JLG Skytrak 6036, Operation & Safety Manual

Page 1: ...Oshkosh Corporation Company Models 6036 6042 8042 10042 10054 SN 0160069719 to Present including 0160065791 0160065792 0160065796 0160065798 0160065824 0160065825 0160065826 0160069336 0160069359 0160...

Page 2: ...ead 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...

Page 3: ...11 2016 E Revised covers and pages d 2 5 2 6 2 8 2 9 2 14 3 5 3 20 3 21 4 4 5 2 5 3 5 30 5 31 5 38 thru 5 41 5 46 thru 5 48 7 3 7 4 7 7 thru 7 9 7 27 7 28 8 3 9 1 thru 9 4 9 7 9 10 9 11 April 10 2017...

Page 4: ...ires 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...

Page 5: ...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...

Page 6: ...f machine is equipped with Ultra Low Sulfur Fuel Decal 1 as indicated below If equipped with the Ultra Low Sulfur decal all specific references to this machine configuration will be referred to as Ult...

Page 7: ...lling Hazard 1 8 Lifting Personnel 1 9 Driving Hazards on Slopes 1 10 Pinch Points and Crush Hazards 1 11 Fall Hazard 1 13 Chemical Hazards 1 14 1 4 ClearSky if equipped 1 15 Federal Communications Co...

Page 8: ...vel Joystick 3 14 Outrigger Switches 10042 10054 3 15 Accessory Control Lever if equipped 3 16 3 3 Steer Modes 3 17 Steer Mode Change 3 17 3 4 Stabil Trak System 6042 8042 10042 10054 3 18 Free Pivot...

Page 9: ...haust System Cleaning 4 5 4 3 Operating with a Non Suspended Load 4 6 Lift Load Safely 4 6 Picking Up a Load 4 6 Transporting a Load 4 7 Leveling Procedure 4 7 Placing a Load 4 8 Disengaging a Load 4...

Page 10: ...iage 5 16 Side Tilt Carriage 5 18 Swing Carriage 5 20 Dual Fork Positioning Carriage 5 22 Mast Carriage 5 24 Pipe Grapple 5 26 Fork Extension 5 28 Coupler Mounted Hook 5 30 Fork Mounted Hook 5 32 Buck...

Page 11: ...or 3 Years 7 7 Every 5000 Hours or 4 Years 7 7 7 4 Lubrication Schedules 7 8 50 Hour Lubrication Schedule 7 8 250 Hour Lubrication Schedule 7 11 1000 Hour Lubrication Schedule 7 13 7 5 Operator Maint...

Page 12: ...Table of Contents vi 31211018 Section 9 Specifications 9 1 Product Specifications 9 1 Fluids 9 1 Capacities 9 4 Tires 9 6 Performance 9 7 Dimensions 9 9 Index Inspection Maintenance and Repair Log...

Page 13: ...d or attachment position Precautions to avoid all hazards in the work area must be taken by the user before and during operation of the machine DANGER DANGER indicates an imminently hazardous situatio...

Page 14: ...sulated parts according to the Minimum Approach Distance MAD Note This requirement shall apply except where employer local or governmental regulations are more stringent Allow for machine movement and...

Page 15: ...ached to the machine The minimum approach distance shall be reduced to a distance within the designed working dimensions of the insulating barrier This determination shall be made by a qualified perso...

Page 16: ...d lift capacity Be sure that the ground conditions are able to support the machine Be aware of wind conditions Wind may cause load swing and dangerous side loads Keep the machine a minimum of 2 ft 0 6...

Page 17: ...ecifications for proper fill ratio and pressure requirements for tires equipped with ballast Always wear seat belt Keep head arms hands legs and all other body parts inside operator s cab at all times...

Page 18: ...oad DO NOT attempt to use telehandler frame leveling to compensate for load swing Keep heavy part of load closest to attachment Never drag the load lift vertically When driving with a suspended load S...

Page 19: ...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...

Page 20: ...31211018 Load Falling Hazard Never suspend load from forks or other parts of carriage weldment Use only approved lift points DO NOT burn or drill holes in fork s Forks must be centered under load and...

Page 21: ...ices 1 9 31211018 Lifting Personnel When lifting personnel USE ONLY an approved personnel work platform with proper capacity chart displayed in the cab DO NOT drive machine from cab when personnel are...

Page 22: ...opriate capacity chart To avoid overspeeding the engine and drivetrain when driving down slopes downshift to a lower gear before going downhill and use the service brake as necessary to maintain a slo...

Page 23: ...inch Points and Crush Hazards 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 object...

Page 24: ...fety Practices 1 12 31211018 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 OW0240 O...

Page 25: ...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 pa...

