Operation & Safety Manual Original Instructions Keep this manual with machine at all times.
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, birth defects and other reproductive harm.
Revision Log Revision Log REVISION LOG February 21, 2007 - A - Original Issue of Manual February 24, 2009 - B - Added additional models and revised manual. April 23, 2009 - C - Revised page 9-2. June 30, 2010 - D - Revised covers and pages a, b, 1-5, 1-6, 1-9, 2-1, 2-3, 2-5 thru 2-11, 2-15, 4-3, 4-4, 4-6, 4-9, 4-10, 5-3 thru 5-6, 5-21, 5-22, 5-24, 5-26, 5-28, 5-30, 5-32, 5-34, 5-36, 5-38, 5-40, 5-42, 7-4 thru 7-7, 7-13, 7-16, 7-20, 7-22, 7-23, 9-1 & 9-2.
Read This First Read This First This manual is a very important tool! Keep it with the machine at all times. The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and operating procedures essential for the safe and proper machine operation for its intended purpose. Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without prior notification. Contact JLG Industries, Inc.
Read This First This product must comply with all safety related bulletins. Contact JLG Industries, Inc. or the local authorized JLG representative for information regarding safetyrelated 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. JLG Industries, Inc.
Read This First Other Publications Available Service Manual 6036 (Before S/N 0160039338 excluding 0160024571 & 0160037911)..........................................................................................8990416 6042 (Before S/N 0160039075).............................................................8990466 6036 (S/N 0160039338 thru 0160044900 including 0160024571 & 0160037911), 6042 (S/N 0160039075 thru 0160045063 excluding 0160042742, 0160042747 & 0160042755), 8042, 10042, 10054...................
Table of Contents Table of Contents TABLE OF CONTENTS Revision Log Read This First Operator Qualifications ...................................................... b Modifications ...................................................................... b Other Publications Available .............................................. d Table of Contents Section 1 - General Safety Practices 1.1 Hazard Classification System ..............................................
Table of Contents 3.3 3.4 3.5 3.6 3.7 Park Brake...................................................................... 3-7 Parking Procedure.......................................................... 3-7 Transmission Control Lever............................................ 3-8 Boom Joystick .............................................................. 3-10 Frame Level and Attachment Tilt Joystick.................... 3-11 Auxiliary Hydraulic Joystick ..........................................
Table of Contents 4.4 Loading and Securing for Transport ..................................4-11 Tiedown ........................................................................4-11 Lifting ............................................................................4-12 Section 5 - Attachments 5.1 Approved Attachments ........................................................5-1 5.2 Unapproved Attachments ....................................................5-2 5.3 JLG Supplied Attachments ....................
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 .............
Section 1 - General Safety Practices SECTION 1 - GENERAL SAFETY PRACTICES 1.1 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 result in death or serious injury.
Section 1 - General Safety Practices 1.3 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. • Always check for power lines before raising the boom.
Section 1 - General Safety Practices Tip Over Hazard General • For additional load requirements, refer to the appropriate capacity chart. OW0050 • Never use an attachment without the appropriate JLG approved capacity chart installed on the telehandler. • Understand how to properly use the capacity charts located in cab. • DO NOT exceed rated lift capacity. • Be sure that the ground conditions are able to support the machine.
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 • Always wear the seat belt. • Keep head, arms, hands, legs and all other body parts inside operator’s cab at all times.
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. • Beware of wind. Wind can cause a suspended load to swing and cause dangerous side loads - even with tag lines. • DO NOT attempt to use telehandler frame-leveling to compensate for load swing. • Keep heavy part of load closest to attachment.
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. • Visually verify proper wheel alignment after each steer mode change.
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.
Section 1 - General Safety Practices Lifting Personnel OW0170 • When lifting personnel, USE ONLY a JLG approved personnel work platform, with proper capacity chart displayed in the cab. OW0190 • DO NOT drive machine from cab when personnel are in platform.
Section 1 - General Safety Practices Driving Hazards on Slopes OW0200 To maintain sufficient traction and braking capabilities, travel on slopes as follows: • When unloaded, drive with forks pointed downhill. • When loaded, drive with the forks pointed uphill. • For additional travel requirements, refer to the appropriate capacity chart. • 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.
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 • Keep clear from under boom.
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.
Section 1 - General Safety Practices Fall Hazard OW0280 • Enter using the proper hand holds and steps provided. Always maintain 3-point contact when mounting or dismounting. Never grab control levers or steering wheel when mounting or dismounting the machine. • DO NOT get off the machine until the shutdown procedure on page 4-4 has been performed. OW0290 • DO NOT carry riders. Riders could fall off machine causing death or serious injury.
Section 1 - General Safety Practices Chemical Hazards Exhaust Fumes • 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. • If spark arrestors are required, ensure they are in place and in good working order.
Section 1 - General Safety Practices This Page Intentionally Left Blank 1-14 31200352
Section 2 - Pre-Operation and Inspection SECTION 2 - PRE-OPERATION AND INSPECTION 2.1 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.
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 2-14) of all systems in an area free of overhead and ground level obstructions. See Section 3 - Controls and Indicators for more specific operating instructions. WARNING If telehandler does not operate properly, immediately bring machine to a stop, lower boom and attachment to ground and stop the engine.
Section 2 - Pre-Operation and Inspection 2.2 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 6036 Before S/N 0160038391, 6042 Before S/N 0160038497, 8042 Before S/N 0160038609, 10042 Before S/N 0160038375, 10054 Before S/N 0160038545 4110137 4108991 4110188 4110187 4110188 4107971 (10042 & 10054) DANGER 1. Read operator's manual before operating. 3. Allow no riders. 2.
