SkyTrak 6036 Service Manual

Service Manual

Model

6036

S/N 14834 & After

8990416

Revised February 11, 2005

EFFECTIVITY PAGE

September, 2001 - Original issue.

February 11, 2005 - B - Replaced all branding with JLG.

Model 6036 Legacy

EFFECTIVITY PAGE

Model 6036 Legacy

SECTION CONTENTS

Section Subject Page

Section 1

Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

1.2 Owners/Operators Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

1.3 Training Mechanics as Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

1.4 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

1.5 Accident Prevention Tag Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

1.6 Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

1.7 Emergency Exit Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

1.8 Hazard/Emergency Information Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7

Section 2

General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1

2.1 6036 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

2.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4

2.3 Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5

2.4 Metric Conversion Factors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

2.5 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8

2.6 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16

2.7 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20

2.8 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21

2.9 Hoses and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21

2.10 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21

2.11 Pressure Testing and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22

2.12 After Service Startup and Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22

Section 3

Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1

3.1 Boom System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2

3.2 Boom System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

3.3 Boom Assembly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

3.4 Quick Attach Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.59

3.5 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.61

Section 4

Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1

4.1 Operator’s Cab and Covers Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . 4.2

4.2 Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3

4.3 Open Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4

4.4 Enclosed Cab (Optional) Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19

4.5 Cab Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.25

4.6 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.29

4.7 Access Panels and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.32

Model 6036 Legacy

Section Subject Page

Section 5

Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1

5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . 5.2

5.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3

5.3 Axle Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3

5.4 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15

5.5 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.21

Section 6

Transmission: ZF 4 WG-98 TC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1

6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2

6.2 Transmission Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

6.3 Transmission Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

6.4 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

6.5 Transmission Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4

6.6 Transmission Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4

6.7 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6

6.8 Towing a Disabled Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13

6.9 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.14

Section 7

Engine: Cummins 4BT3.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2

7.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4

7.3 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6

7.4 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6

7.5 Standard Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6

7.6 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7

7.7 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14

7.8 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.15

7.9 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23

7.10 Air Cleaner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24

7.11 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25

7.12 Engine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.37

7.13 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.38

Section 8

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1

8.1 Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3

8.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4

8.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5

8.4 Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.5

8.5 Hoses, Tube Lines, Fittings, Etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6

8.6 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7

8.7 Hydraulic System Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10

8.8 Hydraulic Circuits and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13

8.9 Four-Wheel Steer Indexing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.58

8.10 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.60

8.11 Hydraulic System Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.61

8.12 Valves and Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.68

8.13 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.100

Model 6036 Legacy

Section Subject Page

Section 9

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1

9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3

9.2 Service Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5

9.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5

9.4 Effective Ground Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6

9.5 Wiring Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6

9.6 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8

9.7 Electrical System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10

9.8 Transmission Gear Selection Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.40

9.9 Dash Panel Warning Indicator Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.48

9.10 Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.57

9.11 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.59

9.12 Electrical System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.65

9.13 Window Wiper/Washer (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.70

9.14 Cab Heater and Fan (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.75

9.15 Switches and Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.76

Section 10

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1

Accident Prevention Tags

Model 6036 Legacy

iii

Section Subject Page

This Page Intentionally Left Blank

Model 6036 Legacy

Section 1

Safety Practices

Contents

PARAGRAPH TITLE PAGE

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

1.2 Owners/Operators Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

1.3 Training Mechanics as Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

1.4 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

1.4.1 Safety Alert Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

1.4.2 Hazard Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

1.5 Accident Prevention Tag Usage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

1.6.1 Personal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

1.6.2 Equipment Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

1.6.3 General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

1.6.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

1.7 Emergency Exit Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

1.8 Hazard/Emergency Information Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7

Model 6036 Legacy

1.1

Safety Practices

1.1 INTRODUCTION

JLG products meet all applicable industry safety standards. JLG actively promotes safe practices in the use and maintenance of its products through training programs, instructional manuals and the pro-active efforts of all employees involved in engineering, design, manufacture, marketing and service.

