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Operation 3126021

1. 2 MH45802 Model 6036 113 General Maintenance NOTE Use the hose attached to the petcock to allow draining directly into a container 4 Allow coolant to drain from the radiator Detach line from bottom of coolant overflow bottle and drain bottle 5 Flush system with clean water and drain again NOTE On vehicles equipped with a cab heater option a shut off valve is installed at the engine inlet Disconnect hose from shut off valve to drain the heater 6 Transfer the coolant into a properly labelled container Dispose of properly 7 Reconnect line to bottom of overflow bottle and close petcock on the radiator Reconnect heater hose 8 Fill radiator completely with 50 50 mixture of ethylene glycol and water Total System Capacity is 4 gallons 15 liter Add coolant to overflow bottle until bottle is about 1 2 to 3 4 full This overfilling will compensate for any air in the cooling system 9 Clean dirt and debris from radiator fins and core if required 10 Start engine and run vehicle to normal operating temperature and then shut OFF the engine While the engine is cooli
2. OH1772 Model 6036 25 Operation Park Brake Switch The Parking Brake Switch 1 has two positions gt P toggle switch downward t osu HP DISENGAGED toggle switch upward RI bes The Parking Brake Switch 1 must be ENGAGED to permit engine starting A red LED on the parking brake switch and a light in the instrument cluster will indicate the brake is ENGAGED The parking brake may be used to stop in an EMERGENCY situation However use caution because the stop will be abrupt and the operator and the load may be jolted forward unexpectedly OH1772 26 Model 6036 Operation Neutral Lock Lever The Travel Select Lever 2 is equipped with a neutral lock The Neutral Lock Lever 3 locks the Travel Select Lever in NEUTRAL or unlocks the Travel Select Lever so that it can be moved into the FORWARD or REVERSE drive position OH1782 To lock the Travel Select Lever 2 in the NEUTRAL position place the lever in the NEUTRAL position and move the Neutral Lock Lever 3 to the N NEUTRAL LOCK 4 position To unlock move th
3. 2 points NOTE Shorten the lubrication interval on all lube points when operating in severe conditions General Maintenance Lubrication Points OA1260 Model 6036 107 General Maintenance 2 Air Cleaner amp Restriction Indicator NEVER operate the vehicle without the air cleaner assembly and both filters in place A Filter Check 10 Hour Intervals gt OH2660 e 4 OF1190 1 Ground the carriage place the travel select lever NEUTRAL move the neutral lock lever to NEUTRAL LOCK position engage the parking brake switch and shut off the engine 2 Unlock and open the left rear engine access door to access air cleaner restriction indicator 1 Check indicator If red band 2 has appeared filter must be replaced NOTE Depress button 3 on top of indicator to reset indicator after servic ing element IMPORTANT Only remove canister cover to service the elements as restriction indicator indicates or during scheduled maintenance intervals Excessive access to check an element can lead to premature element failure and increase the possibility of dirt entering the engine OH3370 108 Model 6036 General Maintenance 3 Remove dust from vacuator valve 4 by squeezing bottom of vacu ator to allow loose particles to fall out Replace elements if required as described in paragraph 2B OA1280 B Element Change As Restriction Indicator Indicates or 2505
4. sssssssssssseeeeeeeeeenenn 10 Amp Optional Washer Wipers sssssseseeeeennnneeennn 10 Amp Optional eee ie Temi re eee teas va aad un 20 Amp Transmission o eerte 7 5 Amp Optional Road Work Lights eessseseseeeeeennnn 40 Amp Relay Ratings Park Brake Disengage 12V Optional Headlight Switch sessssseeeeeeneenne 12V Light Switch eoi pete re n E Cs 12V E 12V BACKUP tette E d 12V Grid Heater Fuse Ratings Optional 125 Ami cot EE DD e Dade eoa Qty 2 Model 6036 171 Specifications Engine Cummins Model 8 ceed E B4 5T 99C Turbo Charged HOrS POWEM oe reete dete entere ends 99 hp 2500 rpm 172 Model 6036 Accelerator Pedal 23 Accident Prevention Tags 5 Air Cleaner 108 Air Intake System 111 Air Pressure 169 Alternator Charging Warning Indicator Light 38 Attachment Reconnect 67 Attachment Removal 66 Attachment 31 Auger Operation 41 Auxiliary Attachment Control Lever 41 Avoidance Symbols 8 Axle
5. 29 Normal Starting 53 H Hazard Classification System 3 Oil Level Check 115 Hazard Symbols 7 Operating 59 Headlights 46 Operator s Seat Adjustment 33 High Beam Light 36 Outer Primary Element 109 High Low Beam Switch 46 P OM C ioi irt d cete 23 Park Brake Light 36 Hourmeter 34 Park Brake Switch uidens 26 Hydraulic Fluid eene 11 Parking Brake Test Procedures 165 Hydraulic Line Failure 88 Parking Lights 46 Hydraulic Oil amp Filter Change 127 Pick Carry amp Place A Load 77 Hydraulic oil and Filter 125 Pre Operation Inspection 52 Hydraulic Oil Level 126 Preparation and Prevention 14 Hydraulic Oil Temperature Primary Element 109 Warning Indicator Light 38 Q Hydraulic Pump Failure 87 Hydraulic System _ 168 Quick Attach E Somit 66 Hydraulic System p RR rs 125 Reading The Capacity Chart 70 Rear View Mirrors 40 Ignition Switch 24 Rear Window Lateh 51 174 Model 6036 Index Ref
6. 3 Allow no riders AVOID CRUSHING VEHICLE AY 5 if vehicle tips can cause 4 Use a compliant Jumping can death or 2 Fasten seat belt work platform to lift result in death serious 27 Y or lower personnel or serious ry injury ioe P gm diamounting CR SHING falling off vehicle can OH17431 Part Number Quantity Decal Description 4110188 No Riders Warning 4110188 Vehicle Rollaway Warning 4108991 Electrocution Danger 7139452 Load Chart Booklet 4110137 Tipover Danger 4110187 Do Not Jump Danger 4110188 Safety Instructions Model 6036 21 Safety Practices Keep sparks flames and lighted materials away from batteries OA1780 Part Number Quantity Decal Description 4110184 Moving Parts Warning 4110172 Explosive Gases Warning 4110389 Elevating Personnel Warning 4107442 Boom Extend Letters 4105262 Boom Angle Indicator 4109791 Emergency Exit Enclosed Cab Only Ether Starting Warning Optional Grid Heater Cold Start Aid 4110460 22 Model 6036 Operation Operator Controls Accelerator Pedal Pressing down the accelerator pedal 8 increases engine and hydraulic speed of the vehicle T
7. DANGER Use of the frame sway control with the boom raised above horizontal can cause tipover resulting in death or serious personal injury Always use the frame sway control to level the vehicle before raising the boom above horizontal If the vehicle cannot be leveled using the frame sway control reposition the vehicle Model 6036 65 Operation Quick Attach This vehicle is equipped with a quick attach system for easy attachment changing Attachment Removal Be sure you are performing this procedure on level ground 1 Place the travel select lever in NEUTRAL come to a complete stop move the neutral lock lever to NEUTRAL LOCK position and engage the parking brake switch 2 Extend the boom approximately 10 feet 3 meters and tilt the car riage backward 3 Exit the vehicle using the hand holds NOTE If you are removing a standard carriage with forks spread the forks apart on the carriage shaft This will provide the carriage adequate support to stand alone 4 Raise the quick attach pin lock lever 1 and pull out the pin 2 at the bottom of the quick attach link 3 0S0331 5 Return to the operators compartment fasten the seat belt and lower the attachment to the ground in a level position Tilt the attachment forward This will rotate the quick attach link back away from the attachment 6 Lower and then retract the boom until th
8. General Maintenance E Wear Pad Inspection 50 Hour Intervals 50 X SD OH2680 2400 Visually inspect boom wear pads between the boom sections at the rear and front of the boom for excessive wear at every 50 hour interval The average expected life of boom pads will vary depending upon vehicle use weight of loads operating conditions and the location of boom pads inside the boom If the vehicle is used continuously and the weights of the loads are at or near maximum capacity or if you are operating in very dusty or dirty conditions the boom pads will wear much faster The pads that are under the most stress from the weight of the load will also wear faster than other pads For example the lower pads at the front of the boom and the upper pads at the rear of the boom are under far more stress than the pads attached to any other surface of the boom Consequently the lower pads at the front and the upper pads at the rear will require service more often Model 6036 161 General Maintenance F Wear Pad Replacement As Wear Pad Indicators Indicate Each boom pad 1 is manufactured with a convenient wear pad indicator 2 This is the angled cut 2 at each end of all wear pads 1 The total thickness 3 of a new wear pad is 625 16 mm The angled cut will provide a total wear thickness 4 of 25 6 mm This will leave approximately 375 10 mm of total unused base material The pa
9. Lead Acid Batteries Rotating Fan Blades Vehicle Tipover Can Generate Explosive Can Cut Crush Gases OH2140 OH2300 OH2150 Rotating Belts Can Electrocution Can Vehicle Roll Away Can Cut Or Entangle Cause Death Or Cause Death Or Serious Serious Injury Injury OH3160 AVOID CRUSHING Falling Off Vehicle Can Cause Death Or Serious Injury OH2161 FALLING OFF ATTACHMENT Can Result In Death Or Serious Injury OH3110 Swinging Loads Can Cause Vehicle Tipover Which Can Result In Death Or Serious Injury OU1450 ENGINE EXPLOSION Can Result In Death Or Serious Injury Model 6036 Safety Practices Avoidance Symbols CN OH2320 OH2330 Keep Lit Cigarettes Keep Flames and Away Ignition Sources Away om STOP NU Keep Away From Rotating Fan Blades OH2270 OU1520 Do Not Travel With Stop Operation At Boom Raised This Point Dead OH2280 OH2290 Do Not Raise Boom DUSO Maintain Proper Air While On A Slope Prohibition Pressure In Tire Symbol DO NOT Operate To Avoid Vehicle Tipover ALWAYS Travel Slowly Rig Properly Use Two Tethers OH3120 8 Model 6036 Safety Practices Avoidance Symbols cont d gt P Engage Parking Brake OH2240 Do Not Travel With Personnel In Work Platform OU1460 DO NOT Use Ether Or Other High Energy Starting Aids Engine Equipped With Grid Heating System QD N OH2220 bo OH2250
10. B High Beam Light 2 used with optional road light package only OH2490 The high beam light 2 illuminates when the road option headlights are on full high beam and will turn OFF when the headlights are switched to low beam C Turn Signal Light used with optional road light package only OH2510 The turn signal light 3 will illuminate and flash when the road option turn signals are activated in either direction or when the road option hazard lights are activated eS E M 0000 00 OH1810 36 6036 Operation Warning Indicator Lights There are five additional indicator lights in the instrument cluster that will illuminate during critical circumstances All five warning indicator lights demand immediate attention and vehicle servicing In many cases the vehicle should be shut down AS SOON AS PRACTICAL to prevent serious mechanical failure The five warning indicator lights are A Engine Coolant Temperature Warning Indicator Light 2520 The engine coolant temperature light 4 illuminates when the engine coolant temperature is too high above 210 F 99 C SHUT THE VEHICLE DOWN AS SOON AS PRACTICAL B Transmission Temperature Warning Indicator Light 5 2530 The transmission temperature light 5 illuminates when the transmission oil temperature is too high above 250 F 121 C Stop the vehicle place the travel select lever in NEUTRAL
11. NORMAL STEPS EMERGENCY STEPS FOLLOW FOLLOW iii quie THIS STEP THIS STEP THAT IF PARTS IF PARTS FAILED ARE ARE NOT FOLLOW THIS STEP AVAILABLE AVAILABLE AS A LAST RESORT eO BOOM LIFT LINES LIFT CYLINDERS TO STEP 1 STEP 2 CONTROL VALVE BOOM LOWER LINES LIFT CYLINDERS TO STEP 1 STEP 3 CONTROL VALVE BOOM EXTEND STEP 1 STEP 2 LINE BOOM RETRACT STEP 1 STEP 4 LINE Model 6036 89 Emergency Operations STEP 1 1 Clear the area of any unnecessary personnel 2 Place the travel select lever in NEUTRAL move the neutral lock lever to NEUTRAL LOCK position and engage the parking brake switch Block all four wheels WARN NG DO NOT get under a raised boom unless the boom is blocked up Always block the boom before doing any ser vicing that requires the boom to be up If the load is in a position where it can be removed safely com pletely remove the load from the carriage and or attachment other wise leave the load in place Temporarily block up or support the outer boom WARN NG Wear protective clothing and proper eye pro tection when working with or around hydraulic oil Wait for hydrau lic oil to cool before attempting to repair the failure Hot hydraulic oil can cause severe burns and other serious injury 10 11 12 Replace the failed hydraulic line with
12. OH2660 OS0660 1 Be sure all cylinders are fully retracted and oil is at reom temperature 2 Level the vehicle ground the carriage place travel select lever in N NEUTRAL move the neutral lock lever to NEUTRAL LOCK position engage the parking brake switch and shut OFF the engine 3 Check level of hydraulic oil in tank at the sight gauge 1 on the back side of the hydraulic tank 2 4 The oil level should be visible in the gauge window 5 If it is not add ISO 46 or MIL L 2104C oil see table on page 125 a Remove the four capscrews 3 holding the hydraulic oil tank cover 4 to the tank remove the cover b Turn the hydraulic oil cap 5 and remove from the filler neck Add hydraulic oil as needed The hydraulic oil level should be within 1 2 inch of the upper mark on the sight gauge 6 Install hydraulic oil cap 5 Reposition the cover 4 on the tank 2 and secure in place with the four capscrews 3 OH2340 General Maintenance C Hydraulic Oil amp Filter Change First 50 Hours 1 A OH2670 2 y Filter Only dh 1000 Hour Intervals Cil amp Filter 1 000 X 4 Change the hydraulic oil filter after the first 50 hours of operation and change the hydraulic oil and filter every 1000 hours of operation thereafter Other than the 1000 hour interval the hydraulic oil must be changed when a hydraulic component h
13. oP pu c4 qp gh OA1362 No Amp Volt Color Circuit Protected 3 40 Amp Orange Main 4 7 5 Amp Brown Light Switch Relay 5 10 Amp Red Instrument Cluster 6 15 Amp Blue Horn Heater 7 10 Amp Red Steer Select Switch 8 10 Amp Red Optional Washer Wiper 9 7 5 Amp Brown Transmission 10 20 Amp Yellow Optional Lights 11 40 Amp Orange Optional Road Work Lights 12 12 Volt Park Brake Disengage Relay 13 12 Volt Neutral Start Relay 14 12 Volt 15 12 Volt Light Switch Relay 16 12 Volt Optional Headlight Switch Relay Model 6036 145 Cold Start Grid Heater Fuses Optional The two 125 amp fuses 1 that protect the cold start grid heater are located inside the frame on the left side 1 Unlock and open the left engine access door 2 To access the fuses open the protective covers 2 Allow the cov ers to rotate on the tethers on the holder 3 Remove the two hex nuts 4 and lockwashers 5 securing the fuse 1 and wires to the fuse holder 3 Remove the fuse and replace with a new fuse Place the new fuse and then the wires onto the studs of the holder Secure the fuse and wires in place with the lockwashers 5 and hex nuts 4 Torque the hex nuts to 7 9 Ib ft 10 12 Nm Snap the protective cover back in place Be sure
14. Keep Clear Of Power Lines 4 ll Gin A A Carry No Riders CX Use Only Compliant Work Platforms To Raise Or Lower Personnel DO NOT JUMP Brace Yourself and Stay With Vehicle Keep Seat Belt Fastened Hold On Firmly Lean Away From The Point Of Impact Model 6036 Safety Practices Personal Considerations 1 Seat Belt Always fasten the seat belt before starting the engine 2 Clothing and Safety Gear DO NOT wear loose clothing or jewelry that can get caught on controls or moving parts Wear protective clothing and personal safety gear issued or called for by job conditions 3 Dismounting DO NOT get off the vehicle until you level the vehicle ground the carriage place the travel select lever in N NEUTRAL place the neutral lock lever in N NEUTRAL LOCK engage the parking brake switch turn the engine OFF if appropriate unbuckle the seat belt WARNING VEHICLE ROLLAWAY can cause death or serious injury ALWAYS engage parking brake before dismounting iP OH1650 exit the vehicle using the hand holds 4 Chemical Hazards A Exhaust Fumes Fumes from the engine exhaust can cause death or serious personal injury DO NOT operate vehicle in an enclosed area without a ventilation system capable of routing the hazardous fumes outdoors B Explosive Fuel Engine fuel is flammable and can cause a fi
15. ON changed at shorter intervals OT150 eG 050870 with evidence of water or contaminated fuel 1 Unlock and open the right rear engine access door 2 Clean around the fuel filter head 1 3 Unscrew the fuel filter 2 and dispose of properly 4 Clean the gasket surface of the filter head and replace the o ring i E SN z AR et 1700 5 Fill the new fuel filter with clean No 2 diesel fuel 6 Lubricate the o ring seal with clean No 2 diesel fuel 7 Install the fuel filled filter and hand tighten DO NOT overtighten NOTE Mechanical over tightening may distort the threads or damage the sealing ring 8 Close and lock the right rear engine access door Controlled venting is provided at the injection pump through the fuel drain manifold Small amounts of air introduced by changing the fuel filter element will be vented automatically as long as the element was filled with fuel prior to installation C Replace In line Fuel Strainer 250 Hour Intervals 500Z General Maintenance OT1150 1 Unlock and open the right rear engine access door The in line fuel strainer 3 is located down line from the engines lift pump 4 Loosen the two hose clamps 5 that secure the strainer in place Remove the old in line fuel strainer and dispose of properly 4 Install the new in line fuel strainer 3 with arrow pointing toward the lift pump 4 Assemble the hoses t
16. 17 18 19 Check the hydraulic oil level and add oil if needed Return to the cab fasten your seat belt and start the engine Tilt the carriage and or attachment upward if necessary for clearance before retracting the boom SLOWLY RETRACT the boom 12 SLOWLY LOWER the boom and ground the carriage and or attachment Completely remove the load from the carriage and or attachment if you haven t already done so Have the vehicle serviced immediately Replace any faulty hydraulic lines Return to the cab fasten your seat belt and start the engine Cycle the extend retract cylinder several times to bleed air from the system Check for leaks Transfer the waste oil to a container with a cover and label as used oil Dispose of properly Recheck the hydraulic oil level Add if necessary 98 Model 6036 Emergency Operations OA1240 Model 6036 99 General Maintenance General Maintenance This section of the manual contains a maintenance schedule and checklist with references to pertinent procedures and instructions To prevent problems before they occur follow the maintenance schedule NOTE The Lubrication 1 and Maintenance Chart 2 decals are located inside the right side engine cover 3 They contain a general maintenance schedule that should be followed to maintain the vehicle in good operating condition The same schedule information is presented in this manual except it contains a mo
