Operator & Safety Manual Keep this manual with machine at all times.
WARNING IMPROPER OPERATION OF THIS VEHICLE CAN CAUSE INJURY OR DEATH. BEFORE STARTING THE ENGINE, DO THE FOLLOWING: 1. READ THIS OPERATOR'S MANUAL. 2. READ ALL THE SAFETY DECALS ON THE VEHICLE. 3. CLEAR THE AREA OF OTHER PERSONS. LEARN AND PRACTICE SAFE USE OF VEHICLE CONTROLS IN A SAFE, CLEAR AREA BEFORE YOU OPERATE THIS VEHICLE ON A WORK SITE. It is your responsibility to observe applicable laws and regulations and to follow manufacturer's instructions on vehicle operation and maintenance.
Effectivity Page November, 1999 - 007 - Revised Manual. February 11, 2005 - H - Replaced branding with JLG.
Effectivity Page B 6036/6036T
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 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. JLG Industries, Inc.
Table Of Contents Introduction The Manual ..................................... Replacement Parts ......................... Reports ........................................... Disclaimer ....................................... 2 2 2 2 Safety Practices Signal Words ................................... 3 New or Additional Operators ........... 4 Personal Considerations ................. 4 Operational Considerations ............ 7 Equipment Considerations ............ 11 Operation Controls ..................
Introduction The Manual This Owners/Operator’s manual provides the information you need to correctly operate and maintain this vehicle. IMPORTANT! Before you operate this vehicle, read this manual completely and carefully so you will understand the safety instructions and the operation of the controls and safety equipment. You must comply with all Danger, Warning, and Caution notices. They are for your benefit.
Safety Practices The information in this manual does not replace any safety rules and laws used in your area. Before operating this telescopic handler, learn the rules and laws for your area. Make sure the vehicle has the correct equipment according to these rules and laws. Your safety and the safety of others in the work area depend significantly upon your knowledge and understanding of all correct operating practices and procedures for this vehicle.
New or Additional Operators 3. Dismounting At the time of original purchase, the purchaser of this vehicle was instructed by the seller on its safe and correct use. If this vehicle is to be used by an employee or is loaned, rented or sold to someone other than the purchaser, make certain that the new operator reads and understands the Operator’s Manual and the Rough Terrain Forklift Safety Manual that are provided with the vehicle before operating the vehicle.
4. Chemical Hazards A. Exhaust Fumes Fumes from the engine exhaust can cause injury or death. If operating in an enclosed area, provide good ventilation to replace hazardous exhaust fumes with fresh air. B. Explosive Fuel Engine fuel is flammable and can cause a fire and/or an explosion. Avoid danger by keeping sparks, open flames and smoking materials away from vehicle and fuel during refueling or fuel system servicing. Know where fire extinguishers are kept on the worksite and how to use them. C.
When jump starting the vehicle, carefully follow instructions found under "Jump Starting" later in this manual. 5. Moving Parts Hazard WARNING Keep sparks, flames, and lit cigarettes away from battery at all times. Lead acid batteries generate explosive gases. Severe chemical burns can result from improper handling of battery electrolyte. Wear safety glasses and proper protective gear when handling batteries to prevent electrolyte from coming in contact with eyes, skin or clothing.
operating the vehicle in a new work area. Operational Considerations 1. Prevent accidents when you move the vehicle around the work site. Know the rules for movement of people and vehicles on the work site. Follow the instructions of signals and signs.
4. 5. Electrocution Hazard Lifting Personnel OG0350 NEVER operate this vehicle in an area in which overhead power lines, overhead or underground cables, or power sources exist without first requesting that the appropriate power company or utility company de-energize the lines or take other suitable precautions. OG0341 Use only an approved work platform for lifting and lowering personnel. NEVER transport personnel in a work platform for even the shortest distance.
6. Tip Over Hazard ALWAYS make sure that all four tires have been properly filled with hydrofill by a qualified tire service center. DO NOT exceed the rated lift capacity of the vehicle, as structural damage and unstable vehicle conditions will result. Traveling with the boom raised is dangerous and can cause tipover. Keep the load as low as possible. Travel with extreme caution and at the slowest possible speed. Driving across a slope is dangerous, as unexpected changes in the slope can cause tipover.
7. Slopes 8. Falling Load Hazard DO NOT exceed the total rated load capacity of the specific type fork being used. Each fork is stamped with a maximum load capacity. If capacity is exceeded, forks may break. See "Fork Ratings" later in this manual. DO NOT park the vehicle on an incline and leave it unattended. • Driving across a slope is dangerous, as unexpected changes in the slope can cause tipover. Ascend or descend slopes slowly and with caution.
Equipment Considerations ALWAYS make sure that all four tires have been properly filled with hydrofill by a qualified tire service center. Improper hydrofill can cause instability which can result in tipover. Warning DO NOT modify or repair (welding, drilling, etc.) any part of this vehicle. Modifications can weaken the structure creating a hazard that can cause injury or death.
Operation STEERING WHEEL Controls Ignition Switch (See Figure 1) Using the ignition switch key, the switch may be turned clockwise from the OFF position to the RUN, THERMO START and START positions. The THERMO START and START positions are spring-loaded to return to the RUN position and must be manually held in place for cold starting or normal starting. Off position — The entire electrical system is shut down. IGNITION SWITCH SERVICE BRAKE PEDAL Run position — All controls and indicators are operable.