This manual is designed to provide service technicians with complete information on the maintenance and repair of the Sky Trak Model 6036 Legacy Telescopic Material Handler.

Particular effort has been made to produce a manual to serve as a reference handbook for the experienced service technician, but also provide essential step-bystep procedures for the professional development of the less experienced person. Remember, even the best manual in the world is no substitute for an appropriate education, skill development that comes through experience alone, safety, wise and judicious discernment, and ultimately, proper performance of service procedures.

This service manual provides general directions for accomplishing service and repair procedures with tested, effective techniques. Following the procedures in this manual will help assure safety and equipment reliability.

Read, understand and follow the information in this manual, and obey all locally approved safety practices, procedures, rules, codes, regulations and laws. Prior to performing any maintenance on the vehicle, consider all factors, circumstances and conditions which can have an effect upon the safety of personnel and equipment, and take appropriate action to ensure the safety of all involved.

These instructions cannot cover all details or variations in the equipment, procedures or processes described, nor provide directions for meeting every possible contingency during operation, maintenance or testing. When additional information is desired to satisfy a situation not covered sufficiently, consult the local JLG Authorized Service Center (ASC) or the JLG Service Department at 1-877-554- 5438 (Domestic) or 1-717-485-5161 (Internationally).

Many factors contribute to unsafe conditions: carelessness, fatigue, overload, inattentiveness, unfamiliarity, even drugs and alcohol, among others. Although equipment damage can usually be repaired in a brief period of time, death and irreparable injury are permanent. For optimal safety, encourage everyone to think, and to act, safely.

Appropriate service methods and proper repair procedures are essential for the safety of the individual doing the work, for the safety of the operator, and for the safe, reliable operation of the vehicle.

Provisions for supplementary information are made by JLG in the form of Service Bulletins, Service Campaigns, Service Training Schools, the JLG website, other literature, and through updates to the manual itself. Comments and suggestions for improvement are welcome and encouraged.

All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication approval. JLG reserves the right to make changes and improvements to its products, and to discontinue the manufacture of any product, at its discretion at any time without public notice or obligation.

1.2 OWNERS/OPERATORS MANUAL

The vehicle must be driven and operated as a consequence of, or when performing, service, maintenance and test procedures. The service technician must, therefore, thoroughly read, understand and follow the Sky Trak Model 6036 Legacy Telescopic Material Handler Owners/Operators Manual.

An owners/operators manual is supplied with each vehicle and must be kept in the owners/operators manual holder (Fig. 1-1, 1) located on the cab post to the left and below the operator’s seat.

MH0770

Figure 1- 1 The Owners/Operators Manual Holder

In the event that the owners/operators manual is missing, consult the local JLG Authorized Service Center (ASC) or the JLG Service Department before proceeding.

1.2

Model 6036 Legacy

Safety Practices

1.3 TRAINING MECHANICS AS OPERATORS

Because it is necessary to move the vehicle to service or maintain the vehicle, it is necessary that all mechanics are OSHA trained and certified as operators. A mechanic trained in the proper operation of the vehicle can better determine whether all functions are operating correctly.

At the time of original purchase, the purchaser of this vehicle was instructed by the seller on its proper use. When this vehicle is to be serviced or maintained by someone other than the purchaser, make certain that the mechanic is trained, in accordance with the OSHA regulations listed in the NOTICE below, and reads and understands the SKY TRAK Model 6036 Legacy Telescopic Material Handler Owners/Operators Manual before

operating or maintaining the vehicle.

NOTICE: Under OSHA rules, it is the responsibility of the employer to provide operator training. Successful completion and certification of Safety Training for Rough Terrain Forklifts is required. Operator Training Kits are available by calling the Ken Cook Company at (414) 466-

6060. An order form for these kits is available through our

website, http://www.jlg.com.

In addition, make sure that the mechanic has completed a walk-around inspection of the vehicle, is familiar with all decals and/or decal plates on the vehicle, and has demonstrated the correct use of all controls.

