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WARNING Operating, servicing and maintaining this vehicle or equipment can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other re- productive harm. To minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your vehicle or equipment in a well-ventilated area and wear gloves or wash your hands frequently when servicing.
REVISION LOG DATE REVISION DESCRIPTION May 16, 2022 Original Issue of Manual. October 17, 2022 Revision of Manual. 6036, 6042, 8042, 10042, 10054, 12054 31211849...
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.
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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.
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Other Publications Available Service Manual............31211850 Parts Manual 6036 .
SECTION 1 General Safety Practices HAZARD CLASSIFICATION SYSTEM 1.1.1 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.
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. 1.3.1 Electrical Hazards •...
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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.
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General Safety Practices • DO NOT level machine with boom/attachment above 4 ft (1,2 m). (AUS - DO NOT level machine with load more than 11.8 in (300 mm) above ground surface.) • MAINTAIN proper tire pressure at all times. If proper tire pressures are not maintained, this machine could tip over.
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General Safety Practices Non-Suspended Load • DO NOT drive with boom raised. Suspended Load • Tether suspended loads to restrict movement. • Weight of all rigging (slings, etc.) must be included as part of load. • DO NOT attempt to use telehandler frame-leveling to compensate for load swing. •...
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General Safety Practices 1.3.3 Travel Hazard 2-Wheel Front Steer 4-Wheel Circle Steer 4-Wheel Crab Steer • 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.
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General Safety Practices 1.3.4 Load Falling Hazard • Never suspend load from forks or other parts of carriage weldment. Use only approved lift points. • DO NOT burn or drill holes in fork(s). • Forks must be centered under load and spaced apart as far as possible. 1.3.5 Lifting Personnel •...
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General Safety Practices • To avoid overspeeding the engine and drivetrain when driving down slopes, downshift to a lower gear and use the service brake as necessary to maintain a slow speed. DO NOT shift into neutral and coast downhill. •...
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General Safety Practices • Keep arms and hands clear of attachment tilt cylinder. • Keep hands and fingers clear of carriage and forks. • Keep others away while operating. 1.3.8 Fall Hazard • Enter using the proper hand holds and steps provided. Always maintain 3-point contact when mounting or dismounting.
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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. Flammable Fuel •...
General Safety Practices CLEARSKY (IF EQUIPPED) 1.4.1 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.
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General Safety Practices Antenna Installation A minimum separation distance of eight inches (20 centimeters) must be maintained between the antenna and all persons. The combined cable loss and antenna gain must not exceed +7.5 dBi (850 band). The combined cable loss and antenna gain must not exceed +2.5 dBi and total system output must not exceed 2.0W EIRP in the PCS (1900) band in order to comply with the EIRP limit of 24.232 (b).
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.
Pre-Operation and Inspection 1. Cleanliness - Check all surfaces for leakage (oil, fuel or battery fluid) or foreign objects. Report any leakage to the proper maintenance personnel. 2. Structure - Inspect the machine structure for dents, damage, weld or parent metal cracks or other discrepancies.
Pre-Operation and Inspection WALK-AROUND INSPECTION Oh5704 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.
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Pre-Operation and Inspection 4. Front Lights (if equipped) — Clean and undamaged. 5. Wheel/Tire Assembly — Properly inflated and secured; no loose or missing lug nuts. Inspect for worn tread, cuts, tears or other discrepancies. 6. Mirrors — Clean and undamaged. 7.
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.
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Pre-Operation and Inspection 2.7.1 Cab Door Window (if equipped) • Cab door window (2) must either be latched open or closed during operation. • Open cab door window and secure it in latch (3). • Turn knob (4) to unlatch window. NOTICE EQUIPMENT DAMAGE.
SECTION 3 Controls and Indicators GENERAL This section provides the necessary information needed to understand control functions. CONTROLS O 4982 1. Transmission Control Lever: 2. Dash Controls and Indicators: 3. Steering Wheel: Turning the steering wheel to the left or right steers the machine in the corresponding direction.
