Operator & Safety Manual Keep this manual with machine at all times.
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.
Revision Log Revision Log REVISION LOG May, 2002 - 001 - Original Issue February 11, 2005 - B - Replaced branding with JLG.
Revision Log b 8990415
Read This First Read This First This manual is a very important tool! Keep it with the machine at all times. The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and operating procedures essential for the safe and proper machine operation for its intended purpose. Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without prior notification. Contact JLG Industries, Inc.
Read This First This product must comply with all safety related bulletins. Contact JLG Industries, Inc. or the local authorized JLG representative for information regarding safetyrelated bulletins which may have been issued for this product. JLG Industries, Inc. sends safety related bulletins to the owner of record of this machine. Contact JLG Industries, Inc. to ensure that the current owner records are updated and accurate. JLG Industries, Inc.
Table of Contents Revision Log Read This First Introduction The Manual....................................2 Replacement Parts ........................2 Reports ..........................................2 Safety Practices Disclaimer......................................3 Hazard Classification System........3 Accident Prevention Tags..............5 New or Additional Operators .........5 Instructional Symbols ....................6 Hazard Symbols ............................7 Avoidance Symbols ................
Introduction 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, Warning, and Caution notices. They are for your benefit.
Safety Practices 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 also 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.
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. DANGER: The signal word “DANGER” indicates an imminently hazardous situation which, if not avoided, will result in death or serious personal injury. WARNING: The signal word “WARNING” indicates a potentially hazardous situation which, if not avoided, could result in death or serious personal injury.
Safety Practices Accident Prevention Tags Before beginning any maintenance or service, place an Accident Prevention Tag (Figure 1, 1) on both the starter key switch and the steering wheel (Figure 1), stating 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.
Safety Practices Instructional Symbols The following symbol definitions will help you understand all hazard related decals used on this vehicle. OP0330 Safety Alert Symbol OH2100 Read Operator’s Manual OH2090 Fasten Seat Belt OH3100 This Symbol Signifies That Specific Attachments Must Only Be Used On Vehicles Equipped With Auxiliary Hydraulics. Always Connect Couplers.
Safety Practices Hazard Symbols OH2110 OH2120 OH2130 - Lead Acid Batteries Generate Explosive Gases Vehicle Tipover Can Crush Rotating Fan Blades Can Cut OH2140 OH2150 OH2300 Rotating Belts Can Cut Or Entangle Electrocution Can Cause Death Or Serious Injury Vehicle Roll Away Can Cause Death Or Serious Injury OH3160 AVOID CRUSHING, Falling Off Vehicle Can Cause Death Or Serious Injury OH3110 Swinging Loads Can Cause Vehicle Tipover Which Can Result In Death Or Serious Injury OH2161 FALLING O
Safety Practices Avoidance Symbols OH2320 OH2330 Keep Flames and Ignition Sources Away Keep Lit Cigarettes Away OH2310 OH2270 Do Not Travel With Boom Raised Keep Away From Rotating Fan Blades OH2280 OH2290 Maintain Proper Air Pressure In Tire Do Not Raise Boom While On A Slope To Avoid Vehicle Tipover ALWAYS: • • • • Travel Slowly Close Hitch Use Two Slings Use Two Tethers OH3120 8 Model 6036
Safety Practices Avoidance Symbols (cont’d) OH2260 Engage Parking Brake OH2250 Keep Clear Of Power Lines OH2240 Do Not Travel With Personnel In Work Platform OH2230 Carry No Riders OH2170 OH2220 DO NOT JUMP • Brace Yourself and Stay With Vehicle Use Only Approved Work Platforms To Raise Or Lower Personnel • Keep Seat Belt Fastened • Hold On Firmly • Lean Away From The Point Of Impact Model 6036 9
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.
Safety Practices 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 fire 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.
Safety Practices D. 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 57. - OS0621 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.
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. MOVING PARTS can cut. Keep clear of fan and belts while engine is running. MOVING PARTS can entangle. OT0810 6. Lowering Boom or Falling Load Hazard DO NOT get under a raised boom unless it is blocked up safely.
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 serious personal injury.
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.
Safety Practices 6. Carrying Personnel Use only an approved 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 78.
Safety Practices 7. Tip Over Hazard VEHICLE TIPOVER can result in death or serious injury. DANGER MAINTAIN proper tire pressure at all times. DO NOT raise boom while on a slope unless load is level. DO NOT travel with the boom raised. OS0086 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.
Safety Practices 9. Tire Pressure VEHICLE TIPOVER can result in death or serious injury. DANGER DO NOT travel with the boom raised. DO NOT raise boom while on a slope unless load is level. MAINTAIN proper tire pressure at all times. OS0085 MAINTAIN proper tire pressures at all times. An underpressurized tire(s) adversely affects vehicle stability. If proper tire pressures are not maintained, this vehicle can tip over.
Safety Practices 11. Slopes DO NOT park the vehicle on an incline and leave it unattended. • Driving across a slope is dangerous, as unexpected changes in the slope can cause tipover. Ascend or descend slopes slowly and with caution. • 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.
Safety Practices Equipment Considerations WARNING: 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 JLG Authorized Service Center (ASC) if any circuit is malfunctioning.
Safety Practices 5 3 7 6 2 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.
