JLG Skytrak 6036 Operation & Safety Manual
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JLG Skytrak 6036 Operation & Safety Manual

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Operation & Safety
Keep this manual with machine at all times.
6036, 6042, 8042,
Models
10042, 10054
S/N 0160045066 & After including 0160042742,
0160042747 & 0160042755
8042, 10042 & 10054
S/N 0160045250 & After including 0160042754,
0160042762, 0160042877, 0160042911,
0160043185, 0160043220 & 0160043244
excluding 0160045255
31200749
March 30, 2012
Manual
Original Instructions
6036 & 6042
Original
An Oshkosh Corporation Company

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Summary of Contents for JLG Skytrak 6036

  • Page 1 Operation & Safety Manual Original Instructions Keep this manual with machine at all times. Models 6036, 6042, 8042, 10042, 10054 6036 & 6042 S/N 0160045066 & After including 0160042742, 0160042747 & 0160042755 8042, 10042 & 10054 S/N 0160045250 & After including 0160042754, 0160042762, 0160042877, 0160042911, 0160043185, 0160043220 &...
  • 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 March 30, 2012 - A - Original Issue of Manual 31200749...

  • 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.
  • Page 5 Inc. or the local authorized JLG representative for information regarding safety- related bulletins which may have been issued for this product. JLG Industries, Inc. sends safety related bulletins to the owner of record of this machine. Contact JLG Industries, Inc. to ensure that the current owner records are updated and accurate.

  • Page 6: Other Publications Available

    Read This First Other Publications Available Service Manual 6036, 6042, 8042, 10042, 10054............31200796 Illustrated Parts Manual 6036, 6042...................31200731 8042, 10042, 10054................31200732 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 1.2 General Precautions ............1-1 1.3 Operation Safety ..............1-2...
  • Page 8 Table of Contents Section 3 - Controls and Indicators 3.1 General................3-1 3.2 Controls ................3-2 Dash Controls and Indicators ......... 3-3 Instrument Cluster ............3-4 Ignition ................3-6 Park Brake..............3-7 Parking Procedure............3-7 Transmission Control Lever..........3-8 Boom Joystick .............. 3-10 Frame Level and Attachment Tilt Joystick....
  • Page 9 Tiedown ................4-10 Lifting ................4-11 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........5-3 5.5 Use of the Capacity Chart............5-4 Capacity Indicator Locations ...........5-4 Sample Capacity Chart ...........5-6 Example ................5-8 5.6 Attachment Installation ............5-10...
  • Page 10 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 Service and Maintenance Schedule........7-3 10 & 1st 50 Hour Maintenance Schedule ....... 7-3 50, 250 & 1st 500 Hour Maintenance Schedule ..... 7-4 500 &...

  • Page 11: 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 OW0010 DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING OW0021 WARNING indicates a potentially hazardous situation which, if not avoided, could...

  • Page 12: Operation Safety

    Section 1 - General Safety Practices OPERATION SAFETY Electrical Hazards 10 FT (3 M) OW0040 • This machine is not insulated and does not provide protection from contact or being near electrical current. • NEVER operate the telehandler in an area where overhead power lines, overhead or underground cables, or other power sources may exist without ensuring the appropriate power or utility company de-energizes the lines.

  • Page 13: Tip Over Hazard

    • For additional load requirements, refer to the appropriate capacity chart. OW0050 • Never use an attachment without the appropriate JLG approved capacity chart installed on the telehandler. • Understand how to properly use the capacity charts located in cab.
  • Page 14 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 15 Section 1 - General Safety Practices Non-Suspended Load OW0060 • DO NOT drive with boom raised. Suspended Load OW0150 • Tether suspended loads to restrict movement. • Weight of all rigging (slings, etc.) must be included as part of load. •...

  • Page 16: 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 17: Load Falling Hazard

    Section 1 - General Safety Practices Load Falling Hazard OW0130 • Never suspend load from forks or other parts of carriage. • DO NOT burn or drill holes in fork(s). • Forks must be centered under load and spaced apart as far as possible. 31200749...

  • Page 18: Lifting Personnel

    Section 1 - General Safety Practices Lifting Personnel OW0170 • When lifting personnel, USE ONLY an approved personnel work platform, with proper capacity chart displayed in the cab. OW0190 • DO NOT drive machine from cab when personnel are in platform. 31200749...

  • Page 19: 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. •...

  • Page 20: 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 21 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. 31200749 1-11...

  • Page 22: 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. •...

  • Page 23: 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 24 Section 1 - General Safety Practices This Page Intentionally Left Blank 1-14 31200749...