TRAVEL SELECT LEVER STEERING SELECT SWITCH Emergency Brake Switch (See Figure 2) The emergency brake switch has two positions: P P Engaged ............... lift red switch cover then push switch up Disengaged .......... lower red switch cover OG0390 EMERGENCY BRAKE P The emergency brake must be ENGAGED to permit engine starting. Operator should use caution when engaging the emergency brake while the vehicle is moving, because the stop will be abrupt and operator may be jolted forward unexpectedly.
Range Select Lever (See Figure 2) The range select lever has three positions to select the gear range: 1 = Low .............. all the way down 2 = Medium ........ center position 3 = High .............. all the way up Use first gear for highest torque and pulling power. Use third gear for highest ground speed.
Attachment and Frame Tilt Control Lever Circulation Fan (Enclosed Cab Only) (See Figure 3) (Not Pictured) The attachment and frame tilt control is a joystick with four perpendicular motions from the center to control two attachment functions and two frame tilt functions: Frame Tilt Left ................. move lever to the left Frame Tilt Right ............... move lever to the right Attachment Tilt Down ...... move lever forward Attachment Tilt Up ...........
Door Latches (Enclosed Cab Only) (Not Pictured) There are two door latches. The outside latch is a key lockable pull to release type. The inside latch is either a push to release or a pull to release type. SEAT BELT Windshield Washer/Wiper Control (Enclosed Cab Only) Turn the knob counterclockwise to operate the wipers at low speed; turn the knob clockwise to operate the wipers at high speed. Pressing the knob activates the windshield washer for as long as it is held in.
Seat Belt (See Figure 5) The seat belt has a slide on each strap that is used to tighten and loosen the strap on each side of the buckle. To shorten, pull bottom of loop toward buckle. To lengthen, hold slide strap, pull slide toward buckle and readjust buckle on loop. Buckle the two straps together to fasten. Lift the buckle latch or press the center button to unfasten the seat belt. Operator's Seat Adjustment (See Figure 5) The position and suspension of the operator's seat can be adjusted.
Warning Light Bulb Test Button (See Figure 6) HOURMETER WARNING LIGHTS FUEL GAUGE WARNING LIGHT BULB TEST BUTTON Directly to the right of the instrument cluster is a warning light bulb test button. With ignition switch in the RUN position and engine OFF, depress this button to test all warning lights. If any of the lights are burnt out, replace the bulb(s) immediately. Fuel Gauge (See Figure 6) Indicates the quantity of fuel in the fuel tank. Capacity of the fuel tank is 24 gallons (90,8 liters).
Frame Level Indicator (See Figure 7) 4105262 The indicator is mounted on the top inside of the Operator's Protective Structure (cab). This is a bubble type indicator which allows the operator to tell if the vehicle has been positioned in a level condition. Always frame tilt the vehicle either right or left until the indicator reads zero degrees (0°). If zero cannot be achieved, then reposition the vehicle until it is level before placing the load.
Optional Controls DIRECTIONAL SIGNAL LEVER Light Switch (See Figure 9) A three-position push-pull switch controls the lights of the optional light package. EMERGENCY FLASHER SLIDE CONTROL • Switch In = Lights OFF. • Switch Halfway Out = Headlights and Taillights. • Switch Fully Out = Headlights, Taillights, Rear Work Lights and Boom Work Lights.
AUXILIARY ATTACHMENT CONTROL LEVER OH0381 Figure 11 Auxiliary Attachment Control Lever (See Figure 11) The auxiliary attachment control lever controls the functions of an optional attachment that is mounted to the vehicle and requires a hydraulic supply for operation. Some of the optional attachments that require auxiliary hydraulics are: Side Tilt Carriage, Mast, Broom, Auger, and Swing Carriage.
Walk-Around Inspection 1. Check the air cleaner restriction indicator for required service. 2. Check and add engine oil if required. 3. Check cooling system overflow bottle for coolant. Add coolant if required and remove debris or other foreign material from the radiator as necessary. 4. Check hydraulic oil level sight gauge and add oil if required. 5. Walk around the vehicle and check for leakage, damaged or missing parts, proper tire inflation and hydrofill. Make necessary repairs before operating. 6.
Cold Starting (Perkins Engines Only) Use the Thermo Start cold starting aid when the temperature is below 32o F (0o C), but not below 10o F (-12o C) with 10W30 oil in the engine's crankcase. Cold starting aids such as block heaters are recommended when temperatures are below 10° F (-12° C). (Temperature ranges will vary when using different oil weights. Consult the engine manufacturer's manual for other variables).
Cold Starting (Cummins Engines Only) The cummins engine on this vehicle is not normally equipped with a cold starting aid. Cold starting aids such as mechanical or electrical ether metering equipment or block heaters are recommended when temperatures are below 10° F (-12° C). (Temperature ranges will vary when using different oil weights. Consult the engine manufacturer's manual for other variables).
IMPORTANT: It is recommended that two people are present when attempting to start the engine without metered starting fluid equipment. One to operate the ignition switch the other to spray the fluid. Avoid soaking the air cleaner element with ether. This is extremely important because a backfire of flame can completely destroy both the primary and secondary air cleaner elements and other possible engine damage may occur. Turn the ignition switch to the START position to engage the starter motor.
1. The booster battery must be a 12 volt type. The vehicle used for jump starting must have a negative ground electrical system. To jump start the vehicle, proceed as follows. 2. Connect the positive (+) jumper cable to the positive (+) post of the discharged battery. 3. Connect the other end of the same jumper cable to the positive (+) post of the booster battery. 4. Connect one end of the second jumper cable to the negative (-) post of the booster battery. 5.
