JLG Skytrak 6036, Skytrak 8042, Skytrak 6042, Skytrak 10042, Skytrak 10054 Operation & Safety Manual

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Operation & Safety

An Oshkosh Corporation Company

Manual

Original Instructions

Keep this manual with machine at all times.

Models

6036, 6042, 8042,

10042, 10054

SN 0160069719 to Present including 0160065791, 0160065792, 0160065796, 0160065798, 0160065824, 0160065825, 0160065826, 0160069336, 0160069359, 0160069383, 0160069411, 0160069441,

0160069566, 0160069567 & 0160069568

31211018

Revised

July 17, 2017

CALIFORNIA PROPOSITION 65

BATTERY WARNING

Battery posts,

terminals and related

accessories contain

lead and lead compounds,

chemical known to the

State of California

to cause cancer and

reproductive harm.

WASH HANDS

AFTER HANDLING!

CALIFORNIA PROPOSITION 65

EXHAUST WARNING

Diesel Engine exhaust and

some of its constituents

are known to the State of

California to cause cancer,

birth defects and other

reproductive harm.

Revision Log

REVISION LOG

April 2, 2015 - A - Original Issue of Manual

April 17, 2015 - B - Revised pages d & 5-1.

April 30, 2015 - C - Revised page 9-4.

October 12, 2015 - D - Revised cover and pages d, 2-1, 2-4 thru 2-11, 3-7, 3-23, 4-5, 5-2, 6-2, 7-3 thru 7-6, 7-15 thru 7-21, 9-1, 9-3, 9-4 & 9-6.

April 11, 2016 - E - Revised covers and pages d, 2-5, 2-6, 2-8, 2-9, 2-14, 3-5, 3-20, 3-21, 4-4, 5-2, 5-3, 5-30, 5-31, 5-38 thru 5-41, 5-46 thru 5-48, 7-3, 7-4, 7-7 thru 7-9, 7-27, 7-28, 8-3, 9-1 thru 9-4, 9-7, 9-10 & 9-11.

April 10, 2017 - F - Revised pages 1-1, 1-4, 2-4, 2-5, 2-7, 2-8, 5-15, 5-16, 5-18, 5-20, 5-22, 5-24, 5-26, 5-28, 5-30, 5-32, 5-34, 5-36, 5-38, 5-40, 5-42, 5-44, 5-46, 5-48, 5-50 & rear cover.

July 17, 2017 - G - Revised pages c, 1-1, 1-2, 1-4, 1-10, 2-4 thru 2-8, 3-5, 3-7, 3-24, 4-3, 4-12, 4-13, 5-2, 5-6, 6-1, 6-2, 7-3 thru 7-7, 7-16, 7-23, 8-3 & 9-1 thru 9-4.

a31211018

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 Operation & Maintenance Manual

• Telehandler Safety Manual (ANSI only)

• All instructional decals and plates

• Any optional equipment instructions furnished

The operator must also read, understand and comply with all applicable Employer, Industry and Governmental rules, standards and regulations.

Modifications

Modifications to this machine may affect compliance with Industry Standards and/ or Governmental Regulations. Any modification must be approved by JLG.

b 31211018

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

• 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

In USA:

Toll Free: 1-877-JLG-SAFE (1-877-554-7233)

Outside USA:

Phone: +1-717-485-6591

E-mail:

ProductSafety@JLG.com

c31211018

Read This First

O 5603H

ULTRA LOW

SULFUR DIESEL

FUEL ONLY

S < 15 mg/kg

1001125387A

XXXhp (XXkW) @ XXXX RPM

XXXXXXXXXX_A

2 1

XXXhp (XXkW) @ XXXX RPM

XXXXXXXXXX_A

(8042, 10042, 10054)

(6036, 6042)

Other Publications Available

Service Manual.............................................................................................................................31211015

Parts Manual

6036 & 6042...........................................................................................................................31211016

8042, 10042 & 10054..........................................................................................................31211017

Note: The following standards may be referenced in this manual: ANSI is compliant to ANSI/ITSDF B56.6 AUS is compliant to AS 1418.19 CE is compliant to EN1459 Refer to the machine Serial Number Plate to identify the applicable compliance standard.

Machine Configuration

Two configurations of each machine are included in this manual. Determine if machine is equipped with Ultra Low Sulfur Fuel Decal (1) as indicated below.

• If equipped with the Ultra Low Sulfur decal, all specific references to this machine configuration will be referred to as Ultra Low Sulfur (ULS) from this point forward.

•If

not

equipped with the Ultra Low Sulfur decal, all specific references to this machine

configuration will be referred to as Low Sulfur (LS) from this point forward.

Maximum engine power can be found on the decals (2) located on the inside of the side engine compartment doors.

d 31211018

TABLE OF CONTENTS

Revision Log

Read This First

Operator Qualifications ......................................................b

Modifications ...................................................................... b

Other Publications Available .............................................. d

Machine Configuration ....................................................... d

Table of Contents

Section 1 - General Safety Practices

1.1 Hazard Classification System ....................................................................1-1

Safety Alert System and Safety Signal Words...............................1-1

.......................................................................................................................1-1

1.2 General Precautions .....................................................................................1-1

1.3 Operation Safety............................................................................................1-2

Electrical Hazards ....................................................................................1-2

Tip Over Hazard .......................................................................................1-4

Travel Hazard............................................................................................1-7

Load Falling Hazard ...............................................................................1-8

Lifting Personnel .....................................................................................1-9

Driving Hazards on Slopes................................................................ 1-10

Pinch Points and Crush Hazards.....................................................1-11

Fall Hazard.............................................................................................. 1-13

Chemical Hazards ................................................................................ 1-14

1.4 ClearSky (if equipped)............................................................................... 1-15

Federal Communications Commission (FCC)

Information for Users.......................................................................... 1-15

Table of Contents

Section 2 - Pre-Operation and Inspection

2.1 Preparation, Inspection and Maintenance...........................................2-1

2.2 Pre-Operation Check and Inspection.....................................................2-2

2.3 Safety Decals ...................................................................................................2-4

ANSI (if equipped)...................................................................................2-4

ISO (if equipped) .....................................................................................2-7

2.4 Walk-Around Inspection .......................................................................... 2-10

2.5 Warm-Up and Operational Checks ...................................................... 2-12

Warm-Up Check ................................................................................... 2-12

Operational Check...............................................................................2-12

2.6 Operator Cab................................................................................................2-13

2.7 Windows........................................................................................................2-14

Cab Door Window (if equipped) .................................................... 2-14

i31211018

Table of Contents

Section 3 - Controls and Indicators

3.1 General..............................................................................................................3-1

3.2 Controls ............................................................................................................ 3-2

Dash Controls and Indicators .............................................................3-4

Instrument Cluster .................................................................................3-6

Ignition .......................................................................................................3-8

Park Brake..................................................................................................3-9

Parking Procedure.................................................................................. 3-9

Transmission Control Lever ............................................................. 3-10

Boom Joystick ....................................................................................... 3-12

Auxiliary Hydraulic Joystick ............................................................. 3-13

Frame Level Joystick........................................................................... 3-14

Outrigger Switches (10042 & 10054)............................................ 3-15

Accessory Control Lever (if equipped)......................................... 3-16

3.3 Steer Modes ................................................................................................. 3-17

Steer Mode Change ............................................................................ 3-17

3.4 Stabil-Trak™ System (6042, 8042, 10042 & 10054) ....................... 3-18

Free Pivot Mode ................................................................................... 3-18

Slow Pivot Mode .................................................................................. 3-18

Locked Mode......................................................................................... 3-18

3.5 Boom/Outrigger Interlock System (10054)....................................... 3-19

Extend Interlock Mode ...................................................................... 3-19

Outrigger Interlock Mode................................................................. 3-19

3.6 Operator Seat .............................................................................................. 3-20

Adjustments .......................................................................................... 3-20

Seat Belt .................................................................................................. 3-22

3.7 Boom Angle and Extension Indicators............................................... 3-23

3.8 Reverse Sensing System (if equipped) ............................................... 3-24

ii 31211018

Section 4 - Operation

4.1 Engine................................................................................................................4-1

Starting the Engine ................................................................................4-1

Battery Boosted Starting ......................................................................4-2

Normal Engine Operation....................................................................4-3

Shut-Down Procedure ..........................................................................4-3

4.2 After-Treatment System (ATS) (if equipped for

ULS/85 or 110HP) ..........................................................................................4-4

Automatic Exhaust System Cleaning...............................................4-4

Stationary Exhaust System Cleaning ...............................................4-5

4.3 Operating with a Non-Suspended Load ...............................................4-6

Lift Load Safely.........................................................................................4-6

Picking Up a Load ...................................................................................4-6

Transporting a Load...............................................................................4-7

Leveling Procedure ................................................................................4-7

Placing a Load ..........................................................................................4-8

Disengaging a Load ...............................................................................4-8

4.4 Operating with a Suspended Load.........................................................4-9

Lift Load Safely.........................................................................................4-9

Picking Up a Suspended Load............................................................4-9

Transporting a Suspended Load ....................................................4-10

Leveling Procedure ............................................................................. 4-10

Placing a Suspended Load ...............................................................4-11

Disengaging a Suspended Load ....................................................4-11

4.5 Loading and Securing for Transport ................................................... 4-12

Tie Down .................................................................................................4-12

Lifting .......................................................................................................4-13

Table of Contents

iii31211018

Table of Contents

Section 5 - Attachments

5.1 Approved Attachments ..............................................................................5-1

5.2 Unapproved Attachments .........................................................................5-1

5.3 JLG Supplied Attachments ........................................................................5-2

5.4 Telehandler/Attachment/Fork Capacity...............................................5-4

5.5 Use of the Capacity Chart........................................................................... 5-5

Capacity Indicator Locations ..............................................................5-5

Sample Capacity Chart .........................................................................5-6

Example......................................................................................................5-8

5.6 Attachment Installation ........................................................................... 5-10

Hydraulic Operated Attachment ................................................... 5-12

5.7 Adjusting/Moving Forks .......................................................................... 5-13

5.8 Attachment Operation............................................................................. 5-14

Carriage with Forks ............................................................................. 5-15

Side Shift Carriage ............................................................................... 5-16

Side Tilt Carriage .................................................................................. 5-18

Swing Carriage ..................................................................................... 5-20

Dual Fork Positioning Carriage ....................................................... 5-22

Mast Carriage ........................................................................................ 5-24

Pipe Grapple.......................................................................................... 5-26

Fork Extension ...................................................................................... 5-28

Coupler Mounted Hook .................................................................... 5-30

Fork Mounted Hook............................................................................ 5-32

Bucket ...................................................................................................... 5-34

Grapple Bucket ..................................................................................... 5-36

Bucket - Fork Mounted ...................................................................... 5-38

Trash Hopper - Fork Mounted......................................................... 5-40

Truss Boom ............................................................................................ 5-42

Material Handling Arm ...................................................................... 5-44

Personnel Work Platform - Fork Mounted.................................. 5-46

Sweeper .................................................................................................. 5-48

Boom Mounted Lifting Lug.............................................................. 5-50

Section 6 - Emergency Procedures

6.1 Towing a Disabled Product .......................................................................6-1

Moving Short Distances ....................................................................... 6-1

Moving Longer Distances....................................................................6-1

6.2 Emergency Lowering of Boom.................................................................6-2

6.3 Emergency Exit from Enclosed Cab........................................................6-3

Fixed Window (if equipped) ...............................................................6-3

Latch Window (if equipped) ...............................................................6-3

iv 31211018

Section 7 - Lubrication and Maintenance

7.1 Introduction ....................................................................................................7-1

Clothing and Safety Gear .....................................................................7-1