  • Page 25: Section 2 - Pre-Operation And Inspection

    Section 2 - Pre-Operation 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 26 Section 2 - Pre-Operation and Inspection 8. Operational Check - Once the walk-around inspection is complete, perform a warm-up and operational check (see page 2-12) of all systems in an area free of overhead and ground level obstructions. See Section 3 - Controls and Indicators for more specific operating instructions.

  • Page 27: 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 1706299 1706306 WARNING DANGER WARNING TIPOVER CONTACTING DON NOT place MAINTAIN...
  • Page 28 ROTATING PARTS could crush or cut causing death or serious injury. 1000 1500 Lift or lower personnel DO NOT TRAVEL only in a JLG approved with personnel in work platform. work platform. 2000 Keep clear of rotating parts. 1706298B 1706301B...
  • Page 29 Section 2 - Pre-Operation and Inspection 1001143904 (IF EQUIPPED FOR ULS - 1001109597 (6036) 6036 & 6042) 1001109598 (6042) 1001109596 1001129510 (8042) (IF EQUIPPED FOR LS - 1001129509 (10042) 6036 & 6042) 1001129508 (10054) 1706301 Sky Trak Sky Trak 8042 WARNING ROTATING PARTS could crush or cut causing death...

  • Page 30: Iso (If Equipped)

    Section 2 - Pre-Operation and Inspection ISO (if equipped) 1001092877 1706284 1706288 1706284B 1001125387 (IF EQUIPPED 1706279 FOR ULS) (10042 & 10054) ULTRA LOW SULFUR DIESEL FUEL ONLY S < 15 mg/kg 1001125387 A 1706279A 1001110282 1001129767 1001110282 CAPACITY CHARTS 1001110282 4107462 4107462...
  • Page 31 Section 2 - Pre-Operation and Inspection 1001143904 (IF EQUIPPED FOR ULS - 8042, 10042 & 10054) 1001109596 (IF EQUIPPED FOR LS - 1706282 8042, 10042 & 10054) 1706285 Sky Trak 4105262 1000 1500 2000 1706282C 4110339 4107442 4110226 1701640 1701640 4110226 1001092878 1001143852...
  • Page 32 Section 2 - Pre-Operation and Inspection 1001143904 (IF EQUIPPED FOR ULS - 1001109597 (6036) 6036 & 6042) 1001109598 (6042) 1001109596 1001129510 (8042) (IF EQUIPPED FOR LS - 1001129509 (10042) 6036 & 6042) 1001129508 (10054) 1706285 Sky Trak Sky Trak 8042 1000 1500 2000...
  • Page 33 Section 2 - Pre-Operation and Inspection This Page Intentionally Left Blank 31200749...

  • Page 34: Walk-Around Inspection

    Section 2 - Pre-Operation and Inspection WALK-AROUND INSPECTION OH3781 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 35 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 - •...

  • Page 36: 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 37: 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 38: Windows

    Section 2 - Pre-Operation and Inspection WINDOWS Keep all windows and mirrors clean and unobstructed. Cab Door Window (if equipped) OH4281 • Cab door (1) must be closed during operation. • During operation the cab door window (2) must either be latched open or closed. •...

  • Page 39: 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. Note: The manufacturer has no direct control over machine application and operation. The user and operator are responsible for conforming with good safety practices.

  • Page 40: Controls

    Section 3 - Controls and Indicators CONTROLS OH3791 1. Transmission Control Lever: See page 3-8. 2. Dash Controls and Indicators: See page 3-3. 3. Steering Wheel: Turning the steering wheel to the left or right steers the machine in the corresponding direction. Three steering modes are available. See “Steer Modes”...

  • Page 41: Dash Controls And Indicators

    Section 3 - Controls and Indicators Dash Controls and Indicators OH4720 1. Park Brake Switch: See page 3-7 for details. 2. Frame Level Indicator: Enables operator to determine the left to right level condition of the telehandler. 3. Hazard Light Switch (if equipped): On/Off switch. 4.

  • Page 42: Instrument Cluster

    Section 3 - Controls and Indicators Instrument Cluster 1127 RPM 13.7 V 127° F OH4730 1. Fuel Gauge: Indicates amount of fuel in fuel tank. 2. Maintenance Indicator: Illuminates when maintenance is required. See Service Manual for details. 3. Transmission Temperature Indicator: Illuminates when transmission oil temperature is too high.
  • Page 43 Section 3 - Controls and Indicators 10. Engine Warning Light: Illuminates when the engine is a critical state. Immediately bring machine to a stop, retract and lower boom and stop the engine. Determine cause and correct before continued use. Display Screen 11.

