ATTACHMENT INSTALLATION
3
1
2
OH4000
This installation procedure is designed for one-person operation.

1. Retract quick attach to provide clearance. Check to be sure quick attach pin (1)
is in out position.
2. Align quick attach pivot pin (2) with recess in attachment. Raise boom slightly to
engage attachment pivot pin in recess.
3. Engage quick attach.
4. Shut off engine. Exit cab and lift quick attach lock lever (3). Insert quick attach
pin completely. Ensure quick attach lock lever has lowered into groove on quick
attach pin.
5. If equipped, connect auxiliary hydraulic hoses.
6. If equipped, connect auxiliary electric harness.
WARNING
CRUSH HAZARD. Always be certain that carriage or attachment is properly
positioned on boom and is secured by quick attach pin and lock lever. Failure to
ensure proper installation could permit carriage/attachment/load to disengage
causing death or serious injury.
31200352 5-7
5.6 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. Refer to “Attachment Installation”
page 5-7.
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).
5.7 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.
CAUTION
EQUIPMENT DAMAGE. Some attachments may contact the front tires or
machine structure when the boom is retracted and the attachment is rotated.
Machine or attachment damage may occur from contact.
5-8 31200352
Carriage w/Forks
Description P/N
Carriage, 50 in ................................................................ 1170021
Carriage, 60 in ................................................................ 1170024
Carriage, 72 in ................................................................ 1170027
Fork, Cubing, 2x2x48 in.................................................. 2340037
OY0690
Fork, 2.36x4x48 in .......................................................... 2340045
Fork, 2.36x5x48 in .......................................................... 2340038
Fork, 2.36x6x60 in .......................................................... 2340039
Fork, Lumber, 1.75x7x60 in ............................................ 2340046
Fork, Dual Taper, 2x6x72.......................................... 1001092391
Use Carriage Attachment Capacity Chart
To determine maximum capacity, refer to “Telehandler/Attachment/Fork Capacity” on
page 5-2.
1
2
OH4010
The front joystick (1) controls lift/lower and the extend/retract movement of the
boom.
Fork Tilt Control:
The middle (2) joystick controls the frame sway and fork tilt.
• Move joystick forward to tilt down.
• Move joystick back to tilt up.
Installation Procedure:
• Refer to “Attachment Installation” on page 5-7.
31200352 5-9
Crane Hook
Description P/N
Crane Hook................................................................... 91565094
OY0640
Use Appropriate Carriage Attachment Capacity Chart

page 5-2.
Suspend loads in accordance with requirements set forth in Section

1 - General Safety Practices.
1
2
OH4020
boom.
Crane Hook Tilt Control:
The middle joystick (2) controls the frame sway and crane hook tilt.
• Secure the crane hook to the forks by sliding the crane hook onto the parent
forks and install the retaining pin behind the vertical shank of the fork.
5-10 31200352
Operation:
• Pallet or lumber forks of an appropriate load rating must be used. Do not use with
cubing or block forks.
• Weight of crane hook and rigging must be included as part of total load being
lifted.
• Do not use crane hook with attachments capable of rotating (i.e. side tilt and
swing carriages) without disabling the rotation feature(s).
31200352 5-11
Bucket
Description P/N
Bucket, 94 in - 1-1/4 yd3 ................................................. 7110744
OZ0730
Use Appropriate Bucket Capacity Chart

page 5-2.
1
2
OH4030
boom.
Bucket Tilt Control:
The middle joystick (2) controls the frame sway and bucket tilt.
5-12 31200352
Equipment Damage Precautions
• Drive into stockpile smoothly with boom fully retracted to load bucket. Loading
bucket with boom extended could damage boom or extension chains/cables. Do
not corner-load bucket.
• Do not use bucket as a lever to pry material. Excessive prying forces could
damage bucket.
• Do not use bucket for "back dragging." This could cause severe damage to quick
switch and retraction cables/chains.
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.
31200352 5-13
Truss Boom
Description P/N
Truss Boom, 3 ft w/winch ................................................7160400
Truss Boom, 12 ft, (8042) ...............................................7119700
Truss Boom, 15 ft, (10042 & 10054) ...............................7119800
OY0570
Use Truss Boom Attachment Capacity Chart