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Controls and Indicators 6. Boom Joystick: 7. Frame Level Joystick: 8. Auxiliary Hydraulic Joystick: 9. Outrigger Switches (10042, 10054 & 12054): 10. Accelerator Pedal: Pressing down the pedal increases engine and hydraulic speed. 11. Service Brake Pedal: The further the pedal is depressed, the slower the travel speed.
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Controls and Indicators 3.2.1 Dash Controls and Indicators OH5180 Figure 1. With Heater (If equipped) Figure 2. With Heater and AC (If equipped) 1. Park Brake Switch: On/Off switch. 2. Beacon Light Switch (if equipped): On/Off switch. 3. Hazard Light Switch (if equipped): On/Off switch. 6036, 6042, 8042, 10042, 10054, 12054 31211849...
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Controls and Indicators 4. Work Light Switch (if equipped): Three position switch. Push bottom of switch to turn all work lights on. Move switch to middle position to turn on front and boom work lights. Push top of switch to turn off all work lights. 5.
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Controls and Indicators 3.2.2 Instrument Cluster 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.
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Controls and Indicators 4. Engine Pre-Heat Indicator: Illuminates with ignition key in position 1. Indicator goes out when start temperature is reached. (If equipped for ULS) Pre-heat indicator will flash and fault code will appear on instrument cluster display during starter lockout.
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Controls and Indicators 3.2.3 Ignition • 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. 6036, 6042, 8042, 10042, 10054, 12054 31211849...
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Controls and Indicators • Position 2: Engine start. In event engine does not start, rotate key to position 0 then back to position 2 to re-engage starter. 3.2.4 Park Brake Park brake switch controls application and release of park brake. Indicator on switch illuminates to indicate brake is applied.
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Controls and Indicators • (6042, 8042, 10042, 10054 & 12054 Only) With switch in “ON” position and boom angles greater than 40°, locked mode of Stabil-Trak system is activated. WARNING MACHINE ROLL-AWAY HAZARD. In the event of engine failure, apply constant pressure to service brake pedal while activating the park brake to the ON position.
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Controls and Indicators • When traveling in reverse, back-up alarm will automatically sound. • Drive in reverse and turn only at slow rates of speed. • Do not increase engine speed with transmission in forward or reverse and service brake depressed in an attempt to get quicker hydraulic performances. This could cause unexpected machine movement.
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Controls and Indicators Boom Joystick (1) controls boom and attachment tilt functions. Boom Functions • Move joystick back to lift boom; move joystick forward to lower boom; move joystick right to extend boom; move joystick left to retract boom. • Speed of boom functions depends upon amount of joystick travel in corresponding direction.
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Controls and Indicators 3.2.8 Auxiliary Hydraulic Joystick Auxiliary hydraulic joystick (2) controls function of attachments that require hydraulic supply for operation. See Section 5- Attachments for approved attachments and control instructions. 31211849 6036, 6042, 8042, 10042, 10054, 12054...
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Controls and Indicators 3.2.9 Frame Level Joystick 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.
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Controls and Indicators 3.2.10 Outrigger Switches (10042, 10054 & 12054) 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.
Controls and Indicators Turn Signal • Raise lever (4) to activate left turn signal. • Lower lever (5) to activate right turn signal. • Lever must be manually returned to center position to deactivate either turn signal. Lever will not cancel automatically after a turn. Parking Lights and Headlights •...
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Controls and Indicators 3.3.1 Steer Mode Change Note: Steer mode will change immediately after selection. OH5160 1. Bring machine to a stop using service brake while either circle steer mode (1) or crab steer mode (3) is selected. 2. Turn steering wheel until left rear wheel (4) is aligned with side of machine. 3.
Controls and Indicators 3.5.1 Extend Interlock Mode With outriggers raised (1), telehandler is in extend interlock mode which limits boom extension (2). • Boom is limited from extending beyond a point between the “E” and “F” boom extension indicators. • Vehicle and Stabil-Trak will function normally.
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Controls and Indicators 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. Document Case: Contains unit materials. 4.
Controls and Indicators 3.6.2 Seat Belt 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.
