JLG Skytrak 6036 Manuals

Manuals and User Guides for JLG Skytrak 6036. We have 4 JLG Skytrak 6036 manuals available for free PDF download: Service Manual, Operation & Safety Manual

JLG Skytrak 6036 Service Manual (280 pages)

Brand: JLG | Category: Front End Loaders | Size: 3.13 MB

Caution !

7
- Table of Contents
  7
- Introduction
  7
- Signal Words
  7
- Personal Considerations
  8
- Equipment Considerations
  8
  - Section 1 Safety Practices
    8
- General Considerations
  9
- Operational Considerations
  9
- Final Word
  10
  - Section 2 General Instructions
    12
  - Hoses and Tubes
    13
  - Bearings
    14
  - Bolts and Nuts
    14
  - Painting
    15
  - Straight Thread O-Ring Fitting
    15
  - Orange Paint
    15
  - Black Paint
    15
  - White Paint
    15
  - After Service Startup and Checks
    16
  - After Replacing Transmission
    16
  - Starting after Servicing
    16
  - After Tire Servicing
    16
  - After Engine Servicing
    16
  - After Boom Servicing
    16
  - After Hydraulic Component
    16
  - After Axle Servicing
    16
  - After Brake System Servicing
    16
  - Fluid Levels and
    16
  - Hydraulic Reservoir
    17
  - Drop Box
    17
  - Grease Fittings
    17
  - Engine Oil
    17
  - Cooling System
    17
Section 3 Boom

19
- 3.1 Boom Assembly
  20
  - Inner Boom Replacement
    20
  - Intermediate Boom Replacement
    21
  - Outer Boom Replacement
    23
  - Chain Replacement
    27
  - Chain Lubrication
    28
  - Chain Tension Check
    28
  - Chain Tension Adjustment
    29
  - Wear Pad Replacement
    29
  - Hose Tensioning
    30
  - Boom Lubrication Points
    31
  - Emergency Boom Lowering
    31
  - Long Term Storage Preparation
    31
  - Loss of Engine Power or Hydraulic Pump Failure
    31
  - Hydraulic Line Failure
    32
  - Quick Attach Assembly
    33
  - Troubleshooting
    34
  - Specifications
    35
Section 4 Operator's Cab

37
- 4.2 Mechanical Hand Controls 4-1
  
  38
- 4.1 Seat
  
  38
Section 5 Wheel Assembly, Tires, and Axle

46
- Wheel Assembly and Tire
  47
- Removing Hydrofill from Tire or Tube
  49
- Demounting Standard Tire
  50
- Demounting Tire
  50
- Removing Wheel from Forklift
  50
- Demounting Optional Tire
  51
  - From Single Piece Wheel
    51
- Filling a Tire or a Tube Within a Tire
  52
- Mixing Hydrofill Solution
  52
- Tire and Wheel Lubrication
  52
- Wheel and Tire Inspection
  52
  - And Replacement
    52
- Wheel Cleaning
  52
- Mounting Standard Tire
  53
  - On Three Piece Wheel
    53
- Mounting Tire
  53
- Connecting Core Ejector Tool
  54
  - To Tire Valve Stem
    54
- Mounting Optional Tire
  54
  - On Single Piece Wheel
    54
- Care of Pump
  55
- Installing a Wheel on the Forklift
  55
  - Care of Core Ejector
    55
- Tire Speed and Road Surface Limitations
  55
  - Care and Storage of Tires
    55
- Axle Assembly
  56
- Axle
  57
- Wheel End with Service Brakes
  60
- Axle Steering Joints
  62
- Wheel End Without Service Brakes
  62
- Park Lock Unit
  66
  - Carrier Assembly
    68
- Steering Cylinder and Tie Rod
  66
- Axle Lubrication
  71
- Grease
  71
  - Differential Housing Oil
    71
- Specifications
  72
- Wheel End Brake Oil
  72
- Troubleshooting
  73
  - Section 6 Drive Shafts and Drop Box
    75
Section 5

