JLG Skytrak 6036 Use and care manual

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

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
a31200749
Revision Log REVISION LOG
March 30, 2012 - A - Original Issue of Manual

Read This First
b31200749
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.
for updated information.
Operator Qualifications
The operator of the machine must not operate the machine until this manual has
been read, training is accomplished and operation of the machine has been
completed under the supervision of an experienced and qualified operator.
Operation within the U.S.A. requires training per OSHA 1910.178.
Operators of this equipment must possess a valid, applicable driver’s license, be in
good physical and mental condition, have normal reflexes and reaction time, good
vision and depth perception and normal hearing. Operator must not be using
medication which could impair abilities nor be under the influence of alcohol or any
other intoxicant during the work shift.
In addition, the operator must read, understand and comply with instructions
contained in the following material furnished with the telehandler:
• This Operation & Safety Manual
• Telehandler Safety Manual (ANSI only)
• All instructional decals and plates
• Any optional equipment instructions furnished
The operator must also read, understand and comply with all applicable Employer,
Industry and Governmental rules, standards and regulations.
Modifications
Modifications to this machine may affect compliance with Industry Standards
and/or Governmental Regulations. Any modification must be approved by
JLG.

Read This First
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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. must be notified immediately in all instances where JLG
products have been involved in an accident involving bodily injury or death of
personnel or when damage has occurred to personal property or the JLG product.
FOR:
• Accident Reporting and Product Safety Publications
• Current Owner Updates
• Questions Regarding Product Applications and Safety
• Standards and Regulations Compliance Information
• Questions Regarding Product Modifications
CONTACT:
Product Safety and Reliability Department
JLG Industries, Inc.
13224 Fountainhead Plaza
Hagerstown, MD 21742
USA
or Your Local JLG Office
(Addresses on back cover)
In USA
Toll Free: 1-877-JLG-SAFE (1-877-554-7233)
Outside USA
Phone: [phone]
E-mail
[e-mail]

Read This First
d31200749
Other Publications Available
Service Manual
6036, 6042, 8042, 10042, 10054.........................................................31200796
Illustrated Parts Manual
6036, 6042...........................................................................................31200731
8042, 10042, 10054.............................................................................31200732
Note: The following standards may be referenced in this manual:
ANSI is compliant to ANSI/ITSDF B56.6
AUS is compliant to AS 1418.19
CE is compliant to EN1459
Refer to the machine Serial Number Plate to identify the applicable compliance
standard.
Machine Configuration
Two configurations of each machine are included in this manual. Determine if
machine is equipped with Ultra Low Sulfur Fuel Decal (1) as indicated below.
• If equipped with the Ultra Low Sulfur decal, all specific references to this machine
configuration will be referred to as Ultra Low Sulfur (ULS)from this point forward.
•Ifnot equipped with the Ultra Low Sulfur decal, all specific references to this
machine configuration will be referred to as Low Sulfur (LS) from this point
forward.
OH4912
1
ULTRA LOW
SULFUR DIESEL
FUEL ONLY
S < 15 mg/kg
1001125387 A

Table of Contents
i31200749
TABLE OF CONTENTS
Revision Log
Read This First
Operator Qualifications ...................................................... b
Modifications ...................................................................... b
Other Publications Available .............................................. d
Machine Configuration ....................................................... d
Table of Contents
Section 1 - General Safety Practices
1.1 Hazard Classification System ..............................................1-1
Safety Alert System and Safety Signal Words ................1-1
1.2 General Precautions ............................................................1-1
1.3 Operation Safety ..................................................................1-2
Electrical Hazards ...........................................................1-2
Tip Over Hazard..............................................................1-3
Travel Hazard .................................................................1-6
Load Falling Hazard........................................................1-7
Lifting Personnel .............................................................1-8
Driving Hazards on Slopes .............................................1-9
Pinch Points and Crush Hazards ..................................1-10
Fall Hazard....................................................................1-12
Chemical Hazards.........................................................1-13
Section 2 - Pre-Operation and Inspection
2.1 Pre-Operation Check and Inspection...................................2-1
2.2 Safety Decals.......................................................................2-3
ANSI (if equipped)...........................................................2-3
ISO (if equipped).............................................................2-6
2.3 Walk-Around Inspection.....................................................2-10
2.4 Warm-Up and Operational Checks ....................................2-12
Warm-Up Check ...........................................................2-12
Operational Check ........................................................2-12
2.5 Operator Cab .....................................................................2-13
2.6 Windows ............................................................................2-14
Cab Door Window (if equipped) ....................................2-14
Table of Contents