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Controls and Indicators 3.8.1 Reverse Sensing System The reverse sensing system provides audible indication of objects to rear of machine while in reverse gear. • Alarm sounds when transmission is shifted into reverse. Note: Reverse Sensing System detects objects larger than 36 square inches (232.25 square centimeters) area and is functional when machine is moving in reverse direction.
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. If equipped for extreme cold weather, -20° F to 0° F (-29° C to -18° C), see page 4-3 for starting procedure.
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Operation 7. Operate all boom functions continuously for five minutes to circulate the warm hydraulic fluid. Note: Engine will not start unless transmission is in neutral and park brake is applied. WARNING ENGINE EXPLOSION. Do not use ether for cold weather starting. WARNING UNEXPECTED MOVEMENT HAZARD.
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Operation 4.1.3 Battery Boosted Starting 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. •...
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. 4.1.5 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.
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Operation 4.2.1 Automatic Exhaust System Cleaning ATS is an automatic exhaust cleaning system and will perform as required without any operator interaction. • High Exhaust System Temperature (HEST) (1) Indicator may illuminate during exhaust system cleaning. WARNING HIGH EXHAUST TEMPERATURE. Keep flammables and people away from hot exhaust.
Operation OPERATING WITH A NON-SUSPENDED LOAD 4.3.1 Lift Load Safely • You must know 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 the material. WARNING TIP OVER HAZARD.
Operation 4. Move boom/attachment to 4 ft (1,2 m) off ground. (AUS - Move boom so forks are no more than 11.8 in (300 mm) above ground surface.) Important things to remember: • Never raise boom/attachment more than 4 ft (1,2 m) above ground unless telehandler is level.
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Operation 4.4.2 Picking Up a Suspended Load • Note conditions of terrain. Adjust travel speed and reduce amount of load if conditions warrant. • Avoid lifting double-tiered loads. • Make sure load is clear of any adjacent obstacles. • NEVER operate telehandler without a proper and legible capacity chart in operator cab for telehandler/attachment combination you are using.
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Operation 4.4.3 Transporting a Suspended Load • Travel in accordance with the requirements set forth in Section — General Safety Practices Section — Attachments. • For additional requirements, refer to appropriate capacity chart in operator cab. Important things to remember: •...
Operation 4.4.5 Placing a Suspended Load Before placing any load be sure that: • Landing point can safely support weight of load. • Landing point is level; front to back and side to side. • Use capacity chart to determine safe boom extension range. See Section —...
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Operation 3. Once loaded, apply parking brake and lower boom until boom or attachment is resting on deck. Move all controls to “Neutral,” stop engine and remove ignition key. 4. Secure machine to deck by passing chains through designated tie down points as shown in figure.
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Operation • The appropriate lifting locations are the axle beams, inboard of the kingpins. Take care as not to damage the axles and components. • Ensure that the boom is retracted and lowered. • Ensure that the lifting device and equipment is adequately rated and suitable for the intended purpose.
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. 5.1.2...
Attachments UNAPPROVED ATTACHMENTS Do not use unapproved attachments for the following reasons: • Range and capacity limitations for “will fit,” homemade, altered, or other non- approved attachments cannot be established. • An overextended or overloaded telehandler can tip over with little or no warning and cause serious injury or death to the operator and/or those working nearby.
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Attachments 5.3.2 Non-OEM Attachments User of non-OEM attachments is responsible for: • Design • Fabrication • Workmanship • Structural Integrity • Maximum Capacity • Fit and Function • Overall Quality • Any operation and safety instructions specific to the attachment •...
Equivalent Load must be calculated to use with the carriage capacity chart. Utilizing Equivalent Load Calculation is applicable for all carriage and fork arrangements. The forks of the JLG carriage must support 2/3 of the load length for any load applied. Equivalent Load Calculation The Equivalent Load is determined with the calculation below.
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Attachments 5.4.2 Fork Mounted Attachments Equivalent Load Equivalent Load Calculation The Equivalent Load is determined with the calculation below. The Equivalent Load is the value applied to the respective carriage capacity chart to determine the appropriate use zone(s). Weight of Attachment (lb) x CG Distance of Attachment (in) ) + (Weight of Attach- = Equivalent Load ment Load (lb) x CG Distance of Load (in)
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. USE OF THE CAPACITY CHART To properly use capacity chart (see...