7.2 General Maintenance Instructions..........................................................7-2

7.3 Maintenance Schedules..............................................................................7-3

Every 10 Hours .........................................................................................7-3

First 50 Hours............................................................................................7-3

Every 50 Hours .........................................................................................7-4

First 250 Hours .........................................................................................7-4

Every 250 Hours.......................................................................................7-4

First 500 Hours .........................................................................................7-5

Every 500 Hours.......................................................................................7-5

Every 750 Hours.......................................................................................7-5

Every 1000 Hours ....................................................................................7-6

Every 1500 Hours ....................................................................................7-6

Every 2000 Hours or 2 Years................................................................7-7

Every 4000 Hours or 3 Years................................................................7-7

Every 5000 Hours or 4 Years................................................................7-7

7.4 Lubrication Schedules .................................................................................7-8

50 Hour Lubrication Schedule............................................................7-8

250 Hour Lubrication Schedule......................................................7-11

1000 Hour Lubrication Schedule.................................................... 7-13

7.5 Operator Maintenance Instructions .................................................... 7-14

Fuel System............................................................................................ 7-14

Diesel Exhaust Fluid (DEF) System (if equipped for

ULS/85 or 110HP) ................................................................................. 7-16

Engine Oil................................................................................................ 7-17

Air Intake System ................................................................................. 7-18

Hydraulic Oil ..........................................................................................7-22

Tires........................................................................................................... 7-23

Transmission Oil ................................................................................... 7-25

Engine Cooling System......................................................................7-26

Brake Fluid (SN 0160074878 to Present) .....................................7-27

Battery...................................................................................................... 7-28

Table of Contents

Section 8 - Additional Checks

8.1 Stabil-Trak (6042, 8042, 10042 & 10054)...............................................8-1

8.2 Boom/Outrigger Interlock (10054)..........................................................8-2

8.3 Reverse Sensing System (if equipped)...................................................8-3

v31211018

Table of Contents

Section 9 - Specifications

9.1 Product Specifications.................................................................................9-1

Fluids........................................................................................................... 9-1

Capacities ..................................................................................................9-4

Tires .............................................................................................................9-6

Performance .............................................................................................9-7

Dimensions ...............................................................................................9-9

Index

Inspection, Maintenance and Repair Log

vi 31211018

Section 1- General Safety Practices

SECTION 1 - GENERAL SAFETY PRACTICES

1.1 HAZARD CLASSIFICATION SYSTEM

Safety Alert System and Safety Signal Words

DANGER

DANGER indicates an imminently hazardous situation which, if not avoided, will result

in death or serious injury.

WARNING

WAR NIN G indicates a potentially hazardous situation which, if not avoided, could

result in death or serious injury.

CAUTION

CAUTION indicates a potentiality hazardous situation which, if not avoided, may result

in minor or moderate injury.

1.2 GENERAL PRECAUTIONS

WARNING

Before operation, read and understand this manual. Failure to comply with the safety precautions listed in this manual could result in machine damage, property damage, personal injury or death.

• Hydraulic cylinders are subject to thermal expansion and contraction. This may result in changes to the boom and/or attachment position while the machine is stationary. Factors affecting thermal movement can include the length of time machine is stationary, hydraulic oil temperature, ambient air temperature and boom and/or attachment position.

• Precautions to avoid all hazards in the work area must be taken by the user before and during operation of the machine.

1-131211018

Section 1- General Safety Practices

O 0891D

10 ft

(3m)

1.3 OPERATION SAFETY

Note: The manufacturer has no direct control over machine application and operation. Therefore, safety issues listed in this manual are non-exhaustive. The user and operator are responsible for conforming with good safety practices.

Electrical Hazards

• This machine is not insulated and does not provide protection from contact or being near electrical current.

• Always check for power lines before raising the boom.

• Maintain distance from electrical lines, apparatus, or any energized (exposed or insulated) parts according to the Minimum Approach Distance (MAD).

Voltag e Range

(Phase to Phase)

0 to 50 KV 10 ft (3 m)

Over 50KV to 200 KV 15 ft (5 m) Over 200 KV to 350 KV 20 ft (6 m) Over 350 KV to 500 KV 25 ft (8 m) Over 500 KV to 750 KV 35 ft (11 m)

Over 750 KV to 1000 KV 45 ft (14 m)

Note: This requirement shall apply except where employer, local or governmental regulations are more stringent.

• Allow for machine movement and electrical line swaying.

• Maintain a clearance of at least 10 ft (3m) between any part of the machine and its occupants, their tools and their equipment from any electrical line or apparatus carrying up to 50,000 volts. One foot additional clearance is required for every additional 30,000 volts or less.

Minimum Approach Distance

(MAD)

1-2 31211018

Section 1- General Safety Practices

• The minimum approach distance may be reduced if insulating barriers are installed to prevent contact, and the barriers are rated for the voltage of the line being guarded. These barriers shall not be part of (or attached to) the machine. The minimum approach distance shall be reduced to a distance within the designed working dimensions of the insulating barrier. This determination shall be made by a qualified person in accordance with the employer, local, or governmental requirements for work practices near energized equipment.

DANGER

Do not maneuver machine or personnel inside prohibited zone (MAD). Assume all electrical parts and wiring are energized unless known otherwise.

1-331211018

Section 1- General Safety Practices

OW0050

OW0080

OW0100

4 FT

(1,2 M)

Tip Over Hazard

General

• For additional load requirements, refer to the appropriate capacity chart.

• Never use an attachment without the appropriate original equipment manufacturer (OEM) approved capacity chart installed on the telehandler.

• Understand how to properly use the capacity charts located in cab.

• DO NOT exceed rated lift capacity.

• Be sure that the ground conditions are able to support the machine.

• Be aware of wind conditions. Wind may cause load swing and dangerous side loads.

• Keep the machine a minimum of 2 ft (0,6 m) from holes, drop-offs, obstructions, debris, concealed holes and other potential hazards at ground level.

• DO NOT raise boom unless frame is level (0 degrees), unless otherwise noted on capacity chart.

• DO NOT level machine with boom/attachment above 4 ft (1,2 m). (AUS—DO NOT level machine with load more than 11.8 in (300 mm) above ground surface.)

1-4 31211018

Section 1- General Safety Practices

OH2291

OH20911

OH2221

• MAINTAIN proper tire pressure at all times. If proper tire pressures are not maintained, this machine could tip over.

• Refer to manufacturer’s specifications for proper fill ratio and pressure requirements for tires equipped with ballast.

• Always wear seat belt.

• Keep head, arms, hands, legs and all other body parts inside operator’s cab at all times.

If telehandler starts to tip over:

• DO NOT JUMP

• BRACE YOURSELF and STAY WITH THE MACHINE

• KEEP YOUR SEAT BELT FASTENED

• HOLD ON FIRMLY

• LEAN AWAY FROM THE POINT OF IMPACT

1-531211018

Section 1- General Safety Practices

O 0901D

OW0150

Non-Suspended Load

• DO NOT drive with boom raised.

Suspended Load

• Tether suspended loads to restrict movement.

• Weight of all rigging (slings, etc.) must be included as part of load.

• DO NOT attempt to use telehandler frame-leveling to compensate for load swing.

• Keep heavy part of load closest to attachment.

• Never drag the load; lift vertically.

When driving with a suspended load:

• Start, travel, turn and stop slowly to prevent load from swinging.

• DO NOT extend boom.

• DO NOT raise the load more than 300 mm (11.8 in) above ground surface or the boom more than 45°.

• DO NOT exceed walking speed.

1-6 31211018

Section 1- General Safety Practices

OAL2030

2-WHEEL FRONT STEER 4-WHEEL CIRCLE STEER 4-WHEEL CRAB STEER

Travel Hazard

• Steering characteristics differ between steer modes. Identify the steer mode settings of the telehandler being operated.

• DO NOT change steer modes while traveling. Steer modes must be changed while telehandler is stationary.

• Visually verify proper wheel alignment after each steer mode change.

• Ensure that adequate clearance is provided for both rear tail swing and front fork swing.

• Look out for and avoid other personnel, machinery and vehicles in the area. Use a spotter if you DO NOT have a clear view.

• Before moving be sure of a clear path and sound horn.

• When driving, retract boom and keep boom/attachment as low as possible while maintaining visibility of mirrors and maximum visibility of path of travel.

• Always look in the direction of travel.

• Always check boom clearances carefully before driving underneath overhead obstructions. Position attachment/load to clear obstacles.

• When driving in high speed, use only front wheel steer (if steering modes are selectable).

• Telehandlers equipped with solid or foam filled tires should not be used in applications requiring excessive roading or driving extended distances. In the event an application requires excessive roading or driving expanded distances, it is recommended to use telehandlers not equipped with solid or foam filled tires.

1-731211018

Section 1- General Safety Practices

OW0130

Load Falling Hazard

• Never suspend load from forks or other parts of carriage weldment. Use only approved lift points.

• DO NOT burn or drill holes in fork(s).

• Forks must be centered under load and spaced apart as far as possible.

1-8 31211018

Section 1- General Safety Practices

O 0171W

O 0921D

Lifting Personnel

• When lifting personnel, USE ONLY an approved personnel work platform, with proper capacity chart displayed in the cab.

• DO NOT drive machine from cab when personnel are in platform.

1-931211018

Section 1- General Safety Practices

OW0200

Driving Hazards on Slopes

To maintain sufficient traction and braking capabilities, travel on slopes as follows:

• When unloaded, drive with forks pointed downhill.

• When loaded, drive with the forks pointed uphill.

• For additional travel requirements, refer to the appropriate capacity chart.

• To avoid overspeeding the engine and drivetrain when driving down slopes, downshift to a lower gear before going downhill and use the service brake as necessary to maintain a slow speed. DO NOT shift into neutral and coast downhill.

• Avoid excessively steep slopes or unstable surfaces. To avoid tip over DO NOT drive across excessively steep slopes under any circumstances.

• Avoid turning on a slope. Never engage “inching” or shift to “Neutral” when going downhill.

• DO NOT park on a slope.

1-10 31211018

Section 1- General Safety Practices

OW0210

OW0220

OW02

Pinch Points and Crush Hazards

Stay clear of pinch points and rotating parts on the telehandler.

• Stay clear of moving parts while engine is running.

• Keep clear of steering tires and frame or other objects.

• Keep clear from under boom.

1-1131211018

Section 1- General Safety Practices

OW0240

OW0250

OW0260

OW0960

• Keep clear of boom holes.

• Keep arms and hands clear of attachment tilt cylinder.

• Keep hands and fingers clear of carriage and forks.

• Keep others away while operating.

1-12 31211018

Section 1- General Safety Practices

OW0280

OW0290

Fall Hazard

• Enter using the proper hand holds and steps provided. Always maintain 3-point contact when mounting or dismounting. Never grab control levers or steering wheel when mounting or dismounting the machine.

• DO NOT get off the machine until the shutdown procedure on page 4-3 has been performed.

• DO NOT carry riders. Riders could fall off machine causing death or serious injury.

1-1331211018

Section 1- General Safety Practices

OW0300

OW0950

Chemical Hazards

Exhaust Fumes

• DO NOT operate machine in an enclosed area without proper ventilation.

• DO NOT operate the machine in hazardous environments unless approved for that purpose by JLG and site owner. Sparks from the electrical system and the engine exhaust can cause an explosion.

Flammable Fuel

• DO NOT fill the fuel tank or service the fuel system near an open flame, sparks or smoking materials. Engine fuel is flammable and can cause a fire and/or explosion.

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.

• Stop engine and relieve trapped pressure. Fluid in the hydraulic system is under enough pressure that it can penetrate the skin.

• DO NOT use 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.