1.4 SAFETY INFORMATION

The following information provides general safety instructions, including examples of hazard statements with signal words, notification of hazards, methods to help avoid hazards and the consequences of failing to follow the safety information. To avoid possible death or injury, carefully read and follow all safety messages. Fully understand the potential causes of death or injury.

In the event of an accident, know where to obtain medical assistance and how to use a first-aid kit and fire extinguisher/fire suppression system. Keep emergency telephone numbers (fire department, ambulance, rescue squad/paramedics, police department, etc.) nearby. If working alone, check with another person routinely to help ensure personal safety.

The information in this manual does not replace any other safety rules or proper judgment. Governmental authorities and employers also have their own sets of rules, codes, regulations and laws. Before starting work at a site, check with the supervisor or safety coordinator and ask about the safety policy. Learn the safety requirements in effect before operating, maintaining, servicing or testing the vehicle. Safety depends on following safety requirements.

1.4.1 Safety Alert Symbol

The exclamation mark within a triangle is the Safety Alert Symbol.

Model 6036 Legacy

OP0330

This symbol means “Attention! Become Alert! Your Safety Is Involved!” The symbol is used to attract attention to safety hazards found on the vehicle safety decals and throughout this manual.

1.3

Safety Practices

1.4.2 Hazard Statements

Signal words and messages are used in conjunction with the safety alert symbol to create hazard statements. These hazard statements convey important information about safety.

Four types of hazard statements are used in this manual. Each statement indicates the existence and degree of relative risk of the hazard described within the statement that follows the signal word.

Explanations of the types of hazard statements are as follows:

DANGER:

The signal word “DANGER” indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING:

1.5 ACCIDENT PREVENTION TAG USAGE

MC0690

Figure 1- 2 Accident Prevention Tag

The signal word “WARNING” indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION:

The signal word “CAUTION” indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury.

CAUTION:

The signal word “CAUTION,” used without the safety alert symbol, indicates a potentially hazardous situation which, if not avoided, could result in property damage.

For safe maintenance of the vehicle, read, understand and follow all DANGER, WARNING and CAUTION information.

Before beginning any maintenance or service, place an Accident Prevention Tag (Fig. 1-2) on both the ignition key switch and the steering wheel (Fig. 1 -3), stating that the vehicle should not be operated. Actual Accident Prevention Tags, which can be punched out and used, are included as the last page in this manual. Retain these Accident Prevention Tags for reuse at a later date.

DANGER

OH1720

1.4

Figure 1- 3 Place Accident Prevention Tags on Both the

Ignition Key Switch and the Steering Wheel

Model 6036 Legacy

Safety Practices

1.6 SAFETY INSTRUCTIONS

Following are general safety statements to consider

before

Additional statements related to specific tasks and procedures are located throughout this manual and are listed prior to any work instructions to provide safety information before the hazard occurs.

For all safety messages, carefully read, understand and follow the instructions

1.6.1 Personal Hazards

HAIR and CLOTHING: DO NOT wear loose clothing or jewelry. Tie up or restrain hair. Wear the correct safety equipment for the job (including but not limited to: hard hat; safety shoes; safety glasses, goggles, or face shield; heavy gloves; hearing protection; reflective clothing; wetweather gear; respirator or filter mask).

EYE PROTECTION: Always wear appropriate eye protection when chiseling, grinding, sanding, welding, painting, repairing hydraulic systems, or checking, testing or charging the battery.

BREATHING PROTECTION: Wear respiratory protection when grinding or painting.

HEARING PROTECTION: Always wear hearing protection in a high-noise area.

FOOT PROTECTION: Wear protective footwear with reinforced toe caps and slip-resistant soles.

LIFTING: NEVER lift a heavy object without the help of at least one assistant or a suitable sling and hoist.

performing maintenance procedures on a vehicle.

before

proceeding.

