Page 1 Operation & Safety Manual Original Instructions Keep this manual with machine at all times. Models 6036, 6042, 8042, 10042, 10054 SN 0160069719 to Present including 0160065791, 0160065792, 0160065796, 0160065798, 0160065824, 0160065825, 0160065826, 0160069336, 0160069359, 0160069383, 0160069411, 0160069441, 0160069566, 0160069567 & 0160069568 31211018 Revised July 17, 2017...
Page 2 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,...
Page 3 Revision Log Revision Log REVISION LOG April 2, 2015 - A - Original Issue of Manual April 17, 2015 - B - Revised pages d & 5-1. April 30, 2015 - C - Revised page 9-4. October 12, 2015 - D - Revised cover and pages d, 2-1, 2-4 thru 2-11, 3-7, 3-23, 4-5, 5-2, 6-2, 7-3 thru 7-6, 7-15 thru 7-21, 9-1, 9-3, 9-4 &...
Page 4: Read This First
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.
Page 5 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.
Page 6: Other Publications Available
Read This First Other Publications Available Service Manual..........................31211015 Parts Manual 6036 & 6042...........................31211016 8042, 10042 & 10054 ......................31211017 Note: The following standards may be referenced in this manual: ANSI is compliant to ANSI/ITSDF B56.6 AUS is compliant to AS 1418.19 CE is compliant to EN1459 Refer to the machine Serial Number Plate to identify the applicable compliance standard.
Page 7: Table Of Contents
Table of Contents Table of Contents TABLE OF CONTENTS Revision Log Read This First Operator Qualifications ............b Modifications ..............b Other Publications Available ..........d Machine Configuration ............d Table of Contents Section 1 - General Safety Practices 1.1 Hazard Classification System ..............1-1 Safety Alert System and Safety Signal Words.......1-1 ........................1-1 1.2 General Precautions ..................1-1...
Page 8 Table of Contents Section 3 - Controls and Indicators 3.1 General......................3-1 3.2 Controls ......................3-2 Dash Controls and Indicators.............3-4 Instrument Cluster .................3-6 Ignition .......................3-8 Park Brake....................3-9 Parking Procedure..................3-9 Transmission Control Lever ............. 3-10 Boom Joystick ..................3-12 Auxiliary Hydraulic Joystick ............. 3-13 Frame Level Joystick................
Page 9 Table of Contents Section 4 - Operation 4.1 Engine........................4-1 Starting the Engine ................4-1 Battery Boosted Starting ..............4-2 Normal Engine Operation..............4-3 Shut-Down Procedure ................4-3 4.2 After-Treatment System (ATS) (if equipped for ULS/85 or 110HP) ..................4-4 Automatic Exhaust System Cleaning..........4-4 Stationary Exhaust 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...
Page 10 Table of Contents Section 5 - Attachments 5.1 Approved Attachments ................5-1 5.2 Unapproved Attachments .................5-1 5.3 JLG Supplied Attachments ................5-2 5.4 Telehandler/Attachment/Fork Capacity..........5-4 5.5 Use of the Capacity Chart................5-5 Capacity Indicator Locations ..............5-5 Sample Capacity Chart .................5-6 Example......................5-8 5.6 Attachment Installation................5-10 Hydraulic Operated Attachment ...........
Page 11 Table of Contents 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 Maintenance Schedules................7-3 Every 10 Hours ..................7-3 First 50 Hours....................7-3 Every 50 Hours ..................7-4 First 250 Hours ..................7-4 Every 250 Hours..................7-4 First 500 Hours ..................7-5 Every 500 Hours..................7-5 Every 750 Hours..................7-5...
Page 12 Table of Contents 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 31211018...
Page 13: Section 1 - General Safety Practices
Section 1- General Safety Practices SECTION 1 - GENERAL SAFETY PRACTICES HAZARD CLASSIFICATION SYSTEM Safety Alert System and Safety Signal Words DANGER DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 14: Operation Safety
Section 1- General Safety Practices OPERATION SAFETY Note: The manufacturer has no direct control over machine application and operation. Therefore, safety issues listed in this manual are non-exhaustive. The user and operator are responsible for conforming with good safety practices. Electrical Hazards 10 ft (3m)
Page 15 Section 1- General Safety Practices • The minimum approach distance may be reduced if insulating barriers are installed to prevent contact, and the barriers are rated for the voltage of the line being guarded. These barriers shall not be part of (or attached to) the machine. The minimum approach distance shall be reduced to a distance within the designed working dimensions of the insulating barrier.
Page 16: Tip Over Hazard
Section 1- General Safety Practices Tip Over Hazard General • For additional load requirements, refer to the appropriate capacity chart. OW0050 • Never use an attachment without the appropriate original equipment manufacturer (OEM) approved capacity chart installed on the telehandler. •...
Page 17 Section 1- General Safety Practices 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 •...
Page 18 Section 1- General Safety Practices Non-Suspended Load O 0901 • DO NOT drive with boom raised. Suspended Load OW0150 • Tether suspended loads to restrict movement. • Weight of all rigging (slings, etc.) must be included as part of load. •...
Page 19: Travel Hazard
Section 1- General Safety Practices Travel Hazard 2-WHEEL FRONT STEER 4-WHEEL CIRCLE STEER 4-WHEEL CRAB STEER OAL2030 • Steering characteristics differ between steer modes. Identify the steer mode settings of the telehandler being operated. • DO NOT change steer modes while traveling. Steer modes must be changed while telehandler is stationary.
Page 20: Load Falling Hazard
Section 1- General Safety Practices Load Falling Hazard OW0130 • 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 spaced apart as far as possible. 31211018...
Page 21: Lifting Personnel
Section 1- General Safety Practices Lifting Personnel O 0171 • When lifting personnel, USE ONLY an approved personnel work platform, with proper capacity chart displayed in the cab. O 0921 • DO NOT drive machine from cab when personnel are in platform. 31211018...
Page 22: Driving Hazards On Slopes
Section 1- General Safety Practices Driving Hazards on Slopes OW0200 To maintain sufficient traction and braking capabilities, travel on slopes as follows: • When unloaded, drive with forks pointed downhill. • When loaded, drive with the forks pointed uphill. • For additional travel requirements, refer to the appropriate capacity chart. •...