Page 26: ...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 DO NOT attempt to repair or tighten any hydraul...

Page 27: ...ipment does cause harmful interference to radio or television reception which can be determined by turning the equipment off and on the user is encouraged to try to correct the interference by one or...

Page 28: ...ion with any other antenna or transmitter in order to satisfy FCC RF exposure requirements for mobile transmitting devices Important To comply with the FCC RF exposure limits and to satisfy the catego...

Page 29: ...the machine is used in a severe manner Inspection and Maintenance Type Frequency Primary Responsibility Service Qualification Reference Pre Operation Inspection Beginning of each work shift or at each...

Page 30: ...Manual and AEM Safety Manual ANSI only are located in cab manual holder 5 Walk Around Inspection See page 2 10 for details 6 Fluid Levels Check fluids including fuel diesel exhaust fluid DEF hydraulic...

Page 31: ...e page 2 12 of all systems in an area free of overhead and ground level obstructions See Section 3 Controls and Indicators for more specific operating instructions WARNING If telehandler does not oper...

Page 32: ...H 1001163285 ENGLISH FRENCH 1001125387 ENGLISH 1001163355 ENGLISH FRENCH 1001162736 B 1001162735 B 1001162737 A 1001158319 A Fasten seat belt Operator must be trained and must read and understand all...

Page 33: ...or serious injury 1001210582 A Le non respect de ces instructions peut provoquer des blessures graves voire mortelles Se reporter au tableau de capacit s pour d autres capacit s nominales Refer to cap...

Page 34: ...injury WARNING Keep clear of rot ating p arts 1706301B 1706301 ENGLISH 1001163222 ENGLISH FRENCH 1702300 1702300 4110339 Sky T rak 10 50 250 1000 50 2000 P 500 1500 500 LB FT Nm 1001202627 IF EQUIPPE...

Page 35: ...0042 10054 1001162736 1001162735 CAPACITY CHARTS 1001162734 1001162736 B 1001162735 B 1001162737 A 1001092877 1706284 1706288 1001162737 10042 10054 1001158320 E 1001158321 D 1001158320 1001158321 100...

Page 36: ...Number Year Of Manufacture Model SERIAL NUMBER PLATE 1702300 1702300 VIEW C C 1706098 1001143852 IF EQUIPPED FOR LS 4107442 10 0 10 20 30 40 5 0 6 0 70 80 4105262 1701640 1701640 A A D D B C B C 17023...

Page 37: ...2 5 GPM 9 5 lpm MAX 1001109053 REV A 1001109053 1001139942 D 1001189017 A 1001139942A G G E E F F 1001191992 6036 1001191993 6042 1001191994 8042 1001191995 10042 1001191996 10054 4110217 2 2 2 2 2 Sk...

Page 38: ...ts in addition to any other criteria mentioned Inspect all structural members including attachment for cracks excessive corrosion and other damage 1 Boom Sections and Lift Tilt Extend Retract Compensa...

Page 39: ...r Pins secure hydraulic hoses undamaged not leaking 9 Engine Compartment Drive belts check condition and replace as required Engine mounts See inspection note Battery cables tight no visible damage or...

Page 40: ...nal check 1 Service brake and parking brake operation 2 Forward and reverse travel 3 Each gear 4 Steering in both directions with engine at low idle steering lock to lock will not be reached Check in...

Page 41: ...modification to this machine must be approved by JLG to assure compliance with ROPS FOPS certification for this cab machine configuration If the overhead guard or cab structure is damaged the CAB CAN...

Page 42: ...ucted Cab Door Window if equipped Cab door window 2 must either be latched open or closed during operation Open cab door window and secure it in latch 3 Turn knob 4 to unlatch window NOTICE EQUIPMENT...

Page 43: ...NERAL This section provides the necessary information needed to understand control functions NOTICE EQUIPMENT DAMAGE When a red light illuminates immediately bring machine to a stop lower boom and att...

Page 44: ...Section 3 Controls and Indicators 3 2 31211018 3 2 CONTROLS OH4980 9 2 1 10 11 7 6 4 3 8 5 12 13...

Page 45: ...ge 3 12 7 Frame Level Joystick See page 3 14 8 Auxiliary Hydraulic Joystick See page 3 13 9 Outrigger Switches 10042 10054 See page 3 15 10 Accelerator Pedal Pressing down the pedal increases engine a...

Page 46: ...tion 3 Controls and Indicators 3 4 31211018 Dash Controls and Indicators OH5020 O 4990 H OH5000 OH5180 1 2 3 4 5 6 7 8 9 10 13 15 14 12 13 14 IF EQUIPPED WITH HEATER IF EQUIPPED WITH HEATER AC OH5041...