17. FALLING OFF ATTACHMENT can result in death or serious injury Lift or lower personnel DO NOT TRAVEL only in a compliant with personnel in work platform a work platform 000620 16 6036 Safety Practices 7 Tip Over Hazard DANGER VEHICLE DO NOT DO NOT raise TIPOVER travel Vr boom while can result with the on a slope in death or boom T unless load OUY No serious injury raised is level 50086 Traveling with the boom raised is dangerous and can cause tipover Keep the boom as low as possible Travel with extreme caution and at the slowest possible speed Keep the vehicle under control at all times When negotiating turns slow down and turn the steering wheel in a smooth sweeping motion Avoid jerky turns starts or stops Reduce vehicle speed on rough ground and slopes DO NOT exceed the rated lift capacity of the vehicle as structural damage and unstable conditions will result To ensure that the vehicle is positioned in the most stable condition before operating an attachment use the frame sway control frame tilt to level the vehicle The vehicle is level when the frame level indicator gauge reaches 0 zero degrees If the vehicle cannot be leveled using the frame sway control reposition the vehicle Frame swaying left or right with the boom raised above horizontal is dangerous Always use the frame sway control to level the vehicle before ra
18. Safety Practices Equipment Considerations WARN NG DO NOT modify or alter weld drill etc any part of this vehicle without first consulting JLG Modifications can weaken the structure creating a hazard that can cause death or serious personal injury DO NOT by pass or disconnect any electrical or hydraulic circuits Consult the JLG Service Department or your local JLG Distributor if any circuit is malfunctioning DO check for frayed or cut seat belt webbing damaged buckles or loose mounting brackets Replace immediately if required ALWAYS wear a seat belt when operating the vehicle DO check tire pressure on all four tires Add air if required DO check the condition of all four rims Check for bent flanges and or bead mounting areas DO check the parking brake operation Refer to the test procedures on page 165 Repair immediately if required DO keep all non skid surfaces clean and free of debris Replace if worn damaged or missing DO check the condition of decals Replace decals if missing damaged or illegible The following pages show the proper location of the decals 20 Model 6036 Safety Practices NEVER operate X VEHICLE DO NOT raise MAINTAIN TIPOVER boom while proper tire power k annar i onaslope 5 gt lt 5 pressure at ines P in death boom GN unless load all times y serious injury raised is level SAFETY INSTRUCTIONS AWARNING
19. To heat the cab n 051950 Turn temperature control knob 3 to far right position RED HOT Direct desired air flow by adjusting vent louvers under the seat Turn fan control 2 to 3 4 to assure rapid warm up To defrost the cab OA1390 Turn temperature control knob 3 to the far right position RED HOT Direct desired air flow by adjusting vent louver on the front dash Turn fan control 2 to 3 4 to assure rapid defrost OH3340 50 Model 6036 Operation Rear Window Latch The rear window 5 can be partially opened and secured in place with the rear window latch 6 To open the window grab the latch handle 7 and pull up and then push the window outward To close and secure the window pull the latch handle forward and down NOTE In an emergency situation the operator can exit through the rear window opening by removing the latch pin 8 on the window latch The win dow is then free to swing open OH1730 Door Latches not pictured There are two door latches The outside latch is a key lockable pull to release type The inside latch is also a pull to release latch Door Window Latch not pictured The door window can be swung open by releasing the window from inside the cab Swing the window all the way open and lock in place on the outside of the cab To release the window from the open position push up the release on the lo
20. should be used when loading or unloading the vehicle from a trailer and for on highway travel at higher speeds OH1670 3 Crab Steering WARN NG NEVER use the Crab Steering Mode when traveling at high speed Rapid turning in this mode can cause tipover Use only the Front Wheel Steering Mode at higher speeds and slow the vehicle when turning All wheels will steer in the same direction that the steering wheel is turned This steering mode allows the operator to move the vehicle sideways toward the landing point of a load This is especially useful on a congested worksite in order to line up at the exact spot in front of the loading location OH1680 64 Model 6036 Operation 4 Maximum Fork Sweep CAUTI ON Allow for adequate clearance between the attachment and other objects when turning The attachment 1 extends beyond the end of the vehicle The operator must be aware of the maximum sweep 2 of the attach ment when turning in order to avoid hitting personnel and other objects in the area OH1690 Leveling Frame When placing a load while on a slope use the frame sway control to keep the vehicle level The operator should observe the frame level indicator to assure that the vehicle is level at all times
21. 1 to the tank through the male disconnect coupling UN When the control lever is moved to the left it will provide hydraulic system pressure to the male disconnect coupling for laws the auxiliary attachment Hydraulic fluid will return to the tank oxo451 through the female disconnect coupling The control lever will provide the following typical functions for each specific attachment if they are connected properly Operation will be reversed if incorrectly connected We recommend reversing the disconnect couplings on the hoses that are supplied with the attachment if operation is reversed Side Tilt Carriage Operation Lever tilt right tilt left Auger Operation Lever auger dig auger retract Swing Carriage Lever swing right swing left 3 Foot Truss Boom w Winch Lever cable extends cable retracts OH2910 Model 6036 41 Operation Worklight Switch Front Rear amp Boom Worklights 2 KS OH2570 This three position rocker switch 1 controls the front rear and boom worklights The switch 1 is located in th
22. 2 Unlock and open the right rear engine access door Check level of coolant in overflow bottle 1 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 OH3410 B Drain And Flush Radiator 2000 Hour Intervals 1 General Maintenance 050810 2000 amp Level the vehicle ground the V carriage place the travel OH2700 VA ue S select lever in NEUTRAL move neutral lock lever to NEUTRAL LOCK position engage the parking brake switch and shut off the engine WARN NG DO NOT attempt this procedure when the engine is hot Wait for the engine muffler and tailpipes to cool down before proceeding Failure to do so could result in severe burns Unlock and open the rear radiator access door Allow time for the engine to cool down before proceeding Draining and flushing the engine cooling system while the engine is still hot can cause cracks in the engine block WARN NG NEVER remove the radiator cap while the engine is hot The cooling system is under pressure Hot coolant can cause severe burns or eye injury Wear protective clothing and safety glasses Remove radiator cap and open the petcock 2 on the lower right side of radiator 3
23. 250 Hour Intervals OH2710 50790 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 Adopt the policy that all elements should be replaced with new and not cleaned Inner Safety Element An inner safety element should never be washed or reused Always install a new element Replace inner safety elements after every third primary element change DO NOT remove an inner safety element until you have thoroughly cleaned the inside of the air cleaner canister This will prevent dirt which could damage the engine from entering the induction manifold CAUTI ON NEVER run the engine with only the inner safety element installed Severe engine damage will result from dust entering the engine Model 6036 109 General Maintenance To change elements 1 Pull the air cleaner cover lock 1 OUT turn the air cleaner cover 2 counter clockwise and remove cover from air cleaner canister 3 OA1290 2 Remove the primary element 4 Inspect element for damage Damaged elements should not be reused 3 Thoroughly clean the interior of the air filter canister b and vacua tor valve 6 4 If replacing the inner safety element 7 at this time carefully slide the inner safety
24. After the engine starts run engine at partial throttle for 30 to 60 sec onds before operating the vehicle Return to idle before engaging the travel or range select lever 8 Move the Neutral Lock Lever to the D DRIVE position before you start operating 9 Disengage the parking brake switch before you start operating Model 6036 53 Operation Cold Starting The engine is equipped with a 120 volt 750 watt block heater Block heaters are recommended when temperatures drop below 10 F 12 C Temperature ranges will vary when using different oil weights Consult the engine manufacturer s manual for other variables FOR ENGINES EQUIPPED WITH OPTIONAL COLD STARTING AID WARN NG This diesel engine uses a grid heating system inside the induction manifold DO NOT use ether or any high energy fuels to assist starting An explosion may cause death or serious personal injury or engine damage The engine is equipped with a grid heater inside the induction manifold If the temperature drops below 40 F 4 C the air intake heater system will be activated when the ignition switch is turned to the RUN position When the system is active the air intake heater light will illuminate on the front dash DO NOT turn the ignition switch to START until the air intake heater light goes OFF At temperatures below 10 F 12 C operate the engine at moderate speeds for 5 minutes before full loads are applied 1 Enter the
25. Warning and Caution notices They are for your benefit All reference to the right side left side front or rear are given from the operator s seat looking in a forward direction Replacement Parts For easy reference when ordering replacement parts or making service inquiries on this vehicle record its model and serial number on the back cover of this manual The serial number is stamped into the serial number plate 1 which is located on the vehicle s frame OH0280 IMPORTANT The replacement of any part on this vehicle by anything other than a JLG authorized replacement part may adversely affect the performance durability or safety of this vehicle and may void the warranty JLG assumes no liability for unauthorized replacement parts which adversely affect the performance durability or safety of this vehicle Reports IMPORTANT A Warranty Registration form must be filled out by the JLG Distributor signed by the purchaser and returned to JLG once the product is sold and or put into service This report activates the warranty period assuring that your claims during the warranty period will be processed promptly To guarantee full warranty service make sure your JLG Distributor has returned the business reply card of this form to JLG 2 Model 6036 Safety Practices Disclaimer JLG reserves the right to make changes on and to add improvements upon its products at any time without public notice or obligation JLG a
26. Wheel Steering 1 Front Wheel Steering 2 Crab Steering 3 The steering modes can be changed using a single rocker switch 4 located in the lower switch bank 5 on the right side dash panel OH19421 62 Model 6036 Operation Four Wheel Steer Indexing If the vehicle does not drive straight the steering could be out of phase Perform the Four Wheel Steer Indexing Procedure on page 167 to synchronize the front and rear steering 1 Four Wheel Steering WARNING NEVER use the Four Wheel Steering Mode when traveling at high speed Rapid turning in this mode can cause tipover Use only the Front Wheel Steering Mode at higher 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 steer in the opposite direction This steering mode allows an extremely short turning radius and enables the rear wheels to follow the tracking of the front wheels which can be an advantage in mud and sand conditions o e OH1660 Model 6036 63 Operation 2 Front Wheel Steering The front wheels will steer in the direction that the steering wheel is turned The rear wheels will remain in a fixed forward position This steering mode
27. and idle the vehicle allowing time for cooling If the light does not go out after two minutes shut the vehicle down OH1810 Model 6036 37 Operation C Hydraulic Oil Temperature Warning Indicator Light L w 2540 The hydraulic oil temperature light 1 illuminates when the hydraulic oil temperature is too high above 195 F 91 C Stop and idle the engine allowing time for cooling If the light does not go out after five minutes shut the vehicle down OH1810 D Engine Oil Pressure Warn ing Indicator Light 4 72 The engine oil pressure indicator light 2 will come ON during engine start up and go OUT once the engine has started This is normal If the light comes ON while the engine is running this indicates that the engine oil pressure is too low SHUT THE VEHICLE DOWN AS SOON AS PRACTICAL E Alternator Charging Warning Indicator Light OH2560 The alternator charging light 3 illuminates when the charging system is not working properly Service the engine alternator 38 Model 6036 Operation Frame Level Indicator The indicator 4 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 sway the vehicle either right or left until the indicator reads zero degrees 0 If zero cannot be achieved then rep
28. boom Replace oil fill cap and dipstick 3 Close and lock access door OA1720 General Maintenance B Oil And Filter Change First 50 Hours 250 Hour Intervals OH2670 O T a 1 Operate the engine until 22 i o warm approximately 5 250 ur minutes OH2710 080830 2 Level the vehicle ground the carriage place the travel select lever in NEUTRAL move neutral lock lever to NEUTRAL LOCK position engage the parking brake switch and shut off the engine 3 Place receptacle under engine oil pan drain 4 Remove drain plug 4 from engine oil pan 5 Allow oil to drain completely into a 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 6 Unlock and open the left engine access door Remove oil filter 5 A strap or chain filter wrench may be required OA1730 7 Clean filter sealing surface Make sure the o ring seal from the filter comes off the sealing surface Model 6036 117 General Maintenance NOTE The filter o ring may stick to the filter head Make sure the old o ring is removed before installing the new filter 8 9 10 11 12 13 14 15 118 Apply a thin coat of clean engine oil to seal on new filter Install the new oil filter and hand tighten 1 2 turn after initial contact Install the drain plug 1 into the oil pan and tighten securel
29. boom and ground the carriage 5 Turn the ignition key to the OFF position and remove the key Model 6036 83 Emergency Operations Towing A Disabled Vehicle Towing a disabled vehicle should only be attempted after exhausting all other options Every effort should be made to repair the vehicle and move it under its own power Towing the vehicle improperly can result in damage to the vehicle drivetrain IMPORTANT In the event the vehicle is disabled and cannot be moved under engine power the situation must be properly evaluated and dealt with on an individual basis Contact your local JLG Distributor or the JLG Service Department at 877 554 5438 or 717 485 6657 for specific instructions for your particular situation If itis necessary to tow the vehicle a short distance to avoid a potentially hazardous situation such as being in an unsafe area on the worksite or on a roadway prepare the vehicle for towing as follows 1 Remove the load from the vehicle WARNING BLOCK ALL FOUR WHEELS Failure to do so could result in death or serious injury from vehicle roll away 2 Block all four wheels to help prevent the vehicle from moving after the parking brake is disabled 3 Remove the six hex nuts lockwashers and flat washers 1 secur ing the transmission covers 2 to the frame Remove the covers OH2372 84 Model 6036 Emergency Operations 4 Position the towing vehicle in place Attach any chains
30. failure Hot hydraulic oil can cause severe burns and other serious injury o NOOA 11 Place a container under the failed hose to catch any hydraulic oil that may escape during this procedure Return to the cab fasten your seat belt and start the engine Slowly retract the boom Slowly lower the boom and ground the carriage and or attachment Shut off the engine Completely remove the load from the carriage and or attachment Place an accident prevention tag on both the ignition switch and steering wheel Refer to Accident Prevention Tags on page 5 Actual accident prevention tags can be found as the last page of this manual If you do not have a safety tag tape over the ignition switch Have the vehicle serviced immediately Replace any failed hydraulic lines with new parts Boom Retract Line 1 Boom Extend Line 2 Boom Lift Line 3 Boom Lower Line 4 92 Model 6036 Emergency Operations 12 Return to the cab fasten your seat belt and start the engine 13 Cycle the lift lower cylinder several times to bleed air from the system Check for leaks 14 Recheck the hydraulic oil level Add oil if necessary 15 Transfer any waste oil to a container with a cover and label as used oil Dispose of properly OA1240 Model 6036 93 Emergency Operations BOOM LOWER LINE FAILURE Lift Cylinders to Control Valve 1 Clear the area of any unnecessary perso
31. is located at the lower portion of the instrument cluster on the right side of the dash Fuel Gauge OH2470 The fuel gauge 2 indicates the quantity of fuel in the fuel tank The gauge is located in the center of the instrument cluster on the right side of the dash Capacity of the fuel tank is 37 gallons 140 liters total capacity with a usable capacity of 35 6 gallons 135 liters OH1810 34 6036 Operation Instrument Cluster Light Test Test the bulbs in the instrument cluster before starting the engine Turn the ignition switch to the RUN position ALL nine lights in the instrument cluster will come ON for a few seconds and then go out Replace any bulbs that DO NOT come ON during this test These lights will warn the operator if an abnormal condition should arise during operation and will also inform the operator when the road lights are on high beam or the turn signals are activated OH1810 Position of corresponding lights Alternator Charging Light 3 Park Brake Light 4 Engine Pressure Light 5 Engine Coolant Temperature Light 6 Hydraulic Tank Temperature Light 7 Transmission Temperature Light 8 High Beam Light 9 Not Used 10 Turn Signal Light 11 Model 6036 35 Operation Function Indicator Lights A Park Brake Light The park brake light 1 P illuminates any time the OH2480 park brake is applied and the ignition switch is in the RUN position
32. measurement 4 from the top rear edge of the interme diate boom 5 to the top rear edge of the inner boom 6 This mea surement should be in the range of 8 00 203 mm to 8 5 216 mm NOTE If the measurement is less than 8 0 203 mm the boom may require extensive adjustment and or repair Contact your local JLG Distribu tor REAR OF BOOM 1 Q9x6 9r6 9rG6 9x6 ox6 o6 oc 9 6 96 9 6 9 6 9 6 9 6 96 9 6 9 6 9X6 9 6 916 9 6 O0 un 62 Model 6036 149 General Maintenance 7 If the measurement is more than 8 5 216 mm tighten the retract chain locknut 1 located on the bottom of the outer boom 2 OA0512 8 Start the vehicle and cycle the boom in and out several times Then with the boom horizontal retract the boom completely Turn the vehicle OFF 9 Recheck the measurement at the rear of the boom between the top rear edge of the intermediate boom and the top rear edge of the inner boom If the measurement is still more than 8 5 216 mm repeat steps 7 and 8 NOTE If by adjusting the retract locknut you cannot get the measurement within the range of 8 0 203 mm to 8 5 216 mm the boom may require extensive adjustment and or repair Contact your local JLG Distributor If the measurement is within the range of 8 0 203 mm to 8 5 216 mm measure the top boom extend chain sa