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Attachments 2. Proper Capacity Chart(s). 3. Weight of load being lifted. 4. Load placement information: a. HEIGHT where load is to be placed. b. DISTANCE from front tires of telehandler where load is to be placed. 5. On capacity chart, find the line for height and follow it over to distance. 6.
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Attachments 5.7.2 Sample Capacity Chart 1. This Capacity Chart may be used 3. Boom Extension Indicator (arc) 5. Load zones indicate the maxi- with this model ONLY. The telehan- mum weight that may be safely dler model is indicated on the lifted.
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Attachments WARNING TIP OVER HAZARD. All loads shown on rated capacity chart are based on machine being on firm ground with frame level (see Section — Transporting a Load Section - Transporting a Suspended Load); the forks being positioned evenly on carriage; the load being centered on forks;...
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Attachments Note: This is a sample capacity chart only! DO NOT use this chart, use the one located in your operator cab. WARNING TIP OVER HAZARD. All loads shown on rated capacity chart are based on machine being on firm ground with frame level, the forks being positioned evenly on carriage;...
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Attachments 5.7.4 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. •...
Attachments ATTACHMENT INSTALLATION 1. Attachment 2. Attachment Pin Recess 3. Attachment Pin 4. Lock Pin 5. Lock Lever 6. Quick Coupler (attachment tilt control in cab) WARNING CRUSH HAZARD. Always be certain that carriage or attachment is properly positioned on boom and is secured by lock pin and lock lever. Failure to ensure proper installation could permit carriage/attachment/load to disengage.
Attachments 3. Tilt quick coupler forward to engage attachment. 4. Lift lock lever and insert lock pin completely through quick coupler. Release lock lever and ensure lock pin is secured. 5. If equipped, connect auxiliary hydraulic hoses. See “Hydraulic Operated Attachment”.
Attachments 2. If equipped, loosen fork locking bolt. 3. Elevate attachment to approximately 5 ft (1,5 m) and tilt carriage forward until fork heel is free from attachment. 4. Stand at side of carriage. To slide fork toward center of carriage, push fork near fork eye.
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Attachments 5.10.1 Carriage with Forks Use Carriage Attachment Capacity Chart. To determine maximum capacity, refer to Section — Telehandler/Attachment/Fork Capacity. O 5231 Joystick (1) controls movement of the boom. Roller switch (2) controls fork tilt. • Move joystick back to tilt up. •...
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Attachments 5.10.2 Side Shift Carriage Use Side Shift Carriage Capacity Chart. To determine maximum capacity, refer to Section — Telehandler/Attachment/Fork Capacity. Joystick (1) controls movement of the boom Roller switch (2) controls fork tilt. • Press roller switch down to tilt up. •...
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Attachments Installation Procedure: Refer to Section — Attachment Installation. 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: • Do not use forks as a lever to pry material. Excessive prying forces could damage forks or machine structure.
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Attachments TH000207A Joystick (1) controls movement of the boom Roller switch (2) controls fork tilt. • Press roller switch down to tilt up. • Press roller switch up to tilt down. To Side Tilt: Roller switch (3) controls carriage side tilt. •...
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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. • Level telehandler before side tilting carriage to engage load. •...
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Attachments 5.10.4 Swing Carriage Use Swing Carriage Attachment Capacity Chart. To determine maximum capacity, refer to Section — Telehandler/Attachment/Fork Capacity. Joystick (1) controls movement of the boom Roller switch (2) controls fork tilt. • Press roller switch down to tilt up. •...
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Attachments Installation Procedure: • Refer to Section — Attachment Installation. 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.
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Attachments 5.10.5 Dual Fork Positioning Carriage Use Carriage Attachment Capacity Chart (6036, 6042, 8042, 10042 & 10054). Use Dual Fork Positioning Carriage Attachment Capacity Chart (12054). Joystick (1) controls movement of the boom Roller switch (2) controls fork tilt. • Press roller switch down to tilt up.