1.6.2 Equipment Hazards

OWNERS/OPERATORS MANUAL: Before operating the vehicle, carefully read, understand and follow the owners/ operators manual.

OPERATIONAL PROTECTION: Before operating the vehicle or returning it for operational use, check that the Operator’s Protective Structure is intact, undamaged, unmodified and secure.

LIFTING OF EQUIPMENT: Before using any lifting equipment (chains, slings, brackets, hooks, etc.), verify that it is of the proper capacity, in good working condition and properly attached.

NEVER stand or otherwise become positioned under a suspended load or under raised equipment. The load or equipment could fall or tip.

DO NOT use a hoist or jack to support raised equipment. A hoist or jack failure can allow the equipment to fall or tip.

Always support equipment with proper capacity blocks or stands that are properly rated for the load.

COMPRESSED AIR: Before and during the use of compressed air, wear eye protection and advise other personnel in the work area that compressed air is about to be used.

HAND TOOLS: Always use the proper tool for the job; keep tools clean and in good working order, and use special service tools only as recommended.

Model 6036 Legacy

1.5

Safety Practices

1.6.3 General Hazards

SOLVENTS: Only use approved solvents, and solvents that are known to be safe for use.

HOUSEKEEPING: Keep the work area and operator’s cab clean and remove all hazards (debris, oil, tools, etc.).

FIRST AID: Immediately clean, dress and report all injuries (cuts, abrasions, burns, etc.), no matter how minor. Know the location of a first-aid kit, and know how to use it.

CLEANLINESS: Wear eye protection, and clean all components with a high-pressure or steam cleaner before attempting service.

When removing hydraulic components, plug hose ends and connections to prevent excess leakage and contamination. Place a suitable catch basin beneath the vehicle to capture fluid run-off.

1.6.4 Operational Hazards

OPERATIONAL CONSIDERATIONS: Before operating the vehicle, carefully read, understand and follow the owners/operators manual.

ENGINE: Stop the engine before performing any service.

DANGEROUS START: Place Accident Prevention Tags on both the ignition key switch and the steering wheel before attempting to perform any service or maintenance. Disconnect battery leads. Place a warning sign on a vehicle that is dangerous to start, if leaving the vehicle unattended.

VENTILATION: Avoid prolonged engine operation in enclosed areas without adequate ventilation.

RADIATOR CAP: Always wear steam-resistant, heatprotective gloves when opening the radiator cap. Cover cap with a clean, thick cloth and turn slowly to the first stop to relieve pressure.

SOFT SURFACES AND SLOPES: NEVER work on a vehicle that is parked on a soft surface or slope (inclined ground or hill). The vehicle must be on a hard, level surface with the wheels blocked when performing any service. Obtain assistance, block all wheels, and add supports if necessary before beginning any work.

SUPPORTS AND STRAPS: Install safe, stable supports, slings or straps beneath or around a component or structural member before beginning any work.

FLUID PRESSURE: Before loosening any hydraulic or diesel fuel component, hose or tube, turn engine OFF. Wear heavy, protective gloves and eye protection. NEVER check for leaks using any part of your body; use a piece of cardboard or wood instead. If injured, seek medical attention immediately. Diesel fuel leaking under pressure can explode. Hydraulic fluid and diesel fuel leaking under pressure can penetrate the skin, causing infection, gangrene and other serious personal injury.

Relieve all pressure before disconnecting any component, part, line or hose. Slowly loosen parts and allow release of residual pressure before removing any part or component. Before starting engine or applying pressure, use components, parts, hoses and pipes that are in good condition, connected properly and tightened to the proper torque. Capture fluid in an appropriate container and dispose of it in accordance with prevailing environmental regulations.

PRESSURE TESTING: When conducting any test, only use test equipment that is correctly calibrated and in good condition. Use the correct equipment in the proper manner, and make changes or repairs as indicated by the test procedures to achieve the desired results.

LEAVING VEHICLE: Lower the attachment to the ground before leaving the vehicle.

