JLG Skytrak 6036 Gebrauchs- und Pflegehandbuch

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

c31200749

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: +1-717-485-6591

E-mail

ProductSafety@JLG.com

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

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

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

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