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Attachments Installation Procedure: • Refer to Section — Attachment Installation. 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 —...
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Attachments 5.10.6 Mast Carriage Use Mast Carriage Attachment Capacity Chart. To determine maximum capacity, refer to Section — Telehandler/Attachment/Fork Capacity. TH000210A Joystick (1) controls movement of the boom Roller switch (2) controls fork tilt. • Press roller switch down to tilt up. •...
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Attachments Installation Procedure: • Refer to Section — Attachment Installation. 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. •...
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Attachments 5.10.7 Pipe Grapple Use Pipe Grapple Attachment Capacity Chart To determine maximum capacity, refer to Section — Telehandler/Attachment/Fork Capacity. Joystick (1) controls movement of the boom. Roller switch (2) controls pipe grapple tilt. • Press roller switch down to tilt up. •...
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Attachments Installation Procedure: Refer to Section — Attachment Installation. 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 material.
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Capacity. 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.
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Attachments • 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. 31211849 6036, 6042, 8042, 10042, 10054, 12054...
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Attachments 5.10.9 Coupler Mounted Hook Use Appropriate Coupler Mounted Hook Capacity Chart. To determine maximum capacity, refer to Section — Telehandler/Attachment/Fork Capacity. Suspend loads in accordance with requirements set forth in Section — General Safety Practices. Joystick (1) controls movement of the boom Roller switch (2) controls coupler mounted hook tilt.
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Attachments 5.10.10 Fork Mounted Hook Use Appropriate Carriage Attachment Capacity Chart. To determine maximum capacity, refer to Section — Telehandler/Attachment/Fork Capacity. Suspend loads in accordance with requirements set forth in Section — General Safety Practices. Joystick (1) controls movement of the boom Roller switch (2) controls fork tilt.
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Attachments • Do not use fork mounted hook with attachments capable of rotating (i.e. side tilt and swing carriages) without disabling the rotation feature(s). 6036, 6042, 8042, 10042, 10054, 12054 31211849...
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Attachments 5.10.11 Bucket Use Appropriate Bucket Capacity Chart. To determine maximum capacity, refer to Section — Telehandler/Attachment/Fork Capacity. Joystick (1) controls movement of the boom Roller switch (2) controls bucket tilt. • Press roller switch down to tilt up. • Press roller switch up to tilt down.
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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. •...
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Attachments 5.10.12 Grapple Bucket Use Grapple Bucket Capacity Chart. To determine maximum capacity, refer to Section — Telehandler/Attachment/Fork Capacity. Joystick (1) controls movement of the boom Roller switch (2) controls grapple bucket tilt. • Press roller switch down to tilt up. •...
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Attachments Installation Procedure: • Refer to Section — Attachment Installation. 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.
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Attachments 5.10.13 Bucket - Fork Mounted Use Appropriate Carriage Attachment Capacity Chart. To determine maximum capacity, refer to Section — Telehandler/Attachment/Fork Capacity. Joystick (1) controls movement of the boom Roller switch (2) controls bucket tilt. • Press roller switch down to tilt up. •...
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Attachments • Travel in accordance with requirements set forth in Section — General Safety Practices. • Tilt bucket down to dump load. • Fork mounted bucket weight must be included as part of total load being lifted. • Do not use with mast carriage attachment. •...
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Attachments 5.10.14 Trash Hopper - Fork Mounted Use Appropriate Trash Hopper Capacity Chart. To determine maximum capacity, refer to Section — Telehandler/Attachment/Fork Capacity. Joystick (1) controls movement of the boom Roller switch (2) controls trash hopper tilt. • Press roller switch down to tilt up. •...
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Attachments Operation: • Raise or lower boom to appropriate height for loading material. • Travel in accordance with requirements set forth in Section — General Safety Practices. • To release gate, tilt fork mounted trash hopper down approximately 10 degrees and engage bottom bumper on edge of dumpster.
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Attachments 5.10.15 Truss Boom Use Appropriate Truss Boom Attachment Capacity Chart. To determine maximum capacity, refer to Section — Telehandler/Attachment/Fork Capacity. Suspend loads in accordance with requirements set forth in Section — General Safety Practices. Joystick (1) controls movement of the boom Roller switch (2) controls truss boom tilt.