TIRE PRESSURE: Always keep tires inflated to the proper pressure to help prevent dangerous travel and load-handling situations. DO NOT over-inflate tires.

1.7 EMERGENCY EXIT REAR WINDOW

The rear window in the enclosed cab can be used as an emergency exit by removing the latch pins (Fig. 1 -4, 1) located on the two window latches (2). Once the latch pins have been removed, the window (3) can be swung open.

791

OH1730

1.6

Figure 1- 4 Emergency Exit Rear Window Latch Pins

Model 6036 Legacy

Safety Practices

1.8 HAZARD/EMERGENCY INFORMATION DECALS

Locations of vehicle hazard and other emergency information decals are shown below. As part of routine maintenance, check that ALL hazard and emergency information decals on the vehicle are present and readable. Keep all decals clean.

If a replacement decal is needed, refer to the owners/ operators manual and parts catalog for the latest parts numbers and ordering information, or, contact JLG directly at:

Domestic: 1-877-554-5438

International: 1-717-485-5161

OH17412

1. No Riders WARNING

2. Vehicle Rollaway WARNING

3. Safety Instructions

4. Electrocution DANGER

5. Tipover DANGER - Operating

6. Do Not Jump DANGER

8. Moving Parts WARNING

9. Carrying Personnel WARNING

10. Boom Extend Letters

11. Boom Angle Indicator

12. Explosive Gases WARNING

13. Emergency Exit (Enclosed Cab Only)

OA1652

7. Load Chart Booklet

Note: Many of these hazard related decals are available free of charge by calling JLG at 1-877-554-5438 (Domestic) or 1-717-485-5161 (International).