Safety Practices 9 FALLING OFF ATTACHMENT, can result in death or serious injury.
Operation Operation Operator Controls Accelerator Pedal (Figure 5) Pressing down the accelerator pedal (Figure 5, 1) increases engine and hydraulic speed of the vehicle. The pedal is spring-loaded to return to idle speed. Service Brake Pedal (Figure 5) Pressing down the brake pedal (Figure 5, 2) 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.
Operation Ignition Switch (Figure 6) Using the ignition switch key (Figure 6, 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.
Operation Steering Select Switch (Figure 7) This vehicle has one steering select switch (Figure 7, 1) with three positions. The switch is located in the lower switch bank on right side dash panel. Refer to “Steering Modes” on page 63 for detailed information.
Operation Park Brake Switch (Figure 8) The Parking Brake Switch (Figure 8, 1) has two positions: OS0121 P ENGAGED ............ toggle switch downward P DISENGAGED ........... toggle switch upward OS1323 The Parking Brake Switch (Figure 8, 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.
Operation Neutral Lock Lever (Figure 9) The Travel Select Lever (Figure 9, 1) is equipped with a neutral lock. The Neutral Lock Lever (2) 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. 2 1 ND 3 4 OH1782 Figure 9 To lock the Travel Select Lever (Figure 9, 1) in the NEUTRAL position, place the lever in the NEUTRAL position and move the Neutral Lock Lever (2) to the (N) NEUTRAL LOCK (3) position.
Operation Travel Select Lever (Figure 10) The Travel Select Lever (Figure 10, 1) has three positions to select direction of travel: F = FORWARD ...............all the way FORWARD N = NEUTRAL ................CENTER position R = REVERSE................ all the way REARWARD OS0340 1 OH1792 Figure 10 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.
Operation Gear Select Lever (Figure 11) The Gear Select Lever (Figure 11, 1) has a twist grip handle with four positions. Vehicles have four forward gears and three reverse gears. 1 OH1802 Figure 11 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.
Operation Boom Control Lever (Figure 12) The boom control lever (Figure 12, 1) is a joystick with variable motion from the center to control the boom functions: Boom Raise.........................move lever backward Boom Lower ........................move lever forward Boom Extend....................... move lever to the right Boom Retract ...................... move lever to the left OH0170 Two boom functions can be accomplished at the same time by moving the lever into the proper quadrant.
Operation Attachment Tilt and Frame Sway Control Lever (Figure 13) The attachment tilt and frame sway control (Figure 13, 1) is a joystick with four perpendicular motions from the center to control two attachment tilt functions and two frame sway functions: Frame Sway Left ................. move lever to the left Frame Sway Right............... move lever to the right Attachment Tilt Down...........move lever forward Attachment Tilt Up ...............
Operation Seat Belt (Figure 14) WARNING: 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 Operator’s 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.
Operation Operator’s Seat Adjustment (Figure 15) The operator’s seat (Figure 15, 1) can be adjusted three ways: A. Fore and Aft Adjustment Pull the handle (Figure 15, 2) 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 (Figure 15, 3) on the front of the seat to adjust the suspension to correspond with the operator’s weight. Turn clockwise to increase stiffness.
Operation Instruments and Indicators Hourmeter (Figure 16) OS0260 The hourmeter (Figure 16, 1) records engine operating hours and has a total readout of 9,999.99 hours. It is located at the lower portion of the instrument cluster on the right side of the dash. Fuel Gauge (Figure 16) OH2470 The fuel gauge (Figure 16, 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.
Operation Instrument Cluster Light Test (Figure 17) 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.
Operation Function Indicator Lights A. Park Brake Light P (Figure 18) OH2480 The park brake light (Figure 18, 1) illuminates any time the park brake is applied and the ignition switch is in the RUN position. B. High Beam Light (used with optional road light package only) OH2490 (Figure 18) The high beam light (Figure 18, 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.
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.
Operation C. Hydraulic Oil Temperature Warning Indicator Light (Figure 20) OH2540 The hydraulic oil temperature light (Figure 20, 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. 3 2 P 1 0000 00 OH1810 Figure 20 D.
Operation E. Alternator Charging Warning Indicator Light (Figure 20) OH2560 The alternator charging light (Figure 20, 3) illuminates when the charging system is not working properly. Service the engine alternator. Frame Level Indicator (Figure 21) The indicator (Figure 21, 1) 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.
Operation Boom Angle Indicator (Figure 22) The boom angle indicator is a plumb arrow (Figure 22, 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”). 4105262 1 2 OH0302 Figure 22 Rear View Mirrors (Figure 23) Two rear view mirrors are provided to aid the operator's rear vision.
Operation Optional Controls Auxiliary Attachment Control Lever (Figure 24) The auxiliary attachment control lever (Figure 24, 1) 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, and Swing Carriage.
Operation Worklight Switch (Front, Rear & Boom Worklights) (Figure 25) OH2570 This three position rocker switch (Figure 25, 1) controls the front, rear and boom worklights. The switch (1) is located in the 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 worklights OFF. OH2591 • To turn the front and boom worklight ON, position the rocker switch to the center position.
Operation Beacon Light Switch (Figure 26) OH2580 This rocker switch (Figure 26, 1) 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. • Push the bottom of the switch in to turn the beacon light ON. • Push the top of the switch in to turn the beacon light OFF.