  • Page 44: Ignition

    Section 3 - Controls and Indicators Ignition OH4740 • Position 0 - Engine off, no voltage available. • Position 1 - Voltage available for all electrical functions. Wait to start engine until engine pre-heat indicator light goes out. • Position P - Engine run. •...

  • Page 45: Park Brake

    Section 3 - Controls and Indicators Park Brake OH3821 Park brake switch controls the application and release of the park brake. Indicator on switch illuminates to indicate brake is applied. • With the engine running and the park brake switch in "OFF" position (1), park brakes are disengaged.

  • Page 46: Transmission Control Lever

    Section 3 - Controls and Indicators Transmission Control Lever Direction of Travel Selection OH4750 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 47 Section 3 - Controls and Indicators Gear Selection OH4760 Gear selection is located on the twist grip handle (2) of transmission control lever. • Twist hand grip to select gear. • Select the appropriate gear for the task being performed. Use a lower gear when transporting a load.

  • Page 48: Boom Joystick

    Section 3 - Controls and Indicators Boom Joystick OH3851 The boom joystick (1) controls the boom functions. Boom Functions • Move the joystick back to lift boom; move joystick forward to lower boom; move joystick right to extend boom; move joystick left to retract boom. •...

  • Page 49: Frame Level And Attachment Tilt Joystick

    Section 3 - Controls and Indicators Frame Level and Attachment Tilt Joystick OH3861 The middle joystick (2) controls the left to right frame level and attachment tilt functions. Frame Level • Move the joystick left to rotate frame left, move the joystick right to rotate frame right.

  • Page 50: Auxiliary Hydraulic Joystick

    Section 3 - Controls and Indicators Auxiliary Hydraulic Joystick OH3871 The auxiliary hydraulic joystick (1) controls function of attachments that require hydraulic supply for operation. See Section 5 - Attachments for approved attachments and control instructions. 3-12 31200749...

  • Page 51: Outrigger Switches (10042 & 10054)

    Section 3 - Controls and Indicators Outrigger Switches (10042 & 10054) OH3881 The rear switches (2) control the outriggers. • The left switch controls the left outrigger and the right switch controls the right outrigger. • Push bottom of switches (3) to lower outriggers; push top of switches (4) to raise outriggers.

  • Page 52: Accessory Control Lever (If Equipped)

    Section 3 - Controls and Indicators Accessory Control Lever (if equipped) The accessory control lever (1) operates the turn signals, parking lights and headlights. OH4770 Turn Signals • Raise the lever (2) to activate the left turn signal. • Lower the lever (3) to activate the right turn signal. •...

  • Page 53: 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 OH4780 1.

  • Page 54: Stabil-Trak™ System (6042, 8042, 10042 & 10054)

    Section 3 - Controls and Indicators STABIL-TRAK™ SYSTEM (6042, 8042, 10042 & 10054) OH4940 Free Pivot Mode With boom below 40° (1), the Stabil-Trak system is in Free Pivot Mode. The rear axle pivots freely and frame level functions normally. The Stabil-Trak indicator (3) will be off.

  • Page 55: Boom/Outrigger Interlock System (10054)

    Section 3 - Controls and Indicators BOOM/OUTRIGGER INTERLOCK SYSTEM (10054) The interlock system allows the boom to be extended to its maximum limits. OH4950 Extend Interlock Mode With outriggers raised (6), telehandler is in extend interlock mode which limits boom extension (5).

  • Page 56: Operator Seat

    Section 3 - Controls and Indicators OPERATOR SEAT Adjustments Prior to starting engine adjust seat for position and comfort. OW0480 1. Suspension: Use knob to adjust suspension to the appropriate setting. Turn clockwise to increase stiffness. Turn counterclockwise to reduce stiffness. 2.

  • Page 57: 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 the seat, couple the retractable end (male end) of the belt into the receptacle (buckle) end of the belt.

  • Page 58: Boom Angle And Extension Indicators

    Section 3 - Controls and Indicators BOOM ANGLE AND EXTENSION INDICATORS OH3951 • The boom angle indicator (1) is located on the left side of the boom. Use this indicator to determine the boom angle when using the capacity chart (see “Use of the Capacity Chart”...

  • Page 59: Section 4 - Operation

    Starting the Engine This machine can be operated under normal conditions in temperatures of 0°F to 104°F (-20°C to 40°C). Consult JLG for operation outside this range or under abnormal conditions. 1. Make sure all controls are in “Neutral” and all electrical components (lights, heater, defroster, etc.) are turned off.

  • Page 60: 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 the positive (+) jumper cable to positive (+) post of discharged battery. •...