Page 23: Pinch Points And Crush Hazards
Section 1- General Safety Practices 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 •...
Page 24 Section 1- General Safety Practices 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. 1-12 31211018...
Page 25: Fall Hazard
Section 1- General Safety Practices 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 4-3 has been performed.
Page 26: Chemical Hazards
• 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.
Page 27: Clearsky (If Equipped)
Section 1- General Safety Practices CLEARSKY (IF EQUIPPED) Federal Communications Commission (FCC) Information for Users FCC Statement Regarding Interference This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation.
Page 28 Section 1- General Safety Practices Notice Regarding Radio Frequency Radiation Exposure Do not operate your unit when a person is within eight inches (20 centimeters) of the antenna. A person or object within eight inches (20 centimeters) of the antenna could impair call quality and may cause the unit to operate at a higher power level than necessary, as well as expose that person to RF energy in excess of that established by the FCC RF Exposure Guidelines.
Page 29: Section 2 - Pre-Operation And Inspection
Section 2- Pre-Operation and Inspection SECTION 2 - PRE-OPERATION AND INSPECTION PREPARATION, INSPECTION AND MAINTENANCE The following table covers the periodic machine inspections and maintenance required. Consult local regulations for further requirements for telehandlers. The frequency of inspections and maintenance must be increased as necessary when the machine is used in a harsh or hostile environment, if the machine is used with increased frequency, or if the machine is used in a severe manner.
Page 30: Pre-Operation Check And Inspection
Section 2- Pre-Operation and Inspection PRE-OPERATION CHECK AND INSPECTION Note: Complete all required maintenance before operating unit. WARNING FALL HAZARD. Use extreme caution when checking items beyond your normal reach. Use an approved ladder. The pre-operation check and inspection, performed at beginning of each work shift or at each change of operator, should include the following: 1.
Page 31 Section 2- Pre-Operation and Inspection 8. Operational Check—Once walk-around inspection is complete, perform a warm-up and operational check (see page 2-12) of all systems in an area free of overhead and ground level obstructions. See Section 3- Controls and Indicators for more specific operating instructions.
Page 32: Safety Decals
Section 2- Pre-Operation and Inspection SAFETY DECALS Ensure all DANGER, WARNING, CAUTION and instructional decals and proper capacity charts are legible and in place. Clean and replace as required. ANSI (if equipped) 1706850-ENGLISH 1706306-ENGLISH 1001163304- 1001163285-ENGLISH/FRENCH ENGLISH/FRENCH WARNING Keep others LOWERING BOOM OR FALLING LOAD away while could cause death or serious injury.
Page 33 1001120989 R3 35 A 1001173423 (85HP) Lif t or lower personnel DO NOT TRA VEL (IF EQUIPPED) only in a JLG approved with personnel in R4 35 A work plat form. work plat form. 1706298B ROT ATING P ARTS could...
Page 34 Section 2- Pre-Operation and Inspection 1001191992 (6036) 1001202627 1001191993 (6042) (IF EQUIPPED FOR LS or ULS/74HP) 1001191994 (8042) 1001174152 1001191995 (10042) (IF EQUIPPED FOR ULS/85 or 110HP) 1001191996 (10054) Sky T rak Sky T rak 8042 1001202626 (74HP) 1001173423 (85HP) 1001173422 (110HP) 1000 1500...
Page 35: Iso (If Equipped)
Section 2- Pre-Operation and Inspection ISO (if equipped) 1706288 1706284 1001092877 1001162734 B 1001162734 CAPACITY 1001162737 CHARTS (10042 & 10054) 1001219211 (INSIDE OF RESERVOIR COVER) (SN 0160078382 TO PRESENT) 1001219211A 1001162737 A 1706279 (10042 & 10054) 1001162736 B 1001162735 B 1001162736 1001162735 1001158320 E...
Page 36 Section 2- Pre-Operation and Inspection 1001160916 (IF EQUIPPED WITH REVERSE SENSING SYSTEM) 1706285 1001189328 1706282 1001160916 REV A (10054) 4105262 1001173423 (85HP) R1 35 A R2 35 A 1001173422 (110HP) R3 35 A R4 35 A R5 35 A R6 35 A R7 35 A 1706282C 1001189328A...
Page 37 Section 2- Pre-Operation and Inspection 1001191992 (6036) 1001191993 (6042) 1001191994 (8042) 1001191995 (10042) 1001191996 (10054) 1001202627 Sky T rak 1706285 Sky T rak 8042 1000 1500 2000 4110217 4110339 1001173423 (85HP) 1001173422 (110HP) 1706098 1702300 1001189017 4100181 1001189017 A 4100181 VIEW G-G 1001109053 1001139942...
Page 38: Walk-Around Inspection
Section 2- Pre-Operation and Inspection WALK-AROUND INSPECTION O 5701 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.
Page 39 Section 2- Pre-Operation and Inspection 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 and Electrical • General appearance; no visible damage. •...
Page 40: Warm-Up And Operational Checks
Section 2- Pre-Operation and Inspection 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.
Page 41: Operator Cab
Never operate telehandler unless the overhead guard, cab structure and right side glass or screen are in good condition. Any modification to this machine must be approved by JLG to assure compliance with ROPS/FOPS certification for this cab/ machine configuration. If the overhead guard or cab structure is damaged, the CAB CANNOT BE REPAIRED.
Page 42: Windows
Section 2- Pre-Operation and Inspection WINDOWS Keep all windows and mirrors clean and unobstructed. Cab Door Window (if equipped) OH5570 • Cab door window (2) must either be latched open or closed during operation. • Open cab door window and secure it in latch (3). •...
Page 43: Section 3 - Controls And Indicators
Section 3- Controls and Indicators SECTION 3 - CONTROLS AND INDICATORS GENERAL 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 attachment to ground and stop the engine. Determine cause and correct before continued use.
Page 44: Controls
Section 3- Controls and Indicators CONTROLS OH4980 31211018...
Page 45 Section 3- Controls and Indicators 1. Transmission Control Lever: See page 3-10. 2. Dash Controls and Indicators: See page 3-4. 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 3-17.
Page 46: Dash Controls And Indicators
Section 3- Controls and Indicators Dash Controls and Indicators OH5020 OH5041 O 4990 (IF EQUIPPED WITH HEATER & AC) (IF EQUIPPED WITH HEATER) OH5000 OH5180 31211018...
Page 47 Section 3- Controls and Indicators 1. Park Brake Switch: On/Off switch. See page 3-9 for details. 2. Beacon Light Switch (if equipped): On/Off switch. 3. Hazard Light Switch (if equipped): On/Off switch. 4. Work Light Switch (if equipped): Three position switch. Push bottom of switch to turn all work lights on.