Operation Worklight Switch (with Optional Road Lights) (Figure 27) OH2620 This rocker switch (Figure 27, 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 & High/Low Beam Switch” on page 46 for operation of the road lights. • Push the top of the switch IN to DEACTIVATE the entire worklight system.
Operation Emergency Flashers (Figure 28) OS1920 The emergency flashers switch (Figure 28, 1) is located in the upper switch bank on the right side dash panel. • To ACTIVATE the emergency flashers, push the bottom of the switch IN. • To DEACTIVATE the emergency flashers push the top of the switch IN.
Operation Turn Signals (Figure 29) OH2510 The directional signals are ACTIVATED from the lever (Figure 29, 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.
Operation Windshield Wiper Control (Figure 30) OS1930 This three position rocker switch (Figure 30, 1) controls the speed of the windshield wiper. This switch (1) is located in the lower switch bank on the right side dash panel. • To OPERATE the windshield wiper at HIGH speed, push the top of the switch IN. • To STOP the windshield wiper, position the switch in the CENTER POSITION. • To OPERATE the windshield wiper at LOW speed push the bottom of the switch IN.
Operation Roof Wiper Control (Figure 31) OH1900 This rocker switch (Figure 31, 1) turns the roof 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 roof wiper ON. OH2611 • Push the top of the switch IN to turn the roof wiper OFF.
Operation Windshield & Roof Washer Control (Figure 31) OS1940 OH1910 This rocker switch (Figure 31, 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 will dispense washer fluid to the windshield and roof wiper at the same time. The switch must be held in place to activate the washer control. • Release the switch to deactivate the washer control.
Operation Cab Heater & Fan Control (Figure 32) OS1950 The cab heater controls (Figure 32, 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.
Operation Rear Window Latch (Figure 33) The rear window (Figure 33, 1) can be partially opened and secured in place with the rear window latch (2). To open the window, grab the latch handle (3) 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 (Figure 33, 4) on the window latch. The window is then free to swing open. 1 1.
Operation Pre-Operation Inspection 1. Check safety belt for damage. Check for frayed or cut seat belt webbing, damaged buckles or loose mounting brackets. Make any necessary repairs before operating the vehicle. 2. Check all four tires and rims for damage. Check for proper tire pressure, 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.
Operation Normal Starting 1. Enter the cab using the hand holds and adjust the seat for comfortable operation. 2. Adjust the mirrors to obtain the best rear view from the operator’s position. WARNING: DO NOT start the engine 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. 3. Fasten the seat belt. 4. Make sure the parking brake switch is ENGAGED. 5.
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.) At temperatures below 10° F (-12° C), operate the engine at moderate speeds for 5 minutes before full loads are applied. 1. Enter the cab using the hand holds and adjust the seat for comfortable operation. 2.
Operation 9. If using starting fluid with mechanical or electrical metering equipment: • Turn the ignition switch to the START position to engage the starter motor and inject metered amounts of starting fluid. • As the engine starts, stop injection of starting fluid and release the ignition key to the RUN position. Depress the accelerator pedal enough to provide a smooth idle speed. 10. If using starting fluid without metering equipment: WARNING: NEVER use starting fluid near an open flame.
Operation • Turn the ignition switch (Figure 34, 1) to the START (2) position to engage the starter motor. After the engine has started to crank, not before, the other person can begin spraying starting fluid into the air cleaner intake (Figure 35, 1). 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.
Operation Jump Starting Jump starting at the battery or battery replacement is required when the battery is discharged to the point where the battery will not crank the starter. WARNING: 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 person attempting to jump start the vehicle directly to the starter.
Operation 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 OH0480 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.
Operation Fuel Cap (Figure 36) Unlock the fuel cap (Figure 36, 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. 2 3 1 OH1920 Figure 36 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.
Operation Operating Starting Travel 1. Enter the operator cab, fasten 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 (Figure 37, 1) 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.
Operation 1 2 OH1792 Figure 38 Shifting Gears 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 only. Always use good judgement when traveling with a load.
Operation 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 (N) NEUTRAL and engage the parking brake switch. For longer stops, place the neutral lock lever to NEUTRAL LOCK position and engage the parking brake switch.
Operation Steering Modes (Figure 39) 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 Wheel Steering (1) • Front Wheel Steering (2) • Crab Steering (3) The steering modes can be changed using a single rocker switch (Figure 39, 4) located in the lower switch bank (5) on the right side dash panel.
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 162 to synchronize the front and rear steering. 1. Four Wheel Steering (Figure 40) 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.
Operation 2. Front Wheel Steering (Figure 41) 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 should be used when loading or unloading the vehicle from a trailer and for on-highway travel at higher speeds.
Operation 3. Crab Steering (Figure 42) WARNING: 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.
Operation 4. Maximum Fork Sweep (Figure 43) CAUTION: Allow for adequate clearance between the attachment and other objects when turning. The attachment (Figure 43, 1) extends beyond the end of the vehicle. The operator must be aware of the maximum sweep (2) of the attachment when turning in order to avoid hitting personnel and other objects in the area. 1 2 OH1690 Figure 43 Leveling Frame When placing a load while on a slope, use the frame sway control to keep the vehicle level.
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 (N) 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 carriage backward. 3. Exit the vehicle using the hand holds.