81
- Preventive Maintenance
  81
- 1000 Hour Intervals
  82
- How to Drain Transmission
  82
- How to Tow the Forklift
  82
- How to Back Flush Oil Cooler
  83
- Installation
  83
- Internal Servicing
  83
- Transmission Removal
  83
- Transmission Replacement
  83
- Troubleshooting
  84
- Specifications
  85
- Transmission
  85
Section 6

87
- Par. Title
  88
  - Maintenance
    88
    
    Engine Preventive
    88
    
    Engine Preventive Maintenance
    88
    
    Daily before Operation
    88
    
    First 50 Hours, 250 Hours Thereafter
    88
    
    Daily or 10 Hour Intervals
    88
    
    Hour Intervals
    92
    
    Hour Intervals
    93
    
    Annually
    93
    
    Post Delivery Check
    93
    
    Lubricating Oils
    94
    
    Engine Cooling System
    95
    
    Coolant Requirements
    95
    
    Piston Cooling Jets
    95
    
    Integral Cooler in Oil Filter
    96
    
    Engine Electrical System
    96
    
    Engine Fuel System
    96
    
    Type of Diesel Fuel to Use
    96
    
    Fuel Tank
    96
    
    Fuel Level Sender and Gauge
    98
    
    Fuel Pre-Filter
    98
    
    Fuel Lift Pump
    99
    
    Fuel Filter
    100
    
    Fuel Injection Pump
    102
    
    How to Bleed the Fuel System
    102
    
    Atomizers (Fuel Injectors)
    102
    
    Engine Exhaust System
    103
    
    Engine Removal
    105
    
    Engine Overhaul
    107
    
    Engine Installation
    107
    
    Head Torque Check
    110
    
    Stem Tip to Rocker Arm Clearance Check
    110
    
    Engine Storage
    111
    
    Troubleshooting
    112
Section 9 Hydraulic System Warning !

114
- Section 9 Hydraulic System
  114
- 9.1 Circuits
  
  118
  - Boom Extend/Retract
    118
  - Grille Tilt and Slave Circuit
    121
  - Frame Tilt Circuit
    124
  - Brake Circuits
    127
    
    Steering and Emergency Brake Pump
    127
    
    Service Brake Valve
    127
  - Power Steering Circuit
    130
  - Optional Auxiliary Circuit
    133
- Cylinders
  
  136
  - Boom Hoist Cylinder
    136
  - Extend Cylinder
    137
  - Slave Cylinder
    143
  - Grille Tilt Cylinder
    146
  - Frame Tilt Cylinder
    149
  - Steering Cylinder
    152
  - Side Tilt Carriage Cylinder (Optional)
    155
- Valves
  
  158
  - Main Control Valve Assembly
    158
  - Brake Valve
    163
  - Park Lock Release Valve
    167
  - Steer Select Valve
    169
  - Sequence Valve
    170
  - Steer Relief Valve
    170
  - Pressure Reducing Valve
    171
  - Counterbalance Valve
    172
- Pumps
  
  173
  - Main Tandem Pump
    173
  - Steering and Emergency
    180
  - Steering and Emergency
    181
- Troubleshooting
  