  • Page 61: Normal Engine Operation

    Section 4 - Operation Normal Engine Operation • Observe gauges and indicators frequently to be sure all systems are functioning properly. • Be alert for unusual noises or vibration. When an unusual condition is noticed, park machine in safe position and perform shut-down procedure. Report condition to your supervisor or maintenance personnel.

  • Page 62: Operating With A Non-Suspended Load

    Section 4 - Operation OPERATING WITH A NON-SUSPENDED LOAD Lift Load Safely • You must know the weight and load center of every load you lift. If you are not sure of the weight and load center, check with your supervisor or with the supplier of the material.

  • Page 63: 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 64: 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 65: 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 the weight and load center, check with your supervisor or with the supplier of the material.

  • Page 66: 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 the appropriate capacity chart in the operator cab.

  • Page 67: 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. •...

  • Page 68: Loading And Securing For Transport

    Section 4 - Operation LOADING AND SECURING FOR TRANSPORT OH3971 4110226 4110226 Tiedown 1. Level the telehandler prior to loading. 2. Using a spotter, load the telehandler with boom as low as possible. 3. Once loaded, apply parking brake and lower boom until boom or attachment is resting on deck.

  • Page 69: Lifting

    • When lifting machine, it is very important that the lifting device and equipment is attached only to designated lifting points. If machine is not equipped with lifting lugs contact JLG Product Safety for information. • Make adjustments to the lifting device and equipment to ensure the machine will be level when elevated.
  • Page 70 Section 4 - Operation This Page Intentionally Left Blank 4-12 31200749...

  • Page 71: Section 5 - Attachments

    If any of the above conditions are not met, do not use the attachment. The telehandler may not be equipped with the proper capacity chart or the attachment may not be approved for the model telehandler being used. Contact JLG or a local distributor for further information.

  • Page 72: Jlg Supplied Attachments

    Section 5 - Attachments JLG SUPPLIED ATTACHMENTS Applicable Model Part Attachment Number 6036 6042 8042 10042 10054 Carriage, 50 in (1270 mm) 1170021 Carriage, 60 in (1524 mm) 1170024 Carriage, 72 in (1829 mm) 1001132514 Side Tilt Carriage, 50 in (1270 mm)

  • Page 73: Telehandler/Attachment/Fork Capacity

    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. 31200749...

  • Page 74: Use Of The Capacity Chart

    Section 5 - Attachments USE OF THE CAPACITY CHART To properly use the capacity chart (see page 5-6), the operator must first determine and/or have the following: 1. An approved attachment. See “Approved Attachments” on page 5-1. 2. The proper Capacity Chart(s). 3.
  • Page 75 Section 5 - Attachments This Page Intentionally Left Blank 31200749...

  • Page 76: 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 XXXXX dimensions must <...
  • Page 77 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 31200749...

  • Page 78: 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 79 Section 5 - Attachments This Page Intentionally Left Blank 31200749...

  • Page 80: 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 Attach (attachment tilt control in cab, see page 3-11) 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 81 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 attach back to provide clearance. Check to be sure lock pin is removed. OH4440 2. Align attachment pin with recess in attachment. Raise boom slightly to engage attachment pin in recess.

  • Page 82: 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 31200749...

  • Page 83: 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.

  • Page 84: Attachment Operation

    Section 5 - Attachments ATTACHMENT OPERATION • Capacities and range limits for the telehandler change depending on the attachment in use. • Separate attachment instructions must be kept in manual holder in cab with this Operation & Safety Manual. An additional copy must be kept with the attachment if it is equipped with a manual holder.

  • Page 85: Carriage W/Forks

    Section 5 - Attachments Carriage w/Forks Use Carriage Attachment Capacity Chart determine maximum capacity, refer “Telehandler/ Attachment/Fork Capacity” on page 5-3. OY0690 OH4011 The boom joystick (1) controls lift/lower and extend/retract movement of the boom. The attachment tilt joystick (2) controls fork tilt. •...