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.
Operation Using The Capacity Chart The individual capacity charts are located inside a booklet (Figure 45, 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. 1 6036 OA1220 Figure 45 The vehicle is equipped with two indicators that will assist the operator in determining how to accurately use the capacity chart.
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 (Figure 47) through (Figure 50).
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 (Figure 47, 1). 2. 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.
Operation Standard Carriage Capacity Chart 6036 WITH OMNIQUIP MANUFACTURED STANDARD CARRIAGES ONLY 40 24 20 16 12 36 4 0 ft 70° D 8 60° 32 C 50° B 28 24 20 16 12 8 40° 6 5 0 30° 40 0 3 0 0 0l 20° 2 0 00 b 1 5 0 0l bl 0 0 b 10° 8 0 0 bl 0 bl A 1 24 4 0° 0 ft -2 l b ASME B56.
Operation Side Tilt Carriage Capacity Chart 6036 WITH OMNIQUIP MANUFACTURED SIDE TILT CARRIAGES ONLY SAFETY INSTRUCTIONS 40 24 20 16 12 4 8 70° 36 60° 32 20 16 12 8 4 50° Use only with vehicles equipped with auxiliary hydraulics. Always connect couplers. B A 40° 6 5 0 30° 40 0 3 0 0 2 0 00 l 20° 1 5 0 00 b 5 0 0 l bl 10° 0 0 l b 0 bl b 0° D C 28 24 0 ft 24 l b 0 ft ASME B56.6b -1998 22.
Operation Swing Carriage Capacity Chart 6036 WITH OMNIQUIP MANUFACTURED SWING CARRIAGES ONLY SAFETY INSTRUCTIONS 24 20 16 36 12 4 8 70° 60° 32 B 28 40° Use only with vehicles equipped with auxiliary hydraulics. Always connect couplers. A 30° 20 16 20° 12 8 D C 50° 24 0 ft 10° 4 24 0° 0 ft -4 -8° 23.2 18 11 7.5 13.5 9.5 1000 lbs 2000 lbs 3000 lbs 4000 lbs ASME B56.
Operation 12 Foot Truss Boom Capacity Chart 6036 12' WITH OMNIQUIP MANUFACTURED 12 FT. TRUSS BOOM ONLY 52 36 32 28 24 20 16 12 8 4 0 ft D C B 48 70° 44 40 60° 36 50° 32 40° 28 24 20 16 30° 20° 12 8 4 0 ft -4 10° 0° 1 5 0 0 A 2 0 0 0 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 l b l b -8° ASME B56.6b -1998 31.5 24.
Operation Fork Ratings All approved forks for this vehicle are marked with a maximum load capacity rating. This rating (Figure 51, 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).
Operation How To Pick, Carry & 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.
Operation 5. Engage the parking brake switch. Blocking the wheels is also recommended. 6. Level the platform in both the side-to-side and front-to-back directions before use. WARNING: Never tilt the platform forward or rearward when elevating with personnel aboard. Death or serious personal injury could result.
Operation Using Other Attachments Numerous attachments, marketed by JLG are available for this vehicle. The capacity charts attached to this vehicles dash are 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.
Operation Shut-Off 1. Bring the vehicle to a complete stop using the service brakes. 2. Park the vehicle on level ground. WARNING: 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 (N) NEUTRAL, move the neutral lock lever to NEUTRAL LOCK position and engage the parking brake switch. 4. Lower the boom and ground the carriage. 5.
Emergency Operations 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.
Emergency Operations 4. Position the towing vehicle in place. Attach any chains needed to secure the disabled vehicle. 5. Attach a remote portable hydraulic pressurizing unit to the parking brake gauge port (Figure 53, 1) on the secondary function manifold (2) mounted on the inside wall of the frame (3) on the left side next to the transmission. 3 2 Front OA1230 1 Figure 53 6.
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.
Emergency Operations Emergency Boom Lowering This section discusses emergency boom lowering procedures: Part I In case of loss of engine power or hydraulic pump failure. Part II In case of hydraulic line failure. Part I Loss of 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.
Emergency Operations Part ll - 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 Authorized Service Center or the JLG Service Department.
Emergency Operations able HYDRAULIC LINE THAT FAILED NORMAL STEPS EMERGENCY STEPS FOLLOW FOLLOW THIS STEP THIS STEP IF PARTS IF PARTS ARE ARE NOT AVAILABLE AVAILBLE FOLLOW THIS STEP AS A LAST RESORT BOOM LIFT LINES (LIFT CYLINDERS TO CONTROL VALVE) STEP 1 BOOM LOWER LINES (LIFT CYLINDERS TO CONTROL VALVE) STEP 1 BOOM EXTEND LINE STEP 1 BOOM RETRACT LINE STEP 1 Model 6036 OP0330 STEP 2 STEP 3 STEP 2 STEP 4 87
Emergency Operations STEP 1 1. Clear the area of any unnecessary personnel. 2. Place the travel select lever in (N) NEUTRAL, move the neutral lock lever to NEUTRAL LOCK position and engage the parking brake switch. 3. Block all four wheels. WARNING: 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.
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.
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 (N) NEUTRAL, move the neutral lock lever to NEUTRAL LOCK position and engage the parking brake switch. 3. Block all four wheels. WARNING: Wear protective clothing and proper eye protection when working with or around hydraulic oil.