Page 48: Instrument Cluster
Section 3- Controls and Indicators Instrument Cluster 99999.9 12.0V 2488RPM OH5030 OH5010 99999.9 12.0V 2488RPM OH5030 31211018...
Page 49 Section 3- Controls and Indicators 1. Maintenance Indicator: Flashes when fault code present. Illuminates when maintenance is required. See Service Manual for details. 2. Fuel Gauge: Indicates fuel level. 3. Engine Warning Indicator: Illuminates when the engine is a critical state. Immediately bring machine to a stop, retract and lower boom and stop the engine.
Page 50: Ignition
Section 3- Controls and Indicators Ignition O 4990 OH5050 • Position 0: Engine off, no voltage available. • Position 1: Voltage available for all electrical functions. Wait to start engine until engine pre-heat indicator goes out. • Position 1: Engine run. •...
Page 51: Park Brake
Section 3- Controls and Indicators Park Brake O 4990 OH5060 Park brake switch controls application and release of park brake. Indicator on switch illuminates to indicate brake is applied. • With engine running and the park brake switch in "OFF" position (1), park brakes are disengaged.
Page 52: Transmission Control Lever
Section 3- Controls and Indicators Transmission Control Lever Direction of Travel Selection OH5070 OH5080 Transmission control lever (1) engages forward or reverse travel. • Lift and push lever forward for forward travel; lift and pull lever rearward for reverse travel. Move lever to centered position for neutral. •...
Page 53 Section 3- Controls and Indicators Gear Selection OH5090 OH5080 Gear selection is located on the twist grip handle (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.
Page 54: Boom Joystick
Section 3- Controls and Indicators Boom Joystick 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. OH5100 Boom Joystick (1) controls boom and attachment tilt functions.
Page 55: Auxiliary Hydraulic Joystick
Section 3- Controls and Indicators Auxiliary Hydraulic Joystick OH5120 Auxiliary hydraulic joystick (2) controls function of attachments that require hydraulic supply for operation. See Section 5- Attachments for approved attachments and control instructions. 31211018 3-13...
Page 56: Frame Level Joystick
Section 3- Controls and Indicators Frame Level Joystick OH5130 Frame level joystick (1) controls left to right frame level. • Move joystick left to rotate frame left, move joystick right to rotate frame right. • A level indicator is located above front cab window to permit operator to determine whether telehandler frame is level.
Page 57: Outrigger Switches (10042 & 10054)
Section 3- Controls and Indicators Outrigger Switches (10042 & 10054) OH5140 Outrigger switches control outriggers. • Left switch controls left outrigger and right switch controls right outrigger. • Push bottom of switches (1) to lower outriggers; push top of switches (2) to raise outriggers.
Page 58: Accessory Control Lever (If Equipped)
Section 3- Controls and Indicators Accessory Control Lever (if equipped) Accessory control lever (3) operates turn signals, parking lights and headlights. OH5150 OH5080 Turn Signal • Raise lever (4) to activate left turn signal. • Lower lever (5) to activate right turn signal. •...
Page 59: Steer Modes
Section 3- Controls and Indicators STEER MODES Three steer modes are available for operator use. 2-Wheel Front Steer 4-Wheel Circle Steer 4-Wheel Crab Steer OAL2030 Note: 2-Wheel Front Steer mode is required for travel on public roads. Steer Mode Change Note: Steer mode will change immediately after selection.
Page 60: Stabil-Trak™ System (6042, 8042, 10042 & 10054)
Section 3- Controls and Indicators STABIL-TRAK™ SYSTEM (6042, 8042, 10042 & 10054) OH4941 Free Pivot Mode With boom below 40° (6), Stabil-Trak system is in Free Pivot Mode. Rear axle pivots freely and frame level functions normally. Stabil-Trak indicator (8) will be off. Slow Pivot Mode With boom above 40°...
Page 61: Boom/Outrigger Interlock System (10054)
Section 3- Controls and Indicators BOOM/OUTRIGGER INTERLOCK SYSTEM (10054) Boom/outrigger interlock system allows boom to be extended to its maximum limits. OH4951 Extend Interlock Mode With outriggers raised (1), telehandler is in extend interlock mode which limits boom extension (2). •...
Page 62: Operator Seat
Section 3- Controls and Indicators OPERATOR SEAT Adjustments Prior to starting engine adjust seat for position and comfort. Prior to SN 0160074878 OH5170 1. Suspension: Use knob to adjust suspension to the appropriate setting. Turn clockwise to increase stiffness. Turn counterclockwise to reduce stiffness. 2.
Page 63 Section 3- Controls and Indicators SN 0160074878 to Present Oh5790 1. Suspension: Use knob to adjust suspension to the appropriate setting. Turn clockwise to increase stiffness. Turn counterclockwise to reduce stiffness. 2. Fore/Aft: Pull up on handle to move seat fore and aft. 3.
Page 64: Seat Belt
Section 3- Controls and Indicators 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 seat, couple retractable end (male end) of belt into receptacle (buckle) end of belt.
Page 65: Boom Angle And Extension Indicators
Section 3- Controls and Indicators BOOM ANGLE AND EXTENSION INDICATORS OH3951 • Boom angle indicator (1) is located 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).
Page 66: Reverse Sensing System (If Equipped)
Section 3- Controls and Indicators REVERSE SENSING SYSTEM (IF EQUIPPED) WARNING CRUSH HAZARD. Running into persons or objects can cause death, serious injury, or damage to property and equipment. Always check mirrors and area behind machine before and when backing up. Reverse systems are for supplementary use only. Reverse Sensing System provides audible indication of objects to rear of machine while in reverse gear.
Page 67: Section 4 - Operation
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.
Page 68: Battery Boosted Starting
Section 4- Operation Battery Boosted Starting OW0530 If battery-boost starting (jump-start) is necessary, proceed as follows: • Never allow vehicles to touch. • Ensure boosting vehicle engine is running. • Connect positive (+) jumper cable to positive (+) post of discharged battery. •...
Page 69: Normal Engine Operation
When operating a machine at high temperatures, a decrease in machine performance and an increase in engine coolant temperature may occur. Contact JLG for operation under abnormal conditions. 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.
Page 70: After-Treatment System (Ats) (If Equipped For Uls/85 Or 110Hp)