Page 47: ...h 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 off wiper 8 Windshield and Skylight Washer Switch if equi...

Page 48: ...Section 3 Controls and Indicators 3 6 31211018 Instrument Cluster OH5010 98 242 F 12 0V 99999 9 2488RPM OH5030 10 9 8 7 6 5 1 2 3 4 11 13 12 14 15 98 242 F 12 0V 99999 9 2488RPM OH5030...

Page 49: ...time for cooling If light remains on shut down engine 7 Turn Signal Indicator if equipped Illuminates and flashes while turn signals or hazard lights are activated 8 High Beam Indicator if equipped I...

Page 50: ...ailable Position 1 Voltage available for all electrical functions Wait to start engine until engine pre heat indicator goes out Position 1 Engine run Position 2 Engine start In event engine does not s...

Page 51: ...is activated See page 3 18 Parking Procedure 1 Using service brake stop telehandler in an appropriate parking area 2 Follow Shut Down Procedure on page 4 3 WARNING MACHINE ROLL AWAY HAZARD In the eve...

Page 52: ...lly sound Drive in reverse and turn only at slow rates of speed Do not increase engine speed with transmission in forward or reverse and service brake depressed in an attempt to get quicker hydraulic...

Page 53: ...2 of transmission control lever Twist hand grip to select gear Select appropriate gear for task being performed Use a lower gear when transporting a load Use a higher gear only when driving unloaded f...

Page 54: ...gine speed will also increase function speed For two simultaneous boom functions move joystick between quadrants Example moving joystick forward and to left will lower and retract boom simultaneously...

Page 55: ...13 31211018 Auxiliary Hydraulic Joystick Auxiliary hydraulic joystick 2 controls function of attachments that require hydraulic supply for operation See Section 5 Attachments for approved attachments...

Page 56: ...oystick right to rotate frame right A level indicator is located above front cab window to permit operator to determine whether telehandler frame is level WARNING TIP OVER HAZARD Always move boom as l...

Page 57: ...of switches 2 to raise outriggers Use the outriggers to increase stability and or load capacity and in leveling telehandler Study capacity charts to determine maximum load capacities with and without...

Page 58: ...nal Lever must be manually returned to center position to deactivate either turn signal Lever will not cancel automatically after a turn Parking Lights and Headlights Turn twist grip 6 of lever counte...

Page 59: ...lection 1 Bring machine to a stop using service brake while either circle steer mode 1 or crab steer mode 3 is selected 2 Turn steering wheel until left rear wheel 4 is aligned with side of machine 3...

Page 60: ...Slow Pivot Mode when service brake is not applied and transmission is in gear Rear axle will respond slowly to changes in terrain and frame level functions normally Stabil Trak indicator 8 will be off...

Page 61: ...rmally Outrigger Interlock Mode With outriggers lowered 3 on firm terrain telehandler is in outrigger interlock mode which allows for full boom extension 4 When outriggers are lowered shift travel sel...

Page 62: ...8 1 Suspension Use knob to adjust suspension to the appropriate setting Turn clockwise to increase stiffness Turn counterclockwise to reduce stiffness 2 Fore Aft Pull up on handle to move seat fore an...

Page 63: ...to the appropriate setting Turn clockwise to increase stiffness Turn counterclockwise to reduce stiffness 2 Fore Aft Pull up on handle to move seat fore and aft 3 Document Case Contains unit materials...

Page 64: ...is not twisted or entangled 2 With back straight in seat couple retractable end male end of belt into receptacle buckle end of belt 3 With belt buckle positioned as low on body as possible pull retrac...

Page 65: ...on left side of boom Use this indicator to determine boom angle when using capacity chart see Use of the Capacity Chart on page 5 5 Boom extension indicators 2 are located on left side of boom Use th...

Page 66: ...Pulsing alarm sounds when an object is in range of Reverse Sensing System Alarm increases in frequency as object becomes closer If alarm sounds at a frequency of eight pulses per second 8 Hz an object...

Page 67: ...nd may prevent starter engagement under certain conditions Pre heat indicator will flash and fault code will appear on instrument cluster display Return ignition switch to position 1 for a minimum of...

Page 68: ...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 stand...

Page 69: ...C When operating a machine at high altitudes a decrease in machine performance may occur due to a decrease in air density When operating a machine at high temperatures a decrease in machine performan...

Page 70: ...nt System Automatic Exhaust System Cleaning ATS is an automatic exhaust cleaning system and will perform as required without any operator interaction High Exhaust System Temperature HEST 1 Indicator m...

Page 71: ...ately 30 to 60 minutes Note Stationary exhaust system cleaning will stop and may be incomplete if any controls are inadvertently moved or activated If stationary exhaust cleaning is interrupted HEST 1...