Section 2 - Pre-Operation and Inspection 4110389 4105262 50 60 70 80 4110226 40 20 -10 0 10 30 4107442 B B VIEW A-A A C A C 4110226 4110184 4110184 VIEW B-B 1706300C 1706300 (8042, 10042 & 10054) (6036 & 6042 - IF EQUIPPED W/ COLD START) VIEW C-C 1705881 4110172 2-4 4110226 OH3771 31200352
Section 2 - Pre-Operation and Inspection D E E F D F Sky Trak 8042 Sky Trak 10 LB-FT 50 2/ (Nm) 50 250 500 2 2 2 2 1000 2 P 2000 4110217 4110339 1001109597 (6036) 1001109598 (6042) 4110217 (8042) 4110186 (10042) 4110218 (10054) 1001109596 (6036 & 6042) 1001103930 (8042, 10042 & 10054) VIEW D-D VIEW E-E 4100181 4105171 4100181 1706300C 1706300 (8042, 10042 & 10054) (6036 & 6042 - IF EQUIPPED W/ COLD START) 4105171 4108302 4108302 OH4372 VIEW F-F 31200352 2-5
Section 2 - Pre-Operation and Inspection 6036 S/N 0160038391 & After, 6042 S/N 0160038497 & After, 8042 S/N 0160038609 & After, 10042 S/N 0160038375 & After, 10054 S/N 0160038545 & After 1706850 1706299 WARNING LOWERING BOOM OR FALLING LOAD could cause death or serious injury. 1706306 WARNING DANGER CONTACTING POWER LINES will result in death or serious injury. Keep others away while operating. 10 ft (3m) DON NOT place machine or load within 10 feet (3m) of power lines.
Section 2 - Pre-Operation and Inspection 1001109596 (6036 & 6042) (8042, 10042 & 10054 S/N 0160040220 & AFTER INCLUDING 016003985, 0160040126 thru 016004129 & 0160040171) 1706298 WARNING Sky Trak FALLING OFF ATTACHMENT could result in death or serious injury. 10 4105262 250 500 40 20 -10 0 10 30 DO NOT TRAVEL with personnel in work platform. 1706298B (Nm) 50 50 60 70 80 Lift or lower personnel only in a JLG approved work platform.
Section 2 - Pre-Operation and Inspection 1001109597 (6036) 1001109598 (6042) BEFORE S/N 0160040220 EXCLUDING 016003985, 0160040126 thru 016004129 & 0160040171 4110217 (8042) 4110186 (10042) 4110218 (10054) S/N 0160040220 &AFTER INCLUDING 016003985, 0160040126 thru 016004129 & 0160040171 1001129510 (8042) 1001129509 (10042) 1001129508 (10054) 1001103930 (8042, 10042 & 10054 - BEFORE S/N 0160040220 EXCLUDING 016003985, 0160040126 thru 016004129 & 0160040171) Sky Trak 8042 Sky Trak 10 50 2/ LB-FT (Nm)
Section 2 - Pre-Operation and Inspection ISO 1001092877 1706284 1706288 3m 1706284B 1706279 (10042 & 10054) 1706279A 1001110282 1001110280 1001110282 CAPACITY CHARTS 1001110282 4107462 4107462 4105621 REV.
Section 2 - Pre-Operation and Inspection 1001109596 (6036 & 6042) (8042, 10042 & 10054 S/N 0160040220 & AFTER INCLUDING 016003985, 0160040126 thru 016004129 & 0160040171) 1706282 Sky Trak 10 4105262 (Nm) 50 50 60 70 80 250 500 40 20 -10 0 10 30 1706282C LB-FT 50 1000 P 2000 4110339 C D B A 4107442 B D C A 1705881 (8042, 10042 & 10054) 4110226 1701640 1701640 (S/N 0160040315 & AFTER) 4110226 1001092878 4110226 1001109053 2.5 GPM MAX 9.
Section 2 - Pre-Operation and Inspection 1001109597 (6036) 1001109598 (6042) BEFORE S/N 0160040220 EXCLUDING 016003985, 0160040126 thru 016004129 & 0160040171 4110217 (8042) 4110186 (10042) 4110218 (10054) S/N 0160040220 &AFTER INCLUDING 016003985, 0160040126 thru 016004129 & 0160040171 1001129510 (8042) 1001129509 (10042) 1001129508 (10054) 1001103930 (8042, 10042 & 10054 - BEFORE S/N 0160040220 EXCLUDING 016003985, 0160040126 thru 016004129 & 0160040171) Sky Trak 8042 Sky Trak 10 50 2/ LB-FT (Nm)
Section 2 - Pre-Operation and Inspection 2.3 WALK-AROUND INSPECTION 17 2 16 1 3 15 14 4 5 5 13 6 7 12 8 9 11 10 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.
Section 2 - Pre-Operation and Inspection 4. Wheel/Tire Assembly - Properly inflated and secured; no loose or missing lug nuts. Inspect for worn tread, cuts, tears or other discrepancies. 5. Mirrors - Clean and undamaged. 6. Cab and Electrical • General appearance; no visible damage. • Frame level indicator and window glass undamaged and clean. • Gauges, switches, joysticks, foot controls and horn operational. • Emergency escape hammer in place (enclosed cab only).
Section 2 - Pre-Operation and Inspection 2.4 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. Keep engine cover closed while engine is running except when checking transmission oil level. Operational Check When engine warms, perform an operational check: 1.
Section 2 - Pre-Operation and Inspection 2.5 OPERATOR CAB The telehandler is equipped with an open or enclosed ROPS/FOPS cab. WARNING 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. It must be REPLACED.
Section 2 - Pre-Operation and Inspection 2.6 WINDOWS Keep all windows and mirrors clean and unobstructed. Cab Door Window (if equipped) 3 4 2 1 OH4281 • Cab door (1) must be closed during operation. • During operation the cab door window (2) must either be latched open or closed. • Open the cab door window and secure it in the latch (3). • Press latch release button inside the cab or pull on lever (4) outside the cab to unlatch the window.
