Skytrak 6036 Operation Manual Bedienungsanleitung

Operator & Safety ManualModel6036S/N 9B0500 thru 148338990162Revised February 11, 2005Keep this manual with machine at all times.

Page 4 6036/6036TNew or Additional OperatorsAt the time of original purchase, the purchaser of thisvehicle was instructed by the seller on its safe an

Page 94 6036/6036TSpecifications Fluid and Lubricant CapacitiesENGINE CRANKCASE OILCapacity with filter changePerkins Natural ...

Page 95 6036/6036TTiresAIR PRESSURES13.00 - 24, 10 ply ... 55 psi (379 kPa)13.00 R24, Radial (One Star) ...

Page 96 6036/6036T Electrical SystemRATING ... 12 VDC Negative GroundNUMBER & TYPE OF BATTERY(S) ... 1 (c

Page 97 6036/6036TStability Tipping LimitsThis telescopic handler has been shown to meet orexceed ASME and FEM stability limits in highly structuredan

Page 98 6036/6036TTHIS SIDE UPPosition 3Lateral stability "stacking" with rated load(with frame tilted 4°)Position 2Longitudinal stability &

Page 99 6036/6036TPosition 4Lateral stability "traveling"(with no load)Position 5Lateral stability "stacking"(with no load)40% GRA

Page 100 6036/6036TNotes(Or, on this page, affix second copy of attachmentcapacity chart if supplied with attachment.)

Page 101 6036/6036TNotes(Or, on this page, affix second copy of attachmentcapacity chart if supplied with attachment.)

Page 102 6036/6036TNotes(Or, on this page, affix second copy of attachmentcapacity chart if supplied with attachment.)

REPLACEMENT MANUALSIf the owner/operator or safety manuals that were originally shipped with yourvehicle are lost, stolen or need replacement, contact

Page 5 6036/6036T• DO NOT use your hand to check for leaks.Use a piece of cardboard or paper to searchfor leaks. Wear gloves to protect hands fromspr

JLG Industries (Australia)P.O. Box 511911 Bolwarra RoadPort MacquarieN.S.W. 2444AustraliaPhone: (61) 2 65 811111Fax: (61) 2 65 810122JLG Industries (

Page 6 6036/6036TWhen jump starting the vehicle, carefully followinstructions found under "Jump Starting" later inthis manual.Keep sparks, f

Page 7 6036/6036Toperating the vehicle in a new work area.Prevent accidents when you move the vehiclearound the work site. Know the rules for movemen

Page 8 6036/6036T4. Electrocution HazardNEVER operate this vehicle in an area in whichoverhead power lines, overhead or undergroundcables, or power so

Page 9 6036/6036T6. Tip Over HazardIf proper operating procedures are not followed,this vehicle will tip over. If a vehicle ever becomesunstable and

Page 10 6036/6036T7. SlopesDO NOT park the vehicle on an incline and leave itunattended.• Driving across a slope is dangerous, asunexpected changes in

Page 11 6036/6036TEquipment ConsiderationsALWAYS make sure that all four tires have beenproperly filled with hydrofill by a qualified tire servicecent

Page 12 6036/6036TFigure 1OH0050STEERING WHEELIGNITION SWITCHSERVICE BRAKE PEDALACCELERATOR PEDALControlsIgnition Switch (See Figure 1)Using the ignit

Page 13 6036/6036TEMERGENCYBRAKEPPTravel Select Lever (See Figure 2)The travel select lever has three positions to selectdirection of travel:F = Forwa

WARNINGIMPROPER OPERATION OF THIS VEHICLE CAN CAUSE INJURY OR DEATH.BEFORE STARTING THE ENGINE, DO THE FOLLOWING:1. READ THIS OPERATOR'S MANUAL.2

Page 14 6036/6036TRange Select Lever (See Figure 2)The range select lever has three positions to select thegear range:1 = Low ... all the w

Page 15 6036/6036TAttachment and Frame Tilt Control Lever(See Figure 3)The attachment and frame tilt control is a joystick withfour perpendicular moti

Page 16 6036/6036TOA0071SEATBELTFORWARD/BACKWARDLEVERHEATERCONTROLCAB HEATERSUSPENSIONADJUST KNOBWindshield Washer/Wiper Control(Enclosed Cab Only)Tur

Page 17 6036/6036TSeat Belt (See Figure 5)The seat belt has a slide on each strap that is used totighten and loosen the strap on each side of the buck

Page 18 6036/6036TWarning Light Bulb Test Button (See Figure 6)Directly to the right of the instrument cluster is awarning light bulb test button. Wi