1-14 31211018

Section 1- General Safety Practices

1.4 CLEARSKY (IF EQUIPPED)

Federal Communications Commission (FCC) Information for Users

FCC Statement Regarding Interference

This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:

• Reorient or relocate the receiving antenna.

• Increase the separation between the equipment and receiver.

• Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.

• Consult the dealer or an experienced radio/TV technician for help.

This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.

Changes or modifications not expressly approved by the party responsible for compliance could void the user’s authority to operate the equipment.

1-1531211018

Section 1- General Safety Practices

Notice Regarding Radio Frequency Radiation Exposure

Do not operate your unit when a person is within eight inches (20 centimeters) of the antenna. A person or object within eight inches (20 centimeters) of the antenna could impair call quality and may cause the unit to operate at a higher power level than necessary, as well as expose that person to RF energy in excess of that established by the FCC RF Exposure Guidelines.

Important: The unit must be installed in a manner that provides a minimum separation distance of eight inches (20 centimeters) or more between the antenna and persons and just not be co-located or operate in conjunction with any other antenna or transmitter in order to satisfy FCC RF exposure requirements for mobile transmitting devices.

Important: To comply with the FCC RF exposure limits and to satisfy the categorical exclusion requirements for mobile transmitters, the requirements described in the following section, “Antenna Installation”, must be met.

Antenna Installation

A minimum separation distance of eight inches (20 centimeters) must be maintained between the antenna and all persons.

The combined cable loss and antenna gain must not exceed +7.5 dBi (850 band). The combined cable loss and antenna gain must not exceed +2.5 dBi and total system output must not exceed 2.0W EIRP in the PCS (1900) band in order to comply with the EIRP limit of 24.232 (b). OEM installers must be provided with antenna installation instruction and transmitter operating conditions for satisfying RF exposure compliance.

1-16 31211018

Section 2- Pre-Operation and Inspection

SECTION 2 - PRE-OPERATION AND INSPECTION

2.1 PREPARATION, INSPECTION AND MAINTENANCE

The following table covers the periodic machine inspections and maintenance required. Consult local regulations for further requirements for telehandlers. The frequency of inspections and maintenance must be increased as necessary when the machine is used in a harsh or hostile environment, if the machine is used with increased frequency, or if the machine is used in a severe manner.

Inspection and Maintenance

Typ e Frequency

Pre-Operation

Inspection

Pre-Delivery

Inspection (see note)

Preventative

Maintenance

Note: Inspection forms are available.

Beginning of each

work shift or at each

change of operator.

Before each sale,

lease or rental

delivery.

At intervals as

specified in the

Service Manual and/

or the Maintenance

Charts located on the

machine.

Primary

Responsibility

User or

Operator

Owner, Dealer

or User

Owner, Dealer

or User

Service

Qualification

User or

Operator

Qualified

Mechanic

Qualified

Mechanic

Reference

Operation &

Safety Manual

Service Manual

and applicable

Inspection form.

Service Manual

and

Maintenance

Charts

2-131211018

Section 2- Pre-Operation and Inspection

OAH1000

PARENT METAL CRACK WELD CRACK

2.2 PRE-OPERATION CHECK AND INSPECTION

Note: Complete all required maintenance before operating unit.

WARNING

FAL L HA ZARD. Use extreme caution when checking items beyond your normal reach.

Use an approved ladder.

The pre-operation check and inspection, performed at beginning of each work shift or at each change of operator, should include the following:

1. Cleanliness—Check all surfaces for leakage (oil, fuel or battery fluid) or foreign objects. Report any leakage to the proper maintenance personnel.

2. Structure—Inspect the machine structure for dents, damage, weld or parent metal cracks or other discrepancies.

3. Safety Decals—Ensure all safety decals are legible and in place. Clean or replace as required. See page 2-4 for details.

4. Operation and Safety Manuals—Operation & Safety Manual and AEM Safety Manual (ANSI only) are located in cab manual holder.

5. Walk-Around Inspection—See page 2-10 for details.

6. Fluid Levels—Check fluids, including fuel, diesel exhaust fluid (DEF), hydraulic oil, engine oil, transmission fluid and coolant. When adding fluids, refer to Section 7Lubrication and Maintenance and Section 9- Specifications to determine proper type and intervals. Before removing filler caps or fill plugs, wipe all dirt and grease away from the ports. If dirt enters these ports, it can severely reduce component life.

7. Attachments/Accessories—Ensure correct capacity charts are installed on telehandler. If provided, reference Operation & Safety Manual of each attachment or accessory installed for specific inspection, operation and maintenance instructions.

2-2 31211018

Section 2- Pre-Operation and Inspection

8. Operational Check—Once walk-around inspection is complete, perform a warm-up and operational check (see page 2-12) of all systems in an area free of overhead and ground level obstructions. See Section 3- Controls and Indicators for more specific operating instructions.

WARNING

If telehandler does not operate properly, immediately bring machine to a stop, lower boom and attachment to ground and stop the engine. Determine cause and correct before continued use.

2-331211018

Section 2- Pre-Operation and Inspection

OH5514

1001158319-ENGLISH

1001180176-ENGLISH/FRENCH

1001158272-ENGLISH

1001180175-ENGLISH/FRENCH

4107971-ENGLISH

1001187239-ENGLISH/FRENCH

(10042 & 10054)

1001162736

1001162735

CAPACITY

CHARTS

1706850-ENGLISH

1001163304-

ENGLISH/FRENCH

1706299-ENGLISH

1001163210-

ENGLISH/FRENCH

1706306-ENGLISH

1001163285-ENGLISH/FRENCH

1001125387-ENGLISH

1001163355-ENGLISH/FRENCH

1001162736 B

1001162735 B

1001162737 A

1001158319 A

Fasten

seat belt.

Operator must be trained and

must read and understand

all capacity charts, operator

and safety manuals.

1001158272 A

RUN-OVER

HAZARD

could cause

death or

serious

injury.

4107971B

1706306A

1706850B

Keep others

away while

operating.

WARNING

LOWERINGBOOM OR FALLING LOAD

could cause death or serious injury.

1706299B

CONTACTING

POWERLINES

will result in death

or serious injury.

1001162737

(10042 & 10054)

1001162734

1001162734 B

1001218659 - ENGLISH

1001219211 - ENGLISH/FRENCH

(INSIDE OF RESERVOIR COVER)

(SN 0160078382 TO PRESENT)

ULTRALOW

SULFURDIESEL

FUELONLY

S < 15 mg/kg

1001125387 A

2.3 SAFETY DECALS

Ensure all DANGER, WAR NI NG, CAUTION and instructional decals and proper capacity charts are legible and in place. Clean and replace as required.

ANSI (if equipped)

2-4 31211018

20 A

15 A

7.5 A

10 A

7.5 A

10 A

20 A

7.5 A

F10

20 A

F11

7.5 A

F12

10 A

F13

15 A

F14

5 A

F16

10 A

F17

10 A

F18

5 A

F19

10 A

F20

30 A

35 A

R3N35 A

35 A

R10

35 A

R11

35 A

1001189327A

1001189327

Riders could fall

omachine

causing death or serious

injury.

WARNING

No riders.

1706768A

1706768-ENGLISH

1001163300-ENGLISH/FRENCH

4107442

-10

4105262

ROTATING P ARTS could crush or cut causing death or serious injury .

WARNING

Keep clear of rot ating p arts.

1706301B

1706301-ENGLISH

1001163222-

ENGLISH/FRENCH

1706298-ENGLISH

1001163206-ENGLISH/FRENCH

FALLINGOFF ATTACHMENT could result in death or serious injury .

WARNING

DONOTTRA VEL with personnel in work platform.

Lift or lower personnel only in aJLGapproved work platform.

1706298B

1701640

1702300

1001202626 (74HP) 1001173423 (85HP)

1001173422 (110HP)

1001160072-ENGLISH

1001160945-ENGLISH/FRENCH

(IF EQUIPPED WITHREVERSE SENSING SYSTEM)

IMPORTANT

• VEHICLE EQUIPPED WITH REVERSE

SENSING SYSTEM

• THIS REVERSE SENSING SYSTEM IS

TO BE USEDASANAID ONLY

• LOOK OUTFOR AND AVOID OTHER

PERSONNEL, MACHINERYAND VEHICLES INTHEAREA

• USEA SPOTTER IF YOU DO NOT HAVE

ACLEAR VIEW

1001160072 REVA

(IF EQUIPPED WITHBOOM

MOUNTED LIFTING LUG)

WARNING

SWINGING LOADS could cause MACHINE TIPOVER which could result in death or serious injury.

•Refer to capacity chart for additional capacity ratings.

Failure to follow instructions could result in death or serious injury.

ALWAYS

•travel slowly

•rig properly

•use two tethers

1001207217A

1001207217

(ENGLISH)

WARNING

Failure to follow instructions could result in death or serious injury.

1001210582A

Le non-respect de ces instructions peut provoquer des blessures graves, voire mortelles.

•Se reporter au tableau de capacités pour d'autres capacités nominales.

•Refer to capacity chart for additional capacity ratings.

ALWAYS

•travel slowly

•rig properly

•use two tethers

TOUJOURS

•déplacer la

machine lentement

•l'arrimer

correctement

•utiliser deux

dispositifs d'attache

AVERTISSEMENT

1001210582

WARNING

Failure to follow instructions could result in death or serious injury.

1001210581A

Le non-respect de ces instructions peut provoquer des blessures graves, voire mortelles.

SWINGING LOADS could cause MACHINE TIPOVER which could result in death or serious injury.

Le BALANCEMENT DES CHARGES peut causer le RENVERSEMENT DE LAMACHINE et entraîner des blessures graves, voire mortelles.

AVERTISSEMENT

1001210581

(ENGLISH/FRENCH)

1001120989

(IF EQUIPPED)

1001120989A

1001189328A

7.5 A

35A

7.5 A

1001189328

(10054)

OH5525

VIEW B-B

1706296-ENGLISH

1001163174-ENGLISH/FRENCH

EXPLOSIVEGASES could cause death or serious injury .

WARNING

Keep sparks, ames and lighted materials away from batteries.

1706296B

1706300-ENGLISH

1001163212-ENGLISH/FRENCH

1706300C

VIEW C-C

IMPORTANT

1001160071 Rev A

EMERGENCYEXIT

1001160071-ENGLISH

1001160787-ENGLISH/FRENCH

(IF EQUIPPED WITHLATCH WINDOW)

91404299-

(IF EQUIPPED WITH

FIXED WINDOW)

VIEW D-D

VIEW A-A

1001154575A

*Refer to load capacity chart for truck withattachment, and individualload ratings stamped

onforks,ifequipped.Uselowestcapacityofallratings.

Asreleasedfromfactory thistruck meets design specifications in

ANSI\ITSDFB56.6-2011

Manufacturedby JLGIndustries Inc . McConnellsburg, PA 17233-9533 USA

MaximumWeightWithoutAttac hments (lbs/kg) MaximumCa p a city(lb s /kg)*

SerialNumber

YearOfManufac tur e

Model

SERIAL NUMBER PLATE

1702300

CANADA ICES-002

NMB-002

1001223453A

1001223453

(CANADA)

Section 2- Pre-Operation and Inspection

2-531211018

Section 2- Pre-Operation and Inspection

OH5534

VIEW E-E

4108302

VIEW F-F

(REAR ACCESSDOOR REMOVED)

1001

2.5GPM

9.5 lpm

MAX

1001109053REV A

109053

1001139578-ENGLISH

1001163323-ENGLISH/FRENCH

1001202626 (74HP) 1001173423 (85HP)

1001173422 (110HP)

1001191992 (6036) 1001191993 (6042)

1001191994 (8042) 1001191995 (10042) 1001191996 (10054)

4110217

SkyT rak

8042

1706300-ENGLISH

1001163212-ENGLISH/FRENCH

1706300C

ROTATING P ARTS could crush or cut causing death or serious injury .