Page 72: ...e 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...

Page 73: ...e level indicator to determine whether machine must be leveled prior to lifting load Level machine with frame level joystick see page 3 13 or outrigger switches 10042 10054 only see page 3 14 4 Move b...

Page 74: ...then extend 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 a Load Once the load has be...

Page 75: ...Avoid lifting double tiered loads Make sure load is clear of any adjacent obstacles NEVER operate telehandler without a proper and legible capacity chart in the operator cab for the telehandler attac...

Page 76: ...or must remain in constant communication verbal or hand and be in visual contact with the operator at all times Never place the guide persons between the suspended load and the telehandler Only transp...

Page 77: ...5 Align load at the level load is to be placed then position boom slowly until load is just above area where it is to be placed Ensure that the guide persons and operator remain in constant communicat...

Page 78: ...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 wei...

Page 79: ...ne must remain level at all times while being lifted Machine must never be lifted by any point on the boom Take care not to let cables chains slings etc contact any part of the vehicle during lift The...

Page 80: ...Section 4 Operation 4 14 31211018 This Page Intentionally Left Blank...

Page 81: ...lics and electrics If any of the above conditions are not met do not use attachment Telehandler may not be equipped with proper capacity chart or attachment may not be approved for the model telehandl...

Page 82: ...48in 60x127x1220mm 2340038 X X X X X Fork Pallet2 36x4x48in 60x100x1220mm 7301408 X X X X X Fork Pallet2 36x4x60in 60x100x1524mm 1001227379 X X X X X Fork DualTaper1 75x7x60in 44x178x1524mm 2340046 X...

Page 83: ...ASME 1001103637 X X X X X Platform ForkMounted ASME French 1001103736 X X X X X Platform ForkMounted ISO 1001103730 X X X X X Sweeper 1001202904 X X X X X SheetHandler 1001100227 X X X X X Attachment...

Page 84: ...Total attachment capacity is multiplied by number of forks on attachment if equipped up to maximum capacity of attachment Maximum capacity as indicated on the proper capacity chart See Approved Attac...

Page 85: ...er where load is to be placed 5 On capacity chart find the line for height and follow it over to distance 6 Number in load zone where the two cross is the maximum capacity for this lift If the two cro...

Page 86: ...XXXXXXXXXX XXXXX X XX XX XX XX XX XX XX XX XX XX XX XX XX XX X X X X XX XX XX XX XX XX X 8 0 10 20 30 40 50 60 l b s l b s l b s l b s l b s X X X X XX ANSI ITSDF B56 6 XXXX XX MAX XXXX XX MAX XX XXX...

Page 87: ...fy the proper capacity chart on telehandlers equipped with outriggers refer to the following icons which may be located on the capacity chart Use when lifting a load with outriggers up Use when liftin...

Page 88: ...tractor may encounter and whether or not the load may be lifted Note This is a sample capacity chart only DO NOT use this chart use the one located in your operator cab Load Weight Distance Height OK...

Page 89: ...Section 5 Attachments 5 9 31211018 This Page Intentionally Left Blank...

Page 90: ...ock Lever 6 Quick Coupler attachment tilt control in cab see Boom Joystick page 3 12 WARNING CRUSH HAZARD Always be certain that carriage or attachment is properly positioned on boom and is secured by...

Page 91: ...ure lock pin is removed 2 Align attachment pin with recess in attachment Raise boom slightly to engage attachment pin in recess 3 Tilt quick coupler forward to engage attachment 4 Lift lock lever and...

Page 92: ...ts 5 12 31211018 Hydraulic Operated Attachment 1 Install attachment see page 5 10 2 Lower attachment to ground and perform Shut Down Procedure on page 4 3 3 Connect attachment hoses to both auxiliary...

Page 93: ...led See Attachment Installation on page 5 10 2 Elevate attachment to approximately 5 ft 1 5 m and tilt carriage forward until fork heel is free from attachment 3 Stand at side of carriage To slide for...

Page 94: ...hment if it is equipped with a manual holder NOTICE EQUIPMENT DAMAGE Some attachments may contact front tires or machine structure when the boom is retracted and the attachment is rotated Improper use...

Page 95: ...the boom Roller switch 2 controls fork tilt Move joystick back to tilt up Move joystick forward to tilt down Installation Procedure Refer to Attachment Installation on page 5 10 Equipment Damage Prec...

Page 96: ...ttachment Fork Capacity on page 5 4 Joystick 1 controls movement of the boom Roller switch 2 controls fork tilt Press roller switch down to tilt up Press roller switch up to tilt down To Side Shift Au...

Page 97: ...ecautions Do not use forks as a lever to pry material Excessive prying forces could damage forks or machine structure Do not attempt to lift loads that are attached or connected to another object WARN...