Changing Travel Direction 1. Stop the vehicle. 2. Move travel select lever to opposite direction, (R) reverse or (F) forward. Shifting Gears 1. Shifting to next higher gear may be done at any engine speed while the vehicle is in motion. 2. When downshifting, do not over-rev the engine. Allow machine to slow before shifting to next lower gear. Stopping Travel 1. Apply service brakes and downshift to lower gear as necessary to slow the vehicle until it comes to a complete stop. 2.
3. Two Wheel Steering (See Figure 13) 2. Four Wheel Steering (See Figure 12) Warning NEVER use the four wheel steer mode when traveling at high speed. Rapid turning in this mode will cause tipover. Use only the two wheel steer mode at high speeds and slow the vehicle when turning. The front wheels will steer in the direction that the steering wheel is turned. The rear wheels will remain in the fixed forward position. This mode is used for on-highway travel or at higher speeds.
Caution The forks extend beyond the end of the carriage. The operator must be aware of the maximum sweep of the forks when turning and allow for adequate clearance between the forks, personnel and other objects (See Figure 15). Figure 14 OH0060 CENTER OF TURNING RADIUS 4. Crab Steering (See Figure 14) All wheels will steer in same direction. This mode permits the operator to move the vehicle sideways toward the landing point of the load.
Leveling Frame 4. When placing a load while on a slope, use the frame tilt control lever to keep the load level. The operator should observe the frame level indicator to assure that the load is level at all times. Danger Frame tilting with the boom raised above horizontal can cause tipover resulting in death or serious injury. Always use the frame tilt to level the vehicle before raising the boom above horizontal. If the vehicle cannot be leveled using the frame tilt, reposition the vehicle.
6. Place travel select lever in (N) Neutral, engage emergency brake switch and exit the vehicle using the hand holds. 7. Lift lever. Insert the quick attach pin completely through the attachment and quick attach link. Be sure that the quick attach lock lever has lowered and seated itself into the groove in the quick attach pin. Warning PIN LOCK LEVER QUICK ATTACH PIN Figure 16 4. 5. OA0152 Raise the boom until the boom hook pins have seated fully in the hooks on the attachment.
Using The Capacity Chart The capacity chart is located on the right side wall of the operator’s compartment. The chart is provided to assist the operator in determining how far in front, how high and at what angle a specific load weight can be safely handled with this vehicle. This vehicle is equipped with two major indicators that will assist the operator in determining how to accurately use the capacity chart. These components are the boom extend figures and the boom angle indicator.
36 (11,0) 3. After applying the height of the structure and the distance of load placement away from the vehicle to the capacity chart (Figure 17), the operator knows that it will be safe to place the load if the boom extend letter "C" has just started to show and the boom angle indicator reading does not go below approximately 35°. This condition is however, a maximum limit for this weight, height and distance away from the vehicle.
(12.2) 20 (6.1) 24 (7.3) 16 (4.9) 12 (3.7) 8 (2.4) 60° 32 (9.8) 50° 40° 24 (7.3) 20 (6.1) 6000 LBS 2720 KG 6,000 lb at 24 in (2720 kg at 610 mm) B A Load Ratings per ASME B56.6 1987 8 (2,4) 4 (1,2) (2,4) (3,7) (3,1) 13.00 x 24 Tires Hydrofill per operators manual C 4000 LBS 1810 KG 3000 LBS 1360 KG Load Ratings per ASME B56.6-1987 B A 30° 1225 lb quick attach mounted 5' mast 2000 LBS 910 KG 20° NOT Recommended for use with 15.00 x 19.
40 (12,2) 24 (7,3) 20 (6,1) 16 (4,9) 12 (3,7) 8 (2,4) 70° 36 (11,0) B 28 (8,5) 20 (6,1) 16 (4,9) 4 (1,2) 0 FT (0 M) A 36 (11,0) Hydrofill per operators manual 32 (9,8) Load Ratings per ASME B56.6-1987 DO NOT use this attachment on 6036 equipped with 15-19.5 tires LOAD CENTER 2000 lbs (910 kg) 3000 lbs (1360 kg) D 1500 LBS 680 KG -4 -(1,2) 12 10 8 (3,7) (3,1) (2,4) 4108232 A 6 4 3 2 0° 23.
Notes -8° 4107812 OA1112 Figure 18E The capacity chart for the 12' Truss Boom (Figure 18E) can be interpreted in the same way as the standard capacity chart. Refer to preceding example.
Warning Fork Ratings The maximum load capacity for this vehicle is 6000 lbs (2720 Kg). Forks used on this vehicle should have total load ratings which equal or exceed 6000 lbs (2720 Kg). When the load rating of the vehicle differs from the load capacity rating of the forks, the lower value becomes the overall load capacity. See "WARNING" this page.
How To Pick, Carry & Place a Load To pick up a load, tilt carriage forward so that forks hang freely on the fork shaft. Move the forks inward or outward on the fork shaft so that they are aligned with the openings in the pallet. Tilt the carriage back and extend the boom slowly so that the forks slide into the openings in the pallet. Raise the boom so that the load is lifted. To carry a load, position boom so that the load is as low as possible and the travel area is visible to the operator.
Lifting Personnel Warning NEVER tilt the platform forward or rearward when elevated with personnel aboard. Serious injury or death could result. Danger NEVER operate this or any equipment in an area in which overhead power lines, overhead or underground cables, or power sources exist without first requesting that the appropriate power company or utility company de-energize the lines or take other suitable precautions. 1.
Using Other Attachments Numerous attachments, some marketed by JLG and some sold by third party sources, are available for this vehicle. The general rule is that any attachment used on this vehicle must be intended for the function of lifting only. This vehicle is not designed to PULL, TOW or DRAG other objects. DO NOT use attachments that perform these functions with this vehicle.