  • Page 86: Side Tilt Carriage

    Section 5 - Attachments Side Tilt Carriage Use Side Tilt Carriage Attachment Capacity Chart determine maximum capacity, refer “Telehandler/ Attachment/Fork Capacity” on page 5-3. OAL1550 OH4112 The boom joystick (1) controls lift/lower and extend/retract movement of the boom. The attachment tilt joystick (2) controls fork tilt. •...
  • Page 87 Section 5 - Attachments 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 88: Swing Carriage

    Section 5 - Attachments Swing Carriage Use Swing Carriage Attachment Capacity Chart determine maximum capacity, refer “Telehandler/ Attachment/Fork Capacity” on page 5-3. OU2150 OH4062 The boom joystick (1) controls lift/lower and extend/retract movement of the boom. The attachment tilt joystick (2) controls fork tilt. •...
  • Page 89 Section 5 - Attachments 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 90: Dual Fork Positioning Carriage

    Section 5 - Attachments Dual Fork Positioning Carriage Use Carriage Attachment Capacity Chart determine maximum capacity, refer “Telehandler/ Attachment/Fork Capacity” on page 5-3. OZ3670 OH4710 The boom joystick (1) controls lift/lower and extend/retract movement of the boom. The attachment tilt joystick (2) controls fork tilt. •...
  • Page 91 Section 5 - Attachments 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 the requirements set forth in Section 1 - General Safety Practices.

  • Page 92: Mast Carriage

    Section 5 - Attachments Mast Carriage Use Mast Carriage Attachment Capacity Chart determine maximum capacity, refer “Telehandler/ Attachment/Fork Capacity” on page 5-3. OY0580 OH4490 The boom joystick (1) controls lift/lower and extend/retract movement of the boom. The attachment tilt joystick (2) controls fork tilt. •...
  • Page 93 Section 5 - Attachments WARNING CRUSH HAZARD. Do not use mast to push or pull objects or load. Failure to comply could cause object or load to fall. Operation: • Always lower forks fully in mast before engaging load. • To drive with a load, lower forks fully in mast and travel in accordance with the requirements set forth in Section 1 - General Safety Practices.

  • Page 94: Fork Mounted Hook

    Section 5 - Attachments Fork Mounted Hook Use Appropriate Carriage Attachment Capacity Chart determine maximum capacity, refer “Telehandler/ Attachment/Fork Capacity” on page 5-3. OY0640 Suspend loads in accordance with requirements set forth in Section 1 - General Safety Practices. OH4021 The boom joystick (1) controls lift/lower and extend/retract movement of the boom.
  • Page 95 Section 5 - Attachments Operation: • Pallet or lumber forks of an appropriate load rating must be used. Do not use with cubing or block forks. • Weight of fork mounted hook and rigging must be included as part of total load being lifted.

  • Page 96: Fork Extension

    5-3. 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 97 Section 5 - Attachments Operation: • Heavy part of load must be against carriage backrest. • Do not allow load center of gravity to be in front of tip of the supporting fork. • Do not pick up a load or pry materials with tip of fork extensions. 31200749 5-27...

  • Page 98: Truss Boom

    Section 5 - Attachments Truss Boom Use Appropriate Truss Boom Attachment Capacity Chart determine maximum capacity, refer “Telehandler/ Attachment/Fork Capacity” on page 5-3. OY0570 Suspend loads in accordance with requirements set forth in Section 1 - General Safety Practices. OH4051 The boom joystick (1) controls lift/lower and extend/retract movement of the boom.
  • Page 99 Section 5 - Attachments Installation Procedure: • 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. 31200749 5-29...

  • Page 100: Bucket

    Section 5 - Attachments Bucket Use Appropriate Bucket Capacity Chart determine maximum capacity, refer “Telehandler/ Attachment/Fork Capacity” on page 5-3. OZ0730 OH4032 The boom joystick (1) controls lift/lower and extend/retract movement of the boom. The attachment tilt joystick (2) controls bucket tilt. •...
  • Page 101 Section 5 - Attachments Equipment Damage Precautions • Except for lifting or dumping a load, the boom must be fully retracted for all bucket operations. • Do not corner-load bucket. Distribute material evenly within the bucket. Bucket capacity charts are for evenly distributed loads only. •...

  • Page 102: Grapple Bucket

    Section 5 - Attachments Grapple Bucket Use Grapple Bucket Capacity Chart determine maximum capacity, refer “Telehandler/ Attachment/Fork Capacity” on page 5-3. OZ1450 OH4500 The boom joystick (1) controls lift/lower and extend/retract movement of the boom. The attachment tilt joystick (2) controls grapple bucket tilt. •...
  • Page 103 Section 5 - Attachments Operation: • Raise or lower boom to appropriate height and open grapple for loading material from stockpile. • Align telehandler with face of stockpile and drive slowly and smoothly into pile to load bucket. • Tilt bucket up far enough to retain load, close grapple and back away from pile. •...