WARNING

Keep clear of rot ating p arts.

1706301B

1706301-ENGLISH

1001163222-

ENGLISH/FRENCH

1702300

4110339

SkyT rak

250

1000

2000

500

1500

500

LB-F

T( N m )

1001202627

(IF EQUIPPED FOR LS or ULS/74HP)

1001174152

(IF EQUIPPED FOR ULS/85 or 110HP)

VIEW G-G

4100181

1001189017

1001189017 A

1001125387-ENGLISH

1001163355-ENGLISH/FRENCH

ULTRA LOW

SULFUR DIESEL

FUEL ONLY

S < 15 mg/kg

1001125387A

1001230307A

DEF TankAssembly

Prior to servicing contact

Cummins at 1-800-CUMMINS

1001230307-ENGLISH

1001230309-ENGLISH/FRENCH

(IF EQUIPPED FOR ULS/85 or 110HP)

(SN 0160082087 TO PRESENT)

1001196806

(IF EQUIPPED FOR ULS/85 or 110HP)

1001196806A

1001219212

(IF EQUIPPED FOR ULS/85 or 110HP)

2-6 31211018

ISO (if equipped)

OH5562

1706279

(10042 & 10054)

1001162736

1001162735

CAPACITY

CHARTS

1001162734

1001162736 B

1001162735 B

1001162737 A

1001092877

1706284

1706288

1001162737

(10042 & 10054)

1001158320 E

1001158321 D

1001158320 1001158321

1001162734 B

1001219211A

1001219211

(INSIDE OF RESERVOIR COVER)

(SN 0160078382 TO PRESENT)

Section 2- Pre-Operation and Inspection

2-731211018

Section 2- Pre-Operation and Inspection

OH5543

VIEW B-B

1706281

1706281B

91404299

(IF EQUIPPED WITH

FIXED WINDOW)

VIEW D-D

1001160912

(IF EQUIPPED WITH

LATCH WINDOW)

1001160912 RevA

VIEW A-A

1001154575A

*Refer to load capacity chart for truck withattachment, and individualload ratings stamped

onforks,ifequipped. Use lowestcapacityof all ratings.

Asreleasedfromfactory thistruck meets design specifications in

ANSI\ITSDFB56.6-2011

Manufacturedby JLGIndustries Inc . McConnellsburg, PA 17233-9533 USA

MaximumWeight WithoutAttach men ts (lbs/kg) Maximum Capacity (lbs/kg) *

SerialNumber

YearOfManufac tur e

Model

SERIAL NUMBER PLATE

1702300

VIEW C-C

1706098

1001143852

(IF EQUIPPED FOR LS)

4107442

-10

4105262

1701640

1702300

1001173423 (85HP)

1001173422 (110HP)

1001092878

1706282

1706282C

1706285

1001189328

(10054)

1001189328A

7.5 A

35A

7.5 A

1001189327

20 A

15 A

7.5 A

10 A

7.5 A

10 A

20 A

7.5 A

F10

20 A

F11

7.5 A

F12

10 A

F13

15 A

F14

5 A

F16

10 A

F17

10 A

F18

5 A

F19

10 A

F20

30 A

35 A

R3N35 A

35 A

R10

35 A

R11

35 A

1001189327A

1001160916

(IF EQUIPPED WITH

REVERSE SENSING SYSTEM)

1001160916 REVA

1001207218A

1001207218

(IF EQUIPPED WITHBOOM

MOUNTED LIFTING LUG)

2-8 31211018

O 5550H

VIEW F-F

(REAR ACCESSDOOR REMOVED)

VIEW E-E

VIEW G-G

4108302

4100181

1001189017

2.5GPM

9.5 lpm

MAX

1001109053REV A

1001109053

1001139942

1001189017 A

1001139942A

1001191992 (6036) 1001191993 (6042)

1001191994 (8042) 1001191995 (10042) 1001191996 (10054)

4110217

SkyT rak

8042

1702300

4110339

SkyT rak

250

1000

2000

500

1500

500

LB-F T

( N m )

1001202627

1706098

1706285

1001173423 (85HP)

1001173422 (110HP)

Section 2- Pre-Operation and Inspection

2-931211018

Section 2- Pre-Operation and Inspection

O 5701H

2.4 WALK-AROUND INSPECTION

Begin your walk-around inspection at item 1, as noted below. Continue to your right (counterclockwise when viewed from top) checking each item in sequence.

INSPECTION NOTE: On all components, make sure there are no loose or missing parts, that they are securely fastened and no visible leaks or excessive wear exists in addition to any other criteria mentioned. Inspect all structural members including attachment for cracks, excessive corrosion and other damage.

1. Boom Sections and Lift, Tilt, Extend/Retract, Compensating (Slave) Cylinders

• Check front, top, side and rear wear pads for presence of grease.

• Pivot pins secure; hydraulic hoses undamaged, not leaking.

2. Left Outrigger (10042 & 10054)—Pins secure; hydraulic hoses and cylinder undamaged, not leaking.

3. Front Axle—Steer cylinders undamaged, not leaking; pivot pins secure; hydraulic hoses undamaged, not leaking.

2-10 31211018

Section 2- Pre-Operation and Inspection

4. Wheel/Tire Assembly—Properly inflated and secured; no loose or missing lug nuts. Inspect for worn tread, cuts, tears or other discrepancies.

5. Mirrors—Clean and undamaged.

6. Cab and Electrical

• General appearance; no visible damage.

• Frame level indicator and window glass undamaged and clean.

• Gauges, switches, joysticks, foot controls and horn operational.

• Emergency escape hammer in place (fixed window only).

• Check seat belt for damage, replace belt if frayed or cut webbing, damaged

buckles or loose mounting hardware.

7. Wheel/Tire Assembly—Properly inflated and secured; no loose or missing lug nuts. Inspect for worn tread, cuts, tears or other discrepancies.

8. Stabil-Trak Cylinder—Pins secure; hydraulic hoses undamaged, not leaking.

9. Engine Compartment

• Drive belts, check condition and replace as required.

• Engine mounts—See inspection note.

• Battery cables tight, no visible damage or corrosion.

• Engine access doors closed and properly secured.

10. Rear Axle—Steer cylinders undamaged, not leaking; pivot pins secure; hydraulic hoses undamaged, not leaking.

11. Wheel/Tire Assembly—Properly inflated and secured; no loose or missing lug nuts. Inspect for worn tread, cuts, tears or other discrepancies.

12. Mirrors—Clean and undamaged.

13. Wheel/Tire Assembly—Properly inflated and secured; no loose or missing lug nuts.

Inspect for worn tread, cuts, tears or other discrepancies.

14. Frame Level Cylinder—Pins secure; hydraulic hoses undamaged, not leaking.

15. Right Outrigger (10042 & 10054)—Pins secure; hydraulic hoses and cylinder

undamaged, not leaking.

16. Attachment—Properly installed, see “Attachment Installation” on page 5-10.

2-1131211018

Section 2- Pre-Operation and Inspection

2.5 WARM-UP AND OPERATIONAL CHECKS

Warm-Up Check

During warm-up period, check:

1. Heater, defroster and windshield wiper (if equipped).

2. Check all lighting systems (if equipped) for proper operation.

3. Adjust mirror(s) for maximum visibility.

WARNING

CUT/CRUSH/BURN HAZARD. Keep engine cover closed while engine is running

except when checking transmission oil level.

Operational Check

When engine warms, perform an operational check:

1. Service brake and parking brake operation.

2. Forward and reverse travel.

3. Each gear.

4. Steering in both directions with engine at low idle (steering lock to lock will not be reached). Check in each steering mode.

5. Horn and back-up alarm. Must be audible from inside operators cab with engine running.

6. All joystick functions operate smoothly and correctly.

7. Perform any additional checks described in Section 8.

2-12 31211018

Section 2- Pre-Operation and Inspection

2.6 OPERATOR CAB

The telehandler is equipped with an open or enclosed ROPS/FOPS cab.

WARNING

Never operate telehandler unless the overhead guard, cab structure and right side glass or screen are in good condition. Any modification to this machine must be approved by JLG to assure compliance with ROPS/FOPS certification for this cab/ machine configuration. If the overhead guard or cab structure is damaged, the CAB

CANNOT BE REPAIRED. It must be REPLACED.

WARNING

Never drill, cut, and/or weld to cab. Any modification to this machine must be approved by JLG to assure compliance with machine configuration. If unauthorized drilling, cutting and/or welding is present, the cab must be REPLACED.

2-1331211018

Section 2- Pre-Operation and Inspection

OH5570

2.7 WINDOWS

Keep all windows and mirrors clean and unobstructed.

Cab Door Window (if equipped)

• Cab door window (2) must either be latched open or closed during operation.

• Open cab door window and secure it in latch (3).

• Turn knob (4) to unlatch window.

NOTICE

EQUIPMENT DAMAGE. Cab door (1) must be closed during operation. Failure to do so may result in machine damage.

2-14 31211018

Section 3- Controls and Indicators

SECTION 3 - CONTROLS AND INDICATORS

3.1 GENERAL

This section provides the necessary information needed to understand control functions.

NOTICE

EQUIPMENT DAMAGE.

lower boom and attachment to ground and stop the engine. Determine cause and correct before continued use.

When a red light illuminates, immediately bring machine to a stop,

3-131211018

Section 3- Controls and Indicators

OH4980

3.2 CONTROLS

3-2 31211018

Section 3- Controls and Indicators

1. Transmission Control Lever: See page 3-10.

2. Dash Controls and Indicators: See page 3-4.

3. Steering Wheel: Turning the steering wheel to the left or right steers the machine in

the corresponding direction. Three steering modes are available. See “Steer Modes” on page 3-17.

4. Horn: Press to sound horn.

5. Accessory Control Lever (if equipped): See page 3-16.

6. Boom Joystick: See page 3-12.

7. Frame Level Joystick: See page 3-14.

8. Auxiliary Hydraulic Joystick: See page 3-13.

9. Outrigger Switches (10042 & 10054): See page 3-15.

10. Accelerator Pedal: Pressing down the pedal increases engine and hydraulic speed.

11. Service Brake Pedal: The further the pedal is depressed, the slower the travel speed.

(6042, 8042, 10042 & 10054 Only) With service brake pedal depressed and boom angles above 40°, the locked mode of the Stabil-Trak system is activated. See page 3-18.

12. Ignition Switch: Key activated. See page 3-8.

13. Frame Level Indicator: Enables operator to determine the left to right level condition

of the telehandler.

3-331211018

Section 3- Controls and Indicators

OH5020

O 4990H

OH5000

OH5180

(IF EQUIPPED WITH HEATER)

(IF EQUIPPED WITH HEATER & AC)

OH5041

Dash Controls and Indicators

3-4 31211018

Section 3- Controls and Indicators

1. Park Brake Switch: On/Off switch. See page 3-9 for details.

2. Beacon Light Switch (if equipped): On/Off switch.

3. Hazard Light Switch (if equipped): On/Off switch.

4. Work Light Switch (if equipped): Three position switch. Push bottom of switch to

turn all work lights on. Move switch to middle position to turn on front and boom worklights. Push top of switch to turn off all work lights.

5. Steer Select Switch: Three positions: 4-wheel circle steer, 4-wheel crab steer and 2- wheel front steer. See page 3-17 for details.

6. Windshield Wiper Switch (if equipped): Three position switch. Push bottom of switch to operate wiper at high speed. Move switch to middle position to operate wiper at low speed. Push top of switch to turn off wiper.