Model 6036 Legacy

1.7

Safety Practices

This Page Intentionally Left Blank

1.8

Model 6036 Legacy

Section 2

General Information and Specifications

Contents

PARAGRAPH TITLE PAGE

2.1 6036 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

2.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4

2.2.1 Service Methods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4

2.2.2 The Owners/Operators Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4

2.2.3 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . 2.4

2.2.4 Disclaimer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4

2.3 Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5

2.3.1 Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5

2.3.2 Bolts and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5

2.3.3 Straight Thread O-ring Fitting (Non-Adjustable) . . . . . . . . . . . . . . . . . . . . . . . . 2.5

2.3.4 Straight Thread O-ring Fitting (Adjustable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5

2.3.5 Flat-Face O-ring Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

2.4 Metric Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

2.4.1 Approximate American to Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

2.4.2 Approximate Metric to American Conversions . . . . . . . . . . . . . . . . . . . . . . . . . 2.7

2.5 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8

2.5.1 Vehicle Dimensions (With Standard 12-ply 13.00-24 Tires) . . . . . . . . . . . . . . . 2.8

2.5.2 Vehicle Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10

2.5.3 Attachment Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11

2.5.4 Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11

2.5.5 Hydraulic Cylinder Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . 2.12

2.5.6 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12

2.5.7 Engine Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13

2.5.8 Fluid and Lubricant Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14

2.5.9 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15

2.5.10 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15

2.5.11 Miscellaneous Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15

2.5.12 Tamper Proofing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16

2.5.13 Fork Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16

Model 6036 Legacy

2.1

General Information and Specifications

2.6 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16

2.6.1 Axles (Differential Housings) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16

2.6.2 Axle Wheel Ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17

2.6.3 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17

2.6.4 Lubrication Points (Grease Fittings) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17

2.6.5 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18

2.6.6 Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18

2.6.7 Drive Shaft Splines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19

2.6.8 General Anti-Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19

2.6.9 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19

2.6.10 Paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20

2.6.11 Thread Locking Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20

2.7 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20

2.8 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21

2.9 Hoses and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21

2.9.1 Hose and Tube Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21

2.9.2 Hose and Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21

2.10 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21

2.10.1 Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21

2.10.2 Bearing Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21

2.10.3 Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22

2.11 Pressure Testing and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22

2.12 After Service Startup and Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22

2.12.1 After Service Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22

2.12.2 After Electrical/Electronic Component Service . . . . . . . . . . . . . . . . . . . . . . . . . 2.22

2.12.3 After Hydraulic Component Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23

2.12.4 After Brake System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23

2.12.5 After Fuel System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23

2.12.6 After Transmission Service or Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23

2.12.7 After Tire and Wheel Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24

2.12.8 After Engine Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24

2.12.9 After Boom Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24

2.12.10 After Axle Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24

2.2

Model 6036 Legacy

2.1 6036 COMPONENT TERMINOLOGY

To understand the safety, operation and maintenance information presented in this manual, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies on this vehicle. The following illustration identifies the components that are referred to throughout this manual.

Operator’s

Protective

Structure

General Information and Specifications

Boom

Assembly

Rear Door

(Not Visible)

Engine

Compartment

Cylinders (2)

Lift/Lower

Cylinders (2)

Slave

Carriage

Assembly

Extend/Retract

Cylinder

Frame Sway

Cylinder

Hydraulic

Oil Tank

MA8240

Model 6036 Legacy

2.3

General Information and Specifications

2.2 INTRODUCTION

2.2.1 Service Methods

Appropriate service methods and proper repair procedures are essential for safe, reliable operation of this vehicle and the safety of the individual doing the work. This Service Manual provides general direction for accomplishing service and repair work with tested, effective techniques. Following them will assure reliability.

There are many variations in procedures, techniques, tools and parts for servicing vehicles, as well as work skills. This manual cannot possibly anticipate all such variations and provide advice or cautions for each one. Accordingly, anyone who intends to depart from the instructions in this manual must first consider personal safety and then vehicle integrity.

IMPORTANT:

environmentally sound waste storage and disposal practices. NEVER drain fluids on the ground or into a sewer or catch basin. Use suitable collection containers, then store and/or dispose of waste products in an approved and safe manner. Check and obey all Federal, State and/or Local regulations regarding waste storage, disposal and recycling.

2.2.2 The Owners/Operators Manual

The Owners/Operators Manual provides information you need to properly operate and maintain this vehicle.

IMPORTANT: Before you operate this vehicle, read the manual completely and carefully, so that you will understand the safety instructions and the operation of the controls and safety equipment. You must comply with all Danger, Warning and Caution notices. They are for your benefit.

All references to the right side, left side, front and rear are given from the operator’s seat looking in a forward direction.

JLG

recommends the use of

The vehicle serial number plate (Fig. 2-1, 1) is located at the front of the vehicle on the frame sway cylinder upright.

OH0280

Figure 2- 1 Vehicle Serial Number Plate Location

IMPORTANT: The replacement of any part on this

vehicle with any other than a

JLG

authorized replacement part can adversely affect the performance, durability, or safety of the vehicle, and will void the warranty.

JLG

disclaims liability for any claims or damages, whether regarding property damage, personal injury or death arising out of the use of unauthorized replacement parts.

A warranty registration form must be filled out by the JLG Authorized Service Center (ASC), signed by the purchaser and returned to JLG when the vehicle is sold and/or put into use.

Registration activates the warranty period and helps to assure that warranty claims are promptly processed. To guarantee full warranty service, verify that the distributor has returned the business reply card of the warranty registration form to JLG.

2.2.3 Replacement Parts and Warranty Information

For reference when ordering replacement parts or making service inquiries about the vehicle, the vehicle serial number is required to help assure the provision of correct parts and information. Before ordering parts or initiating service inquiries, make note of the serial number.

2.4

2.2.4 Disclaimer

JLG reserves the right to make changes to and to add improvements upon its product at any time, without public notice or obligation. JLG also reserves the right to discontinue manufacturing any product at its discretion at any time.

Model 6036 Legacy

General Information and Specifications

2.3 TORQUES

2.3.1 Fasteners

All fasteners (nuts, bolts, washers, etc.) are equal to SAE Grade 5 (PC8.8) and are plated, unless otherwise specified.