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.
Emergency Operations STEP 3 BOOM LOWER LINE FAILURE (Lift Cylinders to Control Valve) 1. Clear the area of any unnecessary personnel. 2. Place the travel select lever in (N) NEUTRAL, move the neutral lock lever to NEUTRAL LOCK position and engage the parking brake switch. 3. Block all four wheels. WARNING: 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.
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. 1 2 1 2 OA1240 Figure 57 IMPORTANT! Have the vehicle serviced and hoses replaced as soon as the boom has been lowered and the vehicle is in a secure location.
Emergency Operations 12. Tilt the carriage and/or attachment upward if necessary for clearance before retracting the boom. 13. SLOWLY RETRACT the boom. 14. SLOWLY LOWER the boom and ground the carriage. 15. Completely remove the load from the carriage and/or attachment if you haven’t already done so. 16. Have the vehicle serviced immediately. 17. Replace any faulty hydraulic lines. 18. Return to the cab, fasten your seat belt and start the engine. 19.
Emergency Operations STEP 4 BOOM RETRACT LINE FAILURE 1. Clear the area of any unnecessary personnel. 2. Place the travel select lever in (N) NEUTRAL, move the neutral lock lever to NEUTRAL LOCK position and engage the parking brake switch. 3. Block all four wheels. WARNING: 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.
Emergency Operations WARNING: 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 (Figure 58) can be used to replace the failed boom retract line. 6. Remove the failed boom retract line (Figure 58, 1) from the circuit. 7.
Emergency Operations 1 2 1 2 1 OA1240 Figure 58 Model 6036 97
General Maintenance 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 (Figure 59, 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.
General Maintenance Maintenance Schedule And Checklist 10 Hour Intervals OH1980 10 Drain Fuel/ Water Separator Paragraph Ref. 5A Check Check Check Engine Check Engine Hydraulic Oil Transmission Coolant Level Oil Level Level Oil Level 3A 4A 7B 8A Check Tire Pressure 12A OF1190 Air Filter Restriction Indicator Paragraph Ref.
General Maintenance At First 50 Hours of Use OA1540 LB-F T (N m) 50 Change Engine Oil and Filter Change Transmission Filter Change Hydraulic Filter Check Wheel Lug Nut Torque 4B 8B 7C 12B Paragraph Ref. OH2000 Change Axle Oil Change Wheel End Oil Check Boom Chain Tension 9B 11B 15A Paragraph Ref. 50 Hour Intervals OH2010 50 Paragraph Ref.
General Maintenance 250 Hour Intervals OH2021 250 Paragraph Ref. Change Air Filter Lubricate Pivot Points Change Engine Oil and Filter 2B 1 4B OA1460 Check Wheel End Oil Level Check Axle Oil Level Inspect Extend Chains 11A 9A 15C Paragraph Ref. 500 Hour Intervals OH3150 500 Change Fuel Filter Paragraph Ref.
General Maintenance 1000 Hour Intervals OH2040 1000 Check Boom Chain Tension Inspect Wear Pads Change Transmission Oil And Filter 15A 15E 8B Paragraph Ref. OH2050 Change Axle Oil Change Wheel End Oil Change Hydraulic Oil And Filter 9B 11B 7C Paragraph Ref. OH2061 P Check Fan Belt Paragraph Ref. Check Air Lubricate Intake System Pivot Points 6A 2C 1 Check Axle Brake Discs 10A OA1470 Lubricate Boom Chains Paragraph Ref.
General Maintenance 2000 Hour Intervals OH2070 2000 Change Engine Coolant Paragraph Ref.
General Maintenance 1. Lubrication Points 50 OH2680 Lubricate the following grease fittings using Multi-Purpose Grease (MPG) every 50 hours: OS1750 A. Carriage pivot pins .......................................... (2 points) B. Attachment tilt cylinder pins .......................... (2 points) C. Boom attachments .......................................... (all points) D. Extend Chain Sheave...................................... (1 point) E. Retract Chain Sheave ...................................
General Maintenance Lubrication Points F I I 2/ 2/ D E F K C H G B A F B F J G G J OA1260 Figure 60 Model 6036 105
General Maintenance 2. Air Cleaner & Restriction Indicator NEVER operate the vehicle without the air cleaner assembly and both filters in place. A. Filter Check (10 Hour Intervals) 10 OH2660 OF1190 1. 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. 2. Unlock and open the left rear engine access door to access air cleaner restriction indicator (Figure 61, 1). Check indicator.
General Maintenance 3. Remove dust from vacuator valve (Figure 62, 1) by squeezing bottom of vacuator to allow loose particles to fall out. Replace elements, if required, as described in paragraph 2B. OA1280 1 Figure 62 B. Element: Change (As Restriction Indicator Indicates or 250 Hour Intervals) 250 OH2710 OS0790 Outer Primary Element All air cleaner manufacturers agree that attempting to clean or wash an element increases the chance for element damage.
General Maintenance To change elements: 1. Pull the air cleaner cover lock (Figure 63, 1) OUT, turn the air cleaner cover (2) counter-clockwise and remove cover from air cleaner canister (3). 1 2 3 OA1290 Figure 63 2. Remove the primary element (Figure 64, 1). Inspect element for damage. Damaged elements should not be reused. 3. Thoroughly clean the interior of the air filter canister (Figure 64, 2) and vacuator valve (3). 4.