Section 3 - Controls and Indicators SECTION 3 - CONTROLS AND INDICATORS 3.1 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. NOTICE EQUIPMENT DAMAGE. When a red light illuminates, immediately bring machine to a stop, lower boom and attachment to ground and stop the engine.
Section 3 - Controls and Indicators 3.2 CONTROLS 4 3 2 5 1 6 7 8 9 12 11 10 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” on page 3-15. 4. Horn: Depress button to sound horn. 5. Accessory Control Lever (if equipped): See page 3-14. 6. Boom Joystick: See page 3-10. 7.
Section 3 - Controls and Indicators Dash Controls and Indicators 3 4 5 7 8 9 10 11 6 2 1 P OH3801 14 13 12 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. Work Light Switch (if equipped): Three position switch. Push top of switch to turn all work lights on. Move switch to middle position to turn on front and boom worklights.
Section 3 - Controls and Indicators Instrument Cluster 6 5 4 7 8 P 9 3 2 0000 00 1 10 11 OH3910 1. Hourmeter: Records and indicates engine operating hours. 2. Stabil-Trak Indicator (6042, 8042, 10042 & 10054): Illuminates when Stabil-Trak system has been activated. See page 3-16. 3. Transmission Temperature Indicator: Illuminates when transmission oil temperature is too high. Stop and idle engine with transmission in neutral, allowing time for cooling. If light remains on, shut-down engine. 4.
Section 3 - Controls and Indicators Engine Function Indicators 1 2 3 P OH3901 The engine function indicators (1) illuminate when an engine fault occurs during operation. • If red indicator (2) illuminates during operation, stop the engine immediately and diagnose the fault using the ECM diagnostic system. See Service Manual for details. • If amber indicator (3) illuminates during operation, the diagnostic system has detected a fault within the engine.
Section 3 - Controls and Indicators Ignition OFF RUN START OH3811 • In the "RUN" position, voltage is available for all electrical functions. • Full clockwise rotation to "START" engages starter motor. • Counter-clockwise rotation to "OFF" stops engine and removes voltage from all electrical functions.
Section 3 - Controls and Indicators Park Brake 1 2 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. • With switch in "ON" position (2), park brake is engaged and transmission will not engage forward or reverse.
Section 3 - Controls and Indicators Transmission Control Lever Direction of Travel Selection F N R 1 OH3831 Transmission control lever (1) engages forward or reverse travel. • Push lever forward for forward travel; pull lever rearward for reverse travel. Move lever to centered position for neutral. • Forward or reverse travel can be selected while in any gear. • When traveling in reverse, the back-up alarm will automatically sound. • Drive in reverse and turn only at slow rates of speed.
Section 3 - Controls and Indicators Gear Selection 1st 2nd 3rd 4th 2 OH3841 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. Use a higher gear only when driving unloaded for longer distances. • Slow down prior to downshifting. Do not downshift more than one gear at a time.
Section 3 - Controls and Indicators Boom Joystick 1 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. • The speed of boom functions depends upon the amount of joystick travel in corresponding direction. Increasing engine speed will also increase function speed. • For two simultaneous boom functions, move the joystick between quadrants.
Section 3 - Controls and Indicators Frame Level and Attachment Tilt Joystick 2 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. • A level indicator is located above the front cab window to permit operator to determine whether the telehandler frame is level. WARNING TIP OVER HAZARD.
Section 3 - Controls and Indicators Auxiliary Hydraulic Joystick 1 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.
Section 3 - Controls and Indicators Outrigger Switches (10042 & 10054) 2 3 4 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. • Use outriggers to increase stability and/or load capacity and in leveling the telehandler. Study capacity charts to determine maximum load capacities, with and without outriggers.
Section 3 - Controls and Indicators Accessory Control Lever (if equipped) The accessory control lever (1) operates the turn signals, parking lights and headlights. 2 7 5 4 3 6 1 OH3891 Turn Signals • Raise the lever (2) to activate the left turn signal. • Lower the lever (3) to activate the right turn signal. • The lever must be manually returned to the center position to deactivate either turn signal. The lever will not cancel automatically after a turn.
Section 3 - Controls and Indicators 3.3 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 1 2 3 OH4390 1. Bring machine to a stop using service brake while either circle steer mode (1) or crab steer mode (3) is selected. 4 5 OAM2400 2.
Section 3 - Controls and Indicators 3.4 STABIL-TRAK™ SYSTEM (6042, 8042, 10042 & 10054) 2 P 1 3 0000 00 OH4290 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. Slow Pivot Mode With boom above 40° (2), the Stabil-Trak system is in Slow Pivot Mode when the service brake is not applied and the transmission is in gear.
Section 3 - Controls and Indicators 3.5 BOOM/OUTRIGGER INTERLOCK SYSTEM (10054) The interlock system allows the boom to be extended to its maximum limits. 5 P 4 8 0000 00 7 6 OH4361 Extend Interlock Mode With outriggers raised (6), telehandler is in extend interlock mode which limits boom extension (5). • The boom is limited from extending beyond a point between the “E” and “F” boom extension indicators. • Vehicle and Stabil-Trak will function normally.
Section 3 - Controls and Indicators 3.6 OPERATOR SEAT Adjustments Prior to starting engine adjust seat for position and comfort. 3 4 1 2 OW0480 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. Arm Rest: Arm rest can be moved up or down for comfort. 4. Seat Belt: Always fasten seat belt during operation.
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. 3. With belt buckle positioned as low on the body as possible, pull the retractable end of the belt away from the buckle until it is tight across the lap. 4.