Shut-Off 1. Park the vehicle on level ground. Warning To prevent personal injury or death, be certain to lower the boom, shut off the engine, and engage the emergency brake switch before exiting the vehicle. 2. Place travel select lever in (N) Neutral and engage the emergency brake switch. 3. Lower the boom and ground the carriage. 4. Turn ignition key to OFF position and remove key.
General Maintenance Routine Equipment Checklist Inspect the following equipment daily: This section of the manual contains a routine equipment checklist and a maintenance schedule and checklist with references to pertinent procedures and instructions. To prevent problems before they occur, follow the schedule.
2 A 75 B 60 WARNING 4 3 -15 15 30 45 CARRYING PERSONNEL can result in death or serious injury. Only Use an Approved Work Platform. 1 Only Lift or Lower personnel when using a work platform. Never move machine with personnel on the work platform. 7 8 WARNING 1. Read operator's manual before operating. 2. Fasten seat belt. 3. Allow no riders. MACHINE ROLL AWAY can cause death or serious injury. 4. Use an approved work platform to lift or lower personnel.
Maintenance Schedule and Checklist Daily or 10 Hour Intervals Check Air Cleaner Restriction Indicator (Air Filter Elements) Air Cleaner Vacuator Valve Engine Coolant Level Engine Oil Level Drain Fuel Water Separator Hydraulic Oil Level and Leaks in System Tire Pressure/Hydrofill and Wear Change Clean X X X X X X X Reference Paragraph 2A 2A 3A 4A 5C 7B 12A & B At First 50 Hours of Use Check Fan Belt Tension (Perkins Engine Only) Hydraulic Oil Filter Wheel Lug Nuts Boom Chain Tension Page 44 Change Clea
50 Hour Intervals Check Carriage Pivot Pin Hydraulic Cylinder Pins Boom Pivot Pins Axle Pivot Pins Drive Shaft Slip Joints Boom Chain Sheaves Boom Attachments Transmission Oil Level Boom Wear Pads Change Lube X X X X X X X Change Lube X X Reference Paragraph 1 1 1 1 1 1 1 8A 15D 250 Hour Intervals Fuel Lift Pump Sediment Bowl Fan Belt Tension (Perkins) Transmission Oil Level Axle Oil Level Drop Box Oil Level Boom Wear Pads Air Intake Hoses Hydraulic Cylinder Pins Drive Shaft Slip Joints Boom Pivot P
250 Hour Intervals (continued) Check Carriage Pivot Pin Axle Pivot Pins Axle Steer Knuckles Axle Tie Rod Ball Joints Axle Steer Cylinder Ball Joints Boom Chain Sheaves Boom Attachments Engine Oil and Filter Drain or Change Fuel Filters Wheel End Oil Change Lube X X X X X X X X X X Reference Paragraph 1 1 1 1 1 1 1 4B 5C 10B 1,000 Hours or Annually Air Intake Hoses Fan Belt Tension and Wear Boom Chain Tension Boom Wear Pads Hydraulic Cylinder Pins Drive Shaft Slip Joints Boom Pivot Pins Check X X X X
1,000 Hours or Annually (continued) Check Carriage Pivot Pin Boom Chain Sheaves Axle Pivot Pins Axle Steer Knuckles Axle Tie Rod Ball Joints Axle Steer Cylinder Ball Joints Boom Attachments Extend Chains Primary Air Filter Element Engine Coolant Engine Oil and Filter Drain or Change Fuel Filters Hydraulic Oil and Filter Transmission Oil and Filter Axle Oil Drop Box Oil 6036/6036T Change X X X X X X X X Lube X X X X X X X X Reference Paragraph 1 1 1 1 1 1 1 15C 2B 3B 4B 5C 7C 8B & 8C 9B 11B Page 47
1. Lubrication Points Lubricate the following grease fittings using Multi-Purpose Grease (MPG) every 50 hour interval (Fig. 21 and 22): A. Hydraulic cylinder pins .............. (10 points) B. Drive shaft slip joints ................. (3 points) C. Boom chain sheaves ................ (2 or 1 points) D. Boom pivot pins ........................ (2 points) E. Carriage pivot pin ..................... (2 points) F. Axle pivot pins .......................... (4 points) G. Boom Attachments ...................
2. Air Cleaner and Restriction Indicator RESTRICTION INDICATOR AIR CLEANER INDICATOR WINDOW T H EX ER T E VACUATOR VALVE OA0212 Figure 24 Figure 23 A. OA0203 Filter Check (Daily or 10 Hour Intervals) 1. Ground the carriage, place the travel select lever in Neutral (N), engage the emergency brake switch and shut off the engine. 2. Unlock and open the left rear engine access door to access air cleaner restriction indicator (Figure 23). Check indicator.
CANNISTER PRIMARY ELEMENT WING NUT COVER WITH WING NUT Figure 25 OF0110 B. Element: Change or Clean (As Restriction Indicator Indicates or Every 1000 Hour Interval) Outer Primary Element All air cleaner manufacturers agree that attempting to clean or wash an element increases the chance for element damage. It is highly recommended that you consider the value of cleaning an element against the risks which could lead to engine damage.
To change elements: Carefully follow these procedures to clean an element: 1. Loosen cover wing nut and remove cover from air cleaner canister (Figure 25). 1. Remove loose particles from the filter with compressed air (maximum 30 psi [206 kPa]) or water hose (maximum 40 psi [275 kPa] without nozzle). Rotate and apply pressure from the inside of the element. 2. Remove wing nut and primary element. Inspect element for damage. Damaged elements should not be cleaned or reused. 3.