General Maintenance 4 6 2 1 5 OA1300 3 Figure 64 C. Air Intake System-Inspection (1000 Hour Intervals) 1000 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.
General Maintenance 3. Engine Cooling System A. Engine Coolant Level Check (10 Hour Intervals) 10 OH2660 OS0800 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 the right rear engine access door. Check level of coolant in overflow bottle (Figure 65, 1). When coolant is hot, bottle should be 1/2 to 3/4 full.
General Maintenance B. Drain And Flush Radiator (2000 Hour Intervals) OS0810 2000 OH2700 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. WARNING: 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. 2.
General Maintenance NOTE: Attach a hose 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.
General Maintenance 12. Allow engine to cool to ambient temperature. Check radiator coolant level and top off completely. Replace radiator cap. 13. 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. 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.
General Maintenance 4. If oil is low, remove oil fill cap (Figure 69, 1) and add 15W40 motor oil that is equal to API, CD or CE (severe duty diesel engine) specifications to bring oil up to the FULL mark in the crosshatched area. Replace oil fill cap (1) and dipstick (2). Close and lock access door.
General Maintenance B. Oil And Filter Change (First 50 Hours) (250 Hour Intervals) 50 OH2670 250 OH2710 OS0830 1. Operate the engine until warm (approximately 5 minutes). 2. 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. 3. Place receptacle under engine oil pan drain. 4. Remove drain plug from engine oil pan. 5.
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. Apply a thin coat of clean engine oil to seal on new filter. 9. Install the new oil filter and hand tighten 1/2 turn after initial contact. 10. Clean and re-install oil pan drain plug. 11. Unlock and open the right engine access door. 12. Remove oil fill cap (Figure 71, 1) and add 15W40 motor oil that is equal to API, CD or CE specifications.
General Maintenance 5. Engine Fuel System A. Drain Water From Fuel Water Separator/Filter (10 Hour Intervals) 10 OH2660 H 20 OS0851 Unlock and open the right rear engine access door. Loosen drain valve (Figure 72, 1) on under side of the water separator/filter (2) and allow all water to drain into a container until clear fuel is visible. Dispose of properly. Tighten drain valve (1) after draining. Close and lock right engine access door.
General Maintenance B. Change Fuel Filter (500 Hour Intervals) 500 OT1150 OS0870 The fuel filter must be changed at shorter intervals with evidence of water or contaminated fuel. 1. Unlock and open the right rear engine access door. 2. Clean around the fuel filter head (Figure 73, 1). 3. Unscrew the fuel filter (Figure 73, 2) and dispose of properly. 4. Clean the gasket surface of the filter head and replace the o-ring. 1 2 OH2200 Figure 73 5. Fill the new fuel filter with clean No. 2 diesel fuel. 6.
General Maintenance C. Replace In-line Fuel Strainer (250 Hour Intervals) 500 OT1150 1. Unlock and open the right rear engine access door. 2. The in-line fuel strainer (Figure 74, 1) is located down line from the engines lift pump (2). Loosen the two hose clamps (3) that secure the strainer in place. 3. Remove the old in-line fuel strainer and dispose of properly. 4. Install the new in-line fuel strainer (Figure 74, 1) with arrow pointing toward the lift pump (2). 5.
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. WARNING: 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.
General Maintenance The process to vent the high pressure fuel lines (Figure 76, 1) involves energizing the starter motor to rotate the crankshaft which will, in turn, pump any unwanted air from the fuel lines. CAUTION: 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 a time; wait two minutes between engagements. WARNING: KEEP CLEAR of spraying fuel. Fuel can spray when venting high pressure lines.
General Maintenance 6. Engine Fan Belt A. Engine Fan Belt Check (1000 Hour Intervals) 1000 OH2690 OS08802 1. 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. 2. Unlock and open the left rear engine access door. 3. Inspect the fan belt (Figure 77, 1). Replace if cracked or frayed. 4. This engine is equipped with an automatic belt tensioner (Figure 77, 2).
General Maintenance 7. Hydraulic Oil and Filter A. Hydraulic System Oil 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.
General Maintenance B. Hydraulic Oil Level Check 10 (10 Hour Intervals) OH2660 OS0660 1. Be sure all cylinders are fully retracted and oil is at room temperature. 2. Level the vehicle, ground the carriage, place travel select lever in (N) NEUTRAL, 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 (Figure 78, 1) on the back side of the hydraulic tank (2). 4.
General Maintenance C. Hydraulic Oil & Filter Change (First 50 Hours) (Filter Only) 50 (1000 Hour Intervals) (Oil & Filter) OT08402 OH2670 1000 OH2690 OS08402 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 has contaminated the system. 1.
General Maintenance 4. Clean area around filter head (Figure 80, 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 (Figure 80, 1). 6. Remove the seal (Figure 80, 3) and the element (4) from the filter head (1). Dispose of properly. 7. Clean the filter head sealing surfaces. 8. Place a receptacle under the hydraulic reservoir magnetic drain plug. The receptacle must be large enough to hold 38 gallons (144 liters) of oil.
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 OS0890 OH2660 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.