Page 98: ...ttachment Fork Capacity on page 5 4 Joystick 1 controls movement of the boom Roller switch 2 controls fork tilt Press roller switch down to tilt up Press roller switch up to tilt down To Side Tilt Aux...

Page 99: ...d and engage load Raise load slightly and level carriage side to side Travel in accordance with requirements set forth in Section 1 General Safety Practices Equipment Damage Precautions Do not use for...

Page 100: ...er Attachment Fork Capacity on page 5 4 Joystick 1 controls movement of the boom Roller switch 2 controls fork tilt Press roller switch down to tilt up Press roller switch up to tilt down To Swing Aux...

Page 101: ...achine structure Do not attempt to lift loads that are attached or connected to another object WARNING CRUSH HAZARD Always level forks horizontally and telehandler frame before swinging load to side S...

Page 102: ...er Attachment Fork Capacity on page 5 4 Joystick 1 controls movement of the boom Roller switch 2 controls fork tilt Press roller switch down to tilt up Press roller switch up to tilt down To Fork Posi...

Page 103: ...1 General Safety Practices Equipment Damage Precautions Do not use forks as a lever to pry material Excessive prying forces could damage forks or machine structure Do not attempt to lift loads that ar...

Page 104: ...ent Fork Capacity on page 5 4 Joystick 1 controls movement of the boom Roller switch 2 controls fork tilt Press roller switch down to tilt up Press roller switch up to tilt down To Raise Lower Mast Au...

Page 105: ...nts set forth in Section 1 General Safety Practices Use a signal person to assist in positioning of load if necessary Equipment Damage Precautions Do not use forks as a lever to pry material Excessive...

Page 106: ...ge 5 4 Joystick 1 controls movement of the boom Roller switch 2 controls pipe grapple tilt Press roller switch down to tilt up Press roller switch up to tilt down To Open Close Pipe Grapple Auxiliary...

Page 107: ...accordance with requirements set forth in Section 1 General Safety Practices Open pipe grapple and unload material from forks Equipment Damage Precautions Except for lifting or unloading material the...

Page 108: ...carriage when equipped with fork extensions may be reduced to the capacity indicated on the fork extensions If the load exceeds the capacity of the fork extension contact JLG to obtain forks and or fo...

Page 109: ...nt fork arm blade length stamped into the fork extension Secure the fork extensions to the forks by sliding the fork extensions onto the parent forks and install the retaining pin behind the vertical...

Page 110: ...to Telehandler Attachment Fork Capacity on page 5 4 Suspend loads in accordance with requirements set forth in Section 1 General Safety Practices Joystick 1 controls movement of the boom Roller switc...

Page 111: ...Section 5 Attachments 5 31 31211018 Installation Procedure Refer to Attachment Installation on page 5 10 Operation Weight of rigging weight must be included as part of total load being lifted...

Page 112: ...apacity refer to Telehandler Attachment Fork Capacity on page 5 4 Suspend loads in accordance with requirements set forth in Section 1 General Safety Practices Joystick 1 controls movement of the boom...

Page 113: ...stall the retaining pin behind the vertical shank of the fork Operation Pallet or lumber forks of an appropriate load rating must be used Do not use with cubing or block forks Fork mounted hook and ri...

Page 114: ...t Capacity Chart To determine maximum capacity refer to Telehandler Attachment Fork Capacity on page 5 4 Joystick 1 controls movement of the boom Roller switch 2 controls bucket tilt Press roller swit...

Page 115: ...es Tilt bucket down to dump load Equipment Damage Precautions Except for lifting or dumping a load the boom must be fully retracted for all bucket operations Do not corner load bucket Distribute mater...

Page 116: ...Capacity on page 5 4 Joystick 1 controls movement of the boom Roller switch 2 controls bucket tilt Press roller switch down to tilt up Press roller switch up to tilt down To Open Close Grapple Auxilia...

Page 117: ...Practices Open grapple and tilt bucket down to dump load Equipment Damage Precautions Except for lifting or dumping a load the boom must be fully retracted for all bucket operations Do not corner load...

Page 118: ...tachment Capacity Chart To determine maximum capacity refer to Telehandler Attachment Fork Capacity on page 5 4 Joystick 1 controls movement of the boom Roller switch 2 controls bucket tilt Press roll...

Page 119: ...n to dump load Fork mounted bucket weight must be included as part of total load being lifted Do not use with mast carriage attachment Do not use fork mounted bucket with attachments capable of rotati...

Page 120: ...opper Capacity Chart To determine maximum capacity refer to Telehandler Attachment Fork Capacity on page 5 4 Joystick 1 controls movement of the boom Roller switch 2 controls trash hopper tilt Press r...