page 5-2.
Suspend loads in accordance with requirements set forth in Section

1 - General Safety Practices.
1
2
OH4050
boom.
Truss Boom Control:
The middle joystick (2) controls the frame sway and truss boom tilt.
5-14 31200352
Truss Boom W/Winch Control:
The rear joystick (3) controls the truss boom mounted winch.
• Move joystick right to lower cable.
• Move joystick left to raise cable.
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 resulting in
31200352 5-15
Swing Carriage
Description P/N
72 in, Swing Carriage .....................................................7125800
72 in, Sheet Material Handler Swing Carriage ...............7129300
OU2150
Use Swing Carriage Attachment Capacity Chart

page 5-2.
1
2
OH4061
boom.
Fork Tilt Control:
The middle joystick (2) controls the frame sway and fork tilt.
Carriage Swing Control:
The rear joystick (3) controls carriage swing.
• Move joystick right to swing right.
• Move joystick left to swing left.
5-16 31200352
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.
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
resulting in death or serious injury.
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 resulting in death or serious
injury.
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 resulting in death or serious injury.
31200352 5-17
Auger
Description P/N
Auger ........................................................................ 1001092816
OH4080

page 5-2.
1
2
OH4071
boom.
Auger Tilt Control:
The middle joystick (2) controls the frame sway and auger tilt.
Auger Bit Control:
The rear joystick (3) controls the auger bit rotation.
• Move joystick right to rotate clockwise.
• Move joystick left to rotate counter-clockwise.
5-18 31200352
Equipment Damage Precautions:

• Transport the auger unit as low as practical at a slow speed and without rapid
side to side movement.
• Do not engage auger rotation unless the point of the auger cutting head is
touching the ground.
Operation:
Practices.
31200352 5-19
Sweeper
Description P/N
Sweeper.......................................................................... 7301180
OH4090

page 5-2.
1
2
OH4101
boom.
Sweeper Tilt Control:
The middle joystick (2) controls the frame sway and bucket tilt.
Sweeper Broom Control:
The rear joystick (3) controls the broom rotation.
• Move joystick right to rotate forward.
• Move joystick left to rotate backward.
5-20 31200352
Equipment Damage Precautions:

• Keep the sweeper as low as practical when transporting or dumping.
• When sweeping close to a wall or curb, do not use side guards as wear plates or
allow hydraulic motor to contact walls or curbs.
Operation:
Practices.
• Lower sweeper so the dolly wheel is firmly on the ground, then tilt sweeper so
bristles are against the ground.
• Actuate auxiliary hydraulics to begin broom rotation and begin forward travel.
31200352 5-21
Side Tilt Carriage
Description P/N
Side Tilt, 50 in ................................................................. 7161300
Side Tilt, 60 in ................................................................. 7134500
Side Tilt, 72 in ................................................................. 7134600
OY0690
Use Side Tilt Carriage Attachment Capacity Chart

page 5-2.
1
2
OH4111
boom.
Fork Tilt Control:
The middle joystick (2) controls the frame sway and fork tilt.
Side Tilt Control:
The rear joystick (3) controls the carriage side tilt.
• Move joystick right to tilt right.
• Move joystick left to tilt left.
5-22 31200352
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 then level carriage side to side.
Practices.
31200352 5-23
Personnel Work Platform
The operator and personnel in platform must read and understand the
separate personnel work platform manual prior to installing and using a
platform.
Preparation and Setup

1. Check to ensure the personnel platform is securely attached at the Quick
Switch™ or is securely attached to the forks and/or carriage if using a fork
mounted personnel work platform. Follow installation procedure on page 5-7 for
JLG Quick Switch™ mounted personnel work platforms.
2. Ensure the telehandler is on a firm surface and is level.
3. Engage the park brake. Blocking the wheels is also recommended.
4. Level the platform, both side to side (frame sway) and front to back
(attachment tilt).
5. Keep area under the platform free from personnel.
6. When personnel are on platform, the operator must remain seated in cab with
personnel in direct line of sight.
7. DO NOT lift or carry persons in the bucket or on forks.
Never tilt the platform forward, rearward, or sway the machine when the platform is
occupied. Serious injury or death could result.
5-24 31200352
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.
• 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.
Moving Longer Distances
• If the telehandler must be moved longer distances, it must be loaded onto a

trailer of sufficient capacity.
Contact your local Authorized Distributor for specific instructions if neither of

these methods are applicable.
31200352 6-1
6.2 EMERGENCY LOWER 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 your 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