33. needed to secure the disabled vehicle 5 Attach a remote portable hydraulic pressurizing unit to the parking brake gauge port 3 on the secondary function manifold 4 mounted on the inside wall of the frame 5 on the left side next to the transmission OA1230 6 Turn the key switch to the ON position with the engine not run ning release the park brake park brake switch OFF and have an operator seated in the seat CAUTI ON DO NOT exceed 575 psi 40 bar when pressur izing the park brake Applying too much pressure may damage the brake seals 7 Pressurize the park brake with the pressurizing unit Close the pump needle valve on the pressurizing unit Model 6036 85 Emergency Operations 8 Clear the area of all unnecessary personnel 9 Carefully remove the wheel blocks from each of the four tires Tow the vehicle to a secure location IMPORTANT Without engine power service braking power is reduced Only the rear service brakes will function when the brake pedal is depressed Steering is not possible and the vehicle will only travel in the direction that the wheels were last turned Tow or push the vehicle at a very slow speed 86 Model 6036 Emergency Operations Emergency Boom Lowering This section discusses emergency boom lowering procedures Part In case of loss of engine power or hydraulic pump failure Part Il In case of hydraulic line failure Part Loss of
34. neutral lock lever to NEUTRAL LOCK position engage the parking brake switch and shut off the engine 3 Clean the area around the wheel end fill drain plug 5 Slowly loosen the plug Hold a receptacle under the wheel end and remove the plug from the wheel end 4 Allow the oil to drain completely into the receptacle Transfer the oil to a container with a cover and label the container as used oil Dis pose of properly 5 Reposition the vehicle so the wheel end fill drain plug is positioned horizontally 6 Fill the wheel end with Universal Tractor Fluid to the level of the drain plug See chart of approved fluids on page 138 Wheel end capacity is approximately 0 95 quarts 0 9 liters 7 Clean and re install the wheel end fill drain plug 5 Model 6036 139 General Maintenance 12 Wheels and Tires A Tire Air Pressure Check 10 Hour Intervals 10 X ed OH2660 OS0900 DANGER LOW TIRE PRESSURE can result in tipover MAINTAIN proper tire pressure at all times Check all four tires 1 Remove the valve stem cap 2 Check tire pressure using a good quality gauge You cannot tell if a tire is properly inflated simply by looking at it 3 Add air if required Fill the tire s to Standard Tire 13 00 24 12 Ply 55 psi 379 kPa Optional Rock Tire 15 5 25 12 Ply 55 psi 379 kPa 4 DO NOT overinflate 5 Replace the valve stem cap 140 Model 6036 General Mainten
35. new Boom Retract Line 1 Boom Extend Line 2 Boom Lift Line 3 Boom Lower Line 4 Check the hydraulic oil level add oil if needed Remove the blocking or support from the outer boom Return to the cab fasten your seat belt and start the engine Tilt the carriage and or attachment upward if necessary for clear ance before retracting the boom Slowly retract the boom Slowly lower the boom and ground the carriage and or attachment 90 Model 6036 Emergency Operations 13 Shut off the engine 14 Completely remove the load from the carriage and or attachment if you haven t already done so 15 Return to the cab fasten your seat belt and start the engine 16 Cycle the lift lower and extend retract cylinders several times to bleed air from the system Check for leaks 17 Recheck the hydraulic oil level Add oil if necessary OA1240 Model 6036 91 Emergency Operations STEP 2 USE IN CASE OF BOOM LIFT LINE FAILURE Lift Cylinders to Control Valve BOOM EXTEND LINE FAILURE 1 Clear the area of any unnecessary personnel 2 Place the travel select lever in NEUTRAL move the neutral lock lever to NEUTRAL LOCK position and engage the parking brake switch Block all four wheels WARN NG Wear protective clothing and proper eye protection when working with or around hydraulic oil Wait for hydraulic oil to cool before attempting to repair the
36. platform the following precautions must be taken WARN NG Use only a compliant work platform to lift or lower personnel Never drive the vehicle with the work platform in a raised position or with personnel on board even for a short dis tance Defining Platforms For Elevating Personnel The requirements for platforms shall include the following 1 The platform floor must have a slip resistant surface not more than 8 200 mm above the normal load supporting surface of the forks 2 The platform floor dimensions shall not exceed a Two times the load center distance as listed on the load chart that is attached to the vehicle This floor dimension is measured parallel to the longitudinal center plane of the vehicle Model 6036 77 Operation b Width of the platform shall not be wider than the width of the vehicle measured across the load bearing tires plus 10 250 mm on each side c Minimum space requirements for each person on the platform shall not be less than 18 450 mm in either direction 3 The platform shall have a 4 100 mm minimum high toe plate around the perimeter of the platform The toe plate may be omitted at the access opening 4 Protection must be provided for the personnel on the work platform from any pinch points or moving parts while in their normal working position on the platform 5 Information prominently indicated on the work platform shall include a Maximum wo
37. rings 1 Level the vehicle ground the carriage place the travel select lever in NEUTRAL move neutral lock lever to NEUTRAL LOCK posi tion engage the parking brake switch and shut off the engine 2 Clean the area around the axle drain plug 3 the axle fill plug 1 and the axle level plugs 2 3 Place a receptacle under the axle drain plug Remove the plug from the axle housing and allow the oil to drain completely 4 Transfer the oil to a container with a cover and label the container as used oil Dispose of properly 5 Clean off the axle drain plug and re install Remove the axle fill plug and the axle level plugs from the axle housing Check brake disc wear at this time Refer to Brake Disc Inspection on page 134 6 Fill the axle with Universal Tractor Fluid through the axle fill hole until the oil level is even with both axle level holes 2 See chart of approved fluids on page 132 The axle capacity is 12 2 quarts 11 5 liters Fill axle slowly the oil has to run across the differential Allow time for the oil to run across the differential Axle level is cor rect when oil is up to both level plugs 7 Reassemble the level plugs 2 using new o rings 8 Re install the axle fill plug 1 into axle housing Model 6036 133 General Maintenance 10 Brake Disc Inspection A Brake Disc Wear Check 1000 Hour Intervals 1000X C OH2690 Check the brake discs for wear every 1 000 hours of operation or ye
38. third party attachment that would alter the center of gravity or stability IMPORTANT DO NOT use unapproved attachments Following is a list of some of the attachments available through JLG for this vehicle model 48 Standard Carriage 60 Standard Carriage 72 Standard Carriage 1 1 4 Cubic Yard Bucket The standard capacity chart on page 71 is applicable for the above listed attachments The attachments listed below are supplied with their own individual capacity chart 48 60 amp 72 Side Tilt Carriage page 72 52 amp 72 Swing Carriage page 73 12 Foot Truss Boom page 74 3 Foot Truss Boom w winch page 75 Hydraulically actuated attachments also have a maximum hydraulic pressure rating Ensure that the maximum rated hydraulic pressure of the attachment is equal to or slightly greater than 3 000 psi 206 8 bar which is the maximum pressure of the vehicle s auxiliary hydraulics at the quick disconnect couplers 82 Model 6036 Operation Shut Off 1 Bring the vehicle to a complete stop using the service brakes 2 Park the vehicle on level ground WARN NG To prevent death or serious personal injury be certain to lower the boom engage the parking brake switch and shut off the engine prior to exiting the vehicle 3 Place the travel select lever in NEUTRAL move the neutral lock lever to NEUTRAL LOCK position and engage the parking brake switch 4 Lower the
39. 1 717 485 6591 E mail ProductSafety 9 JL G com Other Publications Available Service Mahal oce nietos tout 8990416 Illustrated Parts 8990417 3126021 Table of Contents Revision Log 4 Engine Oil And Filter 115 Introduction 5 Engine Fuel System 119 6 Engine Fan Belt 124 ee 7 Hydraulic Oil and Filter 125 Reports 2 8 iac 9 Axle Oil niim Safety Practices 10 Brake Disc Inspection 134 Disclaimer inen nennen 3 11 Wheel End 138 Hazard Classification System x 12 Wheels and Tires 140 Accident Prevention Tags pcs 13 142 New or Additional Operators 5 14 Fuse and Relay Replacement instructional Symbols cueste OA 144 Hazard Symbols 7 15 Boom Chains Wear Pads Avoidance ee rt a 148 AVoidange Symbols Storage and Transport 163 Personal consideratione 10 163 Operational Considerations asy 1a Transportni 164 Equipment Considerations 20 Test Procedures Operation Parking Brake Transmission De Operator Controls 23 ChitchTest Procedures cc 165 Instruments and Indicators 34 Four Wheel Steer Indexing Proce O
40. 10A P d OA1470 4 m Lubricate Boom Chains Paragraph Ref 198 104 Model 6036 General Maintenance 2000 Hour Intervals z 4 OH2070 20002 EA Change Engine Coolant Paragraph Ref SB Model 6036 105 General Maintenance 1 Lubrication Points Lubricate the following grease fittings using 50 Multi Purpose Grease MPG Pu 092880 every 50 hours il nee A Carriage pivot 2 points B Attachment tilt cylinder pins 2 points C Boom all points D Extend Chain 1 point E Retract Chain Sheave 1 point Lubricate the following grease fittings using 250 Multi Purpose Grease MPG P a OH2710 every 250 hours MC 051750 F Hydraulic cylinder 10 points G Drive shaft slip joints 3 points Boom pivot pin 2 points l Axle U Joints peint nori in i ada 8 points J Axle 4 points Lubricate the following grease fittings using 10002 Multi Purpose Grease MPG a omz every 1000 hours id PRIM Extend cylinder pins
41. 3 772 4 700 Fax 34 93 771 1762 JLG Industries UK Ltd Bentley House Bentley Avenue Middleton Greater Manchester M24 2GP England Phone 44 0 161 654 1000 Fax 44 0 161 654 1001 JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong Phone 852 2639 5783 Fax 852 2639 5797 JLG Polska UI Krolewska 00 060 Warsawa Poland Phone 48 0 914 320 245 Fax 48 0 914 358 200 JLG Sverige AB Enkopingsvagen 150 Box 704 SE 176 27 Jarfalla Sweden Phone 46 0 850 659 500 Fax 46 0 850 659 534
42. After inspection and before being returned to service chains must be lubricated with a quality chain lubricant LUBRIPLATE Chain amp Cable Fluid LPS3 or equivalent OH2690 OA1510 The lubricant must penetrate the chain joint to prevent wear Applying lubricant to the external surfaces will prevent rust but the chains should be articulated to make sure the lubricant penetrates to the working surfaces between the pins and links To prepare the chain for lubrication the chain plates should be brushed with a stiff brush or wire brush to clear the space between the plates so that lubricant can penetrate to the working surfaces Lubricant may be applied with a narrow paint brush or directly poured on but the chain should be well flooded with lubricant and the boom should be extended and retracted to be sure that the lubricant penetrates to the working surfaces All surplus lubricant should be wiped away from the external surfaces DO NOT use a solvent for this wiping operation Regular application of lubricant is necessary to make sure that all working surfaces are adequately lubricated In extremely dusty conditions it may be necessary to lubricate the chains more often Lubrication of chains on vehicles working consistently in extreme hot or cold conditions requires special consideration It is important that a reputable lubrication specialist a JLG Distributor or the vehicle distributor be consulted for guidance
43. Engine Power or Hydraulic Pump Failure IMPORTANT In the event of total loss of engine power or hydraulic pump failure with an elevated load the situation must be properly evaluated and dealt with on an individual basis Contact your local JLG Distributor or the JLG Service Department at 877 554 5438 or 717 485 5161 for specific instructions for your particular situation In any event the vehicle should be secured until the situation has been properly evaluated Secure the vehicle by following the procedures below 1 2 Clear the area around the vehicle of all personnel Place the travel select lever in NEUTRAL move the neutral lock lever to NEUTRAL LOCK position and engage the parking brake switch 3 Block all four wheels 4 Section off a large area under the boom with string or tape to restrict any personnel from entering this potentially dangerous area WARN NG DO NOT get under a raised boom unless the boom is blocked up Always block the boom before doing any ser vicing that requires the boom to be up Temporarily block up or support the outer boom so it cannot be low ered If the load is in a position where it can be removed safely com pletely remove the load from the carriage and or attachment other wise leave the load in place Place an accident prevention tag on both the ignition switch and steering wheel Refer to Accident Prevention Tags on page 5 Actua
44. Fuel Strainer 121 Fork Ratings 76 Inner Safety Element 109 Fork Sweep 65 Instructional Symbols 6 Four Wheel Steer Indexing 63 Instrument Cluster Light Test 35 Four Wheel Steer Indexing Instruments and Indicators 34 Procedure 167 J Four Wheel Steering 63 Jump Starting coco cette 56 Frame Level Indicator 39 L Frame Sway Control Lever 31 Leveling Frame 65 Front Wheel Steering 64 Lossof Engine Power 87 Front Rear amp Boom Worklights 42 Lowering Boom Hazard 13 Fuel zunicnsciscuinincixuritene 57 Lubrication Points 106 F el Cap sev aS 58 M Fuel Filter 55 120 Maintenance Schedule 101 Fuel Gauge 34 Maximum Ground Pressure Fuel Tank 5 168 w full load 169 Fuel Water Separator Filter 119 Maximum Rated Capacity 169 Function Indicator Lights 36 Moving Parts Hazard 13 c 144 N Fuse Ratings 171 Neutral Lock Lever sss 27 G New or Additional Operators 5 Gear Select Lever
45. Maximum play should be 006 inch 0 15 mm To install the fan belt 1 first position the belt over the fan pulley 3 crankshaft pulley 4 alternator pulley 5 and onto the ten sioner pulley 2 To hold the tensioner pulley toward the center of the engine insert a 3 8 breaker bar into the square hole 7 in the tensioner arm 7 Close and lock the left Then while holding the tensioner 2 toward the center of the engine slide the belt over the water pump pulley 6 Release the tensioner pulley to apply tension on the belt engine access door 124 Model 6036 General Maintenance 7 Hydraulic Oil and Filter A Hydraulic System Oil zl OH2630 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 Specifications MIL L 2104C See table below ISO Grade 46 MIL L 2104C Hydraulic Oil 10W Motor Oil Gulf Harmony 46 AW Castrol Deusol CRD Amoco Rykon 46 Esso Essolube D 3HP Mobil DTE 25 Esso Essolube XD 3 Arco Duro AW S 215 Castrol Agricastrol HDD Shell Tullus 46 Shell Rimula CT Benz Petraulic 46 7C Shell Rimula X Sun Sunvis 821 WR Shell Rimula TX Chevron AW 46 5W20 Motor may be Texaco Rando HD 46 substituted for 30 F to 70 F Citgo Pacemaker XD 46 only Model 6036 125 General Maintenance B Hydraulic Oil Level Check 10 Hour Intervals 10 X T
46. OT charge a frozen battery it may explode and cause serious injury Let the battery thaw out before putting on a battery charger Under normal conditions the engine alternator will have no problem keeping the battery or batteries charged The only condition in which the battery may cause a problem is when it has been completely discharged for an extended period of time Under this condition the alternator may not be able to recharge the battery A battery charger will be required for recharging Before using a battery charger an attempt can be made to recharge the battery using the engine alternator by first starting the vehicle and letting the engine run See Jump Starting instructions on page 56 Model 6036 143 General Maintenance 14 Fuse and Relay Replacement The fuses and relays in this vehicle protect the electrical system The fuses most often fail if there is a short or grounded wire in the applicable circuit The fuses will have to be replaced if they fail If fuses continually fail check the system for shorts grounds or defective electrical components The fuses and relays are mounted inside the right side console in the operators cab To gain access remove the screws 1 that secure the access panel 2 in place Refer to the following page for the locations of fuses and relays within the fuse block OH2430 General Maintenance wh qn qp
47. Oil aces 132 Axle Oil Change 133 Axle Oil Level 132 AXIS 2 2 ciara tein Bae 169 B Battery 12 142 Battery Charging 143 Battery Electrolyte First Aid 12 143 Beacon Light Switch 43 Before Storing 163 Bleeding Fuel System 122 Boom Angle Indicator 40 68 Boom Chain Inspection 154 Boom Chain Sag 148 Boom Chain Tension 148 Boom Chain Tension Adjustment 152 Boom Chains 148 Boom Control Lever 30 Boom Extend Letters 68 Brake Disc Inspection 134 C Cab Heater 50 Capacities 168 Capacity Limitations 79 Chain Lubrication 160 Change Elements 110 Change Fuel Filter 120 Index Changing Direction 60 Changing Travel Direction 60 Chemical Hazards 10 Clearances 14 Clothing and Safety Gear 10 Cold Start Grid Heater Fuses Optional 146 Cold Start
48. SKYTHAK Operator amp Safety Manual Keep this manual with machine at all times Model 6036 Tier Il S N 0160004110 thru 0160037778 3126021 Revised February 24 2009 An Oshkosh Corporation Company WARNING Improper operation of this vehicle can cause injury or death Only trained and authorized operators should operate this vehicle Before starting the engine do the following 1 Read this owner operators 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 worksite It is your responsibility to observe applicable laws and regulations and to follow manufacturer s instructions on vehicle operation and maintenance CALIFORNIA Proposition 65 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 CALIFORNIA Proposition 65 Warning Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling Revision Log REVISION LOG February 2004 A Revised Manual February 11 2005 B Replaced all branding with JLG February 24 2009 C Revised covers and page d Added Transfer of O
49. UTRAL LOCK position and engage the parking brake switch Block all four wheels A WARN NG DO NOT get under a raised boom unless the boom is blocked up Always block the boom before doing any servicing that requires the boom to be up If the load is in a position where it can be removed safely completely remove the load from the carriage and or attachment otherwise leave the load in place Place a 10 gallon 40 liter container under the vehicle to catch any hydraulic oil that will escape during this procedure Model 6036 97 Emergency Operations WARN NG Wear protective clothing and proper eye protection when working with or around hydraulic oil Wait for hydraulic oil to cool before attempting to repair the failure Hot hydraulic oil can cause severe burns and other serious injury NOTE If a replacement hose is not available the adjacent boom extend line 2 can be used to replace the failed boom retract line 1 6 7 Remove the failed boom retract line 1 from the circuit Remove and temporarily reposition the adjacent boom extend line 2 in place of the failed boom retract line 1 IMPORTANT During the remaining steps hydraulic oil will drain out of the base end of the boom cylinder The escaping oil should be deflected by some means the failed hose could be used directing the oil into the drain container 8 9 10 11 13 14 15 16
50. Universal Tractor Fluid see chart on page 129 168 Model 6036 Specifications Axles Differential Housing 12 2 quarts 11 5 liters Type of Fluid Universal Tractor Fluid see chart on page 132 Wheel Ends Wheel End Capacity 0 95 quarts 0 9 liters Type of Fluid Universal Tractor Fluid see chart on page 138 Tires Air Pressure Standard Tire13 00 24 12 ply minimum 55 psi 379 kPa Optional Rock Tire 15 5 25 12 55 psi 379 kPa Tire Ballast Minimum per Tire Optional Foam Filled Tire 13 00 24 12 ply 775 lb 351 Kg Wheel Lug Nut Torque 430 470 Ib ft 583 637 Nm Tire Footprint Area w full load Standard Tires 13 00 24 12 150 sq in 968 cm Optional Rock Tire 15 5 25 12 ply 212 sq in 1 368 cm Maximum Ground Pressure w full load Standard Tires 13 00 24 12 87 psi 600 kPa Weights Basic Vehicle Model 6036 Curb Weight with Open Cab 20 095 Ibs 9 115 Kg Model 6036 Curb Weight with Enclosed Cab 20 295 Ibs 9 206 Kg Maximum Rated Capacity Model 6036 P 6 000 Ibs 2 721 Kg Model 6036 169 Specif