Table of Contents
ii 31200749
Section 3 - Controls and Indicators
3.1 General................................................................................ 3-1
3.2 Controls ............................................................................... 3-2
Dash Controls and Indicators ......................................... 3-3
Instrument Cluster .......................................................... 3-4
Ignition ............................................................................ 3-6
Park Brake...................................................................... 3-7
Parking Procedure.......................................................... 3-7
Transmission Control Lever............................................ 3-8
Boom Joystick .............................................................. 3-10
Frame Level and Attachment Tilt Joystick.................... 3-11
Auxiliary Hydraulic Joystick .......................................... 3-12
Outrigger Switches (10042 & 10054) ........................... 3-13
Accessory Control Lever (if equipped) ......................... 3-14
3.3 Steer Modes ...................................................................... 3-15
Steer Mode Change ..................................................... 3-15
3.4 Stabil-Trak™ System (6042, 8042, 10042 & 10054)......... 3-16
Free Pivot Mode ........................................................... 3-16
Slow Pivot Mode........................................................... 3-16
Locked Mode ................................................................ 3-16
3.5 Boom/Outrigger Interlock System (10054) ........................ 3-17
Extend Interlock Mode.................................................. 3-17
Outrigger Interlock Mode .............................................. 3-17
3.6 Operator Seat.................................................................... 3-18
Adjustments.................................................................. 3-18
Seat Belt ....................................................................... 3-19
3.7 Boom Angle and Extension Indicators .............................. 3-20
Section 4 - Operation
4.1 Engine ................................................................................. 4-1
Starting the Engine ......................................................... 4-1
Battery Boosted Starting................................................. 4-2
Normal Engine Operation ............................................... 4-3
Shut-Down Procedure .................................................... 4-3
4.2 Operating with a Non-Suspended Load .............................. 4-4
Lift Load Safely............................................................... 4-4
Picking Up a Load .......................................................... 4-4
Transporting a Load ....................................................... 4-5
Leveling Procedure......................................................... 4-5
Placing a Load................................................................ 4-6
Disengaging a Load........................................................ 4-6

Table of Contents
iii31200749
4.3 Operating with a Suspended Load ......................................4-7
Lift Load Safely ...............................................................4-7
Picking Up a Suspended Load........................................4-7
Transporting a Suspended Load.....................................4-8
Leveling Procedure .........................................................4-8
Placing a Suspended Load .............................................4-9
Disengaging a Suspended Load.....................................4-9
4.4 Loading and Securing for Transport ..................................4-10
Tiedown ........................................................................4-10
Lifting ............................................................................4-11
Section 5 - Attachments
5.1 Approved Attachments ........................................................5-1
5.2 Unapproved Attachments ....................................................5-1
5.3 JLG Supplied Attachments ..................................................5-2
5.4 Telehandler/Attachment/Fork Capacity................................5-3
5.5 Use of the Capacity Chart....................................................5-4
Capacity Indicator Locations ...........................................5-4
Sample Capacity Chart ...................................................5-6
Example ..........................................................................5-8
5.6 Attachment Installation ......................................................5-10
Hydraulic Operated Attachment....................................5-12
5.7 Adjusting/Moving Forks......................................................5-13
5.8 Attachment Operation ........................................................5-14
Carriage w/Forks...........................................................5-15
Side Tilt Carriage ..........................................................5-16
Swing Carriage .............................................................5-18
Dual Fork Positioning Carriage .....................................5-20
Mast Carriage ...............................................................5-22
Fork Mounted Hook ......................................................5-24
Fork Extension ..............................................................5-26
Truss Boom...................................................................5-28
Bucket ...........................................................................5-30
Grapple Bucket .............................................................5-32
Personnel Work Platform ..............................................5-34
Section 6 - Emergency Procedures
6.1 Towing a Disabled Product..................................................6-1
Moving Short Distances ..................................................6-1
Moving Longer Distances ...............................................6-1
6.2 Emergency Lowering of Boom.............................................6-2
6.3 Emergency Exit from Enclosed Cab ....................................6-2

Table of Contents
iv 31200749
Section 7 - Lubrication and Maintenance
7.1 Introduction.......................................................................... 7-1
Clothing and Safety Gear ............................................... 7-1
7.2 General Maintenance Instructions....................................... 7-2
7.3 Service and Maintenance Schedule.................................... 7-3
10 & 1st 50 Hour Maintenance Schedule ....................... 7-3
50, 250 & 1st 500 Hour Maintenance Schedule ............. 7-4
500 & 1000 Hour Maintenance Schedule....................... 7-5
1500 & 2000 Hour Maintenance Schedule..................... 7-6
7.4 Lubrication Schedules ......................................................... 7-7
50 Hour Lubrication Schedule ........................................ 7-7
250 Hour Lubrication Schedule ...................................... 7-9
1000 Hour Lubrication Schedule .................................. 7-11
7.5 Operator Maintenance Instructions ................................... 7-12
Fuel System.................................................................. 7-12
Air Intake System ......................................................... 7-14
Engine Oil..................................................................... 7-18
Hydraulic Oil ................................................................. 7-19
Tires.............................................................................. 7-20
Transmission Oil........................................................... 7-23
Engine Cooling System ................................................ 7-24
Battery .......................................................................... 7-26
Section 8 - Additional Checks
8.1 Stabil-Trak (6042, 8042, 10042 & 10054) ........................... 8-1
8.2 Boom/Outrigger Interlock (10054) ....................................... 8-2
Section 9 - Specifications
9.1 Product Specifications......................................................... 9-1
Fluids .............................................................................. 9-1
Capacities....................................................................... 9-3
Tires................................................................................ 9-4
Performance ................................................................... 9-5
Dimensions..................................................................... 9-6
Index
Inspection, Maintenance and Repair Log