Section 4- Operation AFTER-TREATMENT SYSTEM (ATS) (IF EQUIPPED FOR ULS/85 OR 110HP) This machine is equipped with an exhaust After-Treatment System. O 5610 OH5010 Automatic Exhaust System Cleaning ATS is an automatic exhaust cleaning system and will perform as required without any operator interaction.
Page 71: Stationary Exhaust System Cleaning
Section 4- Operation Stationary Exhaust System Cleaning Selective Catalytic Reduction (SCR) Indicator (2) will illuminate when stationary exhaust system cleaning is required. 1. Move telehandler to an area free of flammables and people that could be exposed to hot exhaust. 2.
Page 72: Operating With A Non-Suspended Load
Section 4- Operation OPERATING WITH A NON-SUSPENDED LOAD Lift Load Safely • You must know 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 material. WARNING TIP OVER HAZARD.
Page 73: Transporting A Load
Section 4- Operation Transporting a 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.
Page 74: Placing A Load
Section 4- Operation Placing a Load Before placing any load be sure that: • The landing point can safely support the weight of the load. • The landing point is level; front to back and side to side. • Use the capacity chart to determine safe boom extension range. See “Use of the Capacity Chart”...
Page 75: Operating With A Suspended Load
Section 4- Operation OPERATING WITH A SUSPENDED LOAD Lift Load Safely • You must know the weight and load center of every load you lift. If you are not sure of weight and load center, check with your supervisor or with supplier of material. WARNING TIP OVER HAZARD.
Page 76: Transporting A Suspended Load
Section 4- Operation Transporting a Suspended Load OZ3160 OW0130 • Travel in accordance with the requirements set forth in Section 1- General Safety Practices and Section 5- Attachments. • For additional requirements, refer to appropriate capacity chart in operator cab. Important things to remember: •...
Page 77: Placing A Suspended Load
Section 4- Operation Placing a Suspended Load Before placing any load be sure that: • The landing point can safely support the weight of the load. • The landing point is level; front to back and side to side. • Use the capacity chart to determine safe boom extension range. See “Use of the Capacity Chart”...
Page 78: Loading And Securing For Transport
Section 4- Operation LOADING AND SECURING FOR TRANSPORT Tie Down OH5260 1. Level telehandler prior to loading. 2. Using a spotter, load telehandler with boom as low as possible. 3. Once loaded, apply parking brake and lower boom until boom or attachment is resting on deck.
Page 79: Lifting
Section 4- Operation Lifting O 5690 The weight of the machine is listed on the serial number plate located at the front of the frame. Actual machine weight and center of gravity will vary depending on attachment, fluid levels and machine options. Actual weight and center of gravity should be verified prior to lifting.
Page 80 Section 4- Operation This Page Intentionally Left Blank 4-14 31211018...
Page 81: Section 5 - Attachments
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 telehandler being used. Contact JLG or a local distributor for further information. UNAPPROVED ATTACHMENTS Do not use unapproved attachments for the following reasons: •...
Page 82: Jlg Supplied Attachments
Section 5- Attachments JLG SUPPLIED ATTACHMENTS Applicable Model Part Attachment Number 6036 6042 8042 10042 10054 1001146084 Carriage, 50 in (1270 mm) 1170021 1001146086 Carriage, 60 in (1524 mm) 1170024 1001146088 Carriage, 72 in (1829 mm) 1001193794 1001211516 Side Shift Carriage, 50 in (1270 mm)
Page 83 Section 5- Attachments Applicable Model Part Attachment Number 6036 6042 8042 10042 10054 Platform, Fork Mounted (ASME) 1001103637 Platform, Fork Mounted (ASME - French) 1001103736 Platform, Fork Mounted (ISO) 1001103730 Sweeper 1001202904 Sheet Handler 1001100227 31211018...
Page 84: Telehandler/Attachment/Fork Capacity
Lifting and placing a load may require use of more than one capacity chart based on machine configuration. Other than block forks, all forks should be used in matched pairs, block forks used in matched sets. WARNING Never use an attachment without the appropriate JLG approved capacity chart installed on the telehandler. 31211018...
Page 85: Use Of The Capacity Chart
Section 5- Attachments USE OF THE CAPACITY CHART To properly use capacity chart (see page 5-6), operator must first determine and/or have the following: 1. An approved attachment. See “Approved Attachments” on page 5-1. 2. Proper Capacity Chart(s). 3. Weight of load being lifted. 4.
Page 86: Sample Capacity Chart
Section 5- Attachments Sample Capacity Chart This Capacity Chart may be used with this model ONLY. The telehandler model is indicated on the boom or chassis. Model XXXXX is used for demonstration purposes only. Attachment type, weight and dimensions must be <...
Page 87 Section 5- Attachments To identify 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. OH4410 • Use when lifting a load with outriggers down. OH4420 31211018...
Page 88: Example
Section 5- Attachments Example A contractor owns a model xxxxx telehandler with a fork carriage. He knows this attachment may be used with his model since: • The attachment style, weight, dimensions and load center match the attachment data on the capacity chart. •...
Page 89 Section 5- Attachments This Page Intentionally Left Blank 31211018...
Page 90: Attachment Installation
Section 5- Attachments ATTACHMENT INSTALLATION OH4430 1. Attachment 2. Attachment Pin Recess 3. Attachment Pin 4. Lock Pin 5. Lock 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 lock pin and lock lever.
Page 91 Section 5- Attachments This installation procedure is designed for one-person operation. Prior to exiting cab, perform “Shut-Down Procedure” on page 4-3. 1. Tilt quick coupler back to provide clearance. Check to be sure lock pin is removed. OH4440 2. Align attachment pin with recess in attachment. Raise boom slightly to engage attachment pin in recess.
Page 92: Hydraulic Operated Attachment
Section 5- Attachments Hydraulic Operated Attachment 1. Install attachment (see page 5-10). 2. Lower attachment to ground and perform “Shut-Down Procedure” on page 4-3. OH4480 3. Connect attachment hoses to both auxiliary fittings (1). 5-12 31211018...
Page 93: Adjusting/Moving Forks
Section 5- Attachments 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.
Page 94: Attachment Operation
Section 5- Attachments ATTACHMENT OPERATION • Capacities and range limits for telehandler change depending on 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 attachment if it is equipped with a manual holder.