  184
- Specifications
  
  191
Section 10 Electrical System

194
- Service Warnings
  195
  - And Recommendations
    195
- System Components
  195
- Effective Ground Connections
  196
- Horn
  196
- Warning Devices
  196
- Backup Alarm and Reverse Switch
  197
- Park Lock Warning Light
  197
- Circuit Breakers
  198
- Warning Lights
  198
- Wiring Harnesses
  198
- Starting Circuit
  203
- Testing Starter in Forklift
  204
- How to Check Voltage Loss
  206
  - In the Starting Circuit
    206
- Starting Motor Relay
  213
- Thermo Start Plug for Cold Weather Starting
  214
- Charging Circuit
  215
- Batteries
  226
- Ignition (Key) Switch
  227
- Switches and Solenoids
  227
- Fuel Run Solenoid
  229
- Neutral Start Switch
  229
- Park Lock Switch
  230
- Park Lock Release Valve Solenoid
  231
- Reverse Switch
  233
- Steer Select Switch
  233
- Gauges and Indicator Lights
  234
- Installation of the Gauge Cluster
  234
- Removal of the Gauge Cluster
  234
- Hourmeter
  235
- Warning Lights
  236
- Alternator Not Charging Light
  238
- Engine Coolant High Temperature Sender
  238
- Transmission High Temperature Sender
  238
- Fuel Gauge
  239
- Directional and Emergency Flasher Switch
  243
- Optional Lighting System
  243
- Momentary Brake Light (Stop Light)
  245
- Momentary Brake Light Switch
  245
- Headlight and Rear Work Light Switch
  246
- Windshield Washer/Wiper
  246
- Windshield Washer/Wiper Switch (Enclosed Cab Only)
  246
- Windshield Washer Motor and Reservoir (Enclosed Cab Only)
  247
- Windshield Wiper Motor (Enclosed Cab Only)
  249
- Cab Heater (Enclosed Cab Only)
  252
- Cab Heater Switch (Enclosed Cab Only)
  252
- Fan Switch and Fan Motor (Optional)
  252
- Heater Fan Motor and Coil (Enclosed Cab Only)
  254
- Emergency Braking and Steering System
  255
- Low Oil Pressure Switch
  255
- Steering and Emergency Hydraulic Pump (S/N 7P0013 and Before)
  256
- Steering and Emergency Hydraulic Pump (S/N 7P0014 and After)
  257
- Troubleshooting
  258

JLG Skytrak 6036 Operation & Safety Manual (188 pages)

Brand: JLG | Category: Trucks | Size: 6.18 MB

Read this First

4
- Operator Qualifications
  4
- Modifications
  4
- Other Publications Available
  6
- Machine Configuration
  6
- Table of Contents
  7
Table of Contents

13
Section 1 - General Safety Practices

13
- Hazard Classification System
  13
  - Safety Alert System and Safety Signal Words
    13
- General Precautions
  13
- Operation Safety
  14
  - Electrical Hazards
    14
  - Tip over Hazard
    16
  - Travel Hazard
    19
  - Load Falling Hazard
    20
  - Lifting Personnel
    21
  - Driving Hazards on Slopes
    22
  - Pinch Points and Crush Hazards
    23
  - Fall Hazard
    25
  - Chemical Hazards
    26
- Clearsky (if Equipped)
  27
  - Federal Communications Commission (FCC) Information for Users
    27
Section 2 - Pre-Operation and Inspection

29
- Preparation, Inspection and Maintenance
  29
- Pre-Operation Check and Inspection
  30
- Safety Decals
  32
  - ANSI (if Equipped)
    32
  - ISO (if Equipped)
    35
- Walk-Around Inspection
  38
- Warm-Up and Operational Checks
  40
  - Warm-Up Check
    40
  - Operational Check
    40
- Operator Cab
  41
- Windows
  42
  - Cab Door Window (if Equipped)
    42
Table of Contents

43
Section 3 - Controls and Indicators

43
- General
  43
- Controls
  44
  - Dash Controls and Indicators
    46
  - Instrument Cluster
    48
  - Ignition
    50
  - Park Brake
    51
  - Parking Procedure
    51
  - Transmission Control Lever
    52
  - Boom Joystick
    54
  - Auxiliary Hydraulic Joystick
    55
  - Frame Level Joystick
    56
  - Outrigger Switches (10042 & 10054)
    57
  - Accessory Control Lever (if Equipped)
    58
- Steer Modes
  59
  - Steer Mode Change
    59
- Stabil-Trak™ System (6042, 8042, 10042 & 10054)
  60
  - Free Pivot Mode
    60
  - Slow Pivot Mode
    60
  - Locked Mode
    60
- Boom/Outrigger Interlock System (10054)
  61
  - Extend Interlock Mode
    61
  - Outrigger Interlock Mode
    61
- Operator Seat
  62
  - Adjustments
    62
  - Seat Belt
    64
- Boom Angle and Extension Indicators
  65
- Reverse Sensing System (if Equipped)
  66
Section 4 - Operation