51. WINGING LOADS can cause MACHINE TIPOVER which can result in death or serious injury travel slowly rig properly use two tethers ASME B56 6 2002 PART III 4110375 OA1770 Model 6036 75 Operation Fork Ratings All approved forks for this vehicle are marked with a maximum load capacity rating This rating 1 is stamped on the left edge of the fork 2 just below the fork pivot shaft 3 The rating is listed in U S pounds and based upon a 24 610 mm load center This rating specifies the maximum load capacity that the individual fork can safely carry at a maximum load center 4 of 24 610 mm Since forks are always used in multiples the total rating of any combination of forks will be the sum of their rated capacity Other than block forks all forks should be used in matched pairs Block forks should be used in matched sets OA1061 WARN NG DO NOT exceed the total rated capacity of the specific pair of forks being used Forks can break causing loss of load and possible death or serious personal injury to the operator or personnel in the area If the total rated capacity of the forks exceeds the capacity of the vehicle the vehicle capacity should not be exceeded The maximum load capacity for this vehicle is 6 000 pounds 2 721 Kg The matched pair or set of forks used on this vehicle should have total load ratings which equal or exceed 6 000 pounds 2 721 Kg When the lo
52. a time wait two minutes between engagements A WARNING KEEP CLEAR of spraying fuel Fuel can spray when venting high pressure lines The fuel pressure is sufficient to penetrate the skin and cause serious bodily injury Wear protec tive clothing and safety glasses 1 To vent the high pressure fuel lines 6 loosen one fitting at the injector 7 2 Turn the ignition key to the START position and crank the engine for a maximum of 15 seconds or until fuel free of air comes out of the injector fitting 8 3 Tighten the fitting Torque to 22 Ib ft 30 Nm 4 Repeat steps 1 through 3 for each fitting until the engine runs smoothly 5 With the engine running visually check for leaks Turn ignition switch OFF OA1690 Model 6036 123 General Maintenance 6 Engine Fan Belt A Engine Fan Belt Check 1000 Hour Intervals 100 X P o onm NOTE 0 fC Ground th rri OH2690 0508802 Ground the carriage place the travel select lever in N NEUTRAL move the neutral lock lever to NEUTRAL LOCK position engage the parking brake switch and shut off the engine Unlock and open the left engine access door Inspect the fan belt 1 Replace if cracked or frayed This engine is equipped with an automatic belt tensioner 2 Inspect the tensioner bearing Spin the bearing and check for rough spots under hand pressure Spin the fan and check for wobble or excessive play
53. ac LM Rar gn MS ry ee D ad M C RE D Poe FONS 05 NOT OPERATE OPERATE com mud lU uenis EU cu cote eee mE c e menm Rb Se e E e Due See dee EO EE ERE mE Ee deme EE E e dE Accident Prevention Tags 0 400 jd 10N ION 72 AL TRANSFER OF OWNERSHIP An Oshkosh Corporation Company To Product Owner If you now own but ARE NOT the original purchaser of the product covered by this manual we would like to know who you are For the purpose of receiving safety related bulletins it is very important to keep JLG Industries Inc updated with the current ownership of all JLG products JLG maintains owner information for each JLG product and uses this information in cases where owner notification is necessary Please use this form to provide JLG with updated information with regard to the current ownership of JLG products Please return completed form to the JLG Product Safety amp Reliability Department via facsimile or mail to address as specified below Thank You Product Safety amp Reliability Department JLG Industries Inc 13224 Fountainhead Plaza Hagerstown MD 21742 USA Telephone 1 717 485 6591 Fax 1 301 745 3713 NOTE Leased or rented units should not be included on this form Mfg Model Serial Number Previous Owner Address Country Telephone Date of Transfer Current Owner Addr
54. ad rating of the vehicle differs from the load capacity of the forks the lower value becomes the overall load capacity 76 6036 Operation How To Pick Carry amp Place A Load To pick a load tilt the carriage forward so the 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 the forks slide into the openings in the pallet Raise the boom so that the load is lifted To carry a load position the boom so that the load is as low as possible and the travel area is visible to the operator Use the capacity chart to determine safe boom extension range for the applicable load To place a load align the forks at the level the load is to be placed and then extend the boom slowly until the load is just above the area where it is to be placed Lower the boom until the pallet rests in position and the forks are free to retract Retract the forks slowly from under the load Elevating Personnel This vehicle is designed to lift and transport materials and should not be used to elevate personnel except as explained in this section Only equipment designed and approved for elevating personnel should be used If the vehicle must be used to elevate personnel use only a compliant work platform Refer to Defining Platforms For Elevating Personnel on page 77 for requirements When using a work
55. aged or missing parts Make any necessary repairs before operat ing the vehicle 9 Check ALL lighting systems if so equipped for proper operation 11 12 Adjust rear view mirrors as required to obtain proper field of vision to the rear Test the back up alarm and horn for proper operation Check condition of cab glass if so equipped looking for cracks or other damage 52 Model 6036 Operation Normal Starting 1 Enter the cab using the hand holds and adjust the seat for comfort able operation 2 Adjust the mirrors to obtain the best rear view from the operator s position WARN NG DO NOT start the engine unless you are in the seat with the seat belt fastened around you Death or serious per sonal injury could result if the belt is not securely fastened 3 Fasten the seat belt 4 Make sure the parking brake switch is ENGAGED 5 Place the travel select lever in NEUTRAL and move the neutral lock lever to NEUTRAL LOCK position 6 Turn the ignition switch to the START position fully clockwise to crank the engine Release the key when the engine starts If the engine fails to start on the first try wait until the engine and starter come to a complete stop before cranking the engine again IMPORTANT DO NOT crank the starting motor continuously for more than 30 seconds Stop cranking the starter and allow the starter to cool for 2 minutes before engaging the starter again 7
56. ake holding performance If the parking brake or transmission de clutch does not pass these tests do the following 1 Immediately remove the vehicle from service WARN NG BLOCK ALL FOUR WHEELS Failure to do so could result in death or serious personal injury from vehicle roll away 2 Block all four wheels to prevent the vehicle from moving 3 Place the accident prevention tags 1 on the ignition switch 2 and the steering wheel 3 4 Service the parking brake immediately or contact your local Sky Trak Distributor to repair the system OH1720 Test Procedures Four Wheel Steer Indexing Procedure If the vehicle does not drive straight the steering could be out of phase Perform the following Four Wheel Steer Indexing Procedure to synchronize the front and rear steering 1 With the steering select switch 4 in the Four Wheel Steer position 5 turn the steering wheel full left 2 While holding the steering wheel full left toggle the steer select switch to the Front Wheel Steer position 6 and steer the front wheels back to center 3 Toggle the steer select switch back to Four Wheel Steer position 5 and turn the steering wheel full left 4 Toggle the steer select switch back to Front Wheel Steer position 6 and steer the front wheels full left 5 Toggle the switch to the Four Wheel Steer position 5 and return to center The vehicle should now be properly indexed
57. ance B Wheel Lug Nut Torque Check First 50 Hours OH2670 A 1550 1 Wire brush the area around the lug nuts if necessary There are separate lockwashers 1 under the lug nuts 2 Be sure the lock washers are installed under each lug nut 2 Using the torque sequence A thru H from the chart below alter nately check the torque of each of the eight lug nuts The recom mended torque should be 430 470 Ib ft 583 637 Nm 000140 C Replacing Tires WARN NG Mis matched tire sizes and PLY ratings may compromise vehicle stability and may result in vehicle tipover IMPORTANT The standard tire size and ply rating for this vehicle is 13 00 24 12 ply Make sure any replacement tire including optional tires are of the same size and ply or star rating DO NOT use lower PLY or star rated tires on this vehicle Model 6036 141 General Maintenance 13 Battery WARN NG Lead acid batteries produce flammable and potentially explosive gases To avoid personal injury when check ing testing or charging batteries DO NOT use smoking materials near batteries Keep arcs sparks and open flames away from batteries Provide ventilation and wear safety glasses The battery in this vehicle is a maintenance free type battery It is shipped in the vehicle filled with electrolyte and charged A warning indicator light will illuminate on the display panel
58. ar riage securely fastened to prevent any tilting or side to side swing ing motion 5 Ensure the vehicle has a firm footing and is level Model 6036 79 Operation 6 10 11 12 13 14 15 Be sure the vehicle is in a level position side to side before any operation is begun Use the frame sway to level the vehicle If the vehicle cannot be leveled reposition the vehicle Place the travel select lever in the NEUTRAL position and move the neutral lock lever to the NEUTRAL LOCK position Engage the parking brake switch Blocking the wheels is also rec ommended Level the platform in both the side to side and front to back direc tions before use Before lifting or lowering personnel be sure the vehicle lifting mechanism operates smoothly through the entire lifting and lower ing of the platform and maintains its self leveling function The vehi cle must operate smoothly both empty and loaded Be sure any lift limiting devices and latches are functioning prop erly Any body belt lanyard or deceleration devices which have sus tained any deformation or damage must be replaced before using the work platform again Before elevating personnel the area around and under the work platform should be marked to warn anyone on the ground that over head work is being done Protection must be provided for the personnel on the work platform from any pinch points or moving parts while in th
59. arallel with the front edge of the boom General Maintenance OHO0252 4 Start the vehicle and cycle the boom in and out several times With the boom horizontal fully extend the boom and then retract it 2 51 mm one inch per section Turn the vehicle OFF 5 Measure the chain sag Acceptable boom chain sag is between 1 5 88 mm and 2 5 64 mm If the chain sag is less than 1 5 38 mm repeat steps 1 through 5 until the sag is within the acceptable range NOTE If the top boom extend chain sag cannot be adjusted within the acceptable range of 1 5 38 mm to 2 5 64 mm the boom may require extensive adjustment and or repair Contact your local JLG Distributor 6 Replace the rear outer boom cover Model 6036 153 General Maintenance C Boom Chain Inspection 250 Hour Intervals 250 2710 owe 1490 WARN NG Worn pins stretched or cracked links or corro sive environments can cause chain failure A chain failure could result in uncontrolled boom movement loss of load or vehicle instability and could cause death or serious injury and or property damage Under normal operating conditions the boom chains will need to be inspected every 250 hours of operation The retract
60. arly MT2830 If the brake discs require service due to wear the axle should be checked serviced and repaired only by experienced service technicians who are aware of all safety instructions and particular component features A Front Axle WARNING BLOCK ALL FOUR WHEELS Failure to do so could result in death or serious injury from vehicle roll away 1 Block all four wheels to help prevent the vehicle from moving after the parking brake is disabled 2 Remove the six hex nuts lockwashers and flat washers 1 secur ing the transmission covers 2 to the frame Remove the covers OH2372 General Maintenance 3 Attach a remote portable hydraulic pressurizing unit to the parking brake gauge port 3 on the secondary function manifold 4 mounted on the inside wall of the frame 5 on the left side next to the transmission OA1230 4 Turn the key switch to the ON position with the engine not run ning release the parking brake park brake switch OFF and have the operator seated in the seat CAUTI ON DO NOT exceed 575 psi 40 bar when pressur izing the park brake Applying too much pressure may damage the brake seals Model 6036 135 General Maintenance 5 Pressurize the parking brake with the pressurizing unit Close the needle valve on the pressurizing unit 6 Working through the level plug hole 1 carefully use a screwdriver to spread the brake
61. as contaminated the system 1 Level the vehicle ground the carriage place travel select lever in N NEUTRAL move the neutral lock lever to NEUTRAL LOCK position engage the parking brake switch 2 Fully retract all cylinders and shut OFF the engine 3 Remove the four capscrews 6 holding the hydraulic oil tank cover 7 to the tank 8 remove the cover OH1920 Model 6036 127 General Maintenance 4 Clean area around filter head 1 Loosen but do not remove the nuts that secure the filter head to the hydraulic tank 2 5 Rotate and remove the filter head 1 6 Remove the seal 3 and the element 4 from the filter head 1 Dispose of properly N Clean the filter head sealing surfaces Place a receptacle under the hydraulic reservoir magnetic drain plug The receptacle must be large enough to hold 38 gallons 144 liters of oil Remove magnetic drain plug and allow oil to drain into receptacle Clean loose particles attached to the drain plug Trans fer the oil to a container with a cover and label the container as used oil Dispose of properly Re install magnetic drain plug into the reservoir o Re install the top seal 3 and push a new filter element 4 all the way onto the filter head 1 until it seats Slide the assembly into the reservoir and secure 1 Remove reservoir cap 5 and fill the reservoir with ISO 46 or MIL L 2104C Oil see tabl
62. cab using the hand holds and adjust the seat for comfort able operation 2 Adjust the mirrors to obtain the best rear view from the operator s position A WARN NG DO NOT start the engine unless you are in the seat with the seat belt fastened around you Death or serious per sonal injury could result if the belt is not securely fastened 3 Fasten the seat belt 4 Make sure the parking brake switch is ENGAGED 5 Place the travel select lever in N NEUTRAL and move the neutral lock lever to NEUTRAL LOCK position 54 Model 6036 Operation 6 Turn the ignition switch to the START position to crank the starter IMPORTANT DO NOT crank the starting motor continuously for more than 30 seconds Stop cranking the starter and allow the starter to cool for 2 minutes before engaging the starter again 7 As the engine starts release the ignition switch to the RUN posi tion Depress the accelerator pedal enough to provide a smooth idle speed 8 The engine oil pressure warning indicator light should go OFF within five seconds after starting If the light remains ON turn the ignition switch OFF immediately and check the oil level or change to a lighter weight oil Consult the engine manufacturer s manual for alternative oils for cold weather operation Model 6036 55 Operation Jump Starting Jump starting at the battery or battery replacement is required when the battery is discharged to the point wh
63. cement MO 162 Steering Select Switch 25 usse decuit 148 Steering Wheel 23 Weights uscita demissis 169 Stopping Travel 61 Wheel End Oil 138 Storage ieu ned 163 Wheel End Oil Change 139 Swing Carriage 41 Wheel End Oil Level 138 Swing Carriage Capacity Chart 73 Wheel Ends 169 T Wheel Lug Nut Torque 141 169 Tip Over Hazard 17 Wheels 140 Tire Air Pressure 140 Windshield amp Skylight Washer Tire Pressure 18 Control cese 49 Tres RR 140 169 Windshield Wiper Control 47 To Defrost The 50 Worklight Switch 42 To Heat The Cab 50 Towing A Disabled Vehicle 84 Transmission 168 Transmission De Clutch Test 165 Transmission Oil and Filter 129 Transmission Oil Filter 130 Transmission Oil Level 129 Transmission Temperature Warning Indicator Light 37 Model 6036 175 Index This Page Intentionally Left Blank 176 Model 6036 Accident Prevention Tags uice c uL LEO M E C
64. chains need to be exposed and inspected every 1000 hours of operation Refer to the Service Manual for the proper procedure Environmental conditions and dynamic impulse shock loads can drastically affect normal operating conditions and require more frequent inspection intervals Environments in which material handling vehicles operate can vary widely from outdoor moisture to temperature to mildly corrosive or highly corrosive industrial atmospheres in addition to abrasive exposures such as sand and grit Some effects can be as follows Moisture Corrosive rusting reduces chain strength by pitting and cracking Temperature Low temperature reduces chain strength by embrittlement Going in and out of cold storage results in moisture from condensation Chemical Solutions or Vapors Corrosive attack on the chain components and or the mechanical connections between the chain components Cracking can be and often is microscopic Going from microscopic cracking to complete failure can be either abrupt or may require an extended period of time Abrasives Accelerated wearing and scoring of the articulating members of the chain pins and plates with a corresponding reduction in chain strength Due to the inaccessibility of the bearing surfaces pin surfaces and plate apertures wear and scoring are not readily noticeable to the naked eye General Maintenance Following are some examples of dynamic shock loading which can impo
65. discs apart IMPORTANT DO NOT damage the surfaces of the brake discs when spreading the brake discs MT2850 7 Using a feeler gauge check the gap 1 between the brake discs 2 If the gap is greater than 167 4 25 mm replace the brake discs NOTE If the brake discs are worn beyond 167 4 25 mm the brake disc must be replaced on both sides of the axle at the same time 8 Repeat steps 6 and 7 for the other side of the axle 9 Continue with step 6 of B Axle Oil Change on page 133 General Maintenance MT2840 B Rear Axle 1 Working through the level plug hole 1 carefully use a screwdriver to spread the brake discs apart IMPORTANT DO NOT damage the surfaces of the brake disks when spreading the brake disks 2 Using a feeler gauge check the gap 2 between the brake discs 3 If the gap is greater than 167 4 25 mm replace the brake discs NOTE If the brake discs are worn beyond 167 4 25 mm the brake disc must be replaced on both sides of the axle at the same time 3 Repeat steps 1 and 2 for the other side of the axle 4 Continue with step 6 of B Axle Oil Change on page 133 Model 6036 137 General Maintenance 11 Wheel End Oil WARN NG DO NOT perform service or maintenance on this vehicle with the engine running Contact with moving part