  • Page 104: Personnel Work Platform

    Section 5 - Attachments Personnel Work Platform Use Appropriate Carriage Attachment Capacity Chart determine maximum capacity, refer “Telehandler/ Attachment/Fork Capacity” on page 5-3. OY1610 The operator and personnel in platform must read and understand the separate personnel work platform manual prior to installing and using a platform.
  • Page 105 Section 5 - Attachments Preparation and Setup: 1. Ensure the telehandler is on a firm surface and is level. 2. Engage the park brake. Blocking the wheels is also recommended. 3. Level the platform, both side to side (frame level) and front to back (attachment tilt).
  • Page 106 Section 5 - Attachments This Page Intentionally Left Blank 5-36 31200749...

  • Page 107: Section 6 - Emergency Procedures

    Section 6 - Emergency Procedures SECTION 6 - EMERGENCY PROCEDURES TOWING A DISABLED PRODUCT The following information assumes the telehandler cannot be moved under its own power. • Before moving the telehandler, read all of the following information to understand options available.

  • Page 108: 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 a local Authorized Distributor for specific instructions. Secure the telehandler using the following procedures: 1.

  • Page 109: Section 7 - Lubrication And Maintenance

    Section 7 - Lubrication and Maintenance SECTION 7 - LUBRICATION AND MAINTENANCE INTRODUCTION Service the product in accordance with the maintenance schedule on the following pages. OH4121 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 detailed service information with specific instructions.

  • Page 110: General Maintenance Instructions

    Section 7 - Lubrication and Maintenance GENERAL MAINTENANCE INSTRUCTIONS Prior to performing any service or maintenance on the telehandler, follow the shut-down procedure on page 4-3 unless otherwise instructed. Ensure telehandler is level, for proper fluid readings. • Clean lubrication fittings before lubricating. •...

  • Page 111: Service And Maintenance Schedule

    Section 7 - Lubrication and Maintenance SERVICE AND MAINTENANCE SCHEDULE 10 & 1st 50 Hour Maintenance Schedule EVERY Check Fuel Drain Fuel/ Air Filter Check Engine Check Hydraulic Level Water Seprator Restriction Oil Level Oil Level Indicator Additional Check Tire Check Check Engine Checks -...

  • Page 112: 50, 250 & 1St 500 Hour Maintenance Schedule

    Section 7 - Lubrication and Maintenance 50, 250 & 1st 500 Hour Maintenance Schedule EVERY Check Boom Check Check Washer Lubrication Wear Pads Fluid Level Schedule Battery (if equipped) EVERY Change Engine Check Axle Change Air Check Wheel Check Boom Oil and Oil Level End Oil Levels...

  • Page 113: 500 & 1000 Hour Maintenance Schedule

    Section 7 - Lubrication and Maintenance 500 & 1000 Hour Maintenance Schedule EVERY Change Fuel Check Wheel Filters Lug Nut Torque EVERY 1000 Check Axle Change Change Change Change Wheel Transmission Hydraulic Axle Oil Brake Discs End Oil Oil & Filter Fluid &...

  • Page 114: 1500 & 2000 Hour Maintenance Schedule

    Section 7 - Lubrication and Maintenance 1500 & 2000 Hour Maintenance Schedule EVERY 1500 Change Crankcase Vent Filter (if equipped for ULS) EVERY 2000 Change Engine Engine Coolant Valve Lash Adjustment OH4961 31200749...

  • Page 115: Lubrication Schedules

    Section 7 - Lubrication and Maintenance LUBRICATION SCHEDULES 50 Hour Lubrication Schedule 6036, 6042, 8042 & 10042 EVERY OH4162 31200749...
  • Page 116 Section 7 - Lubrication and Maintenance 10054 EVERY OH4242 31200749...
  • Page 117 Section 7 - Lubrication and Maintenance 250 Hour Lubrication Schedule 6036 & 6042 EVERY 6042 ONLY OA1820 31200749...
  • Page 118 Section 7 - Lubrication and Maintenance 8042, 10042 & 10054 EVERY OH4172 7-10 31200749...

  • Page 119: 1000 Hour Lubrication Schedule

    Section 7 - Lubrication and Maintenance 1000 Hour Lubrication Schedule EVERY 1000 OH4181 31200749 7-11...

  • Page 120: Operator Maintenance Instructions

    Section 7 - Lubrication and Maintenance OPERATOR MAINTENANCE INSTRUCTIONS Fuel System A. Fuel Level Check OW0970 OW0990 OH4810 VIEW OF FUEL TANK FROM TOP OF MACHINE 1. Check fuel gauge (1) located on instrument cluster in cab. 2. If fuel is low, proceed to fuel source and perform “Shut-Down Procedure” on page 4-3.
  • Page 121 Section 7 - Lubrication and Maintenance B. Drain Fuel/Water Separator OW0970 OW1000 IF EQUIPPED FOR ULS OH4820 IF EQUIPPED FOR LS OH4830 1. Perform “Shut-Down Procedure” on page 4-3. 2. Open engine access door. 3. Loosen drain cock (4) on underside of fuel filter (5) and allow all water to drain into a glass until clear fuel is visible.