Section 1 - General Safety Practices
1-131200749
SECTION 1 - GENERAL SAFETY PRACTICES
1.1 HAZARD CLASSIFICATION SYSTEM
Safety Alert System and Safety Signal Words
DANGER indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION indicates a potentiality hazardous situation which, if not avoided, may
result in minor or moderate injury.
1.2 GENERAL PRECAUTIONS
WARNING
Before operation, read and understand this manual. Failure to comply with the
safety precautions listed in this manual could result in machine damage, property
damage, personal injury or death.
DANGER OW0010
WARNING OW0021
CAUTION
OW0031

Section 1 - General Safety Practices
1-2 31200749
1.3 OPERATION SAFETY
Electrical Hazards
• 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.
• Follow employer, local and governmental regulations for clearance from
powerlines.
OW0040
10 FT
(3 M)

Section 1 - General Safety Practices
1-331200749
Tip Over Hazard
General
• For additional load requirements, refer to the appropriate capacity chart.
• 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.
•DO NOT raise boom unless frame is level (0 degrees), unless otherwise noted
on capacity chart.
•DO NOT level machine with boom/attachment above 4 ft (1,2 m).
(AUS - DO NOT level machine with load more than 11.8 in (300 mm) above
ground surface.)
OW0050
OW0080
OW0100
4 FT
(1,2 M)

Section 1 - General Safety Practices
1-4 31200749
•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.
• Always wear the seat belt.
• Keep head, arms, hands, legs and all other body parts inside operator’s cab at all
times.
If the telehandler starts to tip over:
•DO NOT JUMP
• BRACE YOURSELF and STAY WITH THE MACHINE
• KEEP YOUR SEAT BELT FASTENED
• HOLD ON FIRMLY
• LEAN AWAY FROM THE POINT OF IMPACT
OH2291
OH20911
OH2221

Section 1 - General Safety Practices
1-531200749
Non-Suspended Load
•DO NOT drive with boom raised.
Suspended Load
• Tether suspended loads to restrict movement.
• Weight of all rigging (slings, etc.) must be included as part of load.
• 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.
• Never drag the load; lift vertically.
When driving with a suspended load:
•Start, travel, turn and stop slowly to prevent load from swinging.
•DO NOT extend boom.
•DO NOT raise the load more than 11.8 in (300 mm) above ground surface or
the boom more than 45°.
•DO NOT exceed walking speed.
OW0060
OW0150

Section 1 - General Safety Practices
1-6 31200749
Travel Hazard
• 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.
• Ensure that adequate clearance is provided for both rear tail swing and front fork
swing.
• Look out for and avoid other personnel, machinery and vehicles in the area. Use
a spotter if you DO NOT have a clear view.
• Before moving be sure of a clear path and sound horn.
• When driving, retract boom and keep boom/attachment as low as possible while
maintaining visibility of mirrors and maximum visibility of path of travel.
• Always look in the direction of travel.
• Always check boom clearances carefully before driving underneath overhead
obstructions. Position attachment/load to clear obstacles.
• When driving in high speed, use only front wheel steer (if steering modes are
selectable).
OAL2030
2-Wheel Front Steer 4-Wheel Circle Steer 4-Wheel Crab Steer

Section 1 - General Safety Practices
1-731200749
Load Falling Hazard
• 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.
OW0130

Section 1 - General Safety Practices
1-8 31200749
Lifting Personnel
• When lifting personnel, USE ONLY an approved personnel work platform, with
proper capacity chart displayed in the cab.
•DO NOT drive machine from cab when personnel are in platform.
OW0170
OW0190

Section 1 - General Safety Practices
1-931200749
Driving Hazards on Slopes
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. DO NOT shift into neutral and coast downhill.
• Avoid excessively steep slopes or unstable surfaces. To avoid tip over DO NOT
drive across excessively steep slopes under any circumstances.
• Avoid turning on a slope. Never engage “inching” or shift to “Neutral” when going
downhill.
•DO NOT park on a slope.
OW0200

Section 1 - General Safety Practices
1-10 31200749
Pinch Points and Crush Hazards
Stay clear of pinch points and rotating parts on the telehandler.
• Stay clear of moving parts while engine is running.
• Keep clear of steering tires and frame or other objects.
• Keep clear from under boom.
OW0210
OW0220
OW0230