Section 3 - Controls and Indicators 3.7 BOOM ANGLE AND EXTENSION INDICATORS 2 1 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” on page 5-9). • Boom extension indicators (2) are located on the left side of the boom. Use these indicators to determine boom extension when using the capacity chart (see “Use of the Capacity Chart” on page 5-9).
Section 4 - Operation SECTION 4 - OPERATION 4.1 ENGINE 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. Apply parking brake. 2.
Section 4 - Operation Cold Weather Starting Aids If your telehandler is equipped with a block and grid heater, the following applies: • Grid heater is located inside the induction manifold. • Grid heater is triggered by temperature sensor located on engine. • At start-up, temperature sensor on engine will detect if grid heater is needed. Follow normal start-up procedure. • A second battery is added for additional cold-cranking capacity.
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. • Connect the opposite end of positive (+) jumper cable to positive (+) post of booster battery. • Connect the negative (-) jumper cable to negative (-) post on booster battery.
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. • Avoid prolonged idling. If the engine is not being used, turn it off.
Section 4 - Operation 4.2 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. WARNING TIP OVER HAZARD. Exceeding lift capacity of the telehandler could damage the equipment and/or cause tip over.
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. Position machine in best location to lift or place load. 2. Apply parking brake and move transmission control lever to NEUTRAL. 3.
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” on page 5-9. • Align forks at the level load is to be placed, then extend boom slowly until load is just above area where it is to be placed.
Section 4 - Operation 4.3 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. WARNING TIP OVER HAZARD. Exceeding lift capacity of the telehandler could damage the equipment and/or cause tip over.
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. Important things to remember: • Ensure the boom is fully retracted. • Never raise the load more than 11.8 in (300 mm) above ground surface or the boom more than 45°.
Section 4 - Operation Placing a Suspended Load Before placing any load be sure that: • The landing point can safely support the weight of the load. • The landing point is level; front to back and side to side. • Use the capacity chart to determine safe boom extension range. See “Use of the Capacity Chart” on page 5-9. • Align load at the level load is to be placed, then position boom slowly until load is just above area where it is to be placed.
Section 4 - Operation 4.4 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. Move all controls to “Neutral,” stop engine and remove ignition key. 4. Secure machine to deck by passing chains through the designated tie down points as shown in the figure. 5.
Section 4 - Operation 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. The machine must remain level at all times while being lifted.
Section 5 - Attachments SECTION 5 - ATTACHMENTS 5.1 APPROVED ATTACHMENTS To determine if an attachment is approved for use on the specific telehandler you are using, perform the following prior to installation. Before S/N 0160037788 • Must be an approved SkyTrak attachment. The model/option number on the attachment identification plate must be contained within this section. • The model on the capacity chart must match the model telehandler being used.
Section 5 - Attachments 5.2 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. • The ability of a non-approved attachment to perform its intended function safely cannot be assured.
Section 5 - Attachments 5.
Section 5 - Attachments Applicable Model Attachment Part Number 6036 6042 Truss Boom w/ Winch, 3 ft (914 mm) 7160400 X X X Truss Boom, 12 ft (3658 mm) 7119700 X X X 1001092280 X X X 1001103637 X X 1001097072 X 1001103736 Truss Boom, 15 ft (4572 mm) Platform, Fork Mounted (ASME) Platform, Fork Mounted (ASME - French) Platform, Fork Mounted (ISO) 5-4 8042 10042 10054 X X X X X X X X X X X X X X X X X X 1001096306 X X X X X 1001103730 X X X X X 7119800
Section 5 - Attachments S/N 0160037788 & After Applicable Model Attachment Part Number 6036 6042 Carriage, 48 in (1220 mm) 6040500 X X X X X Carriage, 50 in (1270 mm) 1170021 X X X X X Carriage, 60 in (1524 mm) 6040600 X X X X X Carriage, 60 in (1524 mm) 1170024 X X X X X Carriage, 72 in (1829 mm) 6040700 X X X X X Carriage, 72 in (1829 mm) 1170027 X X X X X Carriage, 72 in (1829 mm) 1001132514 X X X X X Side Tilt Carriage, 48 in (1220 mm) 7134400 X X
Section 5 - Attachments Attachment Bucket, 96 in - 1.5 yd 3 Bucket, 102 in - 2.0 yd3 3 Applicable Model Part Number 6036 6042 1001100823 X X X X X 1001100824 X X X X X 8042 10042 10054 0930020 X X X X X Hook, Fork Mounted 91565094 X X X X X Truss Boom w/ Winch, 3 ft (914 mm) 7160400 X X X X X Truss Boom, 12 ft (3658 mm) 7119700 X X X X Grapple Bucket, 96 in - 1.
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Section 5 - Attachments 5.4 TELEHANDLER/ATTACHMENT/FORK CAPACITY 1 3 2 OW0550 Prior to installing the attachment verify it is approved and the telehandler is equipped with the proper capacity chart. See “Approved Attachments” on page 5-1. To determine the maximum capacity of the telehandler and attachment, use the smallest of the following capacities: • Capacity stamped on the attachment identification plate (1). • Fork capacities and load centers are stamped on the side of each fork (2) (if equipped).
Section 5 - Attachments 5.5 USE OF THE CAPACITY CHART To properly use the capacity chart (see page 5-10), 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. Weight of the load being lifted. 4. Load placement information: a. HEIGHT where the load is to be placed. b. DISTANCE from the front tires of the telehandler where the load is to be placed. 5.
Section 5 - Attachments Sample Capacity Chart Before S/N 0160037788 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.
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.
Section 5 - Attachments S/N 0160037788 & After 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.
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.