67
- Engine
  67
  - Starting the Engine
    67
  - Battery Boosted Starting
    68
  - Normal Engine Operation
    69
  - Shut-Down Procedure
    69
- After-Treatment System (ATS) (if Equipped for ULS/85 or 110HP)
  70
  - Automatic Exhaust System Cleaning
    70
  - Stationary Exhaust System Cleaning
    71
- Operating with a Non-Suspended Load
  72
  - Lift Load Safely
    72
  - Picking up a Load
    72
  - Transporting a Load
    73
  - Leveling Procedure
    73
  - Placing a Load
    74
  - Disengaging a Load
    74
- Operating with a Suspended Load
  75
  - Lift Load Safely
    75
  - Picking up a Suspended Load
    75
  - Transporting a Suspended Load
    76
  - Leveling Procedure
    76
  - Placing a Suspended Load
    77
  - Disengaging a Suspended Load
    77
- Loading and Securing for Transport
  78
  - Tie down
    78
  - Lifting
    79
Table of Contents

81
Section 5 - Attachments

81
- Approved Attachments
  81
- Unapproved Attachments
  81
- JLG Supplied Attachments
  82
- Telehandler/Attachment/Fork Capacity
  84
- Use of the Capacity Chart
  85
  - Capacity Indicator Locations
    85
  - Sample Capacity Chart
    86
  - Example
    88
- Attachment Installation
  90
  - Hydraulic Operated Attachment
    92
- Adjusting/Moving Forks
  93
- Attachment Operation
  94
  - Carriage with Forks
    95
  - Side Shift Carriage
    96
  - Side Tilt Carriage
    98
  - Swing Carriage
    100
  - Dual Fork Positioning Carriage
    102
  - Mast Carriage
    104
  - Pipe Grapple
    106
  - Fork Extension
    108
  - Coupler Mounted Hook
    110
  - Fork Mounted Hook
    112
  - Bucket
    114
  - Grapple Bucket
    116
  - Bucket - Fork Mounted
    118
  - Trash Hopper - Fork Mounted
    120
  - Truss Boom
    122
  - Material Handling Arm
    124
  - Personnel Work Platform - Fork Mounted
    126
  - Sweeper
    128
  - Boom Mounted Lifting Lug
    130
Section 6 - Emergency Procedures

131
- Towing a Disabled Product
  131
  - Moving Short Distances
    131
  - Moving Longer Distances
    131
- Emergency Lowering of Boom
  132
- Emergency Exit from Enclosed Cab
  133
  - Fixed Window (if Equipped)
    133
  - Latch Window (if Equipped)
    133
Section 7 - Lubrication and Maintenance

135
- Introduction
  135
  - Clothing and Safety Gear
    135
- General Maintenance Instructions
  136
- Maintenance Schedules
  137
  - Every 10 Hours
    137
  - First 50 Hours
    137
  - Every 50 Hours
    138
  - First 250 Hours
    138
  - Every 250 Hours
    138
  - First 500 Hours
    139
  - Every 500 Hours
    139
  - Every 750 Hours
    139
  - Every 1000 Hours
    140
  - Every 1500 Hours
    140
  - Every 2000 Hours or 2 Years
    141
  - Every 4000 Hours or 3 Years
    141
  - Every 5000 Hours or 4 Years
    141
- Lubrication Schedules
  142
  - 50 Hour Lubrication Schedule
    142
  - 250 Hour Lubrication Schedule
    145
  - 1000 Hour Lubrication Schedule
    147
- Operator Maintenance Instructions
  148
  - Fuel System
    148
  - Diesel Exhaust Fluid (DEF) System (if Equipped for ULS/85 or 110HP)
    150
  - Engine Oil
    151
  - Air Intake System
    152
  - Hydraulic Oil
    156
  - Tires
    157
  - Transmission Oil
    159
  - Engine Cooling System
    160
  - Brake Fluid (SN 0160074878 to Present)
    161
  - Battery
    162
Section 8 - Additional Checks

163
Table of Contents

167
Section 9 - Specifications

167
- Product Specifications
  167
  - Fluids
    167
  - Capacities
    170
  - Tires
    172
  - Performance
    173
  - Dimensions
    175
Index