Page 95: Carriage With Forks
Section 5- Attachments Carriage with Forks Use Carriage Attachment Capacity Chart. To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-4. OY0690 O 5231 Joystick (1) controls movement of the boom. Roller switch (2) controls fork tilt. • Move joystick back to tilt up. •...
Page 96: Side Shift Carriage
Section 5- Attachments Side Shift Carriage Use Side Shift Carriage Capacity Chart. To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-4. OAL1540 O 5231 OH5360 Joystick (1) controls movement of the boom. Roller switch (2) controls fork tilt. •...
Page 97 Section 5- Attachments Installation Procedure: • Refer to “Attachment Installation” on page 5-10. WARNING CRUSH HAZARD. Do not use side shift to push or pull objects or load. Failure to comply could cause object or load to fall. Equipment Damage Precautions: •...
Page 98: Side Tilt Carriage
Section 5- Attachments Side Tilt Carriage Use Side Tilt Carriage Attachment Capacity Chart. To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-4. OAL1550 O 5231 OH5270 Joystick (1) controls movement of the boom. Roller switch (2) controls fork tilt. •...
Page 99 Section 5- Attachments Installation Procedure: • Refer to “Attachment Installation” on page 5-10. WARNING CRUSH HAZARD. Do not use side tilt to push or pull objects or load. Failure to comply could cause object or load to fall. Operation: • Approach load with forks centered on load and stop telehandler. •...
Page 100: Swing Carriage
Section 5- Attachments Swing Carriage Use Swing Carriage Attachment Capacity Chart. To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-4. OU2150 O 5231 OH5280 Joystick (1) controls movement of the boom. Roller switch (2) controls fork tilt. •...
Page 101 Section 5- Attachments Installation Procedure: • Refer to “Attachment Installation” on page 5-10. WARNING CRUSH HAZARD. Always level forks (horizontally) and telehandler frame before swinging load to side. Swinging unlevel forks could cause load to slide off forks. WARNING CRUSH HAZARD. Do not use swing carriage to push or pull objects or load. Failure to comply could cause object or load to fall.
Page 102: Dual Fork Positioning Carriage
Section 5- Attachments Dual Fork Positioning Carriage Use Carriage Attachment Capacity Chart. To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-4. OZ3670 O 5231 OH5290 Joystick (1) controls movement of the boom. Roller switch (2) controls fork tilt. •...
Page 103 Section 5- Attachments Installation Procedure: • Refer to “Attachment Installation” on page 5-10. WARNING CRUSH HAZARD. Do not use fork positioning to push or pull objects or load. Failure to comply could cause object or load to fall. Operation: • Travel in accordance with requirements set forth in Section 1- General Safety Practices.
Page 104: Mast Carriage
Section 5- Attachments Mast Carriage Use Mast Carriage Attachment Capacity Chart. To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-4. OY0580 O 5231 OH5300 Joystick (1) controls movement of the boom. Roller switch (2) controls fork tilt. •...
Page 105 Section 5- Attachments Installation Procedure: • Refer to “Attachment Installation” on page 5-10. WARNING CRUSH HAZARD. Do not use mast to push or pull objects or load. Failure to comply could cause object or load to fall. Operation: • Always lower forks fully in mast before engaging load. •...
Page 106: Pipe Grapple
Section 5- Attachments Pipe Grapple Use Pipe Grapple Attachment Capacity Chart. To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-4. OH5660 O 5231 O 5651 Joystick (1) controls movement of the boom. Roller switch (2) controls pipe grapple tilt. •...
Page 107 Section 5- Attachments Installation Procedure: • Refer to “Attachment Installation” on page 5-10. Operation: • Raise or lower boom to appropriate height and open pipe grapple for loading material. • Align and center telehandler with face of material. • Drive slowly and smoothly into material for loading. Boom extension may be required for loading of material in some situations.
Page 108: Fork Extension
5-4. The maximum capacity of the 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 fork extensions of the proper load rating and length.
Page 109 Section 5- Attachments Installation Procedure: • Ensure carriage is properly installed. Refer to “Attachment Installation” on page 5-10. • Ensure length and cross section of the parent fork arm is equal to or exceeds the parent fork arm blade length stamped into the fork extension. •...
Page 110: Coupler Mounted Hook
Section 5- Attachments Coupler Mounted Hook Use Coupler Mounted Hook Capacity Chart. To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-4. O 0131 Suspend loads in accordance with requirements set forth in Section 1- General Safety Practices. O 5851 Joystick (1) controls movement of the boom.
Page 111 Section 5- Attachments 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. 31211018 5-31...
Page 112: Fork Mounted Hook
Section 5- Attachments Fork Mounted Hook Use Appropriate Carriage Attachment Capacity Chart. To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-4. OY0640 Suspend loads in accordance with requirements set forth in Section 1- General Safety Practices. O 5351 Joystick (1) controls movement of the boom.
Page 113 Section 5- Attachments Installation Procedure: • Ensure carriage is properly installed. Refer to “Attachment Installation” on page 5-10. • Secure the fork mounted hook to the forks by sliding the fork mounted hook onto the parent forks and install the retaining pin behind the vertical shank of the fork. Operation: •...
Page 114: Bucket
Section 5- Attachments Bucket Use Appropriate Bucket Attachment Capacity Chart. To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-4. OZ0730 O 5321 Joystick (1) controls movement of the boom. Roller switch (2) controls bucket tilt. • Press roller switch down to tilt up. •...
Page 115 Section 5- Attachments Installation Procedure: • Refer to “Attachment Installation” on page 5-10. 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.
Page 116: Grapple Bucket
Section 5- Attachments Grapple Bucket Use Grapple Bucket Attachment Capacity Chart. To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-4. OZ1450 O 5321 OH5330 Joystick (1) controls movement of the boom. Roller switch (2) controls bucket tilt. •...
Page 117 Section 5- Attachments Installation Procedure: • Refer to “Attachment Installation” on page 5-10. Operation: • Raise or lower boom to appropriate height and open grapple for loading material from stockpile. • Align telehandler with face of stockpile and drive slowly and smoothly into pile to load bucket.