WING NUT SAFETY ELEMENT 2. Unlock and open the right rear engine access door. Check level of coolant in overflow bottle (Figure 27). When coolant is hot, bottle should be 1/2 to 3/4 full. When coolant is cool, bottle should be 1/4 to 1/2 full. Add coolant as required through the overflow bottle (50/50 mixture of ethylene glycol and water). Close and lock access door. OIL FILL CAP Figure 26 OF0120 DIPSTICK C.
B. Drain and Flush Radiator (1000 Hours or Annually) Warning To avoid severe burns, DO NOT attempt this procedure when the engine is hot. Wait for engine, muffler and tail-pipe to cool down before proceeding. PETCOCK MUFFLER Figure 28 OA0254 Warning NEVER remove radiator cap while the cooling system is hot. The system is under pressure and hot coolant can cause severe burns or eye injury. Wear protective clothing and safety glasses.
4. CUMMINS ENGINES ONLY A. Level Check (Daily or 10 Hour Intervals) OIL FILTER 072465 0 390 3102 CYLINDER BLOCK DRAIN PLUG Figure 29A OG0030 5. Reconnect line to bottom of overflow bottle and close radiator petcock. Reconnect heater hose. 6. Fill radiator completely with 50/50 mixture of ethylene glycol and water. Total system capacity is 5.4 gallons (20,4 liters). Add coolant to overflow bottle until bottle is 1/2 to 3/4 full [approximately - 2 quarts (1,9 liters)].
4. If oil is below the add mark, add 15W40 or 10W30 motor oil that is equal to API, CD or CE (severe duty diesel engine) specifications. Replace dipstick. Close and lock access door. 5. 6. Engine Oil Type 10W30 15W40 Ambient Temperature Below 23° F (-5° C) Above 23° F (-5° C) Allow oil to drain completely into receptacle. Transfer the oil to a container with a cover and label the container as used oil. Dispose of the used oil at an approved recycling facility.
11. Remove oil fill cap (Figure 27) and add 15W40 or 10W30 motor oil that is equal to API, CD or CE specifications. (Refer to engine manufacturer's manual for recommended oil types for various temperature limits.) DO NOT over fill. Engine oil capacity with filter change is: Perkins Natural ........................... 9.4 quarts (8,9 liters) Perkins Turbo .............................. 9.9 quarts (9,3 liters) Cummins Nat. & Turbo ........... 11.5 quarts (10,9 liters) 12. Clear all personnel from area.
B. Fuel Tank (Daily Before Operation) FUEL FILL ACCESS DOOR Check fuel supply daily before operation. Open fuel fill access door with key (Figure 31). Remove fill cap on tank and fill as required. Replace cap and lock access door. Total tank capacity is 24 gallons (90,8 liters); useable capacity is 22.5 gallons (85,1 liters). C. Fuel System Service 1. Drain water from fuel water separator daily or 10 hour intervals. All engines except Turbo Charged S/N 3617 and After.
2. Change fuel filter element every 250 (500 maximum) hours of operation. Fuel filter must be changed more often with water evidence or contaminated fuel. Unlock and open right rear engine access door. HEX SCREW a. Perkins Engines - Remove hex screw in top of filter (Figure 33), remove filter base and discard element. Clean base and head. Position new filter element between base and head and install hex screw to secure parts. Remove air from fuel system (See “Bleeding Fuel System”). b.
Controlled venting is provided at the injection pump through the fuel drain manifold. Small amounts of air introduced by changing the filter elements will be vented automatically as long as the elements were filled with fuel prior to installation. Close and lock access door. 3. Clean fuel lift pump sediment chamber every 250 hours of operation (Perkins engines only). Unlock and open the left rear engine access door. Remove fuel lift pump cover and strainer (Figure 35).
D. Bleeding Fuel System Air must be vented from the fuel system whenever any part of the system between the fuel tank and injection pump has been disconnected for any reason, or when the system has been emptied of fuel. GOVERNOR VENT SCREW Warning INJECTION PUMP VENT SCREW DO NOT bleed a hot engine as this can cause fuel to spill, creating a danger of fire.
Warning INJECTOR HIGH PRESSURE LINE FITTINGS Fuel will spray when venting high pressure fuel lines. Keep clear of spraying fuel. The pressure of the fuel in the high pressure lines is sufficient to penetrate the skin and cause serious bodily injury. Wear protective clothing and safety glasses.
6. Turn ignition key to the START position and operate starter until fuel, free from air, comes from the injector and Thermo Start fuel line fittings. Turn ignition switch OFF. Tighten all fittings. NATURALLY ASPIRATED & TURBO CHARGED S/N 3616 & BEFORE LOW PRESSURE LINE VENT SCREW 7. Close and lock both access doors. The engine is now ready to start. Cummins Engines - FUEL LIFT PUMP 1. To vent the low pressure lines and fuel filters, open the vent screw (Figure 40 or 40A).
2. (This step not required for Cummins Turbo engines with Bosch fuel injector. Continue with step 3.) To vent the injection pump, open the governor vent screw and the injection pump vent screw. Turn the ignition key to the "RUN" position and energize the starter solenoid for 15 seconds while operating the hand plunger on the lift pump. Continue to pump fuel while closing first the injection pump vent screw and then the governor vent screw. Warning Fuel will spray when venting high pressure fuel lines.
6. Engine Fan Belt Check (Perkins - First 50 Hours and 250 Hour Intervals Thereafter) (Cummins - 1000 Hour Intervals) Check fan belt condition and tension as follows: 1. Ground the carriage, place the travel select lever in (N) Neutral, engage the emergency brake switch and shut off engine. 2. Unlock and open the rear engine access doors. 3. Inspect fan belt. Replace cracked or frayed belt. 4. Perkins Engines only - Check belt tension midway between crankshaft and alternator pulleys (Figure 42).