Page 121: ...equirements set forth in Section 1 General Safety Practices To release gate tilt fork mounted trash hopper down approximately 10 degrees and engage bottom bumper on edge of dumpster The gate will open...

Page 122: ...ccordance with requirements set forth in Section 1 General Safety Practices Joystick 1 controls movement of the boom Roller switch 2 controls truss boom tilt Press roller switch down to tilt up Press...

Page 123: ...Attachment Installation on page 5 10 Operation Weight of rigging must be included as part of total load being lifted WARNING CRUSH HAZARD Maintain a minimum of three wraps of wire rope on the cable dr...

Page 124: ...capacity refer to Telehandler Attachment Fork Capacity on page 5 4 Suspend loads in accordance with requirements set forth in Section 1 General Safety Practices Joystick 1 controls movement of the boo...

Page 125: ...ecure adjustable arm in desired position using the retaining pin Operation Weight of rigging must be included as part of total load being lifted WARNING CRUSH HAZARD Ensure adjustable arm is properly...

Page 126: ...6 6 2016 Standard use Fork Mounted Platform Attachment Capacity Chart To determine maximum capacity refer to Telehandler Attachment Fork Capacity on page 5 4 The operator and personnel in platform mus...

Page 127: ...up 1 Ensure the telehandler is on a firm surface and is level 2 Engage the park brake Blocking the wheels is also recommended 3 Level the platform both side to side frame level and front to back attac...

Page 128: ...page 5 4 Joystick 1 controls movement of the boom Roller switch 2 controls sweeper tilt Press roller switch down to tilt up Press roller switch up to tilt down Sweeper Control Auxiliary hydraulic lev...

Page 129: ...empty hopper raise sweeper over desired dump area ensuring proper clearance Operate auxiliary hydraulic lever to open the hopper allowing the contents to slide out Close the hopper after all contents...

Page 130: ...set forth in Section 1 General Safety Practices Joystick 1 controls movement of the boom Roller switch 2 controls fork tilt Press roller switch down to tilt up Press roller switch up to tilt down Ope...

Page 131: ...ring 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...

Page 132: ...sis Contact the local dealer for specific instructions Secure the telehandler using the following procedures 1 If equipped with platform attachment rescue platform occupants 2 Clear the area around te...

Page 133: ...if equipped In an emergency an escape hammer located directly below the rear window in an enclosed cab can be used to exit the telehandler Latch Window if equipped In an emergency rear window can be r...

Page 134: ...Section 6 Emergency Procedures 6 4 31211018 This Page Intentionally Left Blank...

Page 135: ...es The Lubrication and Maintenance decals 1 contain instructions that must be followed to keep this product in good operating condition The Operation Safety Manual and Service Manual contain more deta...

Page 136: ...ricants 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 inter...

Page 137: ...evel Check Engine Oil Level Check Hydraulic Oil Level Check Transmission Oil Level Check Tire Condition and Pressure Check Air Cleaner Check Fuel Level Check DEF Level if equipped for ULS 85 or 110HP...

Page 138: ...her Fluid Lubrication Schedule Change Axle Oil ChangeWheelEnd Oil Change Transmission Fluid and Filter Lubrication Schedule Check Axle Oil Level Check Wheel End Oil Level Check Boom Wear Pads Check Bo...

Page 139: ...ours Change Engine Oil and Filter if equipped for ULS Check Fan Belt Change Engine Oil and Filter if equipped for LS Check Battery Check Wheel Lug Nut Torque Change Hydraulic Fluid Change Hydraulic Ta...

Page 140: ...fuel consumption is greater than 11 4 liter per hour 3 gallon per hour oil change intervals are 500 hours or 6 months Every 1500 Hours Lubrication Schedule Change Axle Oil ChangeWheelEnd Oil Change E...

Page 141: ...urs or 4 Years Change Engine Coolant and Clean Engine DEF Strainer if equipped for ULS 85 or 110HP Change DEF Tank Filter if equipped for ULS 85 or 110HP Change Engine Coolant if equipped for LS Chang...

Page 142: ...Section 7 Lubrication and Maintenance 7 8 31211018 7 4 LUBRICATION SCHEDULES 50 Hour Lubrication Schedule 6036 6042 O 5721 H 50 EVERY...

Page 143: ...Section 7 Lubrication and Maintenance 7 9 31211018 8042 10042 O 5731 H 50 EVERY...

Page 144: ...Section 7 Lubrication and Maintenance 7 10 31211018 10054 O 5711 H 50 EVERY...

Page 145: ...Section 7 Lubrication and Maintenance 7 11 31211018 250 Hour Lubrication Schedule 6036 6042 O 1830 A EVERY 250 6042 ONLY...