Page 118: Bucket - Fork Mounted
Section 5- Attachments Bucket - Fork Mounted Use Appropriate Carriage Attachment Capacity Chart To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-4. O 2070 O 5321 Joystick (1) controls movement of the boom. Roller switch (2) controls bucket tilt. •...
Page 119 Section 5- Attachments Installation Procedure: • Ensure carriage is properly installed. Refer to “Attachment Installation” on page 5-10. • Secure the fork mounted bucket to the forks by sliding the fork mounted bucket onto the parent forks and install the retaining pin behind the vertical shank of the fork. Operation: •...
Page 120: Trash Hopper - Fork Mounted
Section 5- Attachments Trash Hopper - Fork Mounted Use Appropriate Trash Hopper Capacity Chart To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-4. OD1630 O 5801 Joystick (1) controls movement of the boom Roller switch (2) controls trash hopper tilt. •...
Page 121 Section 5- Attachments Installation Procedure: • Ensure carriage is properly installed. Refer to “Attachment Installation” on page 5-10. • Secure the fork mounted trash hopper to the forks by sliding the fork mounted trash hopper onto the parent forks and install the retaining pin behind the vertical shank of the fork.
Page 122: Truss Boom
Section 5- Attachments Truss Boom Use Appropriate Truss Boom Attachment Capacity Chart. To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-4. OY0570 Suspend loads in accordance with requirements set forth in Section 1- General Safety Practices. O 5311 Joystick (1) controls movement of the boom.
Page 123 Section 5- Attachments Installation Procedures Refer to “Attachment Installation” on page 5-10. WARNING CRUSH HAZARD. Maintain a minimum of three wraps of wire rope on the cable drum at all times. Failure to comply could cause object or load to fall. Operation: •...
Page 124: Material Handling Arm
Section 5- Attachments Material Handling Arm Use Appropriate Material Handling Arm Attachment Capacity Chart. To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-4. OH5670 Suspend loads in accordance with requirements set forth in Section 1- General Safety Practices. Oh5681 Joystick (1) controls movement of the boom.
Page 125 Section 5- Attachments Installation Procedures • Refer to “Attachment Installation” on page 5-10. • Secure adjustable arm in desired position using the retaining pin. WARNING CRUSH HAZARD. Ensure adjustable arm is properly secured using the retaining pin prior to lifting load. Failure to comply could cause object or load to fall. Operation: •...
Page 126: Personnel Work Platform - Fork Mounted
Section 5- Attachments Personnel Work Platform - Fork Mounted For fork mounted platforms utilized on machines built to the B56.6-2011 Standard or older, use Appropriate Carriage Attachment Capacity Chart. For fork mounted platforms utilized on machines built to the OY1610 B56.6-2016 Standard, use Fork Mounted Platform Attachment Capacity Chart.
Page 127 Section 5- Attachments Installation Procedure: • Ensure carriage is properly installed. Refer to “Attachment Installation” on page 5-10. • Secure the fork mounted platform to the forks by sliding the fork mounted platform onto the parent forks and install the retaining pin behind the vertical shank of the fork. Preparation and Setup: 1.
Page 128: Sweeper
Section 5- Attachments Sweeper Use Sweeper Capacity Chart. To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-4. O 5820 O 5831 O 5840 Joystick (1) controls movement of the boom. Roller switch (2) controls sweeper tilt. • Press roller switch down to tilt up. •...
Page 129 Section 5- Attachments Installation Procedure: • Refer to “Attachment Installation” on page 5-10. WARNING CRUSH HAZARD. Remove large objects in path of sweeper before operating. Failure to comply could cause object to be thrown by sweeper. Operation: • Fully retract boom and lower until all four sweeper wheels are in contact with the ground.
Page 130: Boom Mounted Lifting Lug
Section 5- Attachments Boom Mounted Lifting Lug Use Boom Mounted Lifting Lug Capacity Chart. To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-4. O 5810 Suspend loads in accordance with requirements set forth in Section 1- General Safety Practices. O 5231 Joystick (1) controls movement of the boom.
Page 131: Section 6 - Emergency Procedures
Section 6- Emergency Procedures SECTION 6 - EMERGENCY PROCEDURES TOWING A DISABLED PRODUCT The following information assumes 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. •...
Page 132: Emergency Lowering Of Boom
Section 6- Emergency Procedures EMERGENCY LOWERING OF BOOM In the event of total loss of engine power or hydraulic pump failure with an elevated load, the situation must be properly evaluated and dealt with on an individual basis. Contact the local dealer for specific instructions. Secure the telehandler using the following procedures: 1.
Page 133: Emergency Exit From Enclosed Cab
Section 6- Emergency Procedures EMERGENCY EXIT FROM ENCLOSED CAB Fixed Window (if equipped) ANGUS-PALM 005413 OWO740 • In an emergency, an escape hammer located directly below the rear window in an enclosed cab can be used to exit the telehandler. Latch Window (if equipped) O 3510 •...
Page 134 Section 6- Emergency Procedures This Page Intentionally Left Blank 31211018...
Page 135: Section 7 - Lubrication And Maintenance
Section 7- Lubrication and Maintenance SECTION 7 - LUBRICATION AND MAINTENANCE INTRODUCTION This section is intended as information to assist the operator to perform maintenance tasks only. Service product in accordance with maintenance schedule on the following pages. OH5370 The Lubrication and Maintenance decals (1) contain instructions that must be followed to keep this product in good operating condition.
Page 136: General Maintenance Instructions
Section 7- Lubrication and Maintenance GENERAL MAINTENANCE INSTRUCTIONS Prior to performing any service or maintenance on telehandler, follow shut-down procedure on page 4-3 unless otherwise instructed. Ensure telehandler is level, for proper fluid readings. • Clean lubrication fittings before lubricating. •...
Page 137: Maintenance Schedules
Section 7- Lubrication and Maintenance MAINTENANCE SCHEDULES Note: If hour and year intervals are listed, perform maintenance at interval that occurs first. Every 10 Hours O 0960 O 0910 O 0920 O 0970 Drain Fuel/Water Check Engine Check Engine Oil Check Hydraulic Separator Coolant Level...
Page 138: Every 50 Hours
Section 7- Lubrication and Maintenance Every 50 Hours O 1010 O 1020 Check Washer Lubrication Fluid Schedule First 250 Hours O 1040 O 1050 O 1070 Change Axle Oil Change Wheel End Change Transmission Fluid and Filter Every 250 Hours O 1010 O 1110 O 1130...