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: Before S/N 0160037788 • The attachment is SkyTrak approved and the model/option number matches an attachment number within this section. • The capacity chart is clearly marked for model xxxxx and corresponds with machine configuration being used.
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Section 5 - Attachments 5.6 ATTACHMENT INSTALLATION 1 2 3 6 4 5 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 3-10) 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.
Section 5 - Attachments This installation procedure is designed for one-person operation. Prior to exiting cab, perform “Shut-Down Procedure” on page 4-4. 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. OH4450 3. Tilt quick attach forward to engage attachment. OH4460 4. Lift lock lever and insert lock pin completely through quick attach.
Section 5 - Attachments Hydraulic Operated Attachment 1. Install attachment (see page 5-16). 2. Lower attachment to ground and perform “Shut-Down Procedure” on page 4-4. 1 OH4480 3. Connect attachment hoses to both auxiliary fittings (1).
Section 5 - Attachments 5.7 ADJUSTING/MOVING FORKS Carriages may have different locations where forks can be positioned. Two different methods can be used for repositioning, depending upon the carriage structure. Note: Apply a light coating of appropriate lubricant to ease sliding of forks or fork bar. To slide forks: 1. Ensure attachment is properly installed. See “Attachment Installation” on page 5-16. 2.
Section 5 - Attachments 5.8 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. NOTICE EQUIPMENT DAMAGE. Some attachments may contact the front tires or machine structure when the boom is retracted and the attachment is rotated.
Section 5 - Attachments Carriage w/Forks Use Carriage Attachment Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-8. to “Telehandler/ OY0690 1 2 OH4011 The boom joystick (1) controls lift/lower and extend/retract movement of the boom. The attachment tilt joystick (2) controls fork tilt. • Move joystick back to tilt up. • Move joystick forward to tilt down. Installation Procedure: Refer to “Attachment Installation” on page 5-16.
Section 5 - Attachments Side Tilt Carriage Use Side Tilt Carriage Attachment Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-8. to “Telehandler/ OAL1550 1 2 3 OH4112 The boom joystick (1) controls lift/lower and extend/retract movement of the boom. The attachment tilt joystick (2) controls fork tilt. • Move joystick back to tilt up. • Move joystick forward to tilt down. To Side Tilt: The auxiliary hydraulic joystick (3) controls the carriage side tilt.
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. • Level telehandler before side tilting carriage to engage load. • Side tilt carriage to left or right to align forks with load and engage load. • Raise load slightly and level carriage side to side.
Section 5 - Attachments Swing Carriage Use Swing Carriage Attachment Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-8. to “Telehandler/ OU2150 1 2 3 OH4062 The boom joystick (1) controls lift/lower and extend/retract movement of the boom. The attachment tilt joystick (2) controls fork tilt. • Move joystick back to tilt up. • Move joystick forward to tilt down. To Swing: The auxiliary hydraulic joystick (3) controls the swing function.
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. WARNING CRUSH HAZARD. Use retaining pin (if equipped) for locking swing frame to fixed frame when carrying loads greater than 5000 lb.
Section 5 - Attachments Dual Fork Positioning Carriage Use Carriage Attachment Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-8. to “Telehandler/ OZ3670 1 2 3 OH4710 The boom joystick (1) controls lift/lower and extend/retract movement of the boom. The attachment tilt joystick (2) controls fork tilt. • Move joystick back to tilt up. • Move joystick forward to tilt down. To Fork Position: The auxiliary hydraulic joystick (3) controls fork position.
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. Equipment Damage Precautions: • Do not use forks as a lever to pry material. Excessive prying forces could damage forks or machine structure. • Do not attempt to lift loads that are attached or connected to another object.
Section 5 - Attachments Mast Carriage (S/N 0160037788 & After) Use Mast Carriage Attachment Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-8. to “Telehandler/ OY0580 1 2 3 OH4490 The boom joystick (1) controls lift/lower and extend/retract movement of the boom. The attachment tilt joystick (2) controls fork tilt. • Move joystick back to tilt up. • Move joystick forward to tilt down.
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. • Use a signal person to assist in positioning of load if necessary. Equipment Damage Precautions: • Do not use forks as a lever to pry material.
Section 5 - Attachments Fork Mounted Hook Use Appropriate Carriage Attachment Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-8. to “Telehandler/ OY0640 Suspend loads in accordance with requirements set forth in Section 1 - General Safety Practices. 1 2 OH4021 The boom joystick (1) controls lift/lower and extend/retract movement of the boom. The attachment tilt joystick (2) controls fork tilt. • Move joystick back to tilt up.
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. • Do not use with mast carriage attachment. • Do not use fork mounted hook with attachments capable of rotating (i.e. side tilt and swing carriages) without disabling the rotation feature(s).
Section 5 - Attachments Fork Extension Use Appropriate Carriage Attachment Capacity Chart OZ0750 To determine maximum capacity, refer to “Telehandler/Attachment/Fork Capacity” on page 5-8. 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.
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.
Section 5 - Attachments Truss Boom Use Appropriate Truss Boom Attachment Capacity Chart OY0570 To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-8. to “Telehandler/ Suspend loads in accordance with requirements set forth in Section 1 - General Safety Practices. 1 2 3 OH4051 The boom joystick (1) controls lift/lower and extend/retract movement of the boom. The attachment tilt joystick (2) controls truss boom tilt. • Move joystick back to tilt up.
Section 5 - Attachments Installation Procedure: • Refer to “Attachment Installation” on page 5-16. 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.
Section 5 - Attachments Bucket Use Appropriate Bucket Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-8. to “Telehandler/ OZ0730 1 2 OH4032 The boom joystick (1) controls lift/lower and extend/retract movement of the boom. The attachment tilt joystick (2) controls bucket tilt. • Move joystick back to tilt up. • Move joystick forward to tilt down. Installation Procedure: • Refer to “Attachment Installation” on page 5-16.