66. ds must never be worn past the angled cut indicator because the metal pad insert 5 that holds the pads in place will begin to wear into the boom pad sliding surfaces If the pad wears past this point the metal insert in the pad will begin to gouge the boom plate surfaces Contact your local JLG Distributor Replacement of boom wear pads must be performed by a JLG Distributor when the wear pads indicate IMPORTANT The boom has been factory lubricated for proper wear pad break in and will normally not require further lubrication However after replacing any wear pad s or after prolonged periods of inoperation light lubrication with LPS3 or LUBRIPLATE chain or cable fluid or equivalent of the boom wear surfaces is recommended to keep the wear pads and boom wear surfaces lubricated properly Light lubricating of the boom wear surfaces is also recommended in salt air climates after cleaning with pressure washer using solvents or when the vehicle is to be put in storage to prevent rusting General Maintenance Storage and Transport Storage A Before Storing Perform the following steps prior to placing the vehicle in storage 1 Clean the entire vehicle 2 Lubricate all grease fittings as described in Lubrication Points on page 106 3 Prepare the engine for storage refer to the engine manual 4 Apply rust inhibiting lubricant to all ex
67. e Neutral Lock Lever 3 to the D DRIVE 5 position L N NEUTRAL LOCK all the way LEFT OT0570 7 m D peers all the way RIGHT OT0580 Model 6036 27 Operation Travel Select Lever The Travel Select Lever 1 has three positions to select direction of travel TERT F FORWARD all the way FORWARD N NEUTRAL w CENTER position SRL R all the way REARWARD OS0340 OH1792 To change travel selections move the lever FORWARD or REARWARD to the desired selection When the Travel Select Lever is shifted to REVERSE the back up alarm will automatically sound NOTE The Travel Select Lever must be in the NEUTRAL position to permit engine starting 28 Model 6036 Operation Gear Select Lever The Gear Select Lever 2 has a twist grip handle with four positions Vehicles have four forward gears and three reverse gears OH1803 Use first gear for highest torque and pulling power Use higher gears for higher ground speed The recommendations listed in the table that follows are guidelines only Always use good judgement when traveling with a load Recommended Gear Speed for Vario
68. e attachment pivot pins have disconnected from the attachment 66 Model 6036 Operation Attachment Reconnect Be sure you are performing this procedure on level ground 1 Position the vehicle directly behind the attachment to be mounted 2 Tilt the quick attach backward 3 Extend the boom approximately 10 feet 3 meters and drive the vehicle forward until the attachment pivot pins are below and between the two hooks on the attachment 4 Raise the boom until the attachment pivot pins have seated fully in the hooks of the attachment 5 Tilt the attachment up slightly The quick attach link should be tight against the rear of the attachment and the holes in the link and the attachment should be aligned 6 Place the travel select lever in NEUTRAL move the neutral lock lever to NEUTRAL LOCK position engage the parking brake switch and exit the vehicle using the hand holds 7 Lift the quick attach lever Insert the quick attach pin completely through the attachment and the quick attach link Be sure that the quick attach lock lever has lowered and seated itself into the groove in the quick attach pin WARN NG DO NOT operate this vehicle unless you are in the seat with the seat belt fastened around you Death or serious personal injury could result if the belt is not securely fastened 8 Return to the cab fasten the seat belt and resume operation Model 6036 67 Operation Using The Capacit
69. e on page 125 until the oil level is filled to the minimum oil level as described on page 126 Reservoir capacity is 32 2 gals 122 liter 12 Reassemble the hydraulic oil tank cover and tighten the hardware securely 1 Co Run vehicle and operate all hydraulic functions Cycle all modes of controls to purge air from the system 14 Check for leaks OH2350 General Maintenance 8 Transmission Oil and Filter APPROVED UNIVERSAL TRACTOR FLUIDS JOHN DEERE JDM J20C HY GARD FORD NEW HOLLAND ESN M2C134 D HYDRAULIC OIL134 MASSEY FERGUSON M 1141 PERMATRAN III CHEVRON CHEVRON 1000 THF A Transmission Oil Level Check 10 Hour Intervals 10 X b OH2660 OS0890 1 Level the vehicle ground the carriage place travel select lever in N NEUTRAL move neutral lock lever to NEUTRAL LOCK position and engage the parking brake switch 2 Check oil level with engine running at idle and oil at normal operating temperature 3 Remove transmission dipstick 6 through access hole 7 in trans mission covers 8 and check reading 4 Add Universal Tractor Fluid to transmission as required to bring up to full mark OH2362 Model 6036 129 General Maintenance B Transmission Oil amp Filter Change First 50 Hours Filter Only EN 50 x OH2670 FL 02 1000 Hour Intervals Cil amp Filter 10003 On o 5 Oso9502 Change the transmission oil fi
70. e upper switch bank on the right side dash panel These lights will only operate when the ignition switch is in the RUN position Push the top of the switch in to turn all the A worklights OFF To turn the front and boom worklight ON position the rocker switch to the center E OH2601 position Push the bottom of the switch in to turn all the worklights ON OH1852 42 Model 6036 Operation Beacon Light Switch 1 iai OH2580 This rocker switch 2 turns the beacon light ON and OFF The switch 1 is located in the upper switch bank on the right side dash panel This light will only operate when the ignition switch is in the RUN position e Push the bottom of the switch in to turn the beacon light ON Gn Push the top of the switch in to turn the Y beacon light OFF OH2591 OH1852 Model 6036 43 Operation Worklight Switch with Optional Road lights p ghts 22 OH2620 This rocker switch 1 activates the worklight system The switch 1 is located in the upper switch bank on the right side dash panel This system will only operate when the ignition switch is in the RUN position See Parking Lights Headlights amp High Low Bea
71. e your hand to check for leaks Use a piece of cardboard or paper to search for leaks Wear gloves to protect hands from spraying fluid Hydraulic fluid can cause permanent eye injury Wear appropriate eye protection and stop engine Relieve pressure before disconnecting lines by moving all joysticks back and forth through all functions If anyone is injured by or if any hydraulic fluid is injected into the skin obtain medical attention immediately or gangrene may result Model 6036 11 Safety Practices E Battery The following WARNING is intended to supplement and does not replace the warnings and information provided on the battery by the battery manufacturer When jump starting the vehicle carefully follow instructions found under Jump Starting on page 56 A WARNING SS EXPLOSIVE GASES can Keep sparks flames and lighted cause serious injury materials away from batteries 50621 Keep sparks flames and lit smoking materials away from the 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 Battery Electrolyte First Aid e External Contact Flush with water Eyes Flush with water for at least 15 minutes and get medical attention immediately Internal C
72. eir normal working position on the platform Provide any overhead protection device as required by worksite conditions or if requested by the user of the platform 80 Model 6036 Operation Elevating Personnel WARN NG Never operate the Attachment Tilt function to tilt the platform forward or rearward when elevating with personnel aboard Death or serious personal injury could result NOTE chains DANGER Never operate this or any equipment in an area in which 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 pre cautions Make sure there are no overhead obstructions or electrical wires above the platform before lifting A trained operator must operate the controls from the operators compartment and must remain with the vehicle at all times Using extreme caution lift and lower personnel smoothly and only at their request The operator should move the platform up and down only in response to instruction from personnel on the platform If the operator must move the platform the operator must alert the per sonnel aboard the platform before moving Personnel aboard the work platform must maintain a firm footing at all times Be certain the personnel and related equipment on the platform do not exceed the available space of the platform The platf
73. element out Always discard this element and replace with a new element 5 Slide the new primary element over the inner safety element mak ing sure the sealing edge is flush with the base of the air cleaner IMPORTANT DO NOT apply any type of petroleum product to the sealing surface of the filter in an attempt to get a more positive seal This will cause sealing surface damage and allow dirt to by pass the filter Use liquid dishwashing soap Ivory Dawn etc on the seal of the filter only 6 Position canister cover 8 in place turn clockwise to lock into posi tion and secure in place by pushing the air cleaner cover lock 9 all the way in General Maintenance OA1300 C Air Intake System Inspection 1000 Hour Intervals 10002 OH2690 OT0880 Inspect the intake piping for cracked hoses loose clamps or punctures which can allow dirt or debris to enter the combustion chamber If dirt or debris are allowed to enter the combustion chamber they can severely damage the engine If necessary tighten or replace parts to prevent air intake system leakage Model 6036 111 General Maintenance 3 Engine Cooling System A Engine Coolant Level Check 10 Hour Intervals 10 gt OH2660 050800 1 Level the vehicle ground the carriage place the travel select lever in NEUTRAL move neutral lock lever to NEUTRAL LOCK position engage the parking brake switch and shut off the engine
74. ent Tilt and Frame Sway Control Lever The attachment tilt and frame sway control 2 is a joystick with four perpendicular motions from the center to control two attachment tilt functions and two frame sway functions dps i Frame Sway Left move lever to the left ih Frame Sway Right move lever to the right D Attachment Tilt Down move lever forward 1 Attachment Tilt Up move lever backward OH0410 The attachment is self leveling and will retain any set angle throughout boom raising lowering retracting or extending operations OH2900 Model 6036 31 Operation Seat Belt WARN NG Serious bodily injury or death may result from failure to wear the seat belt installed on this vehicle The seat belt is a critical component of the Operators Protective Structure and is provided for the operator s protection in case of vehicle upset The seat belt MUST be worn whenever this vehicle is operated IMPORTANT Inspect the seat belt every time it is used looking for cut or worn webbing or any defect in the latch assembly If any wear or damage is noted DO NOT operate the vehicle until the seat belt is replaced Before the engine is started adjust the seat as required for position and comfort Then adjust the seat belt as follows 1 Grasp both free ends of the belt and make certain that the belt web bing is not twisted or entangled in any porti
75. ere the battery will not crank the starter WARN NG NEVER jump start the vehicle directly to the starter solenoid Death or serious personal injury could result from the vehicle lurching forward or backward and running over the per son attempting to jump start the vehicle directly to the starter WARN NG To avoid death or serious personal injury when jump starting with another vehicle be certain that the two vehicles are not touching Never jump start a frozen battery as it will explode Keep sparks flames and lighted smoking materials away from the battery Lead acid batteries generate explosive gases when charging Wear safety glasses when working near batteries 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 1 Connect the positive jumper cable to the positive post of the discharged battery 2 Connect the other end of the positive jumper cable to the posi tive post of the booster battery 3 Connect one end of the negative jumper cable to the negative post of the booster battery 4 Make the final cable connection to the furthest point from the bat tery 5 Follow the steps in Normal Starting on page 53 6 Remove the jumper cables in the reverse order of their connection i e negative cable ground connection first etc 56 Model 6036 Ope
76. es If any one crack is discovered the chain should be replaced in its entirety It is important however to determine the cause of the crack before installing a new chain so the condition does not repeat itself The types of cracks are Fatigue Cracking Fatigue cracks 5 are a result of 5 repeated cyclic loading beyond PR the chain s endurance limit Stress Corrosion Cracking 6 The outside link plates are particularly susceptible to stress corrosion cracking 6 Corrosion Fatigue Cracking Corrosion fatigue cracks are very similar to fatigue cracks in appearance Corrosion fatigue is the combined action of an aggressive environment and cyclic stress Other Modes of Failure Ultimate Strength Failure 7 These types of failures are _ caused by overloads far in 8 MM2090 ND excess of the design load Either fractured plates 7 or enlarged holes 8 can occur If C3 J either of these failures occurs MM2100 the chain should be replaced immediately Tight Joints All joints in the chain should flex freely Tight joints 9 resist flexi SS exing If the problem is caused by Ma dirt or foreign substance MM2110 packed in the joints clean and lubricate thoroughly before re installing the chain If the problem is caused by corrosion and rust or bent pins replace the chain 9 Model 6036 159 General Maintenance D Chain Lubrication 1000 Hour Intervals 10005
77. ess Country Telephone Who in your organization should we notify Name Title SKYTHAK An Oshkosh Corporation Company JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 USA Phone t 1 717 485 5161 Customer Support Toll Free 1 877 554 5438 Fax t 1 717 485 6417 JLG Worldwide Locations JLG Industries Australia P O Box 5119 11 Bolwarra Road Port Macquarie N S W 2444 Australia Phone 61 265 811 111 Fax 61 265 810 122 JLG France SAS 2 1 de Baulieu 47400 Fauillet France Phone 33 0 5 53 88 31 70 Fax 33 0 5 53 88 31 79 JLG Industries Italia s r l Via Po 22 20010 Pregnana Milanese MI Italy Phone 39 029 359 5210 Fax 39 029 359 5845 JLG Industries Scotland Wright Business Centre 1 Lonmay Road Queenslie Glasgow G33 4EL Scotland Phone 44 0 141 781 6700 Fax 44 0 141 773 1907 JLG Latino Americana Ltda Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil Phone 55 193 295 0407 Fax 455 193 295 1025 JLG Deutschland GmbH Max Planck Str 21 D 27721 Ritterhude Ihlpohl Germany Phone 49 0 421 69 350 20 Fax 49 0 421 69 350 45 JLG Europe B V Polaris Avenue 63 2132 JH Hoofddorp The Netherlands Phone 31 0 23 565 5665 Fax 31 0 23 557 2493 Plataformas Elevadoras JLG Iberica S L Trapadella 2 P I Castellbisbal Sur 08755Castellbisbal Barcelona Spain Phone 34 9
78. etract chain The maximum measurement allowed is 12 36 313 mm If the measurement is more than 12 36 313 mm the chain should be replaced MM2120 Model 6036 157 General Maintenance Turning or Protruding Pins Highly loaded chain operating with inadequate lubrication can generate abnormal frictional forces between pin and link plates When chain is allowed to operate in this condition a pin or series of pins can begin to twist out of a chain resulting in failure Examine the pin head rivets to determine if the VEE flats are still in correct alignment 1 Chain with rotated displaced heads 2 or abnormal pin protrusion 3 should be replaced immediately DO NOT attempt to repair the chain by welding or driving the pin s back into the chain Once the press fit integrity between outside plates and pins has been altered it cannot be restored Any wear pattern on the pin heads or the sides of the link plates indicates misalignment in the system This condition damages the chain as well as increases frictional loading and should be corrected MM2060 Distorted or Battered Link Plates Distorted or battered link plates 4 on a leaf chain can cause tight joints and prevent flexing MA9340 General Maintenance Cracked Plates Inspect the chains very carefully front and back as well as side to side for any evidence of cracked plat
79. g again 10 Start the vehicle and cycle the boom in and out several times With the boom horizontal fully extend the boom and then retract it 2 51 mm one inch per section Turn the vehicle OFF General Maintenance 11 Measure the sag 3 in the top boom extend chains 4 between the bottom of the chains and the top of the intermediate boom 5 at their closest point Acceptable boom chain sag is between 1 5 38 mm and 2 5 64 mm If the measurement is less than 1 5 38 mm or more than 2 5 64 mm the top boom chains need to be adjusted See Top Boom Chain Tension Adjustment on page 152 OA0491 Model 6036 151 General Maintenance B Top Boom Chain Tension Adjustment As required NOTE Always perform the Boom Chain Tension Check starting on page 148 before adjusting the boom chain tension 1 Park the vehicle on level ground Place the travel select lever in N NEUTRAL move neutral lock lever to NEUTRAL LOCK position engage the parking brake switch and raise the boom to a horizontal position Retract the boom completely and turn the vehicle OFF 2 Adjust the top extend boom chains 1 by tightening the locknuts 4 located at the rear of the boom Be sure each locknut is tightened equally so that each chain maintains the same tension OHO0240 3 Equal chain tension can be checked by the position of the yoke 2 on the outer boom 3 The front of the yoke should be p
80. he pedal is spring loaded to return to idle speed Service Brake Pedal Pressing down the brake pedal 9 decreases the speed of the vehicle by applying the service brakes located in the axles In the event of engine power loss the service brake pedal can also be used for braking Steering Wheel Turning the steering wheel 10 to the left or right steers the vehicle in the corresponding direction Any one of the steering modes are selectable Refer to Steering Select Switch on page 25 Horn Button Pressing the horn button 11 in the center of the steering wheel sounds the horn OH1760 Model 6036 23 Operation Ignition Switch Using the ignition switch key 1 the switch may be turned clockwise from the OFF 2 position to the RUN 3 and START 4 positions The START position is spring loaded to return to the RUN position and must be manually held in place for starting OFF 2 position The entire electrical system is shut down RUN 3 position All controls and indicators are operable START 4 position Engages starter motor to crank the engine when the parking brake switch is engaged and the transmission is in NEUTRAL OTO0680 24 Model 6036 Operation Steering Select Switch This vehicle has one steering select switch 5 with three positions The switch is located in the lower switch bank on right side dash panel Refer to Steering Modes on page 62 for detailed information
81. his rocker switch 1 turns the skylight wiper ON and OFF This switch is located in the lower switch bank on the right side dash panel Push the bottom of the switch IN to turn the skylight wiper ON H Push the top of the switch IN to turn the skylight wiper OFF OH1852 48 Model 6036 Operation Windshield amp Skylight end Washer Control 051940 OH1910 This rocker switch 2 is spring loaded to return to the OFF position when released This switch is located in the lower switch bank on on the right side dash panel Pressing down on the bottom of the switch A will dispense washer fluid to the windshield H daei and skylight wiper at the same time The switch must be held in place to activate the 5 washer control Release the switch to deactivate the washer Glos control Model 6036 49 Operation Cab Heater amp Fan Control 051950 The cab heater controls 1 are located directly below the switch banks on the right side dash panel The control panel consists of a variable speed fan control knob 2 and a temperature control knob 3 Control of air flow to the windshield is made by opening closing or redirecting the air vent louver on the front dash The cab is heated by the heater unit positioned under the operators seat