Page 19 6036/6036T4105262Boom Angle Indicator (See Figure 8)The boom angle indicator is a plumb arrow with angulargraduations from minus 10° to plus

Page 20 6036/6036TOA0623Figure 10DIRECTIONAL SIGNALLEVEROptional ControlsLight Switch (See Figure 9)A three-position push-pull switch controls the lig

Page 21 6036/6036TAuxiliary Attachment Control Lever(See Figure 11)The auxiliary attachment control lever controls thefunctions of an optional attachm

Page 22 6036/6036TNormal Starting1. Using hand holds, enter the cab and adjust theoperator’s seat for comfortable operation.2. Adjust mirrors to obtai

Page 23 6036/6036TCold Starting (Perkins Engines Only)Use the Thermo Start cold starting aid when the tempera-ture is below 32o F (0o C), but not belo

6036/6036TEffectivity PageNovember, 1999 - 007 - Revised Manual.February 11, 2005 - H - Replaced branding with JLG.A

Page 24 6036/6036TIf using starting fluid without metering equipment:WarningNEVER use starting fluid near an open flame, or withelectric preheater or

Page 25 6036/6036TJump StartingJump starting at the battery or battery replacement isrequired when the battery is discharged to the pointwhere the bat

Page 26 6036/6036T1. The booster battery must be a 12 volt type. Thevehicle used for jump starting must have a negativeground electrical system. To

Page 27 6036/6036TChanging Travel Direction1. Stop the vehicle.2. Move travel select lever to opposite direction, (R)reverse or (F) forward.Shifting G

Page 28 6036/6036T2. Four Wheel Steering (See Figure 12)WarningNEVER use the four wheel steer mode whentraveling at high speed. Rapid turning in this

Page 29 6036/6036TOH0060Figure 144. Crab Steering (See Figure 14)All wheels will steer in same direction. This modepermits the operator to move the ve

Page 30 6036/6036T4. Exit the vehicle using the hand holds.NOTE: Before removing a carriage type attachment,spread the forks out on the carriage shaf

Page 31 6036/6036T4. Raise the boom until the boom hook pins haveseated fully in the hooks on the attachment.5. Pull the attachment tilt control lever

Page 32 6036/6036TUsing The Capacity ChartThe capacity chart is located on the right side wall of theoperator’s compartment. The chart is provided to

Page 33 6036/6036TOA0165Figure 172. The operator then determines that:• The load weight is 3000 pounds (1360 kg).• The height of the structure the loa

6036/6036TBEffectivity Page

Page 34 6036/6036TThe capacity chart for the 5' Straight Mast (Figure 18B)can be interpreted in the same way as the standardcapacity chart. Refe

Page 35 6036/6036TOA1101OA1121The capacity chart for the Side Tilt Carriage (Figure18C) can be interpreted in the same way as the stan-dard capacity c

Page 36 6036/6036TOA1112NotesThe capacity chart for the 12' Truss Boom (Figure 18E)can be interpreted in the same way as the standardcapacity cha

Page 37 6036/6036T3000 x 243000 x 2424610 mmFigure 19OA1061MAXIMUMLOADCENTERWarningDO NOT exceed the total rated load capacity ofthe specific type fo

Page 38 6036/6036THow To Pick, Carry & Place a LoadTo pick up a load, tilt carriage forward so that forks hangfreely on the fork shaft. Move the

Page 39 6036/6036TLifting PersonnelWarningNEVER tilt the platform forward or rearward whenelevated with personnel aboard. Serious injury ordeath coul

Page 40 6036/6036TUsing Other AttachmentsNumerous attachments, some marketed by JLG and somesold by third party sources, are available for this vehicl

Page 41 6036/6036TShut-Off1. Park the vehicle on level ground.WarningTo prevent personal injury or death, be certain tolower the boom, shut off the en

Page 42 6036/6036TGeneral MaintenanceThis section of the manual contains a routine equipmentchecklist and a maintenance schedule and checklist withref

Page 43 6036/6036TAB-153015456075DANGERDANGERCONTACT WITH ELECTRICPOWER LINES can result incan result inelectrocution.Never operate this machine wit

6036/6036TRead this firstCRead This FirstThis manual is a very important tool! Keep it with the machine at all times.The purpose of this manual is to

Page 44 6036/6036TMaintenance Schedule and ChecklistAt First 50 Hours of Use Daily or 10 Hour IntervalsReferenceCheck Change Clean ParagraphAir C