7. Sk ylight Wi per Switc h (if equ ipped) : Three position switch. Push bottom of switch to operate wiper at high speed. Move switch to middle position to operate wiper at low speed. Push top of switch to turn off wiper.

8. Windshield and Skylight Washer Switch (if equipped): Push and hold bottom of switch to activate washer.

9. High Exhaust System Temperature Indicator (HEST) (if equipped for ULS/85 or 110HP):

10. Selective Catalytic Reduction (SCR) Indicator (if equipped for ULS/85 or 110HP):

Illuminates when stationary cleaning is required. Flashes during cleaning process. See page 4-4 for details.

11. Do Not Turn Off Engine Indicator (if equipped for ULS/85 or 110HP): Illuminates when stationary cleaning required. See page 4-4 for details.

12. Instrument Cluster: See page 3-6 for details.

Heater and Air Conditioning Controls (if equipped)

May illuminate during exhaust system cleaning.

See page 4-4 for details.

13. HVAC Fan Speed (if equipped): Adjustable rotary switch.

14. HVAC Temperature Control Switch (if equipped): Adjustable rotary switch.

15. Air Conditioning (AC) Switch (if equipped): Two-position switch.

3-531211018

Section 3- Controls and Indicators

OH5010

98%242

12.0V

99999.9

2488RPM

OH5030

98%242

12.0V

99999.9

2488RPM

OH5030

Instrument Cluster

3-6 31211018

Section 3- Controls and Indicators

1. Maintenance Indicator: Flashes when fault code present. Illuminates when maintenance is required. See Service Manual for details.

2. Fuel Gauge: Indicates fuel level.

3. Engine Warning Indicator: Illuminates when the engine is a critical state.

Immediately bring machine to a stop, retract and lower boom and stop the engine. Determine cause and correct before continued use.

4. Engine Pre-Heat Indicator: Illuminates with ignition key in position 1. Indicator goes out when start temperature is reached. (If equipped for ULS) Pre-heat indicator will flash and fault code will appear on instrument cluster display during starter lockout. Return ignition switch to position 1 for a minimum of two minutes to allow system to reset before trying to start again.

5. Stabil-Trak Indicator (6042, 8042, 10042 & 10054): Illuminates when Stabil-Trak system has been activated. See page 3-18.

6. Transmission Temperature Indicator: Illuminates when transmission oil temperature is high. Stop and idle engine with transmission in neutral, allowing time for cooling. If light remains on, shut-down engine.

7. Turn Signal Indicator (if equipped): Illuminates and flashes while turn signals or hazard lights are activated.

8. High Beam Indicator (if equipped): Illuminates while high beam lights are activated.

9. System Distress Indicator: Illuminates when an issue with the fuel level or machine system is present.

10. Diesel Exhaust Fluid (DEF) Low Indicator (if equipped for ULS/85 or 110HP):

Illuminates when DEF volume is low. Also may illuminate if DEF quality is poor or if DEF system tampering or malfunction occurs. (SN 0160082087 to Present) If DEF tank assembly is still under warranty, contact Cummins prior to servicing.

11. Operating Hours and Fault Codes:

a. Operating Hours—Displays total hours of telehandler operation.

b. Fault Codes—Replaces operating hours. Displays fault codes of engine

and machine systems. See Service manual.

12. Battery Voltage and Operating Hours:

a. Battery Voltage—Displays voltage supplied by battery.

b. Operating Hours—Alternates with battery voltage if fault code present.

13. Engine Speed: Displays engine speed in revolutions per minute (rpm).

14. Engine Coolant Temperature: Displays engine coolant temperature.

15. Diesel Exhaust Fluid (DEF) Level (if equipped for ULS/85 or 110HP): Displays fluid

level.

3-731211018

Section 3- Controls and Indicators

O 4990H

OH5050

Ignition

• Position 0: Engine off, no voltage available.

• Position 1: Voltage available for all electrical functions. Wait to start engine until engine pre-heat indicator goes out.

• Position 1: Engine run.

• Position 2: Engine start. In event engine does not start, rotate key to position 0 then back to position 2 to re-engage starter.

3-8 31211018

Section 3- Controls and Indicators

O 4990H

OH5060

Park Brake

Park brake switch controls application and release of park brake. Indicator on switch illuminates to indicate brake is applied.

• With engine running and the park brake switch in "OFF" position (1), park brakes are disengaged.

• With switch in "ON" position (2), park brake is engaged and transmission will not engage forward or reverse.

• (6042, 8042, 10042 & 10054 Only) With switch in “ON” position and boom angles greater than 40°, locked mode of Stabil-Trak system is activated. See page 3-18.

WARNING

MACHINE ROLL-AWAY HAZARD. In the event of engine failure, apply constant

pressure to service brake pedal while activating the park brake to the ON position.

WARNING

MACHINE ROLL-AWAY HAZARD. Always move park brake switch to ON position,

lower boom to ground and stop engine before leaving cab.

WARNING

CRUSH HAZARD.

turning engine off while traveling will cause unit to stop abruptly and could cause load loss. Either may be used in an emergency situation.

Parking Procedure

1. Using service brake, stop telehandler in an appropriate parking area.

2. Follow “Shut-Down Procedure” on page 4-3.

Turning engine off applies the park brake. Applying park brake or

3-931211018

Section 3- Controls and Indicators

OH5070

OH5080

Transmission Control Lever

Direction of Travel Selection

Transmission control lever (1) engages forward or reverse travel.

• Lift and push lever forward for forward travel; lift and pull lever rearward for reverse travel. Move lever to centered position for neutral.

• Forward or reverse travel can be selected while in any gear.

• When traveling in reverse, back-up alarm will automatically sound.

• Drive in reverse and turn only at slow rates of speed.

• Do not increase engine speed with transmission in forward or reverse and service brake depressed in an attempt to get quicker hydraulic performances. This could cause unexpected machine movement.

• (6042, 8042, 10042 & 10054 Only) With lever in neutral and boom angles greater than 40°, locked mode of Stabil-Trak system is activated. See page 3-18.

WARNING

TIP OVER/CRUSH HAZARD.

transmission control lever. A sudden change in direction of travel could reduce stability and/or cause load to shift or fall.

3-10 31211018

Bring telehandler to a complete stop before shifting

Section 3- Controls and Indicators

OH5080

OH5090

Gear Selection

Gear selection is located on the twist grip handle (2) of transmission control lever.

• Twist hand grip to select gear.

• Select appropriate gear for task being performed. Use a lower gear when transporting a load. Use a higher gear only when driving unloaded for longer distances.

• Slow down prior to downshifting. Do not downshift more than one gear

at a time.

3-1131211018

Section 3- Controls and Indicators

OH5100

Boom Joystick

WARNING

TIP OVER/CRUSH HAZARD.

movement of the load. Such movements could cause the load to shift or fall or could cause the machine to tip over.

Boom Joystick (1) controls boom and attachment tilt functions.

Boom Functions

• Move joystick back to lift boom; move joystick forward to lower boom; move joystick right to extend boom; move joystick left to retract boom.

• Speed of boom functions depends upon amount of joystick travel in corresponding direction. Increasing engine speed will also increase function speed.

• For two simultaneous boom functions, move joystick between quadrants. Example: moving joystick forward and to left will lower and retract boom simultaneously.

Rapid, jerky operation of controls will cause rapid, jerky

Attachment Tilt Functions

Attachment tilt is controlled by roller switch (2).

• Push roller switch up to tilt attachment down; push roller switch down to tilt attachment up.

3-12 31211018

Auxiliary Hydraulic Joystick

OH5120

Section 3- Controls and Indicators

Auxiliary hydraulic joystick (2) controls function of attachments that require hydraulic supply for operation. See Section 5- Attachments for approved attachments and control instructions.

3-1331211018

Section 3- Controls and Indicators

OH5130

Frame Level Joystick

Frame level joystick (1) controls left to right frame level.

• Move joystick left to rotate frame left, move joystick right to rotate frame right.

• A level indicator is located above front cab window to permit operator to determine whether telehandler frame is level.

WARNING

TIP OVER HAZARD.

of right hand mirror before leveling frame. Attempting to level machine with boom raised could cause it to tip over.

3-14 31211018

Always move boom as low as possible while allowing for best visibility

Section 3- Controls and Indicators

OH5140

Outrigger Switches (10042 & 10054)

Outrigger switches control outriggers.

• Left switch controls left outrigger and right switch controls right outrigger.

• Push bottom of switches (1) to lower outriggers; push top of switches (2) to raise outriggers.

• Use the outriggers to increase stability and/or load capacity and in leveling telehandler. Study capacity charts to determine maximum load capacities, with and without outriggers.

WARNING

TIP OVER HAZARD.

properly. Using outriggers on soft surfaces could cause telehandler to tip over. Always ensure surface can support telehandler and load.

Outriggers increase stability and load capacity only if they are used

3-1531211018

Section 3- Controls and Indicators

OH5150

OH5080

Accessory Control Lever (if equipped)

Accessory control lever (3) operates turn signals, parking lights and headlights.

Turn Signal

• Raise lever (4) to activate left turn signal.

•Lower lever (5) to activate right turn signal.

• Lever must be manually returned to center position to deactivate either turn signal. Lever will not cancel automatically after a turn.

Parking Lights and Headlights

• Turn twist grip (6) of lever counterclockwise to first position (7) to turn on parking lights.

• Turn twist grip to second position (8) to turn on headlights.

• Pull lever to switch between low and high beam.

• Turn twist grip clockwise to OFF position (9) to turn all lights off.

3-16 31211018

Section 3- Controls and Indicators

OAL2030

2-Wheel Front Steer 4-Wheel Circle Steer 4-Wheel Crab Steer

OH5160

OAM2400

4 5

3.3 STEER MODES

Three steer modes are available for operator use.

Note: 2-Wheel Front Steer mode is required for travel on public roads.

Steer Mode Change

Note: Steer mode will change immediately after selection.

1. Bring machine to a stop using service brake while either circle steer mode (1) or crab steer mode (3) is selected.

2. Turn steering wheel until left rear wheel (4) is aligned with side of machine.

3. Select front steer mode (2).

4. Turn steering wheel until left front wheel (5) is aligned with side of machine.

5. Wheels are now aligned. Select desired steer mode.

3-1731211018

Section 3- Controls and Indicators

OH4941

3.4 STABIL-TRAK™ SYSTEM (6042, 8042, 10042 & 10054)

Free Pivot Mode

With boom below 40° (6), Stabil-Trak system is in Free Pivot Mode. Rear axle pivots freely and

frame level functions normally. Stabil-Trak indicator (

) will be off.

Slow Pivot Mode

With boom above 40° (7), the Stabil-Trak system is in Slow Pivot Mode when service brake is not applied and transmission is in gear. Rear axle will respond slowly

to changes in terrain and frame level functions normally. Stabil-Trak indicator ( will be off.

)

Locked Mode

With boom above 40° (7), and activating one or more of following functions, Stabil-Trak system is in Locked Mode.

• Park brake switch engaged.

• Transmission control lever in Neutral.

• Service brake pedal depressed.

Rear axle is locked and frame level functions slower than normal. Stabil-Trak indicator (8) will illuminate.

3-18 31211018

Section 3- Controls and Indicators

OH4951

3.5 BOOM/OUTRIGGER INTERLOCK SYSTEM (10054)

Boom/outrigger interlock system allows boom to be extended to its maximum limits.

Extend Interlock Mode

With outriggers raised (1), telehandler is in extend interlock mode which limits boom

extension (

• Boom is limited from extending beyond a point between the “E” and “F” boom extension indicators.

• Vehicle and Stabil-Trak will function normally.