In an emergency, an escape hammer located in the roof of an enclosed cab can be
used to exit the telehandler.
ANGUS-PALM 005413
OWO740
6-2 31200352
SECTION 7 - LUBRICATION AND MAINTENANCE
7.1 INTRODUCTION
Service the product in accordance with the maintenance schedule on the following
pages.
Service intervals are based on machine usage of 1500 hours annually. Use of your
product may vary significantly and you must adjust service frequency for your usage
to obtain maximum service life.
1 2
OH4120
The maintenance chart (1) and lubrication (2) decals contain general service
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.
31200352 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.
• Drain engine and gear cases after operating when oil is hot.
• Check all lubricant levels when lubricant is cool. For ease of filling hydraulic
reservoir, use a funnel with a hose or flexible tube for best results.
Note: Be certain to check boom chain adjustment every 5 weeks or 250 hours and
adjust 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. Failure to comply could cause death or serious injury.
7-2 31200352
7.3 SERVICE AND MAINTENANCE SCHEDULES
10 & 1st 50 Hour Maintenance Schedule
EVERY
10
Drain Fuel/ Check Engine Check Engine Check Hydraulic Check Tire
Water Seprator Coolant Level Oil Level Oil Level Pressure
Air Filter Check Additional

Restriction Transmission Checks -
Indicator Oil Level Section 8
1st
50
LB/F
T (N
m)
Change Engine Change Change Check Wheel Check Boom

Oil & Filter Transmission Hydraulic Lug Nut Chain Tension
Filter Filter Torque
Change Change Wheel

Axle Oil End Oil
OH4130
31200352 7-3
50, 250 & 500 Hour Maintenance Schedule
EVERY
50
Check Boom Check Lubrication

Bearing Battery Schedule
Pads
EVERY
250
Change Engine Check Axle Check Wheel Change Air Check

Oil and Oil Level End Oil Levels Filter Fan Belt
Filter*
Check Boom Lubrication

Chain Schedule
Tension
EVERY
500
LB/F
T (N
m)
Change Fuel Check Wheel

Filter Lug Nut
Torque
OH4140
Note: Engine oil & filter service interval can be extended, see page 7-14 for details.
7-4 31200352
1000 & 2000 Hour Maintenance Schedule
EVERY
1000
Change Change Wheel Lubrication Check Boom Check Boom

Axle Oil End Oil Schedule Chain Bearing
Tension Pads
Change Change Check Check Air Check Axle

Transmission Hydraulic Fan Belt Intake System Brake Discs
Oil & Filter Fluid & Filters
Lubricate
Boom Chains
EVERY
2000
Change Check Forks

Engine Coolant
OH4150
31200352 7-5
7.4 LUBRICATION SCHEDULES
50 Hour Lubrication Schedule for 8042 & 10042
EVERY
50
OH4160
7-6 31200352
50 Hour Lubrication Schedule for 10054
EVERY
50
OH4240
31200352 7-7
250 Hour Lubrication Schedule
EVERY
250
OH4170
7-8 31200352
1000 Hour Lubrication Schedule
EVERY
1000
OH4180
31200352 7-9
7.5 OPERATOR MAINTENANCE INSTRUCTIONS
Fuel System
A. Fuel Level Check 10
0000 00
1
VIEW OF DASH
3 OH4190
VIEW OF FUEL TANK

FROM TOP OF MACHINE
1. Check fuel gauge (1) located on instrument cluster in cab.

2. If fuel is low, proceed to fuel source and perform “Shut-Down Procedure” on
page 4-4.
3. Locate fuel tank (2), turn fuel tank cap (3) to 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.
7-10 31200352
B. Drain Fuel/Water Separator 50
OH4201
1. Perform “Shut-Down Procedure” on page 4-4.