Page 139: First 500 Hours
Section 7- Lubrication and Maintenance First 500 Hours O 1140 Change Engine Oil and Filter (if equipped for ULS) Every 500 Hours O 1170 O 1160 O 0990 O 1150 Check Fan Belt Change Engine Oil Check Battery Check Wheel Lug and Filter (if Nut Torque equipped for LS)
Page 140: Every 1000 Hours
Section 7- Lubrication and Maintenance Every 1000 Hours O 1010 O 1040 O 1050 O 1170 Lubrication Change Axle Oil Change Wheel End Change Engine Oil Schedule and Filter (if equipped for ULS, see note) O 1070 OH5860 O 1000 O 1210 Change Check Boom Chain...
Page 141: Every 2000 Hours Or 2 Years
Section 7- Lubrication and Maintenance Every 2000 Hours or 2 Years O 1250 O 1240 OC1310 Change Engine Change DEF Tank Change Engine Coolant and Clean Filter (if equipped Coolant (if Engine DEF for ULS/85 or equipped for LS) Strainer 110HP) (if equipped for ULS/85 or 110HP)
Page 142: Lubrication Schedules
Section 7- Lubrication and Maintenance LUBRICATION SCHEDULES 50 Hour Lubrication Schedule 6036 & 6042 EVERY O 5721 31211018...
Page 143 Section 7- Lubrication and Maintenance 8042 & 10042 EVERY O 5731 31211018...
Page 144 Section 7- Lubrication and Maintenance 10054 EVERY O 5711 7-10 31211018...
Page 145: 250 Hour Lubrication Schedule
Section 7- Lubrication and Maintenance 250 Hour Lubrication Schedule 6036 & 6042 EVERY 6042 ONLY O 1830 31211018 7-11...
Page 146 Section 7- Lubrication and Maintenance 8042, 10042 & 10054 EVERY EVERY EVERY EVERY EVERY OH5740 OH5740 OH5740 OH5740 OH5740 7-12 31211018...
Page 147: 1000 Hour Lubrication Schedule
Section 7- Lubrication and Maintenance 1000 Hour Lubrication Schedule EVERY 1000 OH4181 31211018 7-13...
Page 148: Operator Maintenance Instructions
Section 7- Lubrication and Maintenance OPERATOR MAINTENANCE INSTRUCTIONS Fuel System A. Fuel Level Check OW0990 OD1350 OH5440 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 4-3. 3.
Page 149 Section 7- Lubrication and Maintenance B. Drain Fuel/Water Separator OW0970 OW1000 IF EQUIPPED FOR ULS O 5451 IF EQUIPPED FOR LS O 5750 1. Perform “Shut-Down Procedure” 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.
Page 150: Diesel Exhaust Fluid (Def) System (If Equipped For Uls/85 Or 110Hp)
Section 7- Lubrication and Maintenance Diesel Exhaust Fluid (DEF) System (if equipped for ULS/85 or 110HP) A. DEF Level Check OW0970 OD1350 OH5580 1. Check DEF level (1) located on instrument cluster in cab. 2. If DEF is low, proceed to DEF source and perform “Shut-Down Procedure” on page 4-3. 3.
Page 151: Engine Oil
Section 7- Lubrication and Maintenance Engine Oil A. Engine Oil Level Check OW0970 OW1020 IF EQUIPPED FOR ULS O 5472 IF EQUIPPED FOR LS O 5760 1. Perform “Shut-Down Procedure” on page 4-3. 2. Open engine access door. 3. Remove dipstick (3) and check oil mark. The oil should be between the full (6) and add (5) marks within the crosshatched area of the dipstick.
Page 152: Air Intake System
Section 7- Lubrication and Maintenance Air Intake System If Equipped for ULS A. Air Cleaner Check OW0970 OW1010 OD0780 1. Perform “Shut-Down Procedure” on page 4-3. 2. Open engine access door. 3. Remove dust from vacuator valve (1) by squeezing bottom of valve to allow loose particles to fall out.
Page 153 Section 7- Lubrication and Maintenance B. Restriction Fault Code 1. Fault Code 107:15 indicates restricted air filter. 2. Primary element (3) must be replaced. C. Element Change Note: Change elements as restriction fault code indicates or every two years. Use the interval that occurs first.
Page 154 Section 7- Lubrication and Maintenance If Equipped for LS A. Air Cleaner Check OW0970 OW1010 OH5770 1. Perform “Shut-Down Procedure” on page 4-3. 2. Open engine access door. 3. Locate air cleaner (1) and check restriction indicator (2). If red band is visible, element(s) must be replaced.
Page 155 Section 7- Lubrication and Maintenance B. Restriction Fault Code 1. Fault Code 107:15 indicates restricted air filter. 2. Primary element (5) must be replaced. C. Element Change (as restriction indicator or fault code indicates) Note: Change elements as air cleaner restriction indicator or restriction fault code indicates or every two years.
Page 156: Hydraulic Oil
Section 7- Lubrication and Maintenance Hydraulic Oil A. Hydraulic Oil Level Check OW0970 OW1030 OH5480 1. Be sure all cylinders are fully retracted and machine is level. 2. Perform “Shut-Down Procedure” on 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.
Page 157: Tires
• 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.
Page 158 Section 7- Lubrication and Maintenance 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.
Page 159: Transmission Oil
Section 7- Lubrication and Maintenance Transmission Oil A. Transmission Oil Level Check OW0970 OW1050 OH4860 1. Apply park brake, shift transmission to "Neutral" and lower forks or attachment to the ground. 2. Check the transmission oil level with the engine at idle and oil at normal operating temperature.
Page 160: Engine Cooling System
Section 7- Lubrication and Maintenance Engine Cooling System A. Engine Coolant Level Check OW0970 OW1070 OH5420 1. Perform “Shut-Down Procedure” on page 4-3. 2. Open rear access door. 3. Coolant level should be visible in surge tank (3). 4. If coolant is low, allow fluid to cool. 5.
Page 161: Brake Fluid (Sn 0160074878 To Present)
Section 7- Lubrication and Maintenance Brake Fluid (SN 0160074878 to Present) A. Brake Fluid Level Check OW0970 OD1380 O 5780 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 reservoir.
Page 162: Battery
Section 7- Lubrication and Maintenance Battery A. Battery Check OW0980 OW1080 OH4900 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 damaged case. 4.
Page 163: Section 8 - Additional Checks
Section 8- Additional Checks SECTION 8 - ADDITIONAL CHECKS STABIL-TRAK (6042, 8042, 10042 & 10054) A. Stabil-Trak Indicator Test OW0970 OH4340 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.
Page 164: Boom/Outrigger Interlock (10054)
Section 8- Additional Checks BOOM/OUTRIGGER INTERLOCK (10054) A. Boom/Outrigger Interlock System Test OW0970 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”...
Page 165: Reverse Sensing System (If Equipped)
Section 8- Additional Checks REVERSE SENSING SYSTEM (IF EQUIPPED) A. Reverse Sensing System Check OW0970 Reverse Sensing System provides audible indication of objects to rear of unit while in reverse gear. 1. Clear all people and/or obstacles behind machine before performing Reverse Sensing System check.
Page 166 Section 8- Additional Checks This Page Intentionally Left Blank 31211018...