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Attachments WARNING CRUSH HAZARD. Maintain a minimum of three wraps of wire rope on the cable drum at all times. Failure to comply could cause object or load to fall. Operation: • Weight of rigging must be included as part of total load being lifted. 5.10.16 Adjustable Truss Boom - Fork Mounted Use Appropriate Adjustable Truss Boom Attachment Capacity Chart.
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Attachments • Secure the adjustable truss boom to the forks by sliding the adjustable truss boom onto the parent forks and install the retaining pin behind the vertical shank of the fork. WARNING CRUSH HAZARD. Ensure adjustable arm is properly secured using the retaining pin prior to lifting load.
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Attachments Operation: • Pallet or lumber forks of an appropriate load rating must be used. Do not use with cubing or block forks. • Weight of rigging must be included as part of total load being lifted. • Do not use with mast carriage attachment. •...
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Attachments 5.10.17 Material Handling Arm Use Appropriate Material Handling Arm Attachment Capacity Chart. To determine maximum capacity, refer to Section — Telehandler/Attachment/Fork Capacity. Suspend loads in accordance with requirements set forth in Section — General Safety Practices. Joystick (1) controls movement of the boom. Roller switch (2) controls material handling arm tilt.
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Attachments Operation: • Weight of rigging must be included as part of total load being lifted. 5.10.18 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.
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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).
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Attachments 5.10.19 Sweeper Use Sweeper Capacity Chart. To determine maximum capacity, refer to Section — Telehandler/Attachment/Fork Capacity. Joystick (1) controls movement of the boom Roller switch (2) controls sweeper tilt. • Press roller switch down to tilt up. • Press roller switch up to tilt down. Sweeper Control: Roller Switch (3) controls the sweeper.
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Attachments Installation Procedure: • Refer to Section — Attachment Installation. 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.
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Attachments 5.10.20 Boom Mounted Lifting Lug Use Boom Mounted Lifting Lug Capacity Chart To determine maximum capacity, refer to Section — Telehandler/Attachment/Fork Capacity. Suspend loads in accordance with requirements set forth in Section — General Safety Practices. O 5231 Joystick (1) controls movement of the boom. Roller switch (2) controls carriage tilt.
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. •...
Emergency Procedures 4. Block all four wheels. 5. Section off a large area under the boom to restrict any personnel from entering this area. 6. See Service Manual for information. EMERGENCY EXIT FROM ENCLOSED CAB 6.3.1 Fixed Window (if equipped) •...
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. The Lubrication and Maintenance decals (1) contain instructions that must be followed to keep this product in good operating condition.
Lubrication and Maintenance GENERAL MAINTENANCE INSTRUCTIONS Prior to performing any service or maintenance on the telehandler, follow the Shut-Down Procedure unless otherwise instructed. Ensure telehandler is level, for proper fluid readings. • Clean lubrication fittings before lubricating. • After greasing telehandler, cycle all functions several times to distribute lubricants. Perform this maintenance procedure without attachment installed.
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Lubrication and Maintenance 7.3.1 Every 10 Hours Check Tire Condition and Check Brake Fluid Level Check Engine Oil Level Check Fuel Level Pressure Check Transmission Oil Check Hydraulic Oil Level Check DEF Level (if Check Air Cleaner Level equipped for ULS/85 or 110HP) Drain Fuel/Water Additional Checks (see...
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Lubrication and Maintenance 7.3.4 First 250 Hours Change Transmission Change Axle Oil Change Wheel End Oil Fluid and Filter 7.3.5 Every 250 Hours Lubrication Schedule Check Boom Chains Check Boom Wear Pads Check Wheel End Oil Level Check Axle Oil Level 31211849 6036, 6042, 8042, 10042, 10054, 12054...
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Lubrication and Maintenance 7.3.6 First 500 Hours Change Engine Oil and Filter (if equipped for ULS) 7.3.7 Every 500 Hours Change Engine Oil and Check Fan Belt Check Wheel Lug Nut Check Battery Filter (if equipped for LS) Torque 7.3.8 Every 750 Hours Change Hydraulic Tank Change Hydraulic Filters...