2. Open engine access door.
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. Tighten drain cock.
4. Close and secure engine access door.
31200352 7-11
Air Intake System
A. Air Filter Restriction Indicator Check 10
7
6
4
OH4211

3. Locate air cleaner (1) and check restriction indicator (2). If red band is visible,
filter(s) must be replaced.
4. Remove dust from vacuator valve (3) 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.
7-12 31200352
B. Element Change (as restriction indicator indicates)
1. Unlock air cleaner cover (4), turn counterclockwise and remove from air cleaner
canister (5).
2. Remove outer primary element (6) 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 (7) 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.
7. Depress button on restriction indicator to reset.
Note: An inner safety element should never be washed or reused. Always install a
new element.
31200352 7-13
Engine Oil
A. Engine Oil Level Check 10
2 4
3 1
OH4221

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. Replace dipstick.
5. 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.
6. Replace oil fill cap.
Note: The service interval for engine oil and filter is 250 hours maximum. If an
extended service interval is desired, see the engine manual for specific guidelines
for optimizing oil change intervals.
7-14 31200352
Hydraulic Oil
A. Hydraulic Oil Level Check 10
7
5
OH4230
1. Be sure all cylinders are fully retracted and machine is level.

3. Check level of hydraulic oil in tank at the sight gauge (6) on the hydraulic
tank (5). The oil level should be visible in the gauge window.
4. If hydraulic oil is low, remove tank cover.
5. Remove oil fill cap (7) from filler neck. Add hydraulic fluid to bring oil up to the
upper mark on the sight gauge.
6. Replace hydraulic oil fill cap.
7. Replace and secure tank cover.
31200352 7-15
Tires
A. Tire Air Pressure Check 10

2. Remove valve stem cap.
3. Check tire pressure using a good quality gauge.
4. Add air if required.
13.00 x 24, G-2/L-2 Bias Ply Traction - 12 ply (8042 only) ...........70 psi (4,8 bar)
13.00 x 24, G-3/L-3 Bias Ply Rock - 12 Ply (8042 Only) ..............70 psi (4,8 bar)
13.00 x 24, G-2/L-2 Radial - 1 Star (8042 Only)...........................75 psi (5,2 bar)
15.50 x 25, G-2/L-2 Bias Ply Traction - 12 Ply (8042 Only)..........70 psi (4,8 bar)
15.50 x 25, G-3/L-3 Bias Ply Rock - 12 Ply (8042 Only) ..............60 psi (4,1 bar)
15.50 x 25, G-2/L-2 Radial - 1 Star (8042 Only)...........................75 psi (5,2 bar)
17.50 x 25, G-2/L-2 Bias Ply Traction - 12 ply (10042 & 10054) ..60 psi (4,1 bar)
17.50 x 25, G-3/L-3 Bias Ply Rock - 12 Ply (10042 & 10054) ......60 psi (4,1 bar)
17.50 x 25, G-2/L-2 Radial - 1 Star (10042 & 10054)...................73 psi (5,0 bar)
5. Replace valve stem cap.
B. Tire Damage
For pneumatic tires, JLG recommends that when any cut, rip or tear is discovered
that exposes sidewall or tread area cords in the tire, measures be taken to remove
the JLG product from service immediately. Arrangements must be made for
replacement of the tire or tire assembly.
For polyurethane foam filled tires, JLG recommends that 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.
7-16 31200352
C. Tire and Wheel Replacement
JLG recommends 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
a JLG approved replacement tire, JLG recommends that replacement tires 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.
31200352 7-17
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 5
1 7
10 9
8 2
6 4
OY1220
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. Failure to comply could result in death or serious injury.
7-18 31200352
Engine Cooling System
A. Engine Coolant Level Check 10
OH4251

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 (50/50 mixture
of ethylene glycol and water) as required.
5. Replace overflow bottle cap.
31200352 7-19
Transmission
A. Transmission Oil Level Check 10

1
T
HO
MIN
LD
CO
OH4260
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.
3. Remove the transmission dipstick (1) through access hole and check oil level.
The oil level should be within the "HOT" zone (2).
4. If oil is low, add hydraulic fluid to bring oil up to the "HOT" zone.
5. Replace transmission dipstick.
7-20 31200352
Battery
A. Battery Check 50
3
OH4270