179
Inspection, Maintenance and Repair Log

183

JLG Skytrak 6036 Operation & Safety Manual (154 pages)

Brand: JLG | Category: Lifting Systems | Size: 5.11 MB

Read this First
4
Operator Qualifications
4
Modifications
4
Other Publications Available
6
Machine Configuration
6
Table of Contents
7
Section 1 - General Safety Practices
11
Hazard Classification System
11
Safety Alert System and Safety Signal Words
11
General Precautions
11
Operation Safety
12
Electrical Hazards
12
Tip over Hazard
13
Travel Hazard
16
Load Falling Hazard
17
Lifting Personnel
18
Driving Hazards on Slopes
19
Pinch Points and Crush Hazards
20
Fall Hazard
22
Chemical Hazards
23
Section 2 - Pre-Operation and Inspection
25
Pre-Operation Check and Inspection
25
Safety Decals
27
ANSI (if Equipped)
27
ISO (if Equipped)
30
Walk-Around Inspection
34
Warm-Up and Operational Checks
36
Warm-Up Check
36
Operational Check
36
Operator Cab
37
Windows
38
Cab Door Window (if Equipped)
38
Section 3 - Controls and Indicators
39
General
39
Controls
40
Dash Controls and Indicators
41
Instrument Cluster
42
Ignition
44
Park Brake
45
Parking Procedure
45
Transmission Control Lever
46
Boom Joystick
48
Frame Level and Attachment Tilt Joystick
49
Auxiliary Hydraulic Joystick
50
Outrigger Switches (10042 & 10054)
51
Accessory Control Lever (if Equipped)
52
Steer Modes
53
Steer Mode Change
53
Stabil-Trak™ System (6042, 8042, 10042 & 10054)
54
Free Pivot Mode
54
Slow Pivot Mode
54
Locked Mode
54
Boom/Outrigger Interlock System (10054)
55
Extend Interlock Mode
55
Outrigger Interlock Mode
55
Operator Seat
56
Adjustments
56
Seat Belt
57
Boom Angle and Extension Indicators
58
Section 4 - Operation
59
Engine
59
Starting the Engine
59
Battery Boosted Starting
60
Normal Engine Operation
61
Shut-Down Procedure
61
Operating with a Non-Suspended Load
62
Lift Load Safely
62
Picking up a Load
62
Transporting a Load
63
Leveling Procedure
63
Placing a Load
64
Disengaging a Load
64
Operating with a Suspended Load
65
Lift Load Safely
65
Picking up a Suspended Load
65
Transporting a Suspended Load
66
Leveling Procedure
66
Placing a Suspended Load
67
Disengaging a Suspended Load
67
Loading and Securing for Transport
68
Tiedown
68
Lifting
69
Section 5 - Attachments
71
Approved Attachments
71
Unapproved Attachments
71
JLG Supplied Attachments
72
Telehandler/Attachment/Fork Capacity
73
Use of the Capacity Chart
74
Capacity Indicator Locations
74
Sample Capacity Chart
76
Example
78
Attachment Installation
80
Hydraulic Operated Attachment
82
Adjusting/Moving Forks
83
Attachment Operation
84
Carriage W/Forks
85
Side Tilt Carriage
86
Swing Carriage
88
Dual Fork Positioning Carriage
90
Mast Carriage
92
Fork Mounted Hook
94
Fork Extension
96
Truss Boom
98
Bucket
100
Grapple Bucket
102
Personnel Work Platform
104
Section 6 - Emergency Procedures
107
Towing a Disabled Product
107
Moving Short Distances
107
Moving Longer Distances
107
Emergency Lowering of Boom
108
Emergency Exit from Enclosed Cab
108
Section 7 - Lubrication and Maintenance
109
Introduction
109
Clothing and Safety Gear
109
General Maintenance Instructions
110
Service and Maintenance Schedule
111
10 & 1St 50 Hour Maintenance Schedule
111
50, 250 & 1St 500 Hour Maintenance Schedule
112
500 & 1000 Hour Maintenance Schedule
113
1500 & 2000 Hour Maintenance Schedule
114
Lubrication Schedules
115
50 Hour Lubrication Schedule
115
1000 Hour Lubrication Schedule
119
Operator Maintenance Instructions
120
Fuel System
120
Air Intake System
122
Engine Oil
126
Hydraulic Oil
127
Tires
128
Transmission Oil
131
Engine Cooling System
132
Battery
134
Section 8 - Additional Checks
135
Stabil-Trak (6042, 8042, 10042 & 10054)
135
Boom/Outrigger Interlock (10054)
136
Section 9 - Specifications
137
Product Specifications
137
Fluids
137
Capacities
139
Tires
140
Performance
141
Dimensions
142
Index
145
Inspection, Maintenance and Repair Log
149