82. ications Vehicle Dimensions With Standard 13 00 24 Tires A Length less 217 inches 5 512 mm B Lp 98 inches 2 489 mm C Height aer teri itt e tede 100 inches 2 540 mm D Wheelbase 113 inches 2 870 mm E Ground Clearance 16 inches 406 mm F Tread Center 84 inches 2 134 mm Turn 13 feet 4 0 meters Max Forward Reach 22 feet 4 inches 6 8 meters J Maximum Lift Height 36 feet 1 inch 11 meters OA1620 Specifications Electrical System Rating ttt ep eran 12V DC Negative Ground Number of Batteries Without Optional Cold Start Aid One With Optional Cold Start Aid Two Type of Batteries Maintenance Free 850 Cold Cranking Amps Each Battery Series of Series 27 Fuse Ratings Ma ter 40 Light Switch Relay sse 7 5 Amp Instrument Cluster 10 Amp HOPG ater iei ctn reete etae eh era eee desee d Nes 15 Amp Steer Select Switch
83. in Four Wheel Steering If the wheels are still out of phase repeat the above procedure OHS200 Model 6036 167 Specifications Fluid amp Lubrication Capacities Engine Crankcase Oil Capacity with Filter Change 10 5 quarts 10 liters Filter Capacity sess 0 85 quart 0 8 liters Nope 15W40 Fuel Tank 2 1 37 gallons 140 liters Usable Capacity 35 6 gallons 135 liters Type of Fuel Below 32 F 099 ics tU eet Winterized 2 Diesel Above 32 F 0 C Standard 2 Diesel Cooling System Cooling System Capacity w o heater 4 gallons 15 liters Overflow Bottle Capacity 3 0 quarts 2 8 liters Type of Coolant 50 50 ethylene glycol and water Hydraulic System System Capacity 57 5 gallons 217 6 liters Reservoir Capacity to Full 32 2 gallons 122 liters Type of Oil SO Grade 46 Hydraulic Oil or MIL L 2104C 10W Motor Oil See Chart On page 125 Transmission Capacity with filter change 12 5 quarts 11 8 liters Type of Fluid
84. ing 54 Cooling System 168 Crab Steering 64 D Dismounting 10 Door Latches 51 Door Window Latch 51 Drain And Flush Radiator 113 E Electrical System 171 Electrocution Hazards 15 Elevating Personnel Emergency Boom Lowering 87 Emergency Exit 17 Emergency Flashers 45 Engine nere 172 Engine Coolant Level Check 112 Engine Coolant Temperature Warning Indicator Light 37 Engine Cooling System 112 Engine Crankcase Oil 168 Engine Fan Belt 124 Engine Fan Belt Check 124 Engine Fuel 10 Engine Fuel System 119 Engine Oil And Filter 115 Engine Pressure Warning Indicator Light 38 Engine Oil Recommendations 115 Exhaust FUMES 10 Explosive Fuel 10 F Falling Load Hazard 13 19 Fan Control 50 Filter Change 117 Model 6036 173 Index Filter Check 108 In line
85. ising the boom above horizontal with or without a load If the vehicle cannot be leveled using frame sway control reposition the vehicle 8 Emergency Exit Rear Window The rear window 1 in the enclosed cab can be used as an emergency exit by removing the latch pin 2 located on the window latch 3 The window is then free to swing open OH1730 Model 6036 17 Safety Practices 9 Tire Pressure DANGER MAINTAIN proper tire De pressure at all times 050085 MAINTAIN proper tire pressures at all times underpressurized tire s adversely affects vehicle stability If proper tire pressures are not maintained this vehicle can tip over To ensure proper vehicle stability check all four tire pressures before operating the vehicle 10 Do Not Jump A DANGER AVOID CRUSHING if vehicle tips Jumping can result in death or serious injury DO NOT JUMP Brace yourself Stay in cab Keep seat belt on OH3190 If a vehicle ever becomes unstable and starts to tip over BRACE YOURSELF and STAY WITH THE VEHICLE KEEP YOUR SEAT BELT FASTENED HOLD ON FIRMLY and LEAN AWAY FROM THE POINT OF IMPACT Indecision and trying to escape from a tipping vehicle can result in death or serious personal injury 18 Model 6036 Safety Practices 11 Slopes DO NOT park the vehicle on an incline and leave it unattended Driving across a slope is dangerous a
86. ission Oil Level Check on page 129 10 Reassemble the transmission covers and secure in place with the six hex nuts washers and lockwashers Tighten securely Model 6036 131 General Maintenance 9 Axle Oil A Axle Oil Level Check 250 Hour Intervals 2505 OH2710 OT0460 APPROVED UNIVERSAL TRACTOR FLUIDS JOHN DEERE JDM J20C HY GARD FORD NEW HOLLAND ESN M2C134 D HYDRAULIC OIL134 MASSEY FERGUSON M 1141 PERMATRAN III CHEVRON CHEVRON 1000 THF 1 Level the vehicle ground the carriage place the travel select lever in NEUTRAL move neutral lock lever to NEUTRAL LOCK posi tion engage the parking brake switch and shut off the engine 2 Clean the area around the axle fill plug 1 and the axle level plugs 2 on the opposite side of the axle and remove the plugs from the axle housing 3 Add Universal Tractor Fluid to bring the oil level up and even with the plug holes See chart of approved fluids above 4 Re install the axle fill plug 1 and axle level plugs 2 FRONT AXLE SHOWN REAR General Maintenance B Axle Oil Change First 50 Hours EA 10005 y 1000 Hour Intervals He OH2670 OH2690 OT0440 NOTE At the 1000 Hour Interval Oil Change also inspect the brake disc wear Refer to Brake Disc Inspection on page 134 and follow the inspec tion procedure After brake disc inspection is complete reassemble the level plugs using new o
87. l accident prevention tags can be found as the last page of this manual If you do not have a safety tag tape over the ignition switch Model 6036 87 Emergency Operations Part Il Hydraulic Line Failure In case of hydraulic line failure there are step by step procedures available to assist you in safely retracting and then lowering the boom Read Part II from start to finish before performing any of these procedures so you fully understand the process and the danger involved If you are unsure about any part of these procedures contact your local JLG Distributor or the JLG Service Department Every attempt should be made to repair the hydraulic line failure and to retract and then lower the boom in its normal fashion We realize this is not always possible Step by step procedures are also available when the boom must be retracted and lowered immediately and replacement parts are not available Only resort to Steps 3 amp 4 when absolutely necessary IMPORTANT Be aware that the boom must first be retracted and then lowered to avoid vehicle tipover In any case of hydraulic line failure it is critical to correctly identify which hydraulic line has failed Identify the hydraulic line that has failed Boom Retract line 1 Boom Extend line 2 Boom Lift line 3 and Boom Lower line 4 Use the table on page 89 to determine which Step to follow to retract and lower the boom OA1240 88 Model 6036 Emergency Operations
88. lso reserves the right to discontinue manufacturing any product at its discretion at any time NOTICE Under OSHA rules it is the responsibility of the employer to provide operator training Successful completion and certification of Safety Training for Rough Terrain Forklifts is required Operator Training Kits are available by calling Ken Cook Company at 414 466 6060 An order form for these kits is available through our website http www jlg com The information in this manual does not replace any safety rules and laws used in your area Before operating this vehicle 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 worksite depend significantly upon your knowlege and understanding of all correct operating practices and procedures for this vehicle A WARN NG DO NOT modify or alter weld drill etc any part of this vehicle without consulting JLG Modifications can weaken the structure creating a hazard that can cause death or serious personal injury Hazard Classification System OP0330 This safety alert symbol is used with the following signal words to attract your attention to messages found within the manual and on hazard decals located on the vehicle They are reproduced herein and pertain to proper operation and procedure messages contained throughout the manual The message that follo
89. lter after the first 50 hours of operation and change the transmission oil and filter every 1000 hours of operation thereafter 1 Level the vehicle ground the carriage place travel select lever in N NEUTRAL move neutral lock lever to NEUTRAL LOCK posi tion engage the parking brake switch and shut OFF the engine 2 Remove the six hex nuts lockwashers and flat washers 1 secur ing the transmission covers 2 to the frame Remove the covers OH2372 General Maintenance 3 Allow the transmission to cool 4 Place a receptacle under the transmission drain plug 3 Remove the drain plug and allow the Universal Tractor Fluid to drain into the receptacle Transfer the used oil into a suitable container with a cover and label the container as used oil Dispose of properly 5 Clean and re install the drain plug 3 into the transmission housing 6 Remove the filter 4 from the filter mount on the front side of the transmission 5 Dispose of the filter properly Clean the mating surface where the filter mounts 7 Apply a thin film of clean Universal Tractor Fluid to the new filter gasket Carefully install a new filter OH2380 8 Remove the dipstick 6 and fill with Universal Tractor Fluid approx imately 2 6 gallons 9 8 liters Re install the dipstick 9 Check the transmission level and add Universal Tractor Fluid as required following the procedures outlined in Transm
90. m Switch on page 46 for operation of the road lights Push the top of the switch IN to A DEACTIVATE the entire worklight system i e To ACTIVATE the boom worklight position the rocker switch to the center OH2601 position Push the bottom of the switch IN to ACTIVATE the boom worklight and d Bue rear worklights OH1862 44 Model 6036 Operation Emergency Flashers A A 0S1920 The emergency flashers switch 2 is located in the upper switch bank on the right side dash panel e To ACTIVATE the emergency flashers push ge the bottom of the switch IN 11 To DEACTIVATE the emergency flashers l an push the top of the switch IN OH2591 OH1862 Model 6036 45 Operation Turn Signals The directional signals are ACTIVATED from the lever 1 on the right side of the steering wheel To activate the left turn signal 2 raise the lever To activate the right turn signal 3 lower the lever To deactivate either directional signal the lever must be manually returned to the center position The lever will not cancel automatically after a turn These lights will only operate when the ignition switch is in the RUN position Parking Lights Headlight
91. ng check for leaks 11 Allow engine to cool to ambient temperature Check radiator cool ant level and top off completely Replace radiator cap 12 Overflow bottle should be 1 4 to 1 2 full If it is not add coolant to overflow bottle Close and lock all access doors 114 Model 6036 General Maintenance 4 Engine Oil And Filter Engine Oil Recommendations The use of quality engine oil combined with the appropriate oil and filter change intervals are critical factors in maintaining engine performance and durability Use 15W40 motor oil that at least meets the manufacturers minimum recommended oil specifications as defined in their operator manual A Oil Level Check 10 Hour Intervals 10 X b OH2660 1 Level the vehicle ground the carriage place the travel select lever in N NEUTRAL move neutral lock lever to NEUTRAL LOCK position engage the parking brake switch and shut off the engine 2 Unlock and open right rear engine access door 3 Remove dipstick 1 and check mark on dipstick Oil should be within the crosshatched area 2 9 m SI OA1710 Model 6036 115 General Maintenance 4 If oil is low remove oil fill cap 1 and add 15W40 motor oil that at least meets the manufacturers minimum recommended oil specifications as defined in their operator manual to bring oil up to the FULL mark 2 in the crosshatched area Add oil through the opening under the
92. nnel 2 Place the travel select lever in NEUTRAL move the neutral lock lever to NEUTRAL LOCK position and engage the parking brake switch 3 Block all four wheels WARN NG DO NOT get under a raised boom unless the boom is blocked up Always block the boom before doing any servicing that requires the boom to be up 4 Temporarily block up or support the outer boom 5 If the load is in a position where it can be removed safely completely remove the load from the carriage and or attachment otherwise leave the load in place 6 Place a 10 gallon 40 liter container under the vehicle to catch any hydraulic oil that will escape during this procedure WARN NG Wear protective clothing and proper eye protection when working with or around hydraulic oil Wait for hydraulic oil to cool before attempting to repair the failure Hot hydraulic oil can cause severe burns and other serious injury NOTE If a replacement hose is not available the adjacent boom lift line 2 can be used to replace the failed boom lower line 1 7 Remove the individual failed boom lower line 1 from the circuit 8 Remove and temporarily reposition the adjacent boom lift line 2 in place of the failed boom lower line 1 IMPORTANT Once either boom lift line is removed and the boom is retracted during the remaining steps hydraulic oil will drain out of the base end of the boom cylinder The escaping oil sho
93. o the in line fuel strainer and tighten the hose clamps Remove air from the fuel system see Bleeding Fuel System on page 122 Close and lock the right rear engine access door OA1700 Model 6036 121 General Maintenance D Bleeding Fuel System Air must be vented from the fuel system whenever any component between the fuel tank and the injection pump has been disconnected or when the system has been emptied or run out of fuel WARN NG DO NOT bleed the fuel system of a hot engine Doing so could create a fire hazard Allow the engine to cool before bleeding the fuel system IMPORTANT DO NOT attempt to start the engine until the injection pump has been filled and primed with fuel Serious damage to the lift pump will result due to lack of proper lubrication 1 To vent the low pressure lines and fuel filter 1 open the vent screw 2 located on the filter head 3 2 Operate the hand plunger 4 on the lift pump 5 until fuel flowing from the fitting is free of air 3 Tighten the vent screw 2 and torque to 7 Ib ft 9 Nm OA1700 General Maintenance The process to vent the high pressure fuel lines 6 involves energizing the starter motor to rotate the crankshaft which will in turn pump any unwanted air from the fuel lines CAUTI ON When using the starting motor to vent the fuel system DO NOT energize the starter solenoid or crank the engine for more than 15 seconds at
94. on of the seat assembly 2 With your back straight in the seat couple both ends of the belt 3 With the belt buckle as low on your body as possible pull the free end of the belt to shorten it until it is tight across the lap OL0430 4 To release the belt latch depress the red button 1 on a 2 inch seat belt 2 or lift the black cover 3 of the buckle on a 3 inch seat belt 4 dependant on belt style installed and pull the free end from the buckle An optional 3 inch wide seat belt is available for those locations that require a 3 inch seat belt 32 Model 6036 Operation Operator s Seat Adjustment The operator s seat 5 can be adjusted three ways A Fore and Aft Adjustment Pull the handle 6 outward to adjust the seat forward and backward Release the handle to lock the seat in the desired position B Suspension Adjustment Turn the knob 7 on the front of the seat to adjust the suspension to correspond with the operator s weight Turn clockwise to increase stiffness Turn counter clockwise to reduce the stiffness C Backrest Angle Adjustment The angle of the seat backrest can be adjusted to suit the operator Move the lever 8 located on the left side of the seat backrest to adjust the angle OH1820 Model 6036 33 Operation Instruments and Indicators Hourmeter xX 050260 The hourmeter 1 records engine operating hours and has total readout of 9 999 99 hours It
95. ontact Drink large quantities of water Follow with Milk of Magnesia beaten egg or vegetable oil Get medical attention immediately IMPORTANT In case of internal contact DO NOT give fluids that would induce vomiting 12 Model 6036 Safety Practices 5 Moving Parts Hazard DO NOT place limbs near moving parts Severing of any body part can result Turn OFF engine and wait until fan and belts stop moving before servicing 4A WARNING MOVING PARTS can cut 7 Keep clear of fan and belts while engine is running MOVING PARTS can entangle OTO0810 7 6 Lowering Boom or Falling Load Hazard DO NOT get under a raised boom unless it is blocked up safely Always empty the attachment of any load and block the boom up before doing any servicing that would require the boom to be raised NEVER allow anyone to walk or stand under the boom A lowering boom or falling load can result in death or serious personal injury Model 6036 13 Safety Practices Operational Considerations 1 Preparation and Prevention Know the location and function of all vehicle controls Make sure all persons are away from the vehicle and that the travel select lever is in the N NEUTRAL position and the Neutral Lock Lever is in the N NEUTRAL LOCK position with the parking brake switch engaged before starting the engine Holes obstructions debris and other worksite hazards can cause death or serio
96. orm shall be lowered to the ground level for personnel to enter or exit the platform through the appropriate platform access opening Personnel must not climb on any part of the vehicle or over the platform guardrails in an attempt to enter or exit the plat form Always position the platform in the travel position approximately one foot above ground level before moving the vehicle Make sure that required restraining equipment such as railings cable body belts with lanyards etc are in place and properly used Never use railings planks ladders etc on the platform for the purpose of achieving additional reach or height Model 6036 81 Operation Using Other Attachments Numerous attachments marketed by JLG are available for this vehicle The capacity charts attached to this vehicles dash to be used with JLG approved attachments only Hydraulically powered attachments must only be used on vehicles equipped with auxiliary hydraulics IMPORTANT This vehicle is intended for the function of lifting only This vehicle is not designed to PULL TOW or DRAG other objects JLG makes no representations or warranties expressed or implied as to the design manufacture or fitness for use with this vehicle of any third party source attachment This vehicle is not intended to be used and should not be used with an attachment that would alter the center of gravity or stability of this vehicle JLG assumes no liability for any
97. osition the vehicle until it is level before placing the load NOTE Maximum frame sway is 10 in either direction 050232 Model 6036 39 Operation Boom Angle Indicator The boom angle indicator is a plumb arrow 1 with angular graduations 2 from minus 10 to plus 80 It is located on the left side of the boom and is visible from the operator s position Use this indicator to determine the boom angle when reading the capacity chart see Using The Capacity Chart OHO0302 Rear View Mirrors Two rear view mirrors are provided to aid the operator s rear vision A rectangular flat lens mirror 3 is mounted on the upper left of the cab 4 A convex lens mirror 5 is mounted on the right side of the frame 6 Both mirrors are adjustable to obtain the best rear view by the operator OH1830 40 Model 6036 Operation Optional Controls Auxiliary Attachment Control Lever The auxiliary attachment control lever 7 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 Auger Swing Carriage and 3 Foot Truss Boom w Winch When the control lever is moved to the right it will provide hydraulic system pressure through the female disconnect 8 coupling for the auxiliary attachment Hydraulic fluid will return