2. Open rear access door.
3. Wearing eye protection, visually inspect the battery (3). Check terminals for
corrosion. Replace battery if it has a cracked, melted or damaged case.
4. Close and secure rear access door.
31200352 7-21
7-22 31200352
SECTION 8 - ADDITIONAL CHECKS
8.1 STABIL-TRAK™
A. Stabil-TRAK™ Indicator Test 10

Stabil-TRAK system operates in three modes. In locked mode the indicator light
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 6
4
3
5
OH4330
1. Test Stabil-TRAK system with vehicle on a level surface and boom fully
retracted, no load.
2. Shift transmission to neutral (6).
3. Raise boom above 40° (2). Stabil-TRAK system locked mode will be activated
and indicator will illuminate.
4. Lower boom below 40° (1).
5. Depress service brake pedal (5) and shift transmission into forward.
6. Raise the boom above 40°. Stabil-TRAK system locked mode will be activated
and indicator (4) will illuminate.
7. Lower boom below 40°.
8. Engage park brake switch (3).
9. Release service brake pedal.
10. Raise the boom above 40°. Stabil-TRAK system locked mode will be activated
and indicator will illuminate.
11. Lower boom below 40°.
12. Shift transmission to neutral.
31200352 8-1
8.2 BOOM/OUTRIGGER INTERLOCK
A. Boom/Outrigger Interlock System Test 10

Boom/Outrigger Interlock system operates in two modes. In extend interlock mode,
with outriggers raised, a sensor in the boom will stop boom from extending past a
point between the “E” and “F” extension indicators. In outrigger interlock mode, with
outriggers lowered, boom will extend fully and Stabil-TRAK indicator will illuminate.
To check the sensor and indicator, perform the following:
12
13
8
11
OH4380
10 9
1. Test Boom/Outrigger Interlock system with vehicle on a level surface and boom
horizontal, no load.
2. Shift transmission to neutral (12) and engage park brake (11).
3. Raise outriggers (9).
4. Extend boom until it stops. Boom should stop on point (8) between the
“E” and “F” extension indicators.
5. Retract boom.
6. Lower outriggers (10) on firm terrain.
7. Extend boom (7) until it stops. Boom should fully extend and Stabil-TRAK
indicator (13) should illuminate.
8-2 31200352
SECTION 9 - SPECIFICATIONS
9.1 PRODUCT SPECIFICATIONS
Fluid and Lubrication Capacities
Engine Crankcase Oil

Capacity with Filter Change ...................................................... 11 quarts (10,4 liters)
Type of Oil ................................................................................................ 15W-40 CD
Fuel Tank
Capacity ....................................................................................37 gallons (140 liters)
Type of Fuel.................................................................................................. #2 Diesel
Cooling System
System Capacity (without heater) ..............................................4 gallons (15,1 liters)
Type of Coolant ............................................................ 50/50 ethylene glycol & water
Hydraulic System
System Capacity, (with outriggers).........................................64 gallons (242,3 liters)
System Capacity, (without outriggers).................................57.5 gallons (217,7 liters)
Reservoir Capacity to Full Mark ..........................................32.2 gallons (121,9 liters)
Type of Oil ........................................Mobilfluid® 424 Tractor Hydraulic Fluid (ISO 46)
Axles
Differential Housing Capacity (Front Axle) ....................................9.5 quarts (9 liters)
Differential Housing Capacity (Rear Axle)................................. 10.6 quarts (10 liters)
Wheel End Capacity (Front Axle) ...............................................1.7 quarts (1,6 liters)
Wheel End Capacity (Rear Axle)................................................1.3 quarts (1,2 liters)
Type of Fluid .....................................Mobilfluid® 424 Tractor Hydraulic Fluid (ISO 46)
31200352 9-1
Tires
Pressure
8042
13.00 x 24, G-2/L-2 Bias-Ply Traction - 12 Ply
Pneumatic ......................................................................................70 psi (4,8 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)

Foam ................................................................................. Approx 600 lb (272 kg)
15.50 x 25, G-2/L-2 Radial - 1 Star

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)
10042 & 10054

Foam ................................................................................. Approx 785 lb (356 kg)
17.50 x 25, G-3/L-3 Bias Ply Rock - 12 Ply

Foam ................................................................................. Approx 785 lb (356 kg)
17.50 x 25, G-2/L-2 Radial - 1 Star