Page 45 6036/6036TReferenceCheck Change Lube ParagraphFuel Lift Pump Sediment Bowl X 5CFan Belt Tension (Perkins) X 6Transmission Oil Level X 8AAxle O

Page 46 6036/6036T250 Hour Intervals (continued)Carriage Pivot Pin X 1Axle Pivot Pins X 1Axle Steer Knuckles X 1Axle Tie Rod Ball Joints X 1Axle Steer

Page 47 6036/6036TCarriage Pivot Pin X 1Boom Chain Sheaves X 1Axle Pivot Pins X 1Axle Steer Knuckles X 1Axle Tie Rod Ball Joints X 1Axle Steer Cylinde

Page 48 6036/6036T1. Lubrication PointsLubricate the following grease fittings using Multi-PurposeGrease (MPG) every 50 hour interval (Fig. 21 and 22)

Page 49 6036/6036T2. Air Cleaner and Restriction IndicatorFigure 23RESTRICTION INDICATORINDICATOR WINDOWAIR CLEANERVACUATOR VALVEOA0212Figure 24A. F

Page 50 6036/6036TCareful cleaning or washing, if done correctly, canextend the life of an element. But you must realizethat each time an element is

Page 51 6036/6036TTo change elements:1. Loosen cover wing nut and remove cover from aircleaner canister (Figure 25).2. Remove wing nut and primary ele

Page 52 6036/6036TOA0242Figure 27COOLANTOVERFLOW BOTTLEOIL FILL CAPOIL FILTERDIPSTICK2. Unlock and open the right rear engine accessdoor. Check level

Page 53 6036/6036TWarningNEVER remove radiator cap while the coolingsystem is hot. The system is under pressure and hotcoolant can cause severe burns

6036/6036TThis product must comply with all safety related bulletins. Contact JLG Industries, Inc. or the local authorized JLG representative forinfo

Page 54 6036/6036TOA0271Figure 30OG0030Figure 29AADDFULLOIL FILTERCUMMINSENGINESONLY072465039031025. Reconnect line to bottom of overflow bottle andcl

Page 55 6036/6036T5. Allow oil to drain completely into receptacle.Transfer the oil to a container with a cover andlabel the container as used oil. D

Page 56 6036/6036T11. Remove oil fill cap (Figure 27) and add 15W40or 10W30 motor oil that is equal to API, CD orCE specifications. (Refer to engine

Page 57 6036/6036TFigure 31OA1080FUEL FILLACCESS DOORB. Fuel Tank (Daily Before Operation)Check fuel supply daily before operation. Open fuelfill acc

Page 58 6036/6036THEX SCREWFILTER ELEMENTFUEL FILTER BASEDRAIN COCKFigure 33OA0302b. Cummins Engines - All Naturally Aspiratedand Turbo Charged S/N 36

Page 59 6036/6036TControlled venting is provided at the injectionpump through the fuel drain manifold. Smallamounts of air introduced by changing the

Page 60 6036/6036TGOVERNORVENT SCREWINJECTION PUMPVENT SCREWFigure 36OA0322NOTE: If the fuel lift pump cam is on maximum lift, itwill not be possibl

Page 61 6036/6036TWarningFuel will spray when venting high pressure fuellines. Keep clear of spraying fuel. The pressure ofthe fuel in the high pres

Page 62 6036/6036TCummins Engines -1. To vent the low pressure lines and fuel filters,open the vent screw (Figure 40 or 40A). Operatethe hand plunger

Page 63 6036/6036T2. (This step not required for Cummins Turboengines with Bosch fuel injector. Continue withstep 3.) To vent the injection pump, op

Page 1 6036/6036T10. Wheel End Oil ... 7111. Drop Box ... 7312. Wheels and Tires ...

Page 64 6036/6036T5. Cummins Engines only (follow next four steps) -Remove the fan belt (Figure 42A) by carefullylifting the tensioner with a 1/2 inch

Page 65 6036/6036T7. Hydraulic Oil and FilterA. Hydraulic System OilHydraulic system oil can be either a hydraulic oilmeeting the requirements of ISO

Page 66 6036/6036TC. Oil ChangeChange hydraulic oil filter after the first 50 hoursof operation and every 1000 hours or annuallythereafter.Replace hyd

Page 67 6036/6036T7. If hydraulic oil is to be changed, retract all cylin-ders, place a receptacle under the reservoir drainplug. Remove magnetic dra

Page 68 6036/6036TACCESSHOLE IN TRANSMISSON COVERCOVER MOUNTING NUTSFigure 45OA0392MIL-L-2104C10W Motor Oil *Castrol Deusol CRDEsso Essolube D-3HPEsso