Outrigger Interlock Mode

With outriggers lowered (3) on firm terrain, telehandler is in outrigger interlock mode which

allows for full boom extension (

When outriggers are lowered, shift travel select lever into neutral and engage parking brake.

With outrigger interlock engaged, additional systems are automatically activated.

• Stabil-Trak is in locked mode and indicator (5) will illuminate.

• Frame level will be slower than normal.

• Outriggers can be lowered to adjust for any changes in outrigger footing.

Boom must be retracted within extension limit (2) for any of these conditions to change.

3-1931211018

Section 3- Controls and Indicators

OH5170

3.6 OPERATOR SEAT

Adjustments

Prior to starting engine adjust seat for position and comfort.

Prior to SN 0160074878

1. Suspension: Use knob to adjust suspension to the appropriate setting. Turn

clockwise to increase stiffness. Turn counterclockwise to reduce stiffness.

2. For e/Aft: Pull up on handle to move seat fore and aft.

3. Document Case: Contains unit materials.

4. Seat Belt: Always fasten seat belt during operation. If required, a 3 in (76 mm) seat

belt is available.

3-20 31211018

SN 0160074878 to Present

Oh5790

Section 3- Controls and Indicators

1. Suspension: Use knob to adjust suspension to the appropriate setting. Turn clockwise to increase stiffness. Turn counterclockwise to reduce stiffness.

2. For e/Aft: Pull up on handle to move seat fore and aft.

3. Document Case: Contains unit materials.

4. Seat Belt: Always fasten seat belt during operation. If required, a 3 in (76 mm) seat

belt is available.

3-2131211018

Section 3- Controls and Indicators

OH20912

Seat Belt

Fasten seat belt as follows:

1. Grasp both free ends of the belt making certain that belt webbing is not twisted or entangled.

2. With back straight in seat, couple retractable end (male end) of belt into receptacle (buckle) end of belt.

3. With belt buckle positioned as low on body as possible, pull retractable end of belt away from buckle until it is tight across lap.

4. To release belt latch, depress red button on buckle and pull free end from buckle.

3-22 31211018

Section 3- Controls and Indicators

OH3951

2 1

3.7 BOOM ANGLE AND EXTENSION INDICATORS

• Boom angle indicator (1) is located on left side of boom. Use this indicator to determine boom angle when using capacity chart (see “Use of the Capacity Chart” on page 5-5).

• Boom extension indicators (2) are located on left side of boom. Use these indicators to determine boom extension when using capacity chart (see “Use of the Capacity Chart” on page 5-5).

3-2331211018

Section 3- Controls and Indicators

3.8 REVERSE SENSING SYSTEM (IF EQUIPPED)

WARNING

CRUSH HAZARD. Running into persons or objects can cause death, serious injury, or

damage to property and equipment. Always check mirrors and area behind machine before and when backing up. Reverse systems are for supplementary use only.

Reverse Sensing System provides audible indication of objects to rear of machine while in reverse gear.

• Alarm sounds when transmission is shifted into reverse.

Note: Reverse Sensing System detects objects larger than 36 square inches (232.25 square centimeters) area and is functional when machine is moving in reverse direction.

• No alarm when detection zone is clear of objects.

•

Pulsing alarm sounds increases in frequency as object becomes closer.

• If alarm sounds at a frequency of eight pulses per second (8 Hz) an object is detected within 5 feet (1.5 m). Stop reverse direction of machine by applying service brake. Perform “Shut-Down Procedure” on page 4-3. Check and clear area behind machine of objects before proceeding in a reverse direction.

when an object is in range of Reverse Sensing System. Alarm

3-24 31211018

Section 4- Operation

SECTION 4 - OPERATION

4.1 ENGINE

Starting the Engine

This machine can be operated under normal conditions in temperatures of 0°F to 104°F (-20°C to 40°C). Consult JLG for operation outside this range or under abnormal conditions.

1. Make sure all controls are in “Neutral” and all electrical components (lights, heater, defroster, etc.) are turned off. Apply park brake.

2. Turn the ignition switch to position 1 and wait until engine pre-heat indicator light goes out.

3. Turn ignition switch to position 2 to engage starting motor. Release key immediately when engine starts. If engine fails to start within 20 seconds, release key and allow starting motor to cool for two minutes before trying again.

Note: (If equipped for ULS) Engine is equipped with starter lockout feature and may prevent starter engagement under certain conditions. Pre-heat indicator will flash and fault code will appear on instrument cluster display. Return ignition switch to position 1 for a minimum of two minutes to allow system to reset before trying to start again.

4. After engine starts, observe instrument cluster. If a red indicator remains on for more than five seconds, stop engine and determine cause before restarting engine.

Note: Battery voltage may read low, and engine speed may fluctuate for a short time after start up when the machine is cold.

5. Warm up engine at approximately 1/2 throttle.

Note: Engine will not start unless transmission is in neutral and park brake is applied.

WARNING

ENGINE EXPLOSION. Do not use ether for cold weather starting.

WARNING

UNEXPECTED MOVEMENT HAZARD. Always ensure that transmission is in neutral

and the service brake is applied before releasing park brake. Releasing park brake in either forward or reverse could cause the machine to move abruptly.

4-131211018

Section 4- Operation

OW0530

Battery Boosted Starting

If battery-boost starting (jump-start) is necessary, proceed as follows:

• Never allow vehicles to touch.

• Ensure boosting vehicle engine is running.

• Connect positive (+) jumper cable to positive (+) post of discharged battery.

• Connect opposite end of positive (+) jumper cable to positive (+) post of booster battery.

• Connect the negative (-) jumper cable to negative (-) post on booster battery.

• Connect opposite end of negative (-) jumper cable to ground point on machine away from discharged battery.

• Follow standard starting procedures.

• Remove cables in reverse order after machine has started.

WARNING

BATTERY EXPLOSION HAZARD. Never jump start or charge a frozen battery as it

could explode. Keep sparks, flames and lighted smoking materials away from the battery. Lead acid batteries generate explosive gases when charging. Wear safety glasses.

4-2 31211018

Section 4- Operation

Normal Engine Operation

• Observe gauges and indicators frequently to be sure all systems are functioning properly.

• Be alert for unusual noises or vibration. When an unusual condition is noticed, park machine in safe position and perform shut-down procedure. Report condition to your supervisor or maintenance personnel.

• Avoid prolonged idling. If engine is not being used, turn it off.

• If prolonged idling is required (park brake applied), engine idle may increase if ambient temperature goes below

• When operating a machine at high altitudes, a decrease in machine performance may occur due to a decrease in air density. When operating a machine at high temperatures, a decrease in machine performance and an increase in engine coolant temperature may occur. Contact JLG for operation under abnormal conditions.

-1°F (-17°C)

Shut-Down Procedure

When parking the telehandler, park in a safe location on flat level ground and away from other equipment and/or traffic lanes.

1. Apply the park brake.

2. Shift the transmission to “Neutral.”

3. Lower forks or attachment to the ground.

4. Operate engine at low idle for 3 to 5 minutes. DO NOT over rev engine.

5. Shut off engine and remove ignition key.

6. Exit telehandler properly.

7. Block wheels (if necessary).

4-331211018

Section 4- Operation

O 5610H

OH5010

4.2 AFTER-TREATMENT SYSTEM (ATS) (IF EQUIPPED FOR ULS/85 OR 110HP)

This machine is equipped with an exhaust After-Treatment System.

Automatic Exhaust System Cleaning

ATS is an automatic exhaust cleaning system and will perform as required without any operator interaction.

• High Exhaust System Temperature (HEST) (1) Indicator may illuminate during exhaust system cleaning.

WARNING

HIGH EXHAUST TEMPERATURE.

4-4 31211018

Keep flammables and people away from hot exhaust.

Section 4- Operation

Stationary Exhaust System Cleaning

Selective Catalytic Reduction (SCR) Indicator (2) will illuminate when stationary exhaust system cleaning is required.

1. Move telehandler to an area free of flammables and people that could be exposed to hot exhaust.

2. Shift transmission to neutral, retract and lower boom and engage park brake.

3. When exhaust system cleaning begins, the HEST (1) and Do Not Turn Off Engine (3) indicators will illuminate. Do not turn off engine.

4. Do not press accelerator pedal or other controls during exhaust system cleaning.

5. SCR indicator (2) flashes during cleaning. Stationary exhaust system cleaning takes approximately 30 to 60 minutes.

Note: Stationary exhaust system cleaning will stop and may be incomplete if any controls are inadvertently moved or activated. If stationary exhaust cleaning is interrupted, HEST (1) and Do Not Turn Off Engine (3) indicators will turn off and SCR Indicator (2) will stop blinking and illuminate solid. To restart stationary exhaust system cleaning, depress service brake and disengage park brake. Return to step 1 and repeat process.

6. Stationary exhaust system cleaning is complete after HEST, SCR and Do Not Turn Off Engine indicators go off.

NOTICE

EQUIPMENT DAMAGE. If exhaust system cleaning continually fails, SCR (2) and System Distress (4) indicators will illuminate. Immediately bring machine to a stop and perform stationary exhaust system cleaning. If exhaust system cleaning is not completed a torque derate is initiated. Contact the local dealer.

4-531211018

Section 4- Operation

4.3 OPERATING WITH A NON-SUSPENDED LOAD

Lift Load Safely

• You must know weight and load center of every load you lift. If you are not sure of the weight and load center, check with your supervisor or with the supplier of material.

WARNING

TIP OVER HAZARD. Exceeding lift capacity of the telehandler could damage the

equipment and/or cause tip over.

• Know the rated load capacities (see Section 5) of the telehandler to determine the operating range in which you can safely lift, transport and place a load.

Picking Up a Load

• Note the conditions of the terrain. Adjust travel speed and reduce amount of load if conditions warrant.

• Avoid lifting double-tiered loads.

• Make sure load is clear of any adjacent obstacles.

• Adjust spacing of forks so they engage the pallet or load at maximum width. See “Adjusting/Moving Forks” on page 5-13.

• Approach load slowly and squarely with fork tips straight and level. NEVER attempt to lift a load with just one fork.

• NEVER operate telehandler without a proper and legible capacity chart in the operator cab for the telehandler/attachment combination you are using.

4-6 31211018

Section 4- Operation

OW0540

Transporting a Load

After engaging the load and resting it against the backrest, tilt the load back to position it for travel. Travel in accordance with the requirements set forth in Section 1- General Safety Practices and Section 5- Attachments.

Leveling Procedure

1. Position machine in best location to lift or place load.

2. Apply parking brake and move transmission control lever to NEUTRAL.

3. Observe level indicator to determine whether machine must be leveled prior to lifting load. Level machine with frame level joystick (see page 3-13) or outrigger switches (10042 & 10054 only, see page 3-14).

4. Move boom/attachment to 4 ft (1,2 m) off ground. (AUS—Move boom so forks are no more than 11.8 in (300 mm) above ground surface.)

Important things to remember:

• Never raise the boom/attachment more than 4 ft (1,2 m) above ground unless telehandler is level. (AUS—Never raise the forks more than 11.8 in (300 mm) above ground surface unless telehandler is level.)

• The combination of frame leveling and load could cause the telehandler to tip over.

4-731211018

Section 4- Operation

Placing a Load

Before placing any load be sure that:

• The landing point can safely support the weight of the load.

• The landing point is level; front to back and side to side.

• Use the capacity chart to determine safe boom extension range. See “Use of the Capacity Chart” on page 5-5.

• Align forks at the level load is to be placed, then extend boom slowly until load is just above area where it is to be placed.

• Lower the boom until the load rests in position and the forks are free to retract.