Pneumatic .........................................................................................73 psi (5 bar)
Foam ................................................................................. Approx 785 lb (356 kg)
Wheel Lug Nut

Torque.............................................................................. 430-470 lb-ft (583-637 Nm)
9-2 31200352
Performance
Maximum Lift Capacity

8042 .......................................................................................... 8,000 lb (3629 kg)
10042 & 10054 ....................................................................... 10,000 lb (4536 kg)
Maximum Lift Height

8042 & 10042....................................................................................42 ft (12,8 m)
10054 ................................................................................................54 ft (16,5 m)
Capacity at Maximum Height

8042 & 10042 ........................................................................... 6,000 lb (2722 kg)
10054 ........................................................................................ 4,000 lb (1814 kg)
Maximum Forward Reach

8042 .................................................................................................25.6 ft (7,8 m)
10042 ...............................................................................................25.3 ft (7,7 m)
10054 .............................................................................................37.5 ft (11,4 m)
Capacity at Maximum Forward Reach

8042 ............................................................................................ 1,800 lb (817 kg)
10042
Outriggers Engaged........................................................... 6,000 lb (2722 kg)
Outriggers Not Engaged ...................................................... 2,000 lb (907 kg)
10054
Outriggers Engaged........................................................... 3,000 lb (1361 kg)
Outriggers Not Engaged ...................................................... 1,400 lb (635 kg)
Reach at Maximum Height

8042 ...................................................................................................4.8 ft (1,5 m)
10042 .................................................................................................4.7 ft (1,4 m)
10054 .................................................................................................9.4 ft (2,9 m)
Maximum Travel Speed ...............................................................20 mph (32,2 kmph)
Towing Capacity
8042 .......................................................................................... 8,000 lb (3629 kg)
10042 & 10054 ....................................................................... 10,000 lb (4536 kg)
Frame Leveling .......................................................................................... 10 degrees
31200352 9-3
Dimensions
Overall Height
8042 ..........................................................................................99.4 in (2525 mm)
10042 & 10054 .......................................................................100.1 in (2543 mm)
Overall Width
8042 ........................................................................................98.25 in (2496 mm)
10042 & 10054
Outriggers Up......................................................................102 in (2591 mm)
Outriggers Down ............................................................156.75 in (3982 mm)
Track Width
8042 .............................................................................................84 in (2134 mm)
10042 & 10054........................................................................84.25 in (2140 mm)
Wheelbase....................................................................................119.5 in (3035 mm)
Length at Front Wheels ................................................................189.6 in (4816 mm)
Overall Length less Forks

8042 ......................................................................................222.25 in (5645 mm)
10042....................................................................................225.25 in (5721 mm)
10054....................................................................................238.75 in (6064 mm)
Ground Clearance
8042 ..........................................................................................17.28 in (439 mm)
10042 & 10054 ..............................................................................18 in (457 mm)
Outside Turning Radius

8042 ........................................................................................158.3 in (4021 mm)
10042 .........................................................................................182 in (4623 mm)
10054 ......................................................................................184.5 in (4686 mm)
Gross Vehicle Weight with Forks

8042 .....................................................................................25,565 lb (11.596 kg)
10042 ...................................................................................26,523 lb (12.030 kg)
10054 ...................................................................................27,523 lb (12.484 kg)
Front Axle Weight

8042 ..........................................................................................8,442 lb (3829 kg)
10042 ........................................................................................9,414 lb (4270 kg)
10054 ......................................................................................10,423 lb (4728 kg)
Rear Axle Weight