Page 146: ...Section 7 Lubrication and Maintenance 7 12 31211018 8042 10042 10054 OH5740 EVERY 250 OH5740 EVERY 250 OH5740 EVERY 250 OH5740 EVERY 250 OH5740 EVERY 250...

Page 147: ...Section 7 Lubrication and Maintenance 7 13 31211018 1000 Hour Lubrication Schedule OH4181 1000 EVERY...

Page 148: ...el source and perform Shut Down Procedure on page 4 3 3 Turn fuel tank cap 2 and remove from filler neck 4 Add fuel as needed 5 Replace and secure fuel tank cap Note Replenish fuel at end of each work...

Page 149: ...edure on page 4 3 2 Open engine access door 3 Loosen drain cock 3 on underside of fuel filter 4 and allow all water to drain into a glass until clear fuel is visible 4 Tighten drain cock 5 Close and s...

Page 150: ...perform Shut Down Procedure on page 4 3 3 Turn DEF tank cap 2 and remove from filler neck 4 Add DEF as needed 5 Replace and secure DEF tank cap Note SN 0160082087 to Present If DEF tank assembly is s...

Page 151: ...k oil mark The oil should be between the full 6 and add 5 marks within the crosshatched area of the dipstick 4 If oil is low remove oil fill cap 4 and add motor oil to bring oil up to the full mark in...

Page 152: ...pen engine access door 3 Remove dust from vacuator valve 1 by squeezing bottom of valve to allow loose particles to fall out 4 Close and secure engine access door NOTICE EQUIPMENT DAMAGE Only remove a...

Page 153: ...erior of air cleaner canister and vacuator valve 6 Replace inner safety element 4 every third primary element change or if primary element was found to be damaged If replacing inner safety element at...

Page 154: ...on indicator 2 If red band is visible element s must be replaced 4 Remove dust from vacuator valve 3 by squeezing bottom of valve to allow loose particles to fall out 5 Close and secure engine access...

Page 155: ...y clean interior of air cleaner canister and vacuator valve 6 Replace inner safety element 6 every third primary element change or if primary element was found to be damaged If replacing inner safety...

Page 156: ...n page 4 3 3 Check level of hydraulic oil at the sight gauge 1 on the hydraulic tank 2 The oil level should be visible in the gauge window 4 If hydraulic oil is low remove tank cover 5 Remove oil fill...

Page 157: ...n 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 bey...

Page 158: ...after each wheel installation 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 dire...

Page 159: ...ks or attachment to the ground 2 Check the transmission oil level with the engine at idle and oil at normal operating temperature 3 Remove the transmission dipstick 1 and check oil level The oil level...

Page 160: ...en rear access door 3 Coolant level should be visible in surge tank 3 4 If coolant is low allow fluid to cool 5 Remove surge tank cap 4 slowly Add coolant as required 6 Replace surge tank cap 7 Close...

Page 161: ...4878 to Present A Brake Fluid Level Check 1 Perform Shut Down Procedure on page 4 3 2 Unlock and open access cover 1 3 Check the brake fluid level Fluid should be between Max and Min marks on brake re...

Page 162: ...k 1 Perform Shut Down Procedure on page 4 3 2 Open rear access door 3 Wearing eye protection visually inspect the battery 1 Check terminals for corrosion Replace battery if it has a cracked melted or...

Page 163: ...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 4 will illuminate 4 Lower boom...

Page 164: ...will extend fully and Stabil Trak indicator will illuminate To check the sensor and indicator perform the following 1 Test Boom Outrigger Interlock system on a level surface and boom horizontal no lo...

Page 165: ...object must be used to test the Reverse Sensing System 4 Verify operation with no objects in detection zone No audible alarm 5 Verify operation when object is in range of approximately 9 to 15 ft 2 7...

Page 166: ...Section 8 Additional Checks 8 4 31211018 This Page Intentionally Left Blank...

Page 167: ...W 80 20 15 29 10 Axle Differential and Wheel End MobilFluid 424 10W 30 15 114 10 45 Mobilfluid LT 75W 80 20 15 29 10 API GL4 with LS Additives or API GL5 with LS Additives 75W 90 20 114 29 45 Hydrauli...

Page 168: ...with axle fluid See Note on page 7 6 for details Diesel Exhaust Fluid DEF 85 or 110HP ISO22241 1 32 5 Urea Brake Fluid SN 0160074878 to Present Mobil ATF D M 20 114 29 45 Air Conditioning Refrigerant...

Page 169: ...d Wheel End MobilFluid 424 10W 30 15 114 10 45 Mobilfluid LT 75W 80 20 15 29 10 API GL4 with LS Additives or API GL5 with LS Additives 75W 90 20 114 29 45 Hydraulic System MobilFluid 424 10W 30 15 114...