Page 69 6036/6036T3. Place a small pan or receptacle under the trans-mission filter (Figure 46) to catch fluid when thefilter is removed.4. Remove the

Page 70 6036/6036T2. Clean area around axle fill/level plug, remove plug(Figure 48) from axle housing and check oil level.Add 80W90 gear oil as requi

Page 71 6036/6036TARROW DOWNTO FILL/CHECK OIL LEVELARROW DOWNTO FILL/CHECK OIL LEVELFILLFILLOA0432VENT PLUGWarningDO NOT perform service or maintenanc

Page 72 6036/6036TIMPORTANT: All wheel ends are factory filled with oil thatcontains friction modifier. DO NOT add additional frictionmodifier to fa

Page 73 6036/6036T11. Drop BoxDrop box information in the following proceduresapplies to Figure 50 for vehicles S/N 9B0500 through9N0941 and Figure 51

Page 2 6036/6036TOA0760 MODEL & SERIAL NUMBERSFor your easy referencewhen ordering replacementparts or making service in-quiries on this vehicle,

Page 74 6036/6036T12. Wheels and TiresA. Air Pressure / Hydrofill Check(Daily or 10 Hour Intervals)IMPORTANT: Before checking air pressure be sure top

Page 75 6036/6036TWarningImproper hydrofill can cause instability which can resultin tipover. ALWAYS make sure that all four tires havebeen properly

Page 76 6036/6036TFigure 531. Level the vehicle, ground the carriage, place thetravel select lever in (N) Neutral, engage theemergency brake switch an

Page 77 6036/6036TCharging rates between 3 and 50 amperes aresatisfactory if excessive gassing or spewing ofelectrolyte does not occur or the battery

Page 78 6036/6036TAUX.BAT.IMPORTANT: Each circuit breaker has a longterminal and a short terminal. The short terminal islabeled “BAT.” and the long

Page 79 6036/6036TFigure 55512346OA0483The following circuit breakers are used (Figure 55): Index Size Circuit Protected1 6 amp Steering Select Switch

Page 80 6036/6036TFigure 55AOA109110 amp7.5 amp20 amp40 amp7.5 amp10 amp1 10 amp Enclosed Cab Windshield(Fuse) Washer/Wiper Switch andCirculation Fan

Page 81 6036/6036TFigure 56OA0491BOOM CHAIN SAG 15. Boom Chains and Wear PadsA. Top Boom Chain Tension Check (First 50 Hoursand 1000 Hour Intervals or

Page 82 6036/6036TB. Top Boom Chain Tension Adjustment (As Required)1. Retract the boom completely to check the positionof the inner boom. The inner

Page 83 6036/6036Tc. Measure the chain sag. Acceptable boomchain sag is between 1-1/2" (38,1 mm) and2-1/2" (63,5 mm). If the chain sag is

Page 3 6036/6036TSafety PracticesThe information in this manual does not replace any safetyrules and laws used in your area. Before operating thistele

Page 84 6036/6036TFigure 60OA0531BOOM EXTEND CHAINSEXTEND CHAIN SHEAVELUBE FITTINGYOKED. Wear Pad Check (50 Hour Intervals)Visually inspect boom wear

Page 85 6036/6036TIMPORTANT: The boom has been factory lubricated forproper wear pad break-in and will normally not requirefurther lubrication. Howe

Page 86 6036/6036T3. Clear area around the vehicle of all personnel.4. Move the boom control lever to the left to retractthe boom.After the boom has b

Page 87 6036/6036TLoosen the retainer nut on each cartridge and turnthe adjusting screws in (clockwise) until theybottom out. Doing this will render

Page 88 6036/6036TIMPORTANT: If the boom has been extended, you mustfirst retract the boom before you attempt to lower the boom.To retract the boom p

Page 89 6036/6036T1. Remove the blocking that is supporting the boom.2. If the line failure is in the boom hoist line the boommust be lowered by follo

Page 90 6036/6036T17. Emergency Boom Lowering —Electrical Control JoystickA. Loss of Engine Power or Hydraulic Pump FailureIn the event of total loss

Page 91 6036/6036T4. Clear the area around the vehicle of all personnel.5. Move the cap screw backward to shift the boomextend/retract spool. This wi

Page 92 6036/6036T3. If the line failure is in the boom retract line,proceed as follows:a. At the base end of the extend/retract cylinder,locate the c

Page 93 6036/6036TAfter the boom has been retracted fully, proceed asfollows:1. If the line failure is in the boom hoist line, proceedas follows. Usi