  • Page 122: Air Intake System

    Section 7 - Lubrication and Maintenance Air Intake System If Equipped for ULS A. Air Filter Restriction Indicator Check OW0970 OW1010 IF EQUIPPED FOR ULS OH4890 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, filter(s) must be replaced.
  • Page 123 Section 7 - Lubrication and Maintenance B. Element Change (as restriction indicator indicates) 1. Unlock air cleaner cover (3) and remove from air cleaner canister. 2. Remove outer primary element (4) and inspect for damage. Damaged elements should not be reused. 3.
  • Page 124 Section 7 - Lubrication and Maintenance If Equipped for LS A. Air Filter Restriction Indicator Check OW0970 OW1010 IF EQUIPPED FOR LS OH4880 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, filter(s) must be replaced.
  • Page 125 Section 7 - Lubrication and Maintenance B. Element Change (as restriction indicator indicates) 1. Unlock air cleaner cover (4), turn counterclockwise and remove from air cleaner. 2. Remove outer primary element (5) and inspect for damage. Damaged elements should not be reused. 3.

  • Page 126: Engine Oil

    Section 7 - Lubrication and Maintenance Engine Oil A. Engine Oil Level Check OW0970 OW1020 IF EQUIPPED FOR ULS OH4840 IF EQUIPPED FOR LS OH4850 1. Perform “Shut-Down Procedure” on page 4-3. 2. Open engine access door. 3. Remove dipstick (1) and check oil mark. The oil should be between the full (2) and add (3) marks within the crosshatched area of the dipstick.

  • Page 127: Hydraulic Oil

    Section 7 - Lubrication and Maintenance Hydraulic Oil A. Hydraulic Oil Level Check OW0970 OW1030 OH4231 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 (6) on the hydraulic tank (5). The oil level should be visible in the gauge window.

  • Page 128: Tires

    Section 7 - Lubrication and Maintenance Tires A. Tire Air Pressure Check OW0970 OW1040 1. Perform “Shut-Down Procedure” on page 4-3. 2. Remove valve stem cap. 3. Check tire pressure. 4. Add air if required. 6036 13.00 x 24, G-2/L-2 Bias Ply Traction - 12 ply ......55 psi (3,8 bar) 15.50 x 25, G-2/L-2 Bias Ply Traction - 12 Ply ......55 psi (3,8 bar) 370/75-28, 14 Ply..............76 psi (5,2 bar) 6042...
  • Page 129 • 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 130 Section 7 - Lubrication and Maintenance E. Wheel Installation Torque lug nuts after first 50 hours and 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 direction of forward travel.

  • Page 131: 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 transmission oil level with engine at idle and oil at normal operating temperature.

  • Page 132: Engine Cooling System

    Section 7 - Lubrication and Maintenance Engine Cooling System A. Engine Coolant Level Check OW0970 OW1070 If Equipped for ULS IF EQUIPPED FOR ULS OH4870 1. Perform “Shut-Down Procedure” on page 4-3. 2. Open rear access door. 3. Coolant level should be visible in surge tank (2). 4.
  • Page 133 Section 7 - Lubrication and Maintenance If Equipped for LS IF EQUIPPED FOR LS OH4920 1. Perform “Shut-Down Procedure” on page 4-3. 2. Open rear access door. 3. Coolant level should be visible in sight gauge (3). 4. If coolant is low, allow fluid to cool. 5.

  • Page 134: 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 (3). Check terminals for corrosion. Replace battery if it has a cracked, melted or damaged case. 4.

  • Page 135: 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 136: 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 137: Section 9 - Specifications

    Section 9 - Specifications SECTION 9 - SPECIFICATIONS PRODUCT SPECIFICATIONS Fluids If Equipped for ULS Ambient Temperature Range Compartment Type and Viscosities or System Classification °F °C Min Max Min Max SAE 0W-30 SAE 5W-30 Engine API CJ-4 Plus Crankcase SAE 10W-30 SAE 15W-40 Transmission...
  • Page 138 Section 9 - Specifications If Equipped for LS Ambient Temperature Range Compartment Type and Viscosities or System Classification °F °C Min Max Min Max SAE 0W-30 SAE 5W-30 Engine API CI-4 Multigrade Crankcase SAE 10W-30 SAE 15W-40 Transmission and Transfer Mobilfluid 424 10W-30 Case...