Disengaging a Load

Once the load has been placed safely at the landing point, proceed as follows:

1. With the forks free from the weight of the load, the boom can be retracted and/or the telehandler can be backed away from under the load if surface will not change level condition of telehandler.

2. Lower the carriage.

3. The telehandler can now be driven from the landing location to continue work.

4-8 31211018

Section 4- Operation

4.4 OPERATING WITH A SUSPENDED LOAD

Lift Load Safely

• You must know the weight and load center of every load you lift. If you are not sure of weight and load center, check with your supervisor or with supplier of material.

WARNING

TIP OVER HAZARD. Exceeding lift capacity of the telehandler could damage the

equipment and/or cause tip over.

• Know the rated load capacities (refer to Section 5) of the telehandler to determine operating range in which you can safely lift, transport and place a load.

Picking Up a Suspended Load

• Note the conditions of the terrain. Adjust travel speed and reduce amount of load if conditions warrant.

• Avoid lifting double-tiered loads.

• Make sure load is clear of any adjacent obstacles.

• NEVER operate telehandler without a proper and legible capacity chart in the operator cab for the telehandler/attachment combination you are using.

• Only use approved lifting devices rated for the lifting of the load.

• Identify the proper lifting points of the load, taking into consideration the center of gravity and load stability.

• Ensure to always properly tether loads to restrict movement.

• Refer to See “Use of the Capacity Chart” on page 5-5. for proper lifting guidelines in addition to the appropriate capacity chart in the operator cab.

4-931211018

Section 4- Operation

OW0130

OZ3160

Transporting a Suspended Load

• Travel in accordance with the requirements set forth in Section 1- General Safety Practices and Section 5- Attachments.

• For additional requirements, refer to appropriate capacity chart in operator cab.

Important things to remember:

• Ensure the boom is fully retracted.

• Never raise the load more than 11.8 in (300 mm) above ground surface or the boom more than 45°.

• The combination of frame leveling and load could cause the telehandler to tip over.

• The guide persons and operator must remain in constant communication (verbal or hand) and be in visual contact with the operator at all times.

• Never place the guide persons between the suspended load and the telehandler.

• Only transport the load at walking speed, 0.9 mph (0.4 m/s), or less.

Leveling Procedure

1. Position machine in best location to lift or place load.

2. Apply parking brake and move transmission control lever to NEUTRAL.

4. Move boom so load is no more than 11.8 in (300 mm) above ground surface and boom/or boom is raised no more than 45°.

4-10 31211018

Section 4- Operation

Placing a Suspended Load

Before placing any load be sure that:

• The landing point can safely support the weight of the load.

• The landing point is level; front to back and side to side.

• Use the capacity chart to determine safe boom extension range. See “Use of the Capacity Chart” on page 5-5.

• Align load at the level load is to be placed, then position boom slowly until load is just above area where it is to be placed.

• Ensure that the guide persons and operator remain in constant communication (verbal or hand) when placing the load.

Disengaging a Suspended Load

• Never place the guide persons between the suspended load and the telehandler.

• Once at the destination of the load, ensure to bring the telehandler to a complete stop and apply the park brake prior to disengagement of the lifting devices and tethers.

4-1131211018

Section 4- Operation

OH5260

4.5 LOADING AND SECURING FOR TRANSPORT

Tie Down

1. Level telehandler prior to loading.

2. Using a spotter, load telehandler with boom as low as possible.

3. Once loaded, apply parking brake and lower boom until boom or attachment is resting on deck. Move all controls to “Neutral,” stop engine and remove ignition key.

4. Secure machine to deck by passing chains through designated tie down points as shown in figure.

5. Do not tiedown front of boom.

Note: The user assumes all responsibility for choosing the proper method 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 local, state or federal/provincial laws are followed.

WARNING

TELEHANDLER SLIDE HAZARD. Before loading telehandler for transport, make sure

deck, ramps and telehandler wheels are free of mud, snow and ice. Failure to do so could cause telehandler to slide.

4-12 31211018

Section 4- Operation

O 5690H

Lifting

The weight of the machine is listed on the serial number plate located at the front of the frame. Actual machine weight and center of gravity will vary depending on attachment, fluid levels and machine options. Actual weight and center of gravity should be verified prior to lifting.

The following precautions must be taken when lifting the machine with a mobile crane:

• Make adjustments to the lifting device and equipment to ensure that the machine will be level when elevated. The machine must remain level at all times while being lifted.

• Machine must never be lifted by any point on the boom.

• Take care not to let cables, chains, slings, etc. contact any part of the vehicle during lift.

• The appropriate lifting locations are the axle beams, inboard of the kingpins. Take care as not to damage the axles and components.

• Ensure that the boom is retracted and lowered.

• Ensure that the lifting device and equipment is adequately rated and suitable for the intended purpose.

• Remove all loose items from machine prior to lifting of the machine.

• Lift at a slow, even pace.

• Obtain any additional training regarding the proper lifting procedures that may be required. Please consult the local, state, and employer regulations.

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Section 4- Operation

This Page Intentionally Left Blank

4-14 31211018

Section 5- Attachments

SECTION 5 - ATTACHMENTS

5.1 APPROVED ATTACHMENTS

To determine if an attachment is approved for use on specific telehandler you are using, perform following prior to installation.

• The machine is authorized for use with original equipment manufactured (OEM) supplied attachments or where explicit written authorization has been provided by the manufacturer.

• The model on the capacity chart must match the model telehandler being used.

• Hydraulically powered attachments must only be used on machines equipped with auxiliary hydraulics.

• Hydraulically powered attachments that require auxiliary electrics must only be used on machines equipped with auxiliary hydraulics and electrics.

If any of the above conditions are not met, do not use attachment. Telehandler may not be equipped with proper capacity chart or attachment may not be approved for the model telehandler being used. Contact JLG or a local distributor for further information.

5.2 UNAPPROVED ATTACHMENTS

Do not use unapproved attachments for the following reasons:

• Range and capacity limitations for “will fit,” homemade, altered, or other non-approved attachments cannot be established.

• An overextended or overloaded telehandler can tip over with little or no warning and cause serious injury or death to the operator and/or those working nearby.

• The ability of a non-approved attachment to perform its intended function safely cannot be assured.

WARNING

Use only approved attachments. Attachments which have not been approved for use with your telehandler could cause machine damage or an accident.

5-131211018

Section 5- Attachments

5.3 JLG SUPPLIED ATTACHMENTS

Attachment

Carriage, 50 in (1270 mm)

Carriage, 60 in (1524 mm)

Part

Number

1001146084 X X X X X

1170021 X X X X X

1001146086 X X X X X

1170024 X X X X X

Applicable Model

6036 6042 8042 10042 10054

1001146088 X X X X X

Carriage, 72 in (1829 mm)

1001193794 X X X X X

1001211516 X X X X X Side Shift Carriage, 50 in (1270 mm) 1001142790 X X X X X Side Tilt Carriage, 50 in (1270 mm) 1170054 X X X X X Side Tilt Carriage, 60 in (1524 mm) 1001101956 X X X X X Side Tilt Carriage, 72 in (1829 mm) 1170057 X X X X X 90° Swing Carriage, 72 in (1829 mm) 1001095418 X X X X X Dual Fork Positioning Carriage, 50 in (1270 mm) 7301295 X X X X X 8 ft Mast Carriage, 50 in (1270 mm) 1001108668 X X X X X Pipe Grapple 1001142247 X X Fork, Pallet 2.36x4x48 in (60x100x1220 mm) 2340045 X X X X X Fork, Pallet 2.36x5x48 in (60x127x1220 mm) 2340038 X X X X X Fork, Pallet 2.36x4x48 in (60x100x1220 mm) 7301408 X X X X X Fork, Pallet 2.36x4x60 in (60x100x1524 mm) 1001227379 X X X X X Fork, Dual Taper 1.75x7x60 in (44x178x1524 mm) 2340046 X X X X X Fork, Dual Taper 2.36x6x60 in (60x152x1524 mm) 2340039 X X X X X Fork, Dual Taper 2x6x72 in (50x152x1830 mm) 1001092391 X X X X X Fork, Block 2x2x48 in (50x50x1220 mm) 2340037 X X X X X Fork Extension, 90 in (2286 mm) 1001137512 X X X X X Trash Hopper, Fork Mounted 1001195082 X X X X X

Bucket, Fork Mounted 60 in–1.3 yd

Bucket, 72 in–1.0 yd

Bucket, 96 in–1.5 yd

Bucket, 102 in–2.0 yd

Grapple Bucket, 96 in–1.75 yd

1001195970 X X X X X

1001100822 X X X X X

1001100823 X X X X X

1001100824 X X X X X

0930020 X X X X X

Hook, Fork Mounted 1001097205 X X X X X Hook, Coupler Mounted 1001207606 X X X X X Truss Boom w/ Winch, 3 ft (914 mm) 1001100967 X X X X X Truss Boom, 12 ft (3658 mm) 1001099902 X X X X X Truss Boom w/ Winch, 12 ft (3658 mm) 1001099351 X X X X X Truss Boom, 15 ft (4572 mm) 1001099901 X X X X X Material Handling Arm 10 01176515 X X X X X

5-2 31211018

Section 5- Attachments

Attachment

Platform, Fork Mounted (ASME) 1001103637 X X X X X Platform, Fork Mounted (ASME - French) 1001103736 X X X X X Platform, Fork Mounted (ISO) 1001103730 X X X X X Sweeper 1001202904 X X X X X Sheet Handler 1001100227 X X X X X

Part

Number

Applicable Model

6036 6042 8042 10042 10054

5-331211018

Section 5- Attachments

OW0550

5.4 TELEHANDLER/ATTACHMENT/FORK CAPACITY

Prior to installing attachment, verify it is approved and telehandler is equipped with proper capacity chart. See “Approved Attachments” on page 5-1.

To determine maximum capacity of telehandler and attachment, use the smallest of the following capacities:

• Capacity stamped on attachment identification plate (1).

• Fork capacities and load centers are stamped on the side of each fork (2) (if equipped). This rating specifies maximum load capacity that the individual fork can safely carry at maximum load center (3). Total attachment capacity is multiplied by number of forks on attachment (if equipped), up to maximum capacity of attachment.

• Maximum capacity as indicated on the proper capacity chart. See “A p pr ov e d Attachments” on page 5-1.

• When load rating of telehandler differs from capacity of the forks or attachment, the lower value becomes the overall load capacity.

Use the proper capacity chart to determine maximum capacity at various machine configurations. Lifting and placing a load may require use of more than one capacity chart based on machine configuration.

Other than block forks, all forks should be used in matched pairs, block forks used in matched sets.

Never use an attachment without the appropriate JLG approved capacity chart installed on the telehandler.

5-4 31211018

WARNING

Section 5- Attachments

OH5620

BOOM

EXTENSION

INDICATOR

BOOM ANGLE

INDICATOR

AT TAC HM E NT

IDENTIFICATION

PLATE

FORK

WEIGHT

STAMP

5.5 USE OF THE CAPACITY CHART

To properly use capacity chart (see page 5-6), operator must first determine and/or have the following:

1. An approved attachment. See “Approved Attachments” on page 5-1.

2. Proper Capacity Chart(s).

3. Weight of load being lifted.

4. Load placement information:

a. HEIGHT where load is to be placed.

b. DISTANCE from front tires of telehandler where load is to be placed.

5. On capacity chart, find the line for height and follow it over to distance.

6. Number in load zone where the two cross is the maximum capacity for this lift. If the two cross at a division between zones, the smaller number must be used.

The number in load zone must be equal to or greater than weight of load to be lifted. Determine limits of load zone on capacity chart and keep within these limits.