General Maintenance B. Transmission Oil & Filter Change (First 50 Hours) (Filter Only) (1000 Hour Intervals) (Oil & Filter) 50 OH2670 1000 OT08302 OS09502 OH2690 Change the transmission oil filter after the first 50 hours of operation and change the transmission oil and filter every 1000 hours of operation thereafter. 1.
General Maintenance 3. Allow the transmission to cool. 4. Place a receptacle under the transmission drain plug (Figure 83, 1). 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 (Figure 83, 1) into the transmission housing. 6.
General Maintenance 9. Axle Oil A. Axle Oil Level Check (250 Hour Intervals) 250 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 (N) NEUTRAL, move neutral lock lever to NEUTRAL LOCK position, engage the parking brake switch and shut off the engine. 2.
General Maintenance B. Axle Oil Change (First 50 Hours) (1000 Hour Intervals) 50 OH2670 1000 OH2690 OT0440 NOTE: At the 1000 Hour Interval Oil Change also inspect the brake disk wear. Refer to “Brake Disk Inspection” on page 132 and follow the inspection procedure. After brake disk inspection is complete, reassemble the level plugs using new o-rings. 1.
General Maintenance 10. Brake Disk Inspection A. Brake Disk Wear Check (1000 Hour Intervals) 1000 P OH2690 MT2830 Check the brake disks for wear every 1,000 hours of operation or yearly. If the brake disks 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.
General Maintenance 3. Attach a remote portable hydraulic pressurizing unit to the parking brake gauge port (Figure 86, 1) on the secondary function manifold (2) mounted on the inside wall of the frame (3) on the left side next to the transmission. 3 2 Front OA1230 1 Figure 86 4. Turn the key switch to the ON position (with the engine not running), release the parking brake switch, and have the operator seated in the seat. CAUTION: DO NOT exceed 575 psi (40 bar) when pressurizing the park brake.
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 (Figure 87, 1), carefully use a screwdriver to spread the brake disks apart. IMPORTANT! DO NOT damage the surfaces of the brake disks when spreading the brake disks. 1 MT2850 Figure 87 7. Using a feeler gauge, check the gap (Figure 88, 1) between the brake disks (2). If the gap is greater than .167" (4,25 mm), replace the brake disks.
General Maintenance 2 1 MT2840 Figure 88 B. Rear Axle 1. Working through the level plug hole (Figure 87, 1), carefully use a screwdriver to spread the brake disks apart. IMPORTANT! DO NOT damage the surfaces of the brake disks when spreading the brake disks. 2. Using a feeler gauge, check the gap (Figure 88, 1) between the brake disks (2). If the gap is greater than .167" (4,25 mm), replace the brake disks. NOTE: If the brake disks are worn beyond .
General Maintenance 11. Wheel End Oil WARNING: DO NOT perform service or maintenance on this vehicle with the engine running. Contact with moving parts 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 M-1141 (PERMATRAN III) CHEVRON CHEVRON 1000 THF A. Wheel End Oil Level Check (250 Hour Intervals) 250 OH2710 OT0430 1.
General Maintenance B. Wheel End Oil Change (First 50 Hours) (1000 Hour Intervals) 50 OH2670 1000 OH2690 OT0450 1. Position the vehicle on level ground, move the vehicle forward or backward enough to ensure that the wheel end (Figure 90, 1) fill/ drain plug (2) is in the 6 o’clock position (3). 1 2 3 OA1340 Figure 90 2. 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. 3.
General Maintenance 12. Wheels and Tires A. Tire Air Pressure Check (10 Hour Intervals) 10 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.
General Maintenance B. Wheel Lug Nut Torque Check (First 50 Hours) 50 LB-F T (N m) OH2670 OA1550 1. Wire brush the area around the lug nuts if necessary. There are separate lockwashers (Figure 91, 1) under the two piece lug nut configuration (2). Be sure the lockwashers are installed under each lug nut. 2. Using the torque sequence (Figure 91, A thru H) from the chart below, alternately check the torque of each of the eight lug nuts.
General Maintenance 13. Battery WARNING: Lead-acid batteries produce flammable and potentially explosive gases. To avoid personal injury when checking, 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.
General Maintenance WARNING: Fluid in electric storage batteries contains sulfuric acid which is POISON and can cause SEVERE CHEMICAL BURNS. Avoid all contact of fluid with eyes, skin or clothing. Use 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.
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.
General Maintenance 7 14 8 7.5 20 13 6 10 10 5 10 11 10 4 10 3 12 7.5 2 40 1 40 9 OA1361 Figure 94 No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Amp/Volt 40 Amp 7.5 Amp 10 Amp 10 Amp 10 Amp 10 Amp 7.
General Maintenance 15. Boom Chains and Wear Pads A. Boom Chain Tension Check (First 50 Hours) (1000 Hour Intervals) 1000 50 OH2390 OH2670 OH2690 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.
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 measurement (Figure 96, 1) from the top rear edge of the intermediate boom (2) to the top rear edge of the inner boom (3). This measurement should be in the range of 8.0" (203 mm) to 8.5" (216 mm).
General Maintenance 7. If the measurement is more than 8.5" (216 mm), tighten the retract chain locknut (Figure 97, 1) located on the bottom of the outer boom (2). 1 2 OA0512 Figure 97 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.