Page 170: ...LS Additives 6 6 qt 6 2 L if utilizing fluid without LS Additives 6 3 qt 6 0 L 8042 10042 10054 Front Axle if utilizing fluid with LS Additives 12 5 qt 11 8 L if utilizing fluid without LS Additives 1...

Page 171: ...n 9 Specifications 9 5 31211018 Brake System SN 0160074878 to Present Capacity 0 8 qt 0 8 L Window Washer Bottle if equipped Capacity 2 2 qt 2 1 L Air Conditioning System if equipped Capacity 1 9 lb 0...

Page 172: ...r Foam Approx 542 lb 246 kg 15 50 x 25 G 2 L 2 Bias Ply Traction 12 Ply Pneumatic 65 psi 4 5 bar Foam Approx 600 lb 272 kg 370 75 28 14 Ply Pneumatic 76 psi 5 2 bar Foam Approx 464 lb 210 kg 8042 15 5...

Page 173: ...8 1 m 10054 Outriggers Engaged 38 8 ft 11 8 m Outriggers Not Engaged 26 5 ft 8 1 m Capacity at Maximum Forward Reach 6036 1 800 lb 816 kg 6042 1 400 lb 635 kg 8042 2 200 lb 998 kg 10042 Outriggers Eng...

Page 174: ...31211018 Hitch Capacity no load on attachment 6036 6042 6 000 lb 2 722 kg 8042 8 000 lb 3 629 kg 10042 10054 10 000 lb 4 536 kg Frame Leveling 10 degrees Maximum Travel Grade Gradeability 24 degrees...

Page 175: ...mm 10042 10054 84 2 in 2 139 mm Wheelbase 6036 6042 113 in 2 870 mm 8042 10042 10054 119 5 in 3 035 mm Overall Length no attachment 6036 224 in 5 690 mm 6042 234 in 5 944 mm 8042 228 in 5 791 mm 10042...

Page 176: ...kg 10054 31 500 lb 14 288 kg Distribution of Maximum Operating Weight no attachment boom level and fully retracted Front Axle 6036 7 530 lb 3 416 kg 6042 8 477 lb 3 845 kg 8042 8 674 lb 3 935 kg 10042...

Page 177: ...g cm Solid 229 lb in 16 1 kg cm 15 50 x 25 Air Filled 143 lb in 10 1 kg cm Foam Filled 184 lb in 12 9 kg cm 370 75 28 Air Filled 113 lb in 7 9 kg cm Foam Filled 148 lb in 10 4 kg cm 8042 13 00 x 24 So...

Page 178: ...1018 10054 Outriggers 102 lb in 7 2 kg cm Tires 14 00 x 24 Solid 233 lb in 16 4 kg cm 17 50 x 25 Air Filled 104 lb in 7 3 kg cm Foam Filled 135 lb in 9 5 kg cm 400 75 28 Air Filled 110 lb in 7 7 kg cm...

Page 179: ...mple 5 6 Capacity Indicator Locations 5 5 Carriage w Forks 5 15 Chemical Hazards 1 14 Controls 3 2 Cooling System 9 4 Coupler Mounted Hook 5 30 D Dash Controls and Indicators 3 4 Decals ANSI 2 4 ISO 2...

Page 180: ...rs 7 5 Mast Carriage 5 24 Material Handling Arm 5 44 O Operating with a Non Suspended Load 4 5 4 6 Operating with a Suspended Load 4 9 Operation 4 1 Operational Check 2 12 Operator Cab 2 13 Operator M...

Page 181: ...rection of Travel 3 10 Gear Selection 3 11 Transmission Oil Level 7 25 Transport Lifting 4 13 Tie Down 4 12 Transporting a Load 4 7 Transporting a Suspended Load 4 10 Trash Hopper Fork Mounted 5 40 Tr...

Page 182: ...Index 4 31211018...

Page 183: ...Inspection Maintenance and Repair Log Serial Number___________________________________ Date Comments Inspection Maintenance and Repair Log...

Page 184: ...Inspection Maintenance and Repair Log Date Comments...

Page 185: ...r rented units should not be included on this form Mfg Model ______________________________________________________________ Serial Number ___________________________________________________________ Pr...

Page 186: ......

Page 187: ...osed point thumb upward LOWER BOOM With either arm extended horizontally fingers closed point thumb downward MOVE SLOWLY Place one hand motionless in front of hand giving motion signal Raise load slow...

Page 188: ...rmany 49 0 421 69350 0 49 0 421 69350 45 Email german parts jlg com JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong 852 2639 5783 852 2639 5797 JLG Indus...