7. Hydraulic Oil and Filter A. Hydraulic System Oil FAN PULLEY OH0460 ALTERNATOR PULLEY Hydraulic system oil can be either a hydraulic oil meeting the requirements of ISO Grade 46 or a 10W motor oil meeting the requirements of U.S. Ordinance Specification MIL-L-2104C. See table on this page. 1/4 TO 3/8 INCH BELT DEFLECTION (6,4 TO 9,4 MM) CRANKSHAFT PULLEY Figure 42 OA0362 FAN BELT MA1881 Figure 42A OH0470 1. Be sure all cylinders are fully retracted and oil is at room temperature.
2. Level the vehicle, ground the carriage, place travel select lever in (N) Neutral, engage the emergency brake switch and shut off the engine. 3. Check level of hydraulic oil in tank at the sight gauge on the right side of the main frame (Figure 43). HYDRAULIC FILL ACCESS DOOR Figure 43 OA1040 Install reservoir cap, close and lock fill access door. Page 66 Replace hydraulic oil annually or as required. Oil must be cool before changing.
9. Push new filter element fully onto the filter head until it seats against the washer. Re-install filter head assembly and gasket into the tank and secure with the nuts removed earlier. 10. Remove reservoir cap and fill the reservoir with ISO-46 or MIL-L-2104C Oil (See table on page 65.) until the oil level is filled to the minimum oil level as described in section 7B. Reservoir capacity is 24 gallons (90,8 liters). NUTS 11.
16. Start the engine and operate the pump at least two minutes at no load and at a speed of over 400 rpm but below 1500 rpm. During this breakin period, the unit should run free and not develop an excessive amount of heat. If the unit operates properly, speed and pressure can be increased to normal operating settings. ACCESS HOLE IN TRANSMISSON COVER 17. Run vehicle and operate all hydraulic functions. Then, check for leaks. 18. Re-install hydraulic tank access cover. COVER MOUNTING NUTS Figure 45 8.
6. Turn new element onto transmission fitting. Torque element to 20 - 25 lb-ft (27 - 34 Nm) . 7. Remove and discard drained fluid. TRANSMISSION FILTER 8. Check transmission level and add MIL-L-2104C Oil (See table on page 68.) as required following procedures in paragraph 8A. TRANSMISSION DIPSTICK 9. Install transmission cover on frame. C. OA0402 B. Figure 46 Filter Change (1000 Hours Intervals or Annually) 1.
ENGINE FLYWHEEL MOUNTING FLANGE 9. A. Axle Oil Level Check (250 Hour Intervals) 1. Level the vehicle, ground the carriage, place travel select lever in (N) Neutral, engage the emergency brake switch and shut off engine. 2. Clean area around axle fill/level plug, remove plug (Figure 48) from axle housing and check oil level. Add 80W90 gear oil as required to bring the oil level up even with the plug hole (for temperatures below -15° F (-26° C) 75W gear oil can be used).
6. Fill axle to level plug hole with 80W90 gear oil (for temperatures below -15° F (-26° C) 75W gear oil can be used). Axle capacity is 13 qts. (12,3 ltr). VENT PLUG 7. Install fill/level plug. FILL ARROW DOWN TO FILL/CHECK OIL LEVEL MAGNETIC WHEEL END DRAIN PLUG ARROW DOWN TO FILL/CHECK OIL LEVEL AXLE FILL/LEVEL PLUG FILL Figure 49 OA0432 AXLE DRAIN PLUG Figure 48 A. Level Check OH0030 10. Wheel End Oil Warning DO NOT perform service or maintenance on the vehicle with the engine running.
B. Oil Change (250 Hour Intervals) 1. Be sure that the drain plug on the wheel end housing (Figure 49) is down. Level the vehicle, ground the carriage, place the travel select lever in (N) Neutral, engage the emergency brake switch and shut off the engine. 2. Clean the areas around the magnetic drain plug and vent plug. 3. Remove vent plug. 4. Remove the drain plug and allow the fluid to drain. 5. Move the vehicle so the arrow on the wheel end housing is pointing down (Figure 49). 6.
TABLE 1 Recommended oils for DANA SPICER® axles P/N 070BP126-13 (front axle) and 070BP139-2 (rear axle) with graphite based friction discs. OIL BRAND NAME AND DESCRIPTION AMOCO Oil Company J.I. CASE JOHN DEERE FORD-NEW HOLLAND MOBIL FLUID AMOCO 1000 Fluid HY-TRAN TCH J20 M2C-134 424 FRICTION MODIFIER BRAND PART NUMBER Sky Trak Ford 8522043 (32 oz) C8AZ19B546A (4 oz) 11.
A. Level Check (250 Hour Intervals) B. Oil Change (1000 Hour Intervals) 1. Level the vehicle, ground the carriage, place the travel select lever in (N) Neutral, engage the emergency brake switch and shut off the engine. 1. Level the vehicle, ground the carriage, place the travel select lever in (N) Neutral, engage the emergency brake switch and shut off the engine. 2. Remove level plug (Figure 50, 51) from drop box. 2. Place a receptacle under the drop box drain plug. 3. Check level of oil.
Clean the area around the valve stems and check air pressure at all four tires: Size 13.00 - 24, 10 PLY 13.00 R24, RADIAL 15.00 - 19.5, 12 PLY 15.5 - 25, 12 PLY Air Pressure 55 psi (379 kPa) 55 psi (379 kPa) 60 psi (413 kPa) 58 psi (400 kPa) Warning Improper hydrofill can cause instability which can result in tipover. ALWAYS make sure that all four tires have been properly filled with hydrofill by a qualified tire service center. B.