2.3.2 Bolts and Nuts

Unless otherwise specified, the following values apply for Grade 5 (PC8.8) nuts and bolts:

Size Torque Size Torque

Inch lb/ft Nm mm Nm lb/ft

1/4 9 12 6,0 10 7

5/16 17 24 8,0 25 18

3/8 31 42 10,0 50 37

7/16 50 68 -- -- --

1/2 75 102 12,0 80 59

9/16 110 150 14,0 130 95

5/8 150 203 16,0 200 146

3/4 250 340 20,0 360 263

7/8 380 515 22,0 510 372

1.0 585 793 24.0 650 475

2.3.3 Straight Thread O-ring Fitting (Non-Adjustable)

When the vehicle leaves the factory, it is equipped only with straight thread o-ring fittings. Customer-added accessories may differ; therefore, consult the manufacturer’s product literature for information.

1. Verify that both threads and sealing surfaces are free of burrs, nicks, scratches and any foreign material.

2. Lubricate the new o-ring with a light coating of hydraulic oil.

3. Tighten the fitting to the proper torque according to the following chart:

SAE Size

4 6

8 10 12 16 20 24

lb/ft Nm

15-17 34-36

58-62 100-110 134-146 202-218 248-272 303-327

Torque

20-23 46-49

79-84 136-149 181-198 274-296 336-369 411-443

2.3.4 Straight Thread O-ring Fitting (Adjustable)

1. Verify that both mating parts are free of burrs, nicks, scratches and any foreign material.

2. Lubricate the new o-ring with a light coat of hydraulic oil.

3. Back off the locknut as far as possible.

4. Screw the fitting into the port by hand until the back-up washer contacts the face of the port and is pushed all the way towards the locknut.

5. To position the fitting, unscrew by the required amount, but not more than one full turn.

6. Hold the fitting in the desired position, and tighten to the proper torque according to the following chart:

Adjustable Straight-Thread O-ring

Fitting Torque Chart

SAE Size

4 6

8 10 12 16 20 24

lb/ft Nm

15-17 34-36

58-62 100-110 134-146 202-218 248-272 303-327

Torque

20-23 46-49

79-84 136-149 181-198 274-296 336-369 411-443

Model 6036 Legacy

2.5

General Information and Specifications

2.3.5 Flat-Face O-ring Fittings

Improper assembly of this type of joint will result in a leaking joint. Undertightening will result in the joint loosening during normal use. Foreign material on either sealing surfaces will cause damage to one or both mating parts when the joint is tightened, resulting in a leaking joint. The absence of the fitting o-ring will cause the joint to leak.

1. Verify that both threads and sealing surfaces are free of burrs, nicks, scratches and any foreign material.

2. Inspect the male fitting for the presence of the o-ring seal. Replace the o-ring if missing or damaged.

3. Place the flat surface of the female connector in full contact with the o-ring in the male connector.

4. Finger-tighten the nut onto the fitting.

5. Hold the fitting in the desired position; for hoses and swivel fittings, use a second wrench to keep the female connector from moving during tightening. Tighten to the proper torque according to the following chart:

SAE Size

4 6

8 10 12 16 20 24

lb/ft Nm

19-36 28-54 42-80

65-126 100-180 130-240 150-280 175-330

Torque

26-49

38-73 57-108 88-171

136-244 176-325 203-380 237-447

2.4 METRIC CONVERSION FACTORS

2.4.1 Approximate American to Metric Conversions

When this is known Multiply by To find

TORQUE (moment of force)

Pound/feet (lb/ft) 1.356 Newton meters (Nm)

Pound/inches (lb/in) 0.113 Newton meters (Nm)

POWER

Horsepower (hp) 745.7 Watts

SPEED (velocity)

Miles per hour (mph) 1.609 Kilometers per hour

(km/hr; kph)

LENGTH (distance)

Inches (in) 25.4 Millimeters (mm)