  • Page 139: Capacities

    Section 9 - Specifications Capacities Engine Crankcase Oil Capacity with Filter Change ............7.6 quart (7,2 liter) Fuel Tank Capacity ..................35.6 gallon (135 liter) Cooling System System Capacity If equipped for ULS .............. 3.8 gallon (14,4 liter) If equipped for LS ..............4.0 gallon (15,1 liter) Hydraulic System System Capacity 6036 &...

  • Page 140: 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 141: Performance

    Section 9 - Specifications Performance Maximum Lift Capacity 6036 & 6042 ................6,000 lb (2722 kg) 8042..................8,000 lb (3629 kg) 10042 & 10054 ............... 10,000 lb (4536 kg) Maximum Lift Height 6036....................36 ft (11,0 m) 6042, 8042 & 10042 .................42 ft (12,8 m) 10054.....................53.2 ft (16,2 m) Capacity at Maximum Height 6036, 6042, 8042 &...

  • Page 142: Dimensions

    Section 9 - Specifications Towing Capacity 6036 & 6042 ................6,000 lb (2722 kg) 8042..................8,000 lb (3629 kg) 10042 & 10054 ...............10,000 lb (4536 kg) Frame Leveling..................10 degrees Maximum Travel Grade Gradeability................24 degrees (45%) Side Slope ................5 degrees (8.75%) Dimensions Overall Height 6036...................100 in (2540 mm)
  • Page 143 Section 9 - Specifications Turning Radius (Curb to Curb) 6036 & 6042 ................165 in (4191 mm) 8042...................156 in (3962 mm) 10042..................170 in (4318 mm) 10054..................165 in (4191 mm) Turning Radius (Clearance) 6036...................165 in (4191 mm) 6042...................168 in (4267 mm) 8042..................158.3 in (4021 mm) 10042..................182 in (4623 mm) 10054..................184.5 in (4686 mm) Maximum Gross Vehicle Weight (no attachment)
  • Page 144 Section 9 - Specifications Maximum Ground Bearing Pressure 6036 13.00 x 24 Air Filled ..............137 lb/in² (9,6 kg/cm²) Foam Filled ............179 lb/in² (12,6 kg/cm²) 15.50 x 25 Air Filled ..............137 lb/in² (9,6 kg/cm²) Foam Filled ............184 lb/in² (12,9 kg/cm²) 370/75-28 Air Filled ..............91 lb/in²...

  • Page 145: Index

    Attachment Operation ....5-14 Driving Hazards on Slopes ....1-9 Attachment Tilt Joystick....3-11 Dual Fork Positioning Carriage ..5-20 Attachments ........5-1 JLG Supplied ......5-2 Auxiliary Hydraulic Joystick .... 3-12 Electrical Hazards ......1-2 Axles..........9-3 Emergency Exit from Enclosed Cab........6-2 Emergency Lowering of Boom..6-2...
  • Page 146 Index Hazard Classification System... 1-1 Park Brake ........3-7 Hydraulic Oil Level......7-19 Parking Procedure ......3-7 Hydraulic Operated Attachment ..5-12 Performance........9-5 Hydraulic System......9-3 Personnel Work Platform ....5-34 Picking Up a Load ......4-4 Picking Up a Suspended Load..4-7 Ignition ..........3-6 Pinch Points and Crush Hazards ..1-10 Instrument Cluster ......
  • Page 147 Index Tip Over Hazard ....... 1-3 Tires ........7-20, 9-4 Air Pressure ......7-20 Damage ........7-20 Replacement......7-21 Towing..........6-1 Transmission ........9-3 Transmission Control Lever Direction of Travel....... 3-8 Gear Selection ......3-9 Transport Lifting ........4-11 Tiedown ........4-10 Transporting a Load ......
  • Page 148 Index 31200749...

  • Page 149: Inspection, Maintenance And Repair Log

    Inspection, Maintenance and Repair Log Inspection, Maintenance and Repair Log Serial Number ______________________________ Date Comments...
  • Page 150 Inspection, Maintenance and Repair Log Date Comments...
  • Page 151 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 153 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 154 McConnellsburg PA. 17233-9533 Phone: +1-717-485-5161 Customer Support Toll Free: 1-877-554-5438 Fax: +1-717-485-6417 JLG Worldwide Locations JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) Ltd P.O. Box 5119 Rua Antonia Martins Luiz, 580 Bentley House 11 Bolwarra Road Distrito Industrial João Narezzi...

This manual is also suitable for:

Skytrak 6042Skytrak 8042Skytrak 10042Skytrak 10054

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