1 9 7 2. Unlock the battery cover and lower or remove the cover (Figure 53) to gain access to the battery(s). 3 3. The battery(s) in this vehicle are maintenance free type batteries. They are shipped in the vehicle filled with electrolyte and charged. 4 10 TIRE VALVE 1. Level the vehicle, ground the carriage, place the travel select lever in (N) Neutral, engage the emergency brake switch and shut off the engine. 5 4. Replace battery(s) that have cracked,melted, or damaged cases.
Warning Fluid in electric storage batteries contains sulfuric acid which is POISON and can cause SEVERE CHEMICAL BURNS. Avoid all contact of fluid with eyes, skin, or clothing. Use proper protective gear when handling batteries. DO NOT tip any battery beyond a 45o angle in any direction. If contact does occur, follow the First Aid suggestions below. Battery Electrolyte First Aid: • External Contact — Flush with water.
The fuses and/or circuit breakers in this vehicle protect the entire electrical system. The breakers will trip or the fuses will blow if there is a shorted or grounded wire in the applicable circuit. The breakers will automatically reset once they cool. The fuses will have to be replaced if they blow. If a breaker continually trips or the fuses continually blow , check the system for shorts, grounds or defective electrical components.
The following circuit breakers are used (Figure 55): FOR VEHICLES WITH CIRCUIT BREAKERS ONLY Index Size 1 6 amp Steering Select Switch and Valve 2 10 amp Horn and Back-up Alarm (Optional - Cab Heater Fan) 3 6 amp Instrument Panel, Emergency Brake Solenoid Switch (Optional - Electric Joystick and TLC System Feed) 5 Ignition Switch Feed for entire Electrical System 3 4 5 6 40 amp 6 amp 20 amp Circuit Protected Enclosed Cab Windshield Washer/Wiper Switch and Circulation Fan (Optional - T
The following fuses/circuit breaker are used (Figure 55A): Index Size FOR VEHICLES WITH FUSES/CIRCUIT BREAKER Circuit Protected 1 10 amp (Fuse) Enclosed Cab Windshield Washer/Wiper Switch and Circulation Fan (Optional this fuse will not be found on vehicles with an open cab) 2 7.5 amp (Fuse) Steering Select Switch and Valve 3 10 amp (Fuse) Horn and Back-up Alarm (Optional - Cab Heater Fan) 1 4 7.5 amp (Fuse) Warning Lights, Emergency Brake Solenoid Switch, Fuel Gauge and Hourmeter 10 7.
15. Boom Chains and Wear Pads BOOM CHAIN SAG A. Top Boom Chain Tension Check (First 50 Hours and 1000 Hour Intervals or Annually Thereafter) Check the boom chain tension by measuring the top boom chain sag. 1. Raise the boom to a horizontal (level) position. Fully extend the boom, then retract it 2" (50,8 mm) (one inch per section). 2. Measure the sag in the top boom chains between the bottom of the chains and the top of the intermediate boom at their closest point (Figure 56).
B. Top Boom Chain Tension Adjustment (As Required) 1. Retract the boom completely to check the position of the inner boom. The inner boom section should extend between 1-1/2" (38,1 mm) to 2-1/2" (63,5 mm) beyond the end of the intermediate boom section (Figure 58). If the measurement is not between 1-1/2" (38,1 mm) and 2-1/2" (63,5 mm), the boom may require more extensive adjustment and/or repair. Contact your authorized JLG distributor.
WEAR PADS EXTEND CHAINS LOCKNUTS WEAR PADS c. Measure the chain sag. Acceptable boom chain sag is between 1-1/2" (38,1 mm) and 2-1/2" (63,5 mm). If the chain sag is less than 1-1/2" (38,1 mm), repeat Steps “a” through “c.” 3. If the distance measured in Step 1 is less than 2" (50,8 mm) (but greater than 1-1/2") (44,5 mm): a. Remove the rear cover from the outer boom and adjust the top extend boom chains. b. Tighten the locknuts (Figure 59) for each chain.
BOOM EXTEND CHAINS d. Measure the chain sag. Acceptable boom chain sag is between 1-1/2" (38,1 mm) and 2-1/2" (63,5 mm). If the chain sag is less than 1-1/2" (38,1 mm), repeat Steps “a” through “d.” e. Replace the rear outer boom cover. EXTEND CHAIN SHEAVE LUBE FITTING Page 84 With the boom fully extended, apply "LPS - 3" or "LUBRIPLATE" chain and cable fluid or equivalent to the two extend chains. D. Wear Pad Check (50 Hour Intervals) YOKE Figure 60 C.
than other pads. For example the lower pads at the front of the boom are under far more stress than the pads attached to the top, rear or sides of the boom. Consequently the lower pads will require service more often. E. Wear Pad Replacement (As Wear Pad Indicators Indicate) Each boom pad is manufactured with a convenient wear pad indicator. This is the angled cut at each end of all wear pads (Figure 61). The total thickness of a new wear pad is .625" (15,9 mm).
16. Emergency Boom Lowering — Cable Control Joystick RETAINER NUT COUNTERBALANCE VALVE A. Loss of Engine Power or Hydraulic Pump Failure: In the event of total loss of engine power or hydraulics, with an elevated load, the boom can be lowered to the ground safely using the following procedures: Warning DO NOT get under a raised boom unless the boom is blocked up. Always block the boom before doing any servicing which requires the boom to be up.