98. posed hydraulic cylinder rods 5 Disconnect the battery cables Remove the battery or batteries from the vehicle and store in a dry place where they are not subject to temperatures near or below freezing 6 If the ambient temperature is expected to drop below freezing at anytime during the storage period make sure the engine coolant is either completely drained from the radiator and engine block or that the amount of anti freeze in the system is adequate to keep the coolant from freezing 7 Preferably store the vehicle inside where it will remain dry If it must be stored outside park it on lumber laid on flat level ground or on a concrete slab and cover with a tarp B Removing From Storage After removing the vehicle from storage and before operating it perform the following steps 1 Reinstall a properly charged battery or batteries Secure the hold down bracket and attach cables 2 Change the engine oil and filter to remove condensation or other residuals 3 If the vehicle has been stored for two years or more drain the cool ant from the engine block and radiator and refill with a 50 50 mix ture of fresh anti freeze and water For detailed information see Drain and Flush Radiator on page 113 4 Wipe off any rust inhibiting lubricant that was applied to vehicles hydraulic cylinder rods prior to storing 5 Refer to Maintenance Schedule And Checklist on page 101 Per form all the maintenance checks listed unde
99. ptional z o UT KE ORO 167 Pre Operation Inspection 52 aean Specifications Cold Stating amp Lubrication Capacities 168 Jump Starting 56 Woche 59 Vehicle Dimensions 170 Using The Capacity Chart 68 Electrical System 171 Fork Ratings aaneen 76 ENGINE einer 172 How To Pick Carry amp Place A Load Index 173 nmn 77 Accident Prevention Tags Elevating Personnel 77 Replacement Manuals 1 Using Other Attachments 82 Shut Off asas 83 Emergency Operations Towing A Disabled Vehicle 84 Emergency Boom Lowering 87 General Maintenance General Maintenance 100 Maintenance Schedule And Check 101 1 Lubrication Points 106 2 Air Cleaner amp Restriction Indi Calor 108 3 Engine Cooling System 112 2005 JLG Industries Inc 1 Introduction The Manual This Owners Operators Manual provides the information you need to properly 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
100. r the 10 Hour Intervals Model 6036 163 General Maintenance 6 Review and familiarize yourself and any other operator with all the safe and proper operating procedures contained in this manual Transport When transporting the vehicle make use of all four tiedown lift point locations 1 on the vehicles frame TIE DOWN LIFT POINT LOCATIONS OA1380 NOTE The user assumes all responsibility for choosing the proper method of transportation and the proper selection and use of transportation and tie down devices making sure the equipment used is capable of supporting the weight of the vehicle being transported and that all manufacturer s instructions and warnings regulations and safety rules of their employer the Department of Transportation and or any other state or federal laws are followed 164 Model 6036 Test Procedures Parking Brake Transmission De Clutch Test Procedures To check that the parking brake transmission de clutch system is functioning properly perform the following tests IMPORTANT These tests should be performed in 1 FIRST gear only WARN NG DO NOT operate this vehicle unless you are in the seat with the seat belt fastened around you Death or serious personal injury could result if the belt is not securely fastened Test 1 Transmission De Clutch Step 1 a Place the vehicle on a level surface b Clear the area in fron
101. raph Ref ap 8B 7C 12B OH2000 7 ota Li e ORO Change Axle Oil Change Wheel End Oil Check Boom Chain Tension Paragraph Ref 9B 11B 15A 50 Hour Intervals OH2010 502 T m P Lubricate Inspect Wear Pads Pivot Points Paragraph Ret 15E 1 General Maintenance 250 Hour Intervals OH2021 NT 250z gt Change Air Lubricate 4 Aa O Change Engine Oil and Filter Filter Pivot Points Paragraph Ref 2B 1 4B 1460 69 OO Check Wheel End Oil Level Check Axle Oil Level Inspect Extend Chains Paragraph Ref 11A 9A 15C 500 Hour Intervals OH3150 500 Change Fuel Filter Paragraph Ref 5B amp 5C Model 6036 103 General Maintenance 1000 Hour Intervals 10002 2040 EN d QOO YTA zz ORO ORO Check Boom Chain Tension Inspect Wear Pads Change Giang Paragraph Ref 15A 15E 8B _____OH2050 EE 4 M qu IE oso Change Axle Oil Change Wheel End Change oil And Paragraph Ref 9B 11B 7C 5 6 m OH2061 QD Le pf ton Check Fan Check Air Lubricate Belt Intake System Pivot Points IB AXIE Brake DISCS Paragraph Ref 6A 2C 1
102. ration Refueling Make sure the vehicle is level to assure an accurate fuel level reading The fuel tank is capable of holding 37 gallons 140 liters of diesel fuel The usable capacity of the fuel tank is 35 6 gallons 135 liters Fuel Types OHO0480 Use ASTM 2 diesel fuel with a minimum Cetane rating of 40 2 diesel fuel gives the best fuel economy and performance under most operating conditions Fuels with Cetane ratings higher than 40 may be needed in higher altitudes or extremely low ambient temperatures to prevent misfiring and excessive smoke When operating at temperatures above 32 F 0 C use standard 2 diesel fuel When operating at temperatures below 32 F 0 C use a blend of 1 amp 2 diesel fuels most commonly known as winterized 2 diesel WARN NG Engine fuel is flammable and can cause a fire or an explosion Keep sparks and open flames away from the vehicle and DO NOT use smoking materials while refueling Model 6036 57 Operation Fuel Cap Unlock the fuel cap 1 through the fuel cap access hole 2 in the cover on the hydraulic oil diesel fuel reservoir 3 Slowly remove the fuel cap from the fuel fill neck OH1920 Fill fuel tank Reassemble the fuel cap onto the fill neck and turn to lock in place Line up the locking tabs to reassemble a lock if desired 58 Model 6036 Operation Operating Starting Travel 1 Enter the operator cab fa
103. re and or an explosion Avoid danger by keeping sparks open flames and smoking materials away from the vehicle and from fuel during refueling or when servicing the fuel system Know where fire extinguishers are kept on the worksite and how to use them 10 Model 6036 Safety Practices Ether or High Energy Starting Aids Optional The engine utilizes a grid heating system inside the induction manifold for cold starting conditions WARN NG This diesel engine uses a grid heating system inside the induction manifold DO NOT use ether or any high energy fuels to assist starting An explosion may cause death or serious personal injury or engine damage DO NOT use ether or any other high energy starting aids during cold starting An A WARNING ENGINE EXPLOSION can DO NOT use Ether or other engine explosion can result result in death or serious high energy starting aids personal injury in death or serious personal injury PN Engine equipped with grid heating system 001470 Hydraulic Fluid DO NOT attempt to repair or tighten any hydraulic hoses or fittings while the engine is running or when the hydraulic system is under pressure Fluid in the hydraulic system is under enough pressure that it can penetrate the skin causing death or serious personal injuries HOT HYDRAULIC FLUID WILL CAUSE SEVERE BURNS Wait for fluid to cool down before disconnecting lines DO NOT us
104. re detailed account of how to perform these specific maintenance operations OA1250 WARN NG DO NOT perform service or maintenance on the vehicle with the engine running with the exception of the transmission level check Contact with moving parts can cause death or serious personal injury NOTE The engine side cover props can be manually pinned in the open position To manually pin the cover in the open position line up the holes in the slide halves of the prop and insert a 1 4 bolt or pin through the lined up holes To close the engine side covers push the cover all the way up to release the locks and then lower down to the closed position General Maintenance Maintenance Schedule And Checklist 10 Hour Intervals OH1980 B y y Y y 10x b bM ee Le Drain Fuel i i Check Check Water Hydraulic Oil Transmission poa Separator Level Oil Level Paragraph 5A 3A 4A 7B 8A 12A Ref 1190 v ae Air Filter Restriction Indicator Paragraph Ref 2 Model 6036 101 General Maintenance At First 50 Hours of Use OA1540 r Dd zm 50 Sie Change Engine Oil Change Change Hydraulic Check andFilter Transmission Filter Wheel Lug Filter Nut Torque Parag
105. rk load including personnel and equipment b Weight of the empty platform 6 Provide a means to securely mount and attach the platform so it can a Only be centered laterally on the vehicle and retained against the vertical face of the forks carriage or the lifting mechanism b Prevent the platform from inadvertent pivoting 7 The platform must have a restraining means such as a guardrail or a means of securing personnel such as a body belt or lanyard for each occupant of the platform 8 The guardrail or similar structure shall have a nominal height to the platform floor of 42 1066 mm around the perimeter of the plat form and include a midrail The guardrail openings may be used to provide alternate access openings provided the opening can be easily made by hinging or removing sections but must be easily put back into original position when alternate openings are no longer required 9 The guardrail shall be capable of withstanding a concentrated hori zontal force of 200 Ib 890 N applied at the point of least resistance without permanent deformation 78 Model 6036 Operation 10 A body belt and lanyard is to have an attaching point for freedom of movement and its length is to limit free fall to 5 feet 1500 mm measured from the point of attachment to the operator The com plete system shall be capable of withstanding three consecutive drop tests to simulate a 250 Ib 113 kg person falling 6 feet 1800 mm witho
106. rooving from the chain 3 Inspect the retract chains every 1000 hours of operation Refer to the Service Manual for proper procedure 4 Inspect the chains for the following conditions Edge Wear Check the chain for wear on the link plate edges caused by running back and forth over the sheave The maximum reduction of material should not exceed 5 This can be compared to a normal link plate height by measuring a portion of chain that does not run over the sheave The new chain link measures 713 18 mm 1 If the measurement of the worn chain is less than 677 17 mm 2 the chain should be replaced MM2051 General Maintenance Elongation When the original length 3 of 12 00 305 mm per foot of new chain has elongated from wear to a length 4 of 12 36 313 mm the chain should be discarded and replaced It is important to measure the chain in the section that moves over the sheaves because it receives the most frequent articulation Measuring the chain near its clevis terminals could give an inaccurate reading The ends of the chains near the clevis terminal will not have flexed as frequently if at all as nearer the middle of the chains Measure across a span of 17 pins at the center of the extend chain Measure from pin center to pin center Because the retract chain is inside the boom you will not be able to measure the chain Refer to the Service Manual for inspection procedure of the r
107. ructional 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 Any modification to this machine must be approved by JLG 3126021 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 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 e 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
108. s amp High Low Beam Switch With the ignition switch in the RUN position use the turn signal switch 1 to control the high low beam headlights turn ON the parking lights and the headlights Turn the twist grip end 4 of the turn signal switch counter clockwise to the first position 5 to turn the parking lights ON Turn the twist grip to the second position 6 to turn the headlights and parking lights ON Turn the twist grip clockwise to the OFF position 7 to turn all the lights OFF Pull the turn signal switch toward you to switch from low beam to high beam When the high beam is ON the high beam indicator light will illuminate OH1872 46 Model 6036 Operation Windshield Wiper Control UP 051930 This three position rocker switch 8 controls the speed of the windshield wiper This switch 8 is located in the lower switch bank on the right side dash panel the top of the switch IN OH2591 To STOP the windshield wiper push B e To OPERATE the windshield wiper at LOW speed position the switch in the CENTER POSITION gt OH2601 OH2611 HIGH speed push the bottom of the switch IN To OPERATE the windshield wiper at OH1852 Model 6036 47 Operation Skylight Wiper Control AC OH1900 T
109. s can cause death or serious personal injury APPROVED UNIVERSAL TRACTOR FLUIDS JOHN DEERE JDM J20C HY GARD FORD NEW HOLLAND ESN M2C134 D HYDRAULIC OIL134 MASSEY FERGUSON 1141 PERMATRAN III CHEVRON CHEVRON 1000 THF A Wheel End Oil Level Check 2505 250 Hour Intervals OH2710 1 Position the vehicle on level ground move the vehicle forward or backward enough to ensure that the lower edge of the wheel end 1 fill drain plug hole 2 is positioned horizontally 3 2 Ground the carriage place the travel select lever in NEUTRAL move neutral lock lever to NEUTRAL LOCK position engage the parking brake switch and shut off the engine 3 Clean the area around the wheel end fill drain plug 2 Slowly remove the plug Check the oil level 4 Add Universal Tractor Fluid to bring the oil level up and even with the plug hole 2 See the above chart for approved fluids OT0430 5 Clean and re install the wheel end fill drain plug 2 OA1330 138 Model 6036 General Maintenance B Wheel End Oil Change First 50 Hours 1000 Hour Intervals 3 1 000 v v OT0450 OH2670 OH2690 1 Position the vehicle on level ground move the vehicle forward or backward enough to ensure that the wheel end 4 fill drain plug 5 is in the 6 o clock position 6 OA1340 2 Ground the carriage place the travel select lever in NEUTRAL move
110. s unexpected changes in the slope can cause tipover Ascend or descend slopes slowly and with caution Ascend or descend slopes with the heavy end of the vehicle pointing up the slope NOTE The rear of the vehicle is normally considered the heavy end unless the carriage is fully loaded In this case the front of the vehicle is now the heavy end Unloaded vehicles should be operated on all slopes with the carriage pointing down the slope On all slopes the load must be tilted back and raised only as far as necessary to clear the ground When operating on a downhill slope reduce travel speed and downshift to a low gear to permit compression braking by the engine and aid the application of the service brakes 12 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 the capacity is exceeded forks may break See Fork Ratings on page 76 DO NOT downshift at a high ground speed Sudden slowing can cause the load to drop off the forks 13 Ventilation DO NOT operate this vehicle in an area with flammable dust or vapors unless good ventilation has removed the hazard Sparks from the electrical system and the engine exhaust can cause an explosion Carbon monoxide fumes from the engine exhaust can cause suffocation in an enclosed area Good ventilation is very important when operating this vehicle Model 6036 19
111. se abnormal loads above the endurance limit of a leaf chain High velocity movement of load followed by sudden abrupt stops Carrying loads in suspension over irregular surfaces such as railroad tracks potholes and rough terrain Attempting to inch loads which are beyond the rated capacity of the vehicle The above load cycles and environmental conditions make it impossible to predict chain life It is therefore necessary to conduct frequent inspections until replacement life can be predicted The boom chain s normal life expectancy can be expressed as a maximum percent of elongation This is generally 3 As the chain flexes back and forth over the sheave the bearing joints pins and inside link plates gradually incur wear due to articulation Model 6036 155 General Maintenance Inspection Guidelines 1 Park the vehicle on level ground Place the travel select lever in N NEUTRAL place the neutral lock lever in the NEUTRAL LOCK position engage the parking brake switch and raise the boom to a horizontal level position 2 Fully extend the boom until the extend chain is taut Shut the engine off The extend chains will be visible for inspection with the vehicle in this state The retract chain can be visually inspected at the rear of the boom as the boom is slowly retracted While doing the chain inspection check all chain clevis ends for distortion or cracking and sheaves for bearing wear or g
112. sten the seat belt start the engine apply the service brake pedal and disengage the parking brake switch Place the Neutral Lock Lever in the D DRIVE position 2 Rotate the twist grip 4 of the range select lever to 1st gear 3 Move the travel select lever to F FORWARD to travel in a forward direction or to R REVERSE to travel backward 4 Slowly remove your foot from the service brake pedal and press the accelerator pedal to start travel IMPORTANT Check for warning lights frequently during operation Any abnormal indication should be corrected as soon as practical OH1803 Model 6036 59 Operation Changing Travel Direction 1 Stop the vehicle by applying the service brakes 2 Grasp the travel select lever 1 pull it toward the steering wheel 2 then move the lever up or down in the opposite direction R REVERSE or F FORWARD OH1792 60 Model 6036 Shifting Gears Operation 1 Rotate the twist grip of the gear select lever to the next desired gear The transmission has four forward gears and three reverse gears 2 Use first gear for highest torque and pulling power Use higher gears for higher ground speed The recommendations listed in the table that follows are guidelines onl
113. t and behind the vehicle of any obstacles c Fasten your seat belt d Turn the key and start the engine e With the parking brake applied move the range select lever to 1 FIRST gear f Move the travel select lever to F FORWARD g Depress the throttle pedal fully The unit should not move Step 2 a Remove your foot from the throttle pedal b Move the travel select lever to R REVERSE c Depress the throttle pedal fully The unit should not move d Remove your foot from the throttle pedal e Move the travel select lever to N NEUTRAL Test 2 Transmission De Clutch Parking Brake Activation a Disengage the parking brake b Move the travel select lever to F FORWARD c Move the unit slowly in a forward direction approximately 1 mph 1 6 km h d Engage the parking brake The unit should stop abruptly Model 6036 165 Test Procedures Test 3 Park Brake Hold Performance a With the rated load of 6 000 Ibs 2 721 Kg on the forks drive the vehicle forward up a 15 grade 15 ft rise over 100 ft run b Stopthe vehicle using the service brakes apply the park brake shift the transmission into NEUTRAL N c Take your foot off the service brake pedal The vehicle should not move d Apply the service brakes shift the transmission into REVERSE R move the park brake switch to the OFF position and back down off the grade e Repeat Test 3 by backing up the grade and checking the park br
114. tating that the vehicle should not be operated Actual Accident Prevention Tags which can be punched out and used are included as the last page of this manual Retain these Accident Prevention Tags for reuse at a later date New or Additional Operators At the time of original purchase the purchaser of this vehicle was instructed by the seller on its proper use If this vehicle is to be used by an employee or is loaned or rented to someone other than the purchaser make certain that the new operator is trained and authorized in accordance with the OSHA regulations referenced on page 3 and reads and understands this Operators Manual before operating the vehicle In addition make sure that the new operator has completed a walk around inspection of the vehicle is familiar with all decals on the vehicle and has demonstrated the correct use of all controls Model 6036 5 Safety Practices Instructional Symbols The following symbol definitions will help you understand all hazard related decals and load charts used on this vehicle OP0330 Safety Alert Symbol OH2100 Read Operator s Manual OH2090 Fasten Seat Belt e 2 800 mile a ee 8 OH3100 msi This Symbol Signifies That Specific Attachments Must Only Be Used On Vehicles Equipped With Auxiliary Hydraulics Always Connect Couplers 6 Model 6036 Safety Practices Hazard Symbols OH2110 OH2120 OH2130