JLG Skytrak 6036 Operation & Safety Manual (168 pages)

Brand: JLG | Category: Boom Lifts | Size: 19.9 MB

Revision Log
3
Read this First
5
Table of Contents
9
General Safety Practices
13
Hazard Classification System
13
General Precautions
13
Operation Safety
14
Clearsky (if Equipped)
23
Pre-Operation and Inspection
25
Preparation, Inspection and Maintenance
25
Pre-Operation Check and Inspection
25
Safety Decals
26
Walk-Around Inspection
35
Warm-Up and Operational Checks
37
Cab
38
Windows
38
Controls and Indicators
41
General
41
Controls
41
Steer Modes
55
Stabil-Trak™ System (6042, 8042, 10042, 10054 & 12054)
57
Boom/Outrigger Interlock System (10054 & 12054)
57
Operator Seat
58
Boom Angle and Extension Indicators
60
Reverse Systems (if Equipped)
60
Operation
63
Engine
63
After-Treatment System (ATS) (if Equipped for ULS/85 or 110HP)
66
Operating with a Non-Suspended Load
68
Operating with a Suspended Load
69
Loading and Securing for Transport
72
Attachments
75
Approved Attachments
75
Unapproved Attachments
76
Fork Mounted Attachments
76
Equivalent Load
78
JLG Supplied Attachments
80
Telehandler/Attachment/Fork Capacity
83
Use of the Capacity Chart
83
Attachment Installation
89
Adjusting/Moving Forks
90
5.10 Attachment Operation
91
Emergency Procedures
129
Towing a Disabled Product
129
Emergency Lowering of Boom
129
Emergency Exit from Enclosed Cab
130
Lubrication and Maintenance
131
Introduction
131
General Maintenance Instructions
132
Maintenance Schedules
132
Lubrication Schedules
137
Operator Maintenance Instructions
140
Additional Checks
147
Stabil-Trak (6042, 8042, 10042, 10054 & 12054)
147
Boom/Outrigger Interlock (10054 & 12054)
148

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JLG Skytrak 6036 Manuals

JLG Skytrak 6036 Service Manual (280 pages)

Table of Contents

Caution !

Section 3 Boom

Section 4 Operator's Cab

4.2 Mechanical Hand Controls 4-1

4.1 Seat

Section 5 Wheel Assembly, Tires, and Axle

Section 5

Section 6

Section 9 Hydraulic System Warning !

9.1 Circuits

Cylinders

Valves

Pumps

Troubleshooting

Specifications

Section 10 Electrical System

JLG Skytrak 6036 Operation & Safety Manual (188 pages)

Table of Contents

Read this First

Table of Contents

Section 1 - General Safety Practices

Section 2 - Pre-Operation and Inspection

Table of Contents

Section 3 - Controls and Indicators

Section 4 - Operation

Table of Contents

Section 5 - Attachments

Section 6 - Emergency Procedures

Section 7 - Lubrication and Maintenance

Section 8 - Additional Checks

Table of Contents

Section 9 - Specifications

Index

Inspection, Maintenance and Repair Log

JLG Skytrak 6036 Operation & Safety Manual (154 pages)

Table of Contents

JLG Skytrak 6036 Operation & Safety Manual (168 pages)

Table of Contents

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