Capacity Indicator Locations

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Section 5- Attachments

OH4401

XXXXXXXXXX

XXXXX

XXXXXXXXXXX

-8°

0°

10°

20°

30°

40°

50°

60°

b s

X X X X

ANSI / ITSDF B56.6

XXXX XX MAX

=XXXX XX MAX

< = XX

XXXXXXXXXX

68°

XXXX

lbs

XXXX lbs

X X X X

This Capacity Chart may be used with this model ONLY.

The telehandler model is indicated on the boom or chassis. Model

XXXXX is used for demonstration purposes only.

Boom Extension

Indicator (arc)

Boom Angle

Load zones indicate the

maximum weight that may

be safely lifted.

Load center must be equal to or less than

value shown.

Attachment type,

weight and

dimensions must be

equal to or less than

the data shown.

Sample Capacity Chart

Note: This is a sample capacity chart only! DO NOT use this chart, use the one located in your operator cab.

TIP OVER HAZARD. All loads shown on rated capacity chart are based on machine being on firm ground with frame level (see page 4-7); the forks being positioned evenly on carriage; the load being centered on forks; proper size tires being properly inflated; and the telehandler being in good operating condition.

5-6 31211018

WARNING

Section 5- Attachments

OH4410

OH4420

To identify the proper capacity chart on telehandlers equipped with outriggers, refer to the following icons which may be located on the capacity chart.

• Use when lifting a load with outriggers up.

• Use when lifting a load with outriggers down.

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Section 5- Attachments

OY1710

12'

16'

20'

24'

28'

32'

36'

40'

44'

-4'

12'

16'

20'

24'

28'

32'

36'

40'

44'

48'

52'

56'

60'

48

30°

50°

4000 LBS

10000 LBS

L8000 BS

L6000 BS

5000 BLS

3000 SLB

-4

0°

10°

20°

40°

60°

71°

Example 1

Example 2

Example 3

Example 4

Example

A contractor owns a model xxxxx telehandler with a fork carriage. He knows this attachment may be used with his model since:

• The attachment style, weight, dimensions and load center match the attachment data on the capacity chart.

• The capacity chart is clearly marked for model xxxxx and corresponds with machine configuration being used.

Below are examples with various conditions the contractor may encounter and whether or not the load may be lifted.

Load Weight Distance Height OK to Lift

1 6000 lb (2722 kg) 18 ft (5,5 m) 12 ft (3,7 m) Yes 2 4000 lb (1814 kg) 30 ft (9,1 m) 26 ft (7,9 m) NO 3 7500 lb (3402 kg) 8 ft (2,4 m) 24 ft (7,3 m) Yes 4 5750 lb (2608 kg) 12 ft (3,7 m) 44 ft (13,4 m) NO

Note: This is a sample capacity chart only! DO NOT use this chart, use the one located in your operator cab.

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Section 5- Attachments

This Page Intentionally Left Blank

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Section 5- Attachments

OH4430

5.6 ATTACHMENT INSTALLATION

1. Attachment

2. Attachment Pin Recess

3. Attachment Pin

4. Lock Pin

5. Lock Lever

6. Quick Coupler (attachment tilt control in cab, see Boom Joystick page 3-12)

WARNING

CRUSH HAZARD. Always be certain that carriage or attachment is properly positioned

on boom and is secured by lock pin and lock lever. Failure to ensure proper installation could permit carriage/attachment/load to disengage.

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Section 5- Attachments

OH4440

OH4450

OH4460

OH44

This installation procedure is designed for one-person operation. Prior to exiting cab, perform “Shut-Down Procedure” on page 4-3.

1. Tilt quick coupler back to provide clearance. Check to be sure lock pin is removed.

2. Align attachment pin with recess in attachment. Raise boom slightly to engage attachment pin in recess.

3. Tilt quick coupler forward to engage attachment.

4. Lift lock lever and insert lock pin completely through quick coupler. Release lock lever and ensure lock pin is secured.

5. If equipped, connect auxiliary hydraulic hoses. See “Hydraulic Operated Attachment” on page 5-12.

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Section 5- Attachments

OH4480

Hydraulic Operated Attachment

1. Install attachment (see page 5-10).

2. Lower attachment to ground and perform “Shut-Down Procedure” on page 4-3.

3. Connect attachment hoses to both auxiliary fittings (1).

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Section 5- Attachments

5.7 ADJUSTING/MOVING FORKS

Carriages may have different locations where forks can be positioned. Two different methods can be used for repositioning, depending upon the carriage structure.

Note: Apply a light coating of appropriate lubricant to ease sliding of forks or fork bar.

To slide forks:

1. Ensure attachment is properly installed. See “Attachment Installation” on page 5-10.

2. Elevate attachment to approximately 5 ft (1,5 m) and tilt carriage forward until fork heel is free from attachment.

3. Stand at side of carriage. To slide fork toward center of carriage, push the fork near the fork eye. To slide fork toward edge of carriage, pull the fork near the fork eye. To avoid pinching, do not place fingers or thumb between fork and carriage structure.

If removing fork bar is necessary:

1. Rest forks on ground.

2. Remove fork bar.

3. Reposition forks.

4. Reinstall fork bar and fork bar retaining mechanism(s).

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Section 5- Attachments

5.8 ATTACHMENT OPERATION

• Capacities and range limits for telehandler change depending on attachment in use.

• Separate attachment instructions must be kept in manual holder in cab with this Operation & Safety Manual. An additional copy must be kept with attachment if it is equipped with a manual holder.

NOTICE

EQUIPMENT DAMAGE. Some attachments may contact front tires or machine structure when the boom is retracted and the attachment is rotated. Improper use of attachment may result in attachment or machine structural damage.

NOTICE

EQUIPMENT DAMAGE. Avoid contact with any structure or object when lifting a load. Maintain clearance around boom structure and load. Failure to maintain clearance may result in attachment or machine structural damage.

5-14 31211018

Carriage with Forks

OY0690

O 5231H

Use Carriage Attachment Capacity Chart.

To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-4.

Section 5- Attachments

Joystick (1) controls movement of the boom.

Roller switch (2) controls fork tilt.

• Move joystick back to tilt up.

• Move joystick forward to tilt down.

Installation Procedure:

Refer to “Attachment Installation” on page 5-10.

Equipment Damage Precautions:

• Do not use forks as a lever to pry material. Excessive prying forces could damage forks or machine structure.

• Do not attempt to lift loads that are attached or connected to another object.

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Section 5- Attachments

OAL1540

O 5231H

OH5360

Side Shift Carriage

Use Side Shift Carriage Capacity Chart.

To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-4.

Joystick (1) controls movement of the boom.

Roller switch (2) controls fork tilt.

• Press roller switch down to tilt up.

• Press roller switch up to tilt down.

To Side Shift:

Auxiliary hydraulic lever (3) controls carriage side shift.

• Move lever left to shift left.

• Move lever right to shift right.

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Section 5- Attachments

Installation Procedure:

• Refer to “Attachment Installation” on page 5-10.

WARNING

CRUSH HAZARD. Do not use side shift to push or pull objects or load. Failure to

comply could cause object or load to fall.

Equipment Damage Precautions:

• Do not use forks as a lever to pry material. Excessive prying forces could damage forks or machine structure.

• Do not attempt to lift loads that are attached or connected to another object.

5-1731211018

Section 5- Attachments

OAL1550

O 5231H

OH5270

Side Tilt Carriage

Use Side Tilt Carriage Attachment Capacity Chart.

To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-4.

Joystick (1) controls movement of the boom.

Roller switch (2) controls fork tilt.

• Press roller switch down to tilt up.

• Press roller switch up to tilt down.

To Side Tilt:

Auxiliary hydraulic lever (3) controls the carriage side tilt.

• Move lever left to side tilt left.

• Move lever right to side tilt right.

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Section 5- Attachments

Installation Procedure:

• Refer to “Attachment Installation” on page 5-10.

WARNING

CRUSH HAZARD. Do not use side tilt to push or pull objects or load. Failure to comply

could cause object or load to fall.

Operation:

• Approach load with forks centered on load and stop telehandler.

• Level telehandler before side tilting carriage to engage load.

• Side tilt carriage to left or right to align forks with load and engage load.

• Raise load slightly and level carriage side to side.

• Travel in accordance with requirements set forth in Section 1- General Safety Practices.

Equipment Damage Precautions:

• Do not use forks as a lever to pry material. Excessive prying forces could damage forks or machine structure.

• Do not attempt to lift loads that are attached or connected to another object.

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Section 5- Attachments

OU2150

O 5231H

OH5280

Swing Carriage

Use Swing Carriage Attachment Capacity Chart.

To determine maximum capacity, refer to “Telehandler/Attachment/ Fork Capacity” on page 5-4.

Joystick (1) controls movement of the boom.

Roller switch (2) controls fork tilt.

• Press roller switch down to tilt up.

• Press roller switch up to tilt down.

To Sw ing:

Auxiliary hydraulic lever (3) controls the swing function.

• Move lever left to swing left.

• Move lever right to swing right.

5-20 31211018

JLG Skytrak 6036, Skytrak 8042, Skytrak 6042, Skytrak 10042, Skytrak 10054 Operation & Safety Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Revision Log

Read This First

Table of Contents

Section 1- General Safety Practices

1.1 HAZARD CLASSIFICATION SYSTEM

Safety Alert System and Safety Signal Words

1.2 GENERAL PRECAUTIONS

1.3 OPERATION SAFETY

Electrical Hazards

Tip Over Hazard

Travel Hazard

Load Falling Hazard

Lifting Personnel

Driving Hazards on Slopes

Pinch Points and Crush Hazards

Fall Hazard

Chemical Hazards

1.4 CLEARSKY (IF EQUIPPED)

Federal Communications Commission (FCC) Information for Users

Section 2- Pre-Operation and Inspection

2.1 PREPARATION, INSPECTION AND MAINTENANCE

2.2 PRE-OPERATION CHECK AND INSPECTION

2.3 SAFETY DECALS

ANSI (if equipped)

ISO (if equipped)

2.4 WALK-AROUND INSPECTION

2.5 WARM-UP AND OPERATIONAL CHECKS

Warm-Up Check

Operational Check

2.6 OPERATOR CAB

2.7 WINDOWS

Cab Door Window (if equipped)

Section 3- Controls and Indicators

3.1 GENERAL

3.2 CONTROLS

Dash Controls and Indicators

Instrument Cluster

Ignition

Park Brake

Parking Procedure

Transmission Control Lever

Boom Joystick

Auxiliary Hydraulic Joystick

Frame Level Joystick

Outrigger Switches (10042 & 10054)

Accessory Control Lever (if equipped)

3.3 STEER MODES

Steer Mode Change

3.4 STABIL-TRAK™ SYSTEM (6042, 8042, 10042 & 10054)

Free Pivot Mode

Slow Pivot Mode

Locked Mode

3.5 BOOM/OUTRIGGER INTERLOCK SYSTEM (10054)

Extend Interlock Mode

Outrigger Interlock Mode

3.6 OPERATOR SEAT

Adjustments

Seat Belt

3.7 BOOM ANGLE AND EXTENSION INDICATORS

3.8 REVERSE SENSING SYSTEM (IF EQUIPPED)

Section 4- Operation

4.1 ENGINE

Starting the Engine

Battery Boosted Starting

Normal Engine Operation

Shut-Down Procedure

4.2 AFTER-TREATMENT SYSTEM (ATS) (IF EQUIPPED FOR ULS/85 OR 110HP)

Automatic Exhaust System Cleaning

Stationary Exhaust System Cleaning

4.3 OPERATING WITH A NON-SUSPENDED LOAD

Lift Load Safely

Picking Up a Load

Transporting a Load

Leveling Procedure

Placing a Load

Disengaging a Load