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. • Do not use bucket as a lever to pry material. Excessive prying forces could damage bucket or machine structure. • Do not attempt to load material which is hard or frozen.
Section 5 - Attachments Grapple Bucket (S/N 0160037788 & After) Use Grapple Bucket Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-8. to “Telehandler/ OZ1450 1 2 3 OH4500 The boom joystick (1) controls lift/lower and extend/retract movement of the boom. The attachment tilt joystick (2) controls grapple bucket tilt. • Move joystick back to tilt up. • Move joystick forward to tilt down.
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. • Travel in accordance with requirements set forth in Section 1 - General Safety Practices. • Open grapple and tilt bucket down to dump load.
Section 5 - Attachments Concrete Bucket (Before S/N 0160037788) To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-8. to “Telehandler/ OH4530 Suspend loads in accordance with requirements set forth in Section 1 - General Safety Practices. 1 2 3 OH4042 The boom joystick (1) controls lift/lower and extend/retract movement of the boom. The attachment tilt joystick (2) controls concrete bucket tilt. • Move joystick back to tilt up. • Move joystick forward to tilt down.
Section 5 - Attachments Operation: • Close bucket gate, level bucket and fully retract and lower boom to load material. • Distribute material evenly within the bucket. • Travel in accordance with requirements set forth in Section 1 - General Safety Practices. • Open gate to dump load in desired location. Equipment Damage Precautions: • Transport the concrete bucket as low as practical at a slow speed and without rapid side to side movement.
Section 5 - Attachments Auger (Before S/N 0160037788) To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-8. to “Telehandler/ OH4080 1 2 3 OH4072 The boom joystick (1) controls lift/lower and extend/retract movement of the boom. The attachment tilt joystick (2) controls auger tilt. • Move joystick back to tilt up. • Move joystick forward to tilt down. Auger Bit Control: The auxiliary hydraulic joystick (3) controls the auger bit rotation.
Section 5 - Attachments Operation: • Travel in accordance with requirements set forth in Section 1 - General Safety Practices. Equipment Damage Precautions: • Transport the auger unit as low as practical at a slow speed and without rapid side to side movement. • Do not engage auger rotation unless the point of the auger cutting head is touching the ground.
Section 5 - Attachments Sweeper (Before S/N 0160037788) To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-8. to “Telehandler/ OH4090 1 2 3 OH4102 The boom joystick (1) controls lift/lower and extend/retract movement of the boom. The attachment tilt joystick (2) controls sweeper tilt. • Move joystick back to tilt up. • Move joystick forward to tilt down. Sweeper Broom Control: The auxiliary hydraulic joystick (3) controls the sweeper broom rotation.
Section 5 - Attachments Operation: • Travel in accordance with requirements set forth in Section 1 - General Safety Practices. • Lower sweeper so the dolly wheel is firmly on the ground, then tilt sweeper so bristles are against the ground. • Actuate auxiliary hydraulics to begin broom rotation and begin forward travel. Equipment Damage Precautions: • Keep the sweeper as low as practical when transporting or dumping.
Section 5 - Attachments Personnel Work Platform Use Appropriate Carriage Attachment Capacity Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-8. to “Telehandler/ OY1610 The operator and personnel in platform must read and understand the separate personnel work platform manual prior to installing and using a platform. 1 2 OH4510 The boom joystick (1) controls lift/lower and extend/retract movement of the boom. The attachment tilt joystick (2) controls platform tilt.
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). 4. Keep area under platform free from personnel. 5. When personnel are on platform, the operator must remain seated in cab with personnel in direct line of sight. 6. DO NOT lift or carry persons in a bucket or on forks. WARNING FALL HAZARD.
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Section 6 - Emergency Procedures SECTION 6 - EMERGENCY PROCEDURES 6.1 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. Then select the appropriate method. • Machine mounted retrieval devices provide suitable means to attach a tow rope, chain or tow bar only in the event the telehandler becomes stuck or disabled.
Section 6 - Emergency Procedures 6.2 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. Clear the area around telehandler of all personnel. 2. Engage the parking brake. Place the transmission control lever in “NEUTRAL”. 3.
Section 7 - Lubrication and Maintenance SECTION 7 - LUBRICATION AND MAINTENANCE 7.1 INTRODUCTION Service the product in accordance with the maintenance schedule on the following pages. 1 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.
Section 7 - Lubrication and Maintenance 7.2 GENERAL MAINTENANCE INSTRUCTIONS Prior to performing any service or maintenance on the telehandler, follow the shut-down procedure on page 4-4 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.
Section 7 - Lubrication and Maintenance 7.
Section 7 - Lubrication and Maintenance 50, 250 & 1st 500 Hour Maintenance Schedule EVERY 50 Check Boom Wear Pads Check Washer Fluid Level (if equipped) Check Battery Lubrication Schedule EVERY 250 Change Engine Oil and Filter* Check Axle Oil Level Check Wheel End Oil Levels Change Air Filter Elements Check Boom Chain Lubrication Schedule 1st 500 Change Axle Oil Change Wheel End (S/N 0160037788 Oil (S/N 0160037788 & After) & After) OH4142 Note: Engine oil and filter service interval can be
Section 7 - Lubrication and Maintenance 500 & 1000 Hour Maintenance Schedule EVERY 500 LB/F T (N m) Change Fuel Filter & Strainer Check Wheel Lug Nut Torque EVERY 1000 P Change Transmission Oil & Filter Change Hydraulic Fluid & Filters Change Axle Oil Change Wheel End Oil Check Axle Brake Discs Check Boom Chain Tension Check Boom Wear Pads Check Fan Belt Check Air Intake System Lubrication Schedule Lubricate Boom Chain OH4152 31200352 7-5
Section 7 - Lubrication and Maintenance 2000 Hour Maintenance Schedule EVERY 2000 Change Engine Coolant Engine Valve Lash Adjustment OH4601 7-6 31200352
Section 7 - Lubrication and Maintenance 7.