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Lubrication and Maintenance 7.3.9 Every 1000 Hours Lubrication Schedule Check Boom Chain Check Air Intake System Check Park Brake Tension Change Transmission Change Axle Oil Change Wheel End Oil Fluid and Filter Grease Boom Chains Change Engine Oil and Change Fuel Filters Filter (if equipped for ULS, see note) Note: If using fully synthetic oil, metal engine oil filter and fuel consumption is less...
Lubrication and Maintenance 7.3.11 Every 2000 Hours or 2 Years Clean Engine Coolant (if Change DEF Tank Filter (if equipped for ULS) and equipped for ULS/85 or Change Engine Coolant (if Clean Engine Coolant 110HP) equipped for LS) Strainer (if equipped for ULS/85 or 110HP) 7.3.12 Every 4000 Hours or 3 Years...
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Lubrication and Maintenance EVERY 8042 & 10042 10054 & 12054 31211849 6036, 6042, 8042, 10042, 10054, 12054...
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Lubrication and Maintenance 1. Check Fuel Gauge (1) located in right side of Instrument Panel in cab. 2. If fuel is low, proceed to fuel source and perform Shut-Down Procedure. 3. Turn fuel tank cap (2) to remove from filler neck. 4.
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Lubrication and Maintenance Drain Fuel/Water Separator 1. Perform Shut-Down Procedure. 2. Open engine cover. 3. Loosen drain cock (3) on underside of fuel filter (4) and allow all water to drain into a glass until clear fuel is visible. 4. Tighten drain cock. 5.
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Lubrication and Maintenance OD1350 1. Check Diesel Emission Fluid (DEF) Gauge (1) located in right side of Instrument Panel in cab. 2. If DEF is low, proceed to DEF source and perform Shut-Down Procedure. 3. Turn DEF tank cap (2) to remove. 4.
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Lubrication and Maintenance 1. Perform Shut-Down Procedure. Note: Allow machine to be shut down for 10 to 15 minutes before removing dip- stick to check engine oil level. 2. Open engine cover. 3. Remove dipstick (3) and check oil mark. Oil should be between full (6) and add (5) marks of dipstick.
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Lubrication and Maintenance 1. Perform Shut-Down Procedure. 2. Open engine cover. 3. Remove dust from vacuator valve (1) by squeezing bottom of valve to allow loose particles to fall out. 4. Close and secure engine cover. NOTICE EQUIPMENT DAMAGE. Only remove air cleaner cover to service elements. Excessive access to check elements can lead to premature element and/or engine failure.
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Lubrication and Maintenance 3. Unlock air cleaner cover (2) and remove from air cleaner. 4. Remove outer primary element (3). Inspect element for damage then discard. 5. Thoroughly clean interior of air cleaner canister and vacuator valve (1). 6. Replace inner safety element (4) every third primary element change or if primary element was found to be damaged.
SECTION 8 Additional Checks STABIL-TRAK (6042, 8042, 10042, 10054 & 12054) Stabil-Trak Indicator Test 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.
Additional Checks 10. Raise the boom above 40°. Stabil-Trak system locked mode will be activated and indicator will illuminate. 11. Lower boom below 40°. 12. Shift transmission to neutral. BOOM/OUTRIGGER INTERLOCK (10054 & 12054) Boom/Outrigger Interlock System Test 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”...
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Additional Checks 5. Retract boom. 6. Lower outriggers (10) on firm terrain. 7. Extend boom (7) until it stops. Boom will fully extend and Stabil-Trak indicator (4) will illuminate. 6036, 6042, 8042, 10042, 10054, 12054 31211849...
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Additional Checks REVERSE SENSING SYSTEM (IF EQUIPPED) Reverse Sensing System Check 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. 2.
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Additional Checks AIR SHUTOFF VALVE (ASOV) (IF EQUIPPED) Air Shutoff Valve Test Air Shutoff Valve (ASOV) is an overspeed protection device mounted to the engine’s air intake system. When the valve is actuated, it obstructs airflow intake and stops the engine.