General Maintenance 11. Measure the sag (Figure 98, 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), the top boom chains need to be adjusted. See “Top Boom Chain Tension Adjustment” on page 148.
General Maintenance B. Top Boom Chain Tension Adjustment (As required) NOTE: Always perform the “Boom Chain Tension Check” starting on page 144 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.
General Maintenance 1 OH0252 Figure 100 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" (38 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.
General Maintenance C. Boom Chain Inspection (250 Hour Intervals) 250 OA1490 OH2710 WARNING: Worn pins, stretched or cracked links or corrosive 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.
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 (N) 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.
General Maintenance Elongation When the original length (Figure 102, 1) of 12.00" (305 mm) per foot of new chain has elongated from wear to a length (2) 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.
General Maintenance Turning or Protruding Pins (Figure 103) 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 (Figure 103, 1).
General Maintenance Cracked Plates Inspect the chains very carefully, front and back as well as side to side, for any evidence of cracked plates. 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 (1) are a result of repeated cyclic loading beyond the chain’s endurance limit.
General Maintenance D. Chain Lubrication (1000 Hour Intervals) 1000 After inspection and before OA1510 OH2690 being returned to service, chains must be lubricated with a quality chain lubricant (“LUBRIPLATE” Chain & Cable Fluid, “LPS3” or equivalent). 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.
General Maintenance E. Wear Pad Inspection (50 Hour Intervals) 50 OH2680 OH2400 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.
General Maintenance F. Wear Pad Replacement (As Wear Pad Indicators Indicate) Each boom pad (Figure 105, 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.
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 104. 3. Prepare the engine for storage (refer to the engine manual). 4. Apply rust inhibiting lubricant to all exposed hydraulic cylinder rods. 5. Disconnect the battery cables.
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 on the vehicles frame (Figure 106).
Test Procedures 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. WARNING: 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.
Test Procedures Test 3 - Park Brake Hold Performance a. With the rated load of 6,000 lbs (2.721 Kg) on the forks, drive the vehicle forward up a 15% grade (15 ft. rise over 100 ft. run). b. Stop the 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.
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 (Figure 108, 1) in the Four Wheel Steer position (2), turn the steering wheel full left. 2.
Specifications Specifications Fluid & Lubrication Capacities Engine Crankcase Oil: Capacity with Filter Change ......................................11 quarts (10,4 liters) Filter Capacity ................................................................ 1 quart (0,9 liters) Type of Oil ....................................................................................... 15W40 Fuel Tank: Total Capacity .......................................................... 37 gallons (140 liters) Usable Capacity.....
Specifications Axles: Differential Housing Capacity ................................ 12.2 quarts (11,5 liters) Type of Fluid .................... Universal Tractor Fluid (see chart on page 130) Wheel Ends: Wheel End Capacity................................................ 0.95 quarts (0,9 liters) Type of Fluid .................... Universal Tractor Fluid (see chart on page 136) Tires Air Pressure: Standard Tire 13.00 - 24, 12 ply (minimum) ..................... 55 psi (379 kPa) Optional Rock Tire 15.
Specifications Vehicle Dimensions With Standard 13.00 - 24 Tires: (A) Length (less forks)............................................ 217 inches (5.512 mm) (B) Width .................................................................. 98 inches (2.489 mm) (C) Height............................................................... 100 inches (2.540 mm) (D) Wheelbase ....................................................... 113 inches (2.870 mm) (E) Ground Clearance.................................................
Specifications Electrical System Rating:.............................................................12V DC Negative Ground Number of Batteries: .................................................................. One Type of Batteries: ..... Maintenance Free (1000 Cold Cranking Amps) Series of Batteries: ............................................................. Series 31 Fuse Ratings: Main................................................................................................
Index A Accelerator Pedal ...........................23 Accident Prevention Tags ................5 Air Cleaner ...................................106 Air Intake System .........................109 Air Pressure .................................164 Alternator Charging Warning Indicator Light ............................39 Attachment Reconnect ...................69 Attachment Removal ......................68 Attachment Tilt ...............................31 Auger Operation .............................
Index Fork Ratings .................................. 77 Fork Sweep ................................... 67 Four Wheel Steer Indexing ............ 64 Four Wheel Steer Indexing Procedure ............................... 162 Four Wheel Steering ..................... 64 Frame Level Indicator .................... 39 Frame Sway Control Lever ............ 31 Front Wheel Steering .................... 65 Front, Rear & Boom Worklights ..... 42 Fuel ............................................... 58 Fuel Cap ..........
Index Relay ............................................142 Relay Ratings ...............................166 Removing From Storage ..............158 Replacement Parts ...........................2 Replacing Tires ............................139 Reports .............................................2 Restriction Indicator .....................106 Roof Wiper Control .........................48 S Safety Element .............................107 Seat Belt ...................................
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Accident Prevention Tags Accident Prevention Tags 8990401 Origin 5/00 OS2180
Accident Prevention Tags 8990401 Origin 5/00 OS2180
Replacement Manuals If the owner/operator or safety manuals that were originally shipped with your vehicle are lost, stolen or need replacement, contact your local distributor for replacement manuals. If for any reason your distributor cannot supply the manuals you need; write, call or send a fax to the following address for ordering information. JLG Industries Inc.
Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA Phone: (717) 485-5161 Customer Support Toll Free: (877) 554-5438 Fax: (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W.