Section 7 - Lubrication and Maintenance 10054 EVERY 50 OH4242 7-8 31200352
Section 7 - Lubrication and Maintenance 250 Hour Lubrication Schedule 6036 & 6042 EVERY 250 6042 ONLY OA1820 31200352 7-9
Section 7 - Lubrication and Maintenance 8042, 10042 & 10054 EVERY 250 OH4172 7-10 31200352
Section 7 - Lubrication and Maintenance 1000 Hour Lubrication Schedule EVERY 1000 OH4181 31200352 7-11
Section 7 - Lubrication and Maintenance 7.5 OPERATOR MAINTENANCE INSTRUCTIONS Fuel System 10 A. Fuel Level Check OW0970 OW0990 P P 0000 00 1 2 3 OH4191 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 4-4. 3. Locate fuel tank (2), turn fuel tank cap (3) and remove from filler neck. 4. Add diesel fuel as needed. 5. Replace and secure fuel tank cap.
Section 7 - Lubrication and Maintenance 10 B.
Section 7 - Lubrication and Maintenance Air Intake System A. Air Filter Restriction Indicator Check 10 OW0970 OW1010 2 1 5 6 7 4 3 OH4212 1. Perform “Shut-Down Procedure” on page 4-4. 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. 4. Remove dust from vacuator valve (3) by squeezing bottom of valve to allow loose particles to fall out. 5. Close and secure engine access door.
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 canister (5). 2. Remove outer primary element (6) and inspect for damage. Damaged elements should not be reused. 3. Thoroughly clean the interior of the air cleaner canister and vacuator valve. 4. Replace inner safety element (7) after every third primary element change.
Section 7 - Lubrication and Maintenance Engine Oil 10 A.
Section 7 - Lubrication and Maintenance 4. If oil is low, remove oil fill cap (4) and add motor oil to bring oil up to the full mark in the crosshatch area. 5. Replace oil fill cap and dipstick. 6. Close and secure engine access door. Note: The standard service interval for engine oil and filter is 250 hours maximum. If an extended service interval is desired, see your engine manual for specific guidelines for optimizing oil change intervals.
Section 7 - Lubrication and Maintenance Hydraulic Oil 10 A. Hydraulic Oil Level Check OW0970 OW1030 7 5 6 OH4231 1. Be sure all cylinders are fully retracted and machine is level. 2. Perform “Shut-Down Procedure” on page 4-4. 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. 4. If hydraulic oil is low remove tank cover. 5. Remove oil fill cap (7) from filler neck.
Section 7 - Lubrication and Maintenance Tires A. Tire Air Pressure Check 10 OW0970 OW1040 1. Perform “Shut-Down Procedure” on page 4-4. 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) 13.00 x 24, G-3/L-3 Bias Ply Rock - 12 Ply .............................55 psi (3,8 bar) 13.00 x 24, G-2/L-2 Radial - 1 Star..........................................55 psi (3,8 bar) 15.
Section 7 - Lubrication and Maintenance B. Tire Damage For pneumatic tires, when any cut, rip or tear is discovered that exposes sidewall or tread area cords in the tire, measures be taken to remove the product from service immediately. Arrangements must be made for replacement of the tire or tire assembly. For polyurethane foam filled tires, when any of the following are discovered, measures must be taken to remove the product from service immediately.
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. 1. Install wheel lug washers. 2. Start all nuts by hand to prevent cross threading. DO NOT use a lubricant on threads or nuts. 3.
Section 7 - Lubrication and Maintenance Transmission Oil 10 A. Transmission Oil Level Check OW0970 OW1050 1 2 T HO LD CO MIN OH4261 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. 3. Remove the transmission dipstick (1) and check oil level. The oil level should be within the "HOT" zone (2). 4.
Section 7 - Lubrication and Maintenance Engine Cooling System 10 A. Engine Coolant Level Check OW0970 OW1070 6036 Before S/N 0160039338 excluding 0160024571 & 0160037911 6042 Before S/N 0160039075 8042, 10042 & 10054 Before S/N 0160040220 excluding 0160039850, 0160040126 thru 0160040129 & 0160040171 8042 S/N 0160044153 & After 10042 & 10054 S/N 016004427 & After 6036 & 6042 8042, 10042 & 10054 2 1 2 1 OH4252 1. Perform “Shut-Down Procedure” on page 4-4. 2. Open engine access door. 3.
Section 7 - Lubrication and Maintenance 6036 S/N 0160039338 & After including 0160024571 & 0160037911 6042 S/N 0160039075 & After 8042 0160040227 thru 0160044148 10042 & 10054 S/N 0160040220 thru 0160044274 including 0160039850, 0160040126 thru 0160040129 & 0160040171 4 3 OA1810 1. Perform “Shut-Down Procedure” on page 4-4. 2. Open rear access door. 3. Coolant level should be visible in sight gauge (3). 4. If coolant is low, allow system to cool. Remove radiator cap (4) and add coolant as required. 5.
Section 7 - Lubrication and Maintenance Battery 50 A. Battery Check OW0980 SINGLE BATTERY CONFIGURATION OW1080 DUAL BATTERY CONFIGURATION 3 3 OH4620 OH4271 1. Perform “Shut-Down Procedure” on page 4-4. 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. Close and secure rear access door.
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Section 8 - Additional Checks SECTION 8 - ADDITIONAL CHECKS 8.1 STABIL-TRAK (6042, 8042, 10042 & 10054) 10 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. To check the indicator, perform the following: 2 6 4 3 1 5 OH4331 1.