Page 167: Section 9 - Specifications
Section 9- Specifications Section 9 - Specifications Product Specifications Fluids If Equipped for ULS Ambient Temperature Range Compartment or Type and Viscosities System Classification °F °C Min Max Min Max SAE 5W-40 SAE 15W-40 API CJ-4 Plus Engine Crankcase CES-20081 SAE 10W-30 Fully Synthetic** SAE 5W-30...
Page 168 Section 9- Specifications Ambient Temperature Range Compartment or Type and Viscosities System Classification °F °C Min Max Min Max Diesel Exhaust Fluid (DEF) ISO22241-1 32.5% Urea (85 or 110HP) Brake Fluid (SN 0160074878 Mobil ATF-D/M to Present) Air Conditioning Refrigerant R-134a Tetrafluoroethane *Friction Modifier may be added to axle differentials when replacing fluid.
Page 169 Section 9- Specifications If Equipped for LS Ambient Temperature Range Compartment or Type and Viscosities System Classification °F °C Min Max Min Max SAE 5W-40 SAE 15W-40 API CI-4 Multigrade Engine Crankcase SAE 10W-30 CES-20078 SAE 5W-30 SAE 0W-30 MobilFluid 424 10W-30 Transmission and Transfer Case...
Page 170: Capacities
Section 9- Specifications Capacities Engine Crankcase Oil Capacity with Filter Change ....................12.7 qt (12 L) Fuel Tank Capacity ............................35 gal (133 L) DEF Tank (if equipped for ULS/85 or 110HP) Capacity ............................5 gal (19 L) Cooling System System Capacity ...........................5 gal (19 L) Hydraulic System System Capacity 6036 &...
Page 171 Section 9- Specifications 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 (0.86 kg) 31211018...
Page 172: Tires
Section 9- Specifications Tires 6036 13.00 x 24, G-2/L-2 Bias Ply Traction - 12 ply Pneumatic ........................55 psi (3,8 bar) Foam ......................... Approx 542 lb (246 kg) 15.50 x 25, G-2/L-2 Bias Ply Traction - 12 Ply Pneumatic ........................55 psi (3,8 bar) Foam .........................
Page 173: Performance
Section 9- Specifications Performance Maximum Lift Capacity 6036 & 6042 ......................6,000 lb (2 722 kg) 8042 ..........................8,000 lb (3 629 kg) 10042 & 10054 ..................... 10,000 lb (4 536 kg) Maximum Lift Height 6036 ............................36 ft (11,0 m) 6042, 8042 & 10042......................42 ft (12,8 m) 10054..........................
Page 174 Section 9- Specifications 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 (45%) Side Slope........................5 degrees (8.75%) 31211018...
Page 175: Dimensions
Section 9- Specifications Dimensions Overall Height 6036 ..........................100 in (2 540 mm) 6042 ..........................102 in (2 591 mm) 8042 ........................... 99.4 in (2 525 mm) 10042 & 10054 .....................100.1 in (2 543 mm) Overall Width 6036 & 6042 ........................99 in (2 515 mm) 8042 ...........................
Page 176 Section 9- Specifications Maximum Operating Weight (no attachment) 6036........................23,550 lb (10 682 kg) 6042........................27,400 lb (12 428 kg) 8042........................28,500 lb (12 927 kg) 10042 ........................30,150 lb (13 676 kg) 10054 ........................31,500 lb (14 288 kg) Distribution of Maximum Operating Weight (no attachment, boom level and fully retracted) Front Axle...
Page 177 Section 9- Specifications Maximum Ground Bearing Pressure 6036 13.00 x 24 Air Filled .....................136 lb/in² (9,6 kg/cm²) Foam Filled..................177 lb/in² (12,4 kg/cm²) Solid ....................204 lb/in² (14,3 kg/cm²) 15.50 x 25 Air Filled .....................137 lb/in² (9,6 kg/cm²) Foam Filled..................178 lb/in² (12,5 kg/cm²) 370/75-28 Air Filled .....................110 lb/in²...
Page 178 Section 9- Specifications 10054 Outriggers ....................102 lb/in² (7,2 kg/cm²) Tires 14.00 x 24 Solid ..................233 lb/in² (16,4 kg/cm²) 17.50 x 25 Air Filled ..................104 lb/in² (7,3 kg/cm²) Foam Filled ................135 lb/in² (9,5 kg/cm²) 400/75-28 Air Filled ..................110 lb/in² (7,7 kg/cm²) Foam Filled ................144 lb/in²...
Page 179: Index
Disengaging a Suspended Load.... 4-11 Attachment Operation ......5-14 Driving Hazards on Slopes ....... 1-10 Attachments.............5-1 Dual Fork Positioning Carriage....5-22 JLG Supplied ..........5-2 Automatic Regeneration ......4-4 Auxiliary Hydraulic Joystick ..... 3-13 Electrical Hazards ...........1-2 Axles ..............9-4 Emergency Exit from Enclosed Cab..6-3 Emergency Lowering of Boom....6-2...
Page 180 Index Hazard Classification System ..... 1-1 Operating with a Non-Suspended Load ............4-5, 4-6 Hydraulic Oil Level ........7-22 Operating with a Suspended Load..4-9 Hydraulic Operated Attachment ....5-12 Operation............4-1 Hydraulic System..........9-4 Operational Check ........2-12 Operator Cab ..........2-13 Ignition............... 3-8 Operator Maintenance Instructions..7-14 Instrument Cluster.........
Page 181 Index Tip Over Hazard..........1-4 Tires ............7-23, 9-6 Air Pressure..........7-23 Damage ........... 7-23 Replacement.......... 7-23 Towing..............6-1 Transmission ............9-4 Transmission Control Lever Direction 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....
Page 182 Index 31211018...
Page 183: Inspection, Maintenance And Repair Log
Inspection, Maintenance and Repair Log Inspection, Maintenance and Repair Log Serial Number ___________________________________ Date Comments...
Page 184 Inspection, Maintenance and Repair Log Date Comments...
Page 185 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.
Page 187 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.
Page 188 +49 (0) 421 69350-45 +39 (0) 2 9359 5211 +(852) 2639 5797 Email:german-parts@jlg.com Email: ricambi@jlg.com J LG EMEA B.V. JLG NZ Access Equipment & Services JLG Industries Polaris Avenue 63 2B Fisher Cresent Vahutinskoe shosse 24b. 2132 JH Hoofdorf Mt Wellington 1060...

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Skytrak 8042 Skytrak 6042 Skytrak 10042 Skytrak 10054

JLG Skytrak 6036 Operation & Safety Manual

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Table of Contents

Section 1 - General Safety Practices

Section 2 - Pre-Operation and Inspection

Table of Contents

Section 3 - Controls and Indicators

Section 4 - Operation

Table of Contents

Section 5 - Attachments

Section 6 - Emergency Procedures

Section 7 - Lubrication and Maintenance

Section 8 - Additional Checks

Table of Contents

Section 9 - Specifications

Index

Inspection, Maintenance and Repair Log

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