115. the cover snaps securely in place on the holder Close and lock the left side engine access door when complete OA1760 146 Model 6036 General Maintenance This Page Intentionally Left Blank Model 6036 147 General Maintenance 15 Boom Chains and Wear Pads A Boom Chain Tension Check First 50 Hours 4st 1000 Hour Intervals 10003 OH2670 OH2690 ow Check the boom chain tension by measuring the top boom extend chain sag 1 Park the vehicle on level ground Place the travel select lever in N NEUTRAL move neutral lock lever to NEUTRAL LOCK position engage the parking brake switch and raise the boom to a horizontal level position 2 Fully extend the boom then retract it 2 51 mm one inch per sec tion Turn the vehicle OFF 3 Measure the sag 1 in the top boom extend chains 2 between the bottom of the chains and the top of the intermediate boom 3 at their closest point Acceptable boom chain sag is between 1 5 38 mm and 2 5 64 mm If the measurement is less than 1 5 38 mm or more than 2 5 64 mm the boom chains need to be adjusted OA0491 General Maintenance Before making any adjustments to the extend chains check the following measurement at the rear of the boom 4 Start the vehicle retract the boom completely and turn the vehicle OFF 5 Go to the back of the vehicle and remove the rear cover from the back of the boom 6 Check the
116. tructure where the load is to be placed 3 Distance where the load will ultimately be placed in front of the front tires WARN NG DO NOT exceed rated capacities Any attempt to lift or carry loads in excess of those shown on the capacity chart in the operator s compartment may cause vehicle tipover loss of load or structural damage which could result in death or serious injury Model 6036 69 Operation Reading The Capacity Chart Example 1 The operator has placed the load onto the forks fully retracted the boom positioned the vehicle perpendicular to the structure and leveled the vehicle Refer to the load placement example 1 The operator then determines that The load weight is 6 000 pounds 2 721 kg The height of the structure the load is to be placed upon is 28 feet 8 5 meters from ground level The distance where the load will ultimately be placed in front of the vehicle is 8 feet 2 4 meters from the front of the front tires After applying the height of the structure and the distance of load placement away from the vehicle to the capacity chart the operator knows that it will be safe to place the load if the boom extend letter B has appeared and the boom angle indicator reading does not go below approximately 55 This condition is however a maximum limit for this weight height and distance away from the vehicle The operator should move the vehicle closer to the struc
117. ture to assure that the vehicle will not exceed the maximum limits for placing the load 70 Model 6036 Operation Standard Carriage Capacity Chart WITH SKY TRAK APPROVED STANDARD CARRIAGES ONLY Model 6036 71 Operation Side Tilt Carriage Capacity Chart 6036 WITH SKY TRAK APPROVED SIDE TILT CARRIAGES ONLY a db ra LLLELS ooo ASME 56 6 2002 PART Ill 4110235 OA1412 72 Model 6036 Operation Swing Carriage Capacity Chart 6036 WITH SKY TRAK APPROVED SWING CARRIAGES ONLY Use only with vehicles LEA with auxiliary hydraulic Always couplers mmm TM Ibs Ibs Ibs 15 4110236 OA1422 Model 6036 73 Operation 12 Foot Truss Boom Capacity Chart 6036 WITH SKY TRAK APPROVED 12 FT TRUSS BOOM ONLY 36 32 28 24 20 16 12 8 4 Oft SWINGING LOADS can cause MACHINE TIPOVER which can result in death or serious injury ALWAYS travel slowly close hitch use two slings use two tethers ASME 56 6 2002 PART III 31 5 24 5 4110237 OA1432 74 Model 6036 Operation 3 Foot Truss Boom w Winch Capacity Chart 6042 WITH SKY TRAK APPROVED TRUSS BOOM WINCH ONLY SAFETY INSTRUCTIONS Use only with vehicles equipped with auxiliary hydraulics Always connect couplers S
118. ueling temen 57 i seniper ies 164 Relay 144 Travel Direction 60 Relay Ratings 171 Travel Select Lever 28 Removing From Storage 163 Truss Boom Capacity Chart 74 Replacement Parts 2 Truss Boom w Winch 41 Replacing Tires 141 Truss Boom w Winch Capacity Repos eee 2 Chart uite 75 Restriction Indicator 108 Turn Signal Light 36 S T rn Signals dating 46 Safety Element 109 U Seat Belt REB 10 32 Underground Hazards 15 Serial Number Plate 2 Using Other Attachments 82 Service Brake Pedal 23 Using The Capacity Chart 68 Shifting Gears 61 V Shut Off i a eee 83 Vehicle Dimensions 170 Side Tilt Carriage Capacity Chart 72 Ventilation 19 Side Tilt Carriage Operation 41 Visual Obstruction 14 Skylight Wiper Control 48 W Slopes 19 Warning Indicator Lights ENT NER 37 Starting Travel iR 59 Wear Pad Inspection 161 Steering Modes nee 62 Wear Pad Repla
119. uld be deflected by some means the failed hose could be used directing the oil into the drain container 94 Model 6036 Emergency Operations 9 Check the hydraulic oil level and add oil if needed 10 Remove the blocking or support from the outer boom 11 Return to the cab fasten your seat belt and start the engine OA1240 IMPORTANT Have the vehicle serviced and hoses replaced as soon as the boom has been lowered and the vehicle is in a secure location Model 6036 95 Emergency Operations 12 13 14 15 16 Tilt the carriage and or attachment upward if necessary for clearance before retracting the boom SLOWLY RETRACT the boom SLOWLY LOWER the boom and ground the carriage Completely remove the load from the carriage and or attachment if you haven t already done so Have the vehicle serviced immediately 17 18 19 20 21 Replace any faulty hydraulic lines Return to the cab fasten your seat belt and start the engine Cycle the lift lower cylinder several times to bleed air from the System Check for leaks Transfer the waste oil to a container with a cover and label as used oil Dispose of properly Recheck the hydraulic oil level Add oil if necessary 96 Model 6036 Emergency Operations STEP 4 BOOM RETRACT LINE FAILURE 1 2 Clear the area of any unnecessary personnel Place the travel select lever in NEUTRAL move the neutral lock lever to NE
120. us Load Travel Conditions Load Size Surface Gear Speed No Load Smooth 4th 0 to 20 mph 0 to 32 km h Improved 0 to 14 mph 0 to 23 km h Rough 2nd 0 to 6 mph 0 to 9 7 km h Load Smooth 3rd 0 to 14 mph 0 to 23 km h up to 3 500 Ibs Improved 2nd 0 to 6 mph 0 to 9 7 km h up to 1 588 kg Rough 2nd 0 to 6 mph 0 to 9 7 km h Load Smooth 3rd 0 to 14 mph 0 to 23 km h 3 500 to 6 000 Ibs Improved 2nd 0 to 6 mph 0 to 9 7 km h 1 588 to 2 721 kg Rough ist 0 to 3 5 mph 0 to 5 6 km h NEVER travel in 4th gear when carrying a load Model 6036 29 Operation Boom Control Lever The boom control lever 1 is a joystick with variable motion from the center to control the boom functions A Boom move lever backward _ move lever forward ft Boom move lever to the right A Boom Retract move lever to the left OHO0170 Two boom functions can be accomplished at the same time by moving the lever into the proper quadrant For example moving the lever forward and to the left will lower and retract the boom simultaneously The speed of the function depends directly upon the amount of lever travel in the corresponding direction Increasing the engine speed will also increase the function speed OH2900 30 Model 6036 Operation Attachm
121. us personal injury Always walk around and look for these and other hazards before operating the vehicle in a new worksite Prevent accidents when you move the vehicle around the worksite Know the rules for movement of people and vehicles on the worksite Have a person act as a lookout for you Follow the instructions of signals and signs DO NOT operate the vehicle unless all hazard and instructional decals are in place and readable Replace all missing illegible or damaged decals 2 Clearances Look out for and avoid other personnel machinery and vehicles in the area Use a spotter if you do not have a clear view of conditions that affect clearances Travel with the boom fully retracted and lowered as far as possible while still maintaining enough ground clearance for conditions Always check boom clearances carefully before driving underneath door openings bridges etc Always check for power lines when raising the boom Beware of overhead wires Contact with electrical power lines can result in electrocution See Electrocution Hazards on page 15 3 Visual Obstruction Dust smoke fog etc can decrease vision and cause an accident Always stop or slow the vehicle until the obstruction clears and the worksite is visible again Have a lookout person assist you Where the load will obstruct the operator s vision it is recommended that the vehicle be operated in REVERSE looking backwards in the direction of travel Tra
122. ut allowing the test weight to fall free to the ground A deceleration device may be included 11 Lanyards when provided shall be arranged so as not to cause a tripping hazard 12 Body belts when provided should have a width of at least 1 75 in 44 mm 13 Structural safety factor all load supporting structural elements of the work platform shall have a structural safety factor of not less than 2 to 1 based on the minimum yield strength of materials used Capacity Limitations The combined mass weight in pounds of the platform load and personnel shall not exceed one third 83 of the capacity of the related load center position indicated on the capacity chart Refer to Using The Capacity Chart on page 68 Preparation and Set up WARN NG Never allow anyone to alter or modify any part of the work platform Any modification to the platform which could result in serious personal injury to anyone on the platform 1 DO NOT alter or modify the work platform in any manner 2 Make sure that the work platform is securely attached to the quick attach or forks Follow the platform manufacturer s instructions 3 Make sure the platform carriage and forks are secured to prevent them from pivoting from side to side 4 On side tilt or swing carriages the carriage must be centered and or leveled horizontally and vertically The hydraulic system quick disconnects must also be disconnected and plugged and the c
123. vel at a slower speed and get someone to direct you 14 Model 6036 Safety Practices 4 Underground Hazards Know the location of all underground hazards before operating this vehicle in a new area or worksite Electrical cables gas and water pipes sewer or other underground objects can cause death or serious personal injury Contact your local underground utility service or diggers hotline to mark all underground hazards 5 Electrocution Hazards NEVER operate this vehicle in an area where overhead power lines overhead or underground cables or other power sources may exist without first requesting that the appropriate power or utility company de energize the lines or take other suitable precautions 4 DANGER CONTACTING NEVER operate ELECTRIC vehicle within POWER LINES 10 feet 3m of can result in electric power electrocution lines OS0063 Model 6036 15 Safety Practices 6 Elevating Personnel Use only a compliant work platform meeting the ASME B56 6 standards for lifting and lowering personnel NEVER transport personnel in a work platform for even the shortest distance Death or serious personal injury can occur if these rules are not obeyed Riders can fall and be crushed or run over Avoid accidents For other specific precautions see Elevating Personnel on page 77 A WARNING AVOID CRUSHING falling off vehicle can Allow no riders OH3180 4 WARNING
124. wer side of the outside hold or release using the release on the side wall of the cab below the left side window Model 6036 51 Operation Pre Operation Inspection Check safety belt for damage Check for frayed or cut seat belt web bing damaged buckles or loose mounting brackets Make any nec essary repairs before operating the vehicle Check all four tires and rims for damage Check for proper tire pres sure add air if required Observe the condition of each tire looking specifically for punctures cracks cuts gouges bulges or any other damage Check the condition of each rim for bent flanges or any other damage Make any necessary repairs before operating the vehicle Check and add engine oil if required This procedure is explained in greater detail on page 115 Check and add transmission oil if required This procedure is explained in greater detail on page 129 Check the cooling system overflow bottle for coolant Add coolant if required This procedure is explained in greater detail on page 112 Remove any debris blocking the radiator cooling fins Check the hydraulic oil level sight glass and add hydraulic oil if required This procedure is explained in greater detail on page 126 Visually inspect the battery for cleanliness Check the terminals for corrosion Check the cable connections to ensure proper tightness Walk around the vehicle and check for oil leakage as well as dam
125. when the alternator is no longer able to charge the battery To service the battery 1 Level the vehicle ground the carriage place the travel select lever in NEUTRAL move neutral lock lever to NEUTRAL LOCK posi tion engage the parking brake switch and shut off the engine 2 Unlock and open the rear door The battery 1 is located inside the frame directly below the radiator and oil cooler 3 Wearing safety glasses visually inspect the battery Check termi nals for corrosion Replace the battery if it has a cracked melted or damaged case 4 Close and lock rear door OH2420 General Maintenance WARN NG Fluid in electric storage batteries contains sul furic acid which is POISON and can cause SEVERE CHEMICAL BURNS Avoid all contact of fluid with eyes skin or clothing Use protective gear when handling batteries DO NOT tip a battery beyond a 45 angle in any direction If contact does occur follow the First Aid suggestions that follows Battery Electrolyte First Aid External Contact Flush with water Eyes Flush with water for at least 15 minutes and get medical attention immediately Internal Contact Drink large quantities of water Follow with Milk of Magnesia beaten egg or vegetable oil Get medical attention immediately IMPORTANT In case of internal contact DO NOT give fluids that would induce vomiting Battery Charging WARN NG DO N
126. wnership page 3126021 a Revision Log b 3126021 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 material handler This Owner Operator Manual Telehandler Safety Manual e All inst
127. ws the symbol contains important information about Safety To avoid possible death or serious personal injury carefully read and follow the messages Be sure to fully understand the potential causes of death or injury Model 6036 3 Safety Practices Signal Word A signal word is a distinctive word located on hazard decals and used throughout this manual that alerts the viewer to the existence of and relative degree of the hazard A DANGER The signal word DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious personal injury A WARNING The signal word WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious personal injury A CAUTION The signal word CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury CAUTION The signal word CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in property damage For safe maintenance of the vehicle read understand and follow all DANGER WARNING and CAUTION information 4 Model 6036 Safety Practices Accident Prevention Tags Before beginning any maintenance or service place an Accident Prevention Tag 1 on both the starter key switch 2 and the steering wheel 3 s
128. y Unlock and open right side engine access door Remove oil fill cap 2 and add 15W40 motor oil that at least meets the manufacturers minimum recommended oil specifications as defined in their operator manual Reference engine manufacturer s manual for recommended oil types to be used in various tempera ture limits Fill oil through the opening under the boom DO NOT over fill Engine oil capacity with filter change is 10 5 qts 10 liters Reinstall the oil fill cap 2 Start engine and run for several minutes Stop engine Let the oil drain back for a few minutes Check oil level on dipstick 3 and check for leaks at filter and drain plug Tighten as necessary Add oil to bring oil level up to the FULL mark in the crosshatched area Replace dipstick and oil fill cap Close and lock access door ie i M OA1720 Model 6036 General Maintenance 5 Engine Fuel System A Drain Water From Fuel Water Separator Filter EN 10 Hour Intervals 10 X EA 0 OH2660 0 8 050851 i069 Unlock and open the right rear engine access door Loosen drain valve 4 on under side of the water separator filter b and allow all water to drain into a container until clear fuel is visible Dispose of properly Tighten drain valve 4 after draining Close and lock right engine access door OA1700 Model 6036 119 General Maintenance B Change Fuel Filter 500 Hour Intervals The fuel filter must be 5002
129. y Always use good judgement when traveling with a load Recommended Gear Speed for Various Load Travel Conditions Load Size No Load Load up to 3 500 Ibs up to 1 588 kg Load 3 500 to 6 000 Ibs 1 588 to 2 721 kg Surface Gear Speed Smooth 4th 0 to 20 mph 0 to 32 km h Improved 3rd 0 to 14 mph 0 to 23 km h Rough 2nd 0 to 6 mph 0 to 9 7 km h Smooth 0 to 14 mph 0 to 23 km h Improved 2nd 0 to 6 mph 0 to 9 7 km h Rough 2nd 0 to 6 mph 0 to 9 7 km h Smooth 3rd 0 to 14 mph 0 to 23 km h Improved 2nd 0 to 6 mph 0 to 9 7 km h Rough 1st 0 to 3 5 mph 0 to 5 6 km h NEVER travel in 4th gear when carrying a load NOTE Shifting to the next higher gear may be done while the vehicle is in motion IMPORTANT When downshifting allow the engine speed to slow down before shifting to the next lower gear Stopping Travel 1 Apply the service brake pedal and downshift the vehicle to a lower gear if necessary to slow the vehicle until it comes to a complete stop 2 Move the travel select lever to NEUTRAL and engage the park ing brake switch For longer stops place the neutral lock lever to NEUTRAL LOCK position and engage the parking brake switch Model 6036 Operation Steering Modes IMPORTANT DO NOT change steering modes unless you are at a complete stop and all four tires are in the straight ahead position The three steering modes are Four
130. y Chart The individual capacity charts are located inside a booklet 1 on the right side of the front dash Capacity charts are provided to assist the operator in determining how far in front how high and at what angle a specific load can be safely handled with this vehicle OA1220 The vehicle is equipped with two indicators that will assist the operator in determining how to accurately use the capacity chart These indicators are Boom Extend Letters 2 on the intermediate boom 3 Boom Angle Indicator 4 on the outer boom 5 OH1960 68 Model 6036 Operation As the boom is extended boom extend letters will appear on the left side of the boom visible to the operator The letters are graduated in four foot increments These letters indicate the point of boom extension and correspond to the capacity chart For example when the letter A first appears the boom is at the point of boom extension corresponding to the arc of line A throughout the entire capacity charts page 71 through page 75 The boom angle indicator located on the left side of the outer boom indicates the angle of the boom and also corresponds with the angles indicated on the capacity chart To accurately use the capacity chart the operator must first determine three important things 1 Weight of the load being lifted 2 Height of the s

Operation 3126021

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