Section 8 - Additional Checks 8.2 BOOM/OUTRIGGER INTERLOCK (10054) 10 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” and “F” extension indicators. In outrigger interlock mode, with outriggers lowered, boom will extend fully and Stabil-Trak indicator will illuminate.
Section 9 - Specifications SECTION 9 - SPECIFICATIONS 9.1 PRODUCT SPECIFICATIONS Capacities Engine Crankcase Oil Capacity with Filter Change 6036 (Before S/N 0160039338 excluding 0160024571 & 0160037911) 6042 (Before S/N 0160039075)..............................................10.5 quart (9,9 liter) 8042, 10042 & 10054 (Before S/N 0160040220 excluding 0160039850, 0160040126 thru 0160040129 & 0160040171).......................
Section 9 - Specifications Overflow Bottle Capacity 6036 (Before S/N 0160039338 excluding 0160024571 & 0160037911) 6042 (Before S/N 0160039075) 8042, 10042 & 10054 (Before S/N 0160040220 excluding 0160039850, 0160040126 thru 0160040129 & 0160040171) 8042 (S/N 0160044153 & After) 10042 & 10054 (S/N 016004427 & After) ................................... 3 quart (2,8 liter) Type of Coolant ............................................................
Section 9 - Specifications 8042 (S/N 0160038967 & After excluding 0160038971 & 0160038984) 10042 (S/N 0160038368 & After excluding 0160038375, 0160038378, 0160038379, 0160038381 & 0160038383) 10054 (S/N 0160038740 & After including 0160021270, 0160036713, 0160036715 & 0160036723) Differential Housing Capacity ...............................................12.5 quart (11,8 liter) Wheel End Capacity Front Axle ...........................................................................2.
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) 13.00 x 24, G-3/L-3 Bias Ply Rock - 12 Ply Pneumatic......................................................................................55 psi (3,8 bar) Foam...............................................
Section 9 - Specifications 8042 13.00 x 24, G-2/L-2 Bias Ply Traction - 12 ply (Before S/N 0160037788 Only) Pneumatic......................................................................................70 psi (4,8 bar) Foam .................................................................................Approx 542 lb (246 kg) 13.00 x 24, G-3/L-3 Bias Ply Rock - 12 Ply (Before S/N 0160037788 Only) Pneumatic......................................................................................
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..................................................................................................
Section 9 - Specifications Maximum Travel Speed ....................................................................20 mph (32 kph) Towing Capacity 6036 & 6042 ............................................................................. 6,000 lb (2722 kg) 8042.......................................................................................... 8,000 lb (3629 kg) 10042 & 10054 ....................................................................... 10,000 lb (4536 kg) Frame Leveling.....................
Section 9 - Specifications 6042...........................................................................................168 in (4267 mm) 8042........................................................................................158.3 in (4021 mm) 10042.........................................................................................182 in (4623 mm) 10054......................................................................................184.
Section 9 - Specifications 8042 13.00 x 24 (Before S/N 0160037788 Only) Air Filled ................................................................148 lb/in² (10,4 kg/cm²) Foam Filled ...........................................................199 lb/in² (14,0 kg/cm²) 15.50 x 25 Air Filled ................................................................149 lb/in² (10,5 kg/cm²) Foam Filled ...........................................................188 lb/in² (13,2 kg/cm²) 370/75-28 Air Filled ................
Section 9 - Specifications This Page Intentionally Left Blank 9-10 31200352
Index Index A D Accessory Control Lever ................ 3-14 Decals ANSI ............................................2-3 ISO ..............................................2-9 Additional Checks............................. 8-1 Adjusting/Moving Forks .................. 5-19 Approved Attachments ..................... 5-1 Attachment Installation ................... 5-16 Attachment Operation .................... 5-20 Attachment Tilt Joystick.................. 3-11 Attachments ..............................
Index H P Hazard Classification System........... 1-1 Park Brake ........................................3-7 Hydraulic Oil Level.......................... 7-18 Parking Procedure ............................3-7 Hydraulic Operated Attachment ..... 5-18 Performance......................................9-6 Hydraulic System.............................. 9-2 Personnel Work Platform ................5-46 I Ignition .............................................. 3-6 Instrument Cluster .....................
Index T Tip Over Hazard ............................... 1-3 Tires ........................................ 7-19, 9-4 Air Pressure .............................. 7-19 Damage .................................... 7-20 Replacement............................. 7-20 Towing.............................................. 6-1 Transmission .................................... 9-2 Transmission Control Lever Direction of Travel....................... 3-8 Gear Selection ............................ 3-9 Neutral Lock......
Index 4 31200352
Inspection, Maintenance and Repair Log Inspection, Maintenance and Repair Log Serial Number ______________________________ Date Comments
Inspection, Maintenance and Repair Log Date Comments
TRANSFER OF OWNERSHIP An Oshkosh Corporation Company To Product Owner: If you now own but ARE NOT the original purchaser of the product covered by this manual, we would like to know who you are. 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.
Hand Signals OY1090 EMERGENCY STOP - With both arms extended laterally, hands open downward, move arms back and forth. OY1120 RAISE BOOM - With either arm extended horizontally, fingers closed, point thumb upward. OY1150 EXTEND BOOM - With both hands clenched, point thumbs outward. OY1180 TILT FORKS UP - With one arm held at side, extend other arm upward at about 45 degrees. OY1100 STOP - With either arm extended laterally, hand open downward, move arm back and forth.
31200352 An Oshkosh Corporation Company JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA Phone: +1-717-485-5161 Customer Support Toll Free: 1-877-554-5438 Fax: +1-717-485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia Phone: +61 2 65811111 Fax: +61 2 65813058 JLG Latino Americana Ltda.