8042 ........................................................................................17,123 lb (7767 kg)
10042 ......................................................................................17,109 lb (7761 kg)
10054 ......................................................................................17,100 lb (7756 kg)
9-4 31200352
Maximum Ground Bearing Pressure
13.00-24 (8042) ................................................................ 111 lbs/in² (7,8 kg/cm²)
15.50-25 (8042) ................................................................ 79 lbs/in² (5,55 kg/cm²)
17.50-25 (10042) ................................................................ 74 lbs/in² (5,2 kg/cm²)
17.50-25 (10054) ................................................................ 77 lbs/in² (5,4 kg/cm²)
31200352 9-5
9-6 31200352
Index
Index
A E
Additional Checks............................. 8-1 Electrical Hazards .............................1-2
Adjusting/Moving Forks .................... 5-8 Emergency Exit from
Attachment Installation ..................... 5-7 Enclosed Cab....................................6-2
Attachment Operation ...................... 5-8 Emergency Lower of Boom...............6-2
Attachments ..................................... 5-1 Emergency Procedures ....................6-1
Auger.............................................. 5-18 Engine...............................................4-1
Normal Operation ........................4-4
Auxiliary Hydraulic Joystick ............ 3-12
Starting ........................................4-1
Axles................................................. 9-1
Engine Crankcase Oil .......................9-1
B Engine Function Indicators ...............3-5
Battery ............................................ 7-21 Engine Oil Level..............................7-14
Battery Boosted Starting .................. 4-3
F
Boom Head-Mounted Winch .......... 5-24
Fall Hazard......................................1-12
Boom Joystick ................................ 3-10
Fuel Level .......................................7-10
Boom/Outrigger Interlock
Fuel Tank ..........................................9-1
System ........................................... 3-17
Test ............................................. 8-2 Fuel/Water Separator......................7-11
Bucket ............................................ 5-12 G
C General Maintenance........................7-2
Capacities......................................... 9-1 H
Capacity ........................................... 5-2 Hazard Classification System ...........1-1
Capacity Chart.................................. 5-3 Headlights .......................................3-14
Example ...................................... 5-6
Sample........................................ 5-4 Hydraulic Oil Level ..........................7-15
Capacity Indicator Locations ............ 5-3 Hydraulic System ..............................9-1
Carriage w/Forks .............................. 5-9 I

Chemical Hazards .......................... 1-13 Ignition ..............................................3-6
Controls ............................................ 3-2 Instrument Cluster.............................3-4
Coolant Level ................................. 7-19
Cooling System ................................ 9-1 L
Crane Hook .................................... 5-10 Leveling Procedure ...........................4-6
Lifting Personnel ...............................1-8
D Load Falling Hazard..........................1-7
Dash Controls and Indicators ........... 3-3 Lubrication and Maintenance............7-1
Decals .............................................. 2-3 Lubrication Schedule ........................7-6
Dimensions....................................... 9-4 1000 Hour....................................7-9
Disengaging the Load ...................... 4-7 250 Hour......................................7-8
50 Hour (10054) ..........................7-7
Driving Hazards on Slopes............... 1-9
50 Hour (8042 & 10042) ..............7-6
31200352 1
Index
M Side Tilt Carriage ............................5-22
Middle Joystick ............................... 3-11 Specifications ....................................9-1
Stabil-TRAK System .......................3-16
O Test..............................................8-1
Operating with a Load ...................... 4-5 Steer Modes....................................3-15
Operational Check............................ 2-8 Sweeper ..........................................5-20
Operator Cab.................................... 2-9 Swing Carriage................................5-16
Operator Maintenance
Instructions ..................................... 7-10 T
Operator Seat ................................. 3-18 Tip Over Hazard................................1-3
Tires ........................................ 7-16, 9-2
P Air Pressure ...............................7-16
Park Brake........................................ 3-7 Damage .....................................7-16
Parking Lights................................. 3-14 Replacement..............................7-17
Parking Procedure............................ 3-7 Towing...............................................6-1
Performance ..................................... 9-3 Transmission Control Lever ..............3-8
Direction of Travel........................3-8
Personnel Work Platform................ 5-24
Gear Selection .............................3-9
Picking Up a Load ............................ 4-5 Neutral Lock Lever.......................3-9
Pinch Points and Crush Transmission Oil Level....................7-20
Hazards .......................................... 1-10
Transport...........................................4-8
Placing the Load............................... 4-7 Lifting ...........................................4-9
Pre-Operation Check and Tiedown .......................................4-8
Inspection ......................................... 2-1 Transporting the Load .......................4-6
Travel Hazard....................................1-6
R
Truss Boom.....................................5-14
Restriction Indicator........................ 7-12
Turn Signal......................................3-14
S
W
Safety Decals ................................... 2-3
Walk-Around Inspection ....................2-6
Safety Practices................................ 1-1
Warm-Up Check................................2-8
Safety Signal Words ......................... 1-1
Wheel Installation............................7-18
Seat Belt ......................................... 3-19
Wheel Lug Nut ..................................9-2
Service and Maintenance
Schedule........................................... 7-3 Wheel Replacement........................7-17
10 Hour ....................................... 7-3
1000 Hour ................................... 7-5
1st 50 Hour.................................. 7-3
2000 Hour ................................... 7-5
250 Hour ..................................... 7-4
50 Hour ....................................... 7-4
500 Hour ..................................... 7-4
Shut-Down Procedure ...................... 4-4
2 31200352
Serial Number ______________________________
Date Comments
Date Comments
TRANSFER OF OWNERSHIP
To: JLG, Gradall, Lull and SkyTrak 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
1 JLG Drive
McConnellsburg, PA 17233-9533
USA
Telephone: (717) 485-5161
Fax: (717) 485-6573
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.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
Phone: (717) 485-5161
Customer Support Toll Free: (877) 554-5438
Fax: (717) 485-6417
JLG Worldwide Locations

JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK)
P.O. Box 5119 Rua Eng. Carlos Stevenson, Unit 4 & 5
11 Bolwarra Road 80-Suite 71 Bentley Avenue
Port Macquarie 13092-310 Campinas-SP M24 2GP Middleton
N.S.W. 2444 Brazil Stockport
Australia Phone: (55) 193 295 0407 England
Phone: (61) 265 811 111 Fax: (55) 193 295 1025 Phone: (44) 161 654 1000
Fax: (61) 265 810 122 Fax: (44) 161 654 1003
JLG EQS JLG Deutschland GmbH JLG Equipment Services Ltd.

Z.I. De Beaulieu Max Planckstrasse 21 Rm 1107 Landmark North
47400 Fuillet D-27721 Ritterhude/lhlpohl 39 Lung Sum Avenue
France Bei Bremen Sheung Shui N.T.
Phone: (33) 553 848 584 Germany Hong Kong
Fax: (33) 553 848 588 Phone: (49) 421 693 500 Phone: (852) 2639 5783
Fax: (49) 421 693 5035 Fax: (852) 2639 5797
JLG Industries (Italia) 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) 235 655 665 Phone: (48) 914 320 245
Fax: (39) 029 359 5845 Fax: (31) 235 572 493 Fax: (48) 914 358 200
JLG Industries (Scotland) Plataformas Elevadoras JLG Industries (Sweden)

Wright Business Centre JLG Iberica, S.L. Enkopingsvagen 150
1 Lonmay Road Trapadella, 2 Box 704
Queenslie, Glasgow G33 4EL P.I. Castellbisbal Sur SE - 17527 Jarfalla
Scotland 08755Castellbisbal, Barcelona Sweden
Phone: (44) 141 781 6700 Spain Phone: (46) 850 659 500
Fax: (44) 141 773 1907 Phone: (34) 937 724 700 Fax: (46) 850 659 534
Fax: (34) 937 711 762

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Operation & Safety

Read This First

Any modification to this machine must be approved by JLG.

or Your Local JLG Office

Other Publications Available

Service Manual .............................................................31200353

This Page Intentionally Left Blank

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 drive with boom raised.

• DO NOT raise boom unless frame is level (0 degrees).

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

• Carry load as low as possible. Tether suspended loads to restrict movement.

• Always wear the seat belt.

If the telehandler starts to tip over:

4-Wheel Steer Pivot Steer OW0120

• 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

FOR SKYTRAK MANUFACTURED

VIEW INSIDE CAB

4110172 4110226 OH3770

4110186 (10042) 4110339

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)

• During operation the window must either be latched open or closed.

1. Transmission Control Lever: See page 3-8.

1. Park Brake Switch: See page 3-7 for details.

1. Hourmeter: Records and indicates engine operating hours.

• 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.

Neutral Lock Lever

Neutral lock lever (3) locks transmission control lever.

The boom joystick (1) controls the boom functions.

Frame Sway Functions

The rear switches (2) control the outriggers.

Parking Lights and Headlights

3.3 STEER MODES

2-Wheel Front Steer

4-Wheel Circle Steer

3.4 STABIL-TRAK™ SYSTEM

Free Pivot Mode

Slow Pivot Mode