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SECTION 9 Specifications PRODUCT SPECIFICATIONS 9.1.1 Fluids If Equipped for ULS Compartment or Type and Classification Viscosities Ambient Temperature System Range °F °C SAE 5W-40 SAE 15W-40 API CJ-4 Plus CES-20081 Engine Crankcase SAE 10W-30 Fully Synthetic* SAE 5W-30 SAE 0W-30 MobilFluid 424 10W-30 Transmission and Transfer...
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Specifications Compartment or Type and Classification Viscosities Ambient Temperature System Range °F °C EN590 ASTM D 975 Grade 1-D Ultra Low Sulfur (S < 15 mg/kg) Fuel ASTM D 975 Grade 2-D (Maximum B5 Biodiesel) Diesel Exhaust Fluid (DEF) ISO22241-1 32.5% Urea (85 or 110HP) Brake Fluid...
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Specifications Wheel Lug Nut Torque 350–400 lb-ft (474–542 Nm) 9.1.8 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) 12054 12,000 lb (5 443 kg) Maximum Lift Height 6036 36 ft (11,0 m)
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Specifications Outriggers Not Engaged 2,000 lb (907 kg) 10054 Outriggers Engaged 3,000 lb (1 361 kg) Outriggers Not Engaged 1,400 lb (635 kg) 12054 Outriggers Engaged 3,500 lb (1 588 kg) Outriggers Not Engaged 0 lb (0 kg) Reach at Maximum Height 6036 5.1 ft (1,6 m) 6042...
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Specifications 9.1.9 Dimensions Overall Height 6036 100 in (2 540 mm) 6042 102 in (2 591 mm) 8042 99.4 in (2 525 mm) 10042, 10054 & 12054 100.1 in (2 543 mm) Overall Width 6036 & 6042 99 in (2 515 mm) 8042 99.2 in (2 520 mm) 10042, 10054 &...
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Specifications 6042 168 in (4 267 mm) 8042 156 in (3 962 mm) 10042 170 in (4 318 mm) Turning Radius (Clearance) 6036 & 6042 151 in (3 835 mm) 8042 156 in (3 962 mm) 10042 176 in (4 470 mm) 10054 &...
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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) 370/75-28 Air Filled 110 lb/in² (7,7 kg/cm²) Foam Filled 144 lb/in² (10,1 kg/cm²) 315/95-28 Solid 168 lb/in² (11,8 kg/cm²) 18 x 625, 16 Ply Pneumatic Not Available at Publication...
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Specifications Foam Filled 150 lb/in² (10,5 kg/cm²) 315/95-28 Solid 187 lb/in² (13,1 kg/cm²) 18 x 625, 16 Ply Pneumatic Not Available at Publication 10042 Outriggers 98 lb/in² (6,9 kg/cm²) Tires 17.50 x 25 Air Filled 104 lb/in² (7,3 kg/cm²) Foam Filled 135 lb/in²...
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Specifications Pneumatic Not Available at Publication 12054 Outriggers 112 lb/in² (7,9 kg/cm²) Tires 17.50 x 25 Air Filled 123 lb/in² (7,9 kg/cm²) Foam Filled 168 lb/in² (8,7 kg/cm²) 400/75-28, 16 Ply Air Filled 112 lb/in² (7,9 kg/cm²) Foam Filled 161 lb/in² (11,3 kg/cm²) 360/85-28 Solid 183 lb/in²...
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Inspection, Maintenance and Repair Log Serial Number ___________________________________ Date Comments...
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Inspection, Maintenance and Repair Log...
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Hand Signals EMERGENCY STOP - With both STOP - With either arm ex- STOP ENGINE - Draw thumb or arms extended laterally, hands tended laterally, hand open forefinger across throat. open downward, move arms downward, move arm back and back and forth. forth.
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Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg, PA 17233-9533 USA (717) 485-5161 (Corporate) (877) 554-5438 (Customer Support) (717) 485-6417 Visit our website for JLG Worldwide Locations. www.jlg.com...
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