Loosen the retainer nut on each cartridge and turn the adjusting screws in (clockwise) until they bottom out. Doing this will render each counterbalance valve inoperative. 2. Remove the blocking that is supporting the boom. 3. Clear the area around the vehicle of all personnel. 4. Move the boom control lever forward to lower the boom. IMPORTANT: This procedure is to be used in emergency situations only.
IMPORTANT: If the boom has been extended, you must first retract the boom before you attempt to lower the boom. To retract the boom proceed as follows: 1. Block the boom so it cannot be lowered. 2. If the line failure is isolated to the hoist circuitry only, boom retraction can be performed by operating the boom control lever in the normal fashion. 3. If the line failure is in the boom extend line the boom must be retracted by following the next step. a.
1. Remove the blocking that is supporting the boom. 2. If the line failure is in the boom hoist line the boom must be lowered by following the next step. a. Using two people to perform this procedure will make boom lowering much easier. At the base end of each hoist cylinder, locate the counterbalance valve cartridges (Figure 63). Loosen the retainer nut and control the rate of boom lowering by turning the adjusting screw on each cartridge simultaneously into the cartridge very slowly (clockwise).
17. Emergency Boom Lowering — Electrical Control Joystick A. EXTEND/RETRACT SPOOL COLLAR Loss of Engine Power or Hydraulic Pump Failure In the event of total loss of engine power or hydraulics, with an elevated load, the boom can be lowered to the ground safely using the following procedures: Warning DO NOT get under a raised boom unless the boom is blocked up. Always block the boom before doing any servicing which requires the boom to be up.
4. Clear the area around the vehicle of all personnel. 5. Move the cap screw backward to shift the boom extend/retract spool. This will allow you to retract the boom in a slow uniform manner. After the boom has been retracted fully, proceed as follows: 1. At the base end of each hoist cylinder, locate the counterbalance valve cartridges (Figure 63). IMPORTANT: This procedure is to be used in emergency situations only.
Warning DO NOT get under a raised boom unless the boom is blocked up. Always block the boom before doing any servicing which requires the boom to be up. IMPORTANT: If the boom has been extended, you must first retract the boom before you attempt to lower it. To retract the boom proceed as follows: 1. Block the boom so it cannot be lowered. NOTE: If the line failure is isolated to the boom hoist/ lower circuit only, boom retraction can be performed by operating the joystick in the normal way. 2.
After the boom has been retracted fully, proceed as follows: 1. If the line failure is in the boom hoist line, proceed as follows. Using two people to perform the procedure will make lowering the boom much easier. a. Remove the blocking that is supporting the boom. b. At the base end of each hoist cylinder, locate the counterbalance valve cartridges (Figure 63). c.
Specifications Fluid and Lubricant Capacities ENGINE CRANKCASE OIL Capacity with filter change Perkins Natural ..................................... 9.4 qts. (8,9 liter) Perkins Turbo ....................................... 9.9 qts. (9,3 liter) Cummins Nat. & Turbo ..................... 11.5 qts. (10,9 liter) Filter .......................................... Perkins - (0.5 qt.) (0,47 liter) Cummins - (1.5 qt.) (1,4 liter) Type of Oil - Below 23° F (-5° C) ................................
Tires AIR PRESSURES 13.00 - 24, 10 ply ......................................... 55 psi (379 kPa) 13.00 R24, Radial (One Star) ....................... 55 psi (379 kPa) 15.00 - 19.5, 12 ply ...................................... 60 psi (413 kPa) 15.5 - 25, 12 ply ........................................... 58 psi (400 kPa) HYDROFILL MIXTURE 13.00 - 24, 10 ply ......................... 164 lbs. (74 kg) Calcium Chloride to 33 gals. (124,9 ltr) of Water (each tire) Total Hydrofill weight (each tire) ..........
Weights BASIC MACHINE *Approximate Curb Weight ................... 18,785 lbs (8528 kg) Shipping Weight .................................... 18,675 lbs (8471 kg) *With open cab, 13.00 x 24 hydrofilled tires and full fuel tank. OPERATING LOAD ................................. 6,000 lbs (2722 kg) Machine Dimensions With Standard 13.00 x 24 Tires Length (less forks) ......................................... 211" (535,9 cm) Width ...............................................................
Stability Tipping Limits This telescopic handler has been shown to meet or exceed ASME and FEM stability limits in highly structured and controlled test situations. These stability tipping limits are extremes and are not intended to be achieved during normal work site operation. The following is provided only as information to the operator of this vehicle and in no way should be used as a guideline for operating this vehicle.
Position 2 Longitudinal stability "traveling" Position 3 Lateral stability "stacking" with rated load (with no more than rated load) (with frame tilted 4°) 22% GRADE (12°) 10% GRADE (6°) THIS SIDE UP OA0562 Page 98 OA0592 6036/6036T
Position 4 Lateral stability "traveling" Position 5 Lateral stability "stacking" (with no load) (with no load) 40% GRADE (22°) 10% GRADE (6°) OA0572 6036/6036T OA0601 Page 99
Notes (Or, on this page, affix second copy of attachment capacity chart if supplied with attachment.
Notes (Or, on this page, affix second copy of attachment capacity chart if supplied with attachment.
Notes (Or, on this page, affix second copy of attachment capacity chart if supplied with attachment.
REPLACEMENT MANUALS If the owner/operator or safety manuals that were originally shipped with your vehicle are lost, stolen or need replacement, contact your local distributor for replacement manuals. If for any reason your distributor cannot supply the manuals you need; write, call or send a fax to the following address for ordering information. JLG Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA.
Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA Phone: (717) 485-5161 Customer Support Toll Free: (877) 554-5438 Fax: (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W.