Inches (in) 2.5 Centimeters (cm)

Feet (ft) 30.5 Centimeters (cm)

Feet (ft) 0.305 Meters (m)

Yards (yd) 0.9 Meters (m)

Miles (mi) 1.6 Kilometers (km)

AREA

Square inches (in

Square feet (ft

Square yards (yd

Square miles (mi

Acres 0.4 Hectares (ha)

MASS (weight)

Ounces (oz) 28.3 Grams (g)

Pounds (lb) 0.4536 Kilograms (kg)

Short tons (2000 lb) 0.9 Metric ton (t)

) 6.5 Square centimeters (cm2)

) 0.09 Square meters (m2)

) 0.8 Square meters (m2)

) 2.6 Square kilometers (km2)

2.6

Model 6036 Legacy

General Information and Specifications

When this is known Multiply by To find

VOLUME

Teaspoons (tsp) 5 Milliliters (ml)

Tablespoons (Tbsp) 15 Milliliters (ml)

Cubic inches (in

) 16 Milliliters (ml)

Fluid ounces (fl oz) 30 Milliliters (ml)

Cups (c) 0.24 Liters

Pints (pt) 0.47 Liters

Quarts (qt) 0.95 Liters

Gallons (gal) 3.8 Liters

Cubic feet (ft

Cubic yards (yd

) 0.03 Cubic meters (m3)

) 0.76 Cubic meters (m3)

AIR PRESSURE

Pounds per square inch (psi) 6.895 Kilopascals (kPa)

HYDRAULIC PRESSURE

Pounds per square inch (psi) 0.069 Bar

TEMPERATURE (exact)

To determine degrees Celsius (° C), subtract 32, then multiply by 0.56; (° F -32) x 0.56 = ° C.

2.4.2 Approximate Metric to American Conversions

When this is known Multiply by To find

TORQUE (moment of force)

Newton meters (Nm) 0,738 Pounds/feet (lb/ft)

Newton meters (Nm) 8,85 Pounds/inches (lb/in)

POWER

Watts 0,0013 Horsepower (hp)

SPEED (velocity)

Kilometers per hour (km/hr; kph) 0,621 Miles per hour (mph)

LENGTH (distance)

Millimeters (mm) 0,0394 Inches (in)

Centimeters (cm) 0,394 Inches (in)

Meters (m) 3,281 Feet (ft)

Meters (m) 1,1 Yards (yd)

Kilometers (km) 0,621 Miles (mi)

When this is known Multiply by To find

AREA

Square centimeters

(cm

) 0,4 Square inches (in2)

Square meters (m

Square kilometers

) 0,6 Square miles (mi2)

(km

Hectares (10000 m

) 1,1 Square yards (yd2)

)2,5 Acres

MASS (weight)

Grams (g) 0,035 Ounces (oz)

Kilograms (kg) 2,2 Pounds (lb)

Metric ton

(1000 kg) (t) 1,1 Short tons

VOLUME

Milliliters (ml) 0,03 Fluid ounces (fl oz)

Milliliters (ml) 0,06 Cubic inches (in

)

Liters 2,1 Pints (pt)

Liters 1,06 Quarts (qt)

Liters 0,26 Gallons (gal)

Cubic meters (m

) 35 Cubic feet (ft3)

) 1,3 Cubic yards (yd3)

AIR PRESSURE

Kilopascals (kPa) 0,145 Pounds per square

inch (psi)

HYDRAULIC PRESSURE

Bar 14,5 Pounds per square

inch (psi)

TEMPERATURE (exact)

To determine degrees Fahrenheit (° F), multiply degrees Celsius (° C) by 1.8, then add 32; (° C x 1.8) + 32 = ° F.

Model 6036 Legacy

2.7

General Information and Specifications

2.5 SPECIFICATIONS

2.5.1 Vehicle Dimensions (With Standard 12-ply 13.00-24 Tires)

Description (Fig. 2- 2)

(A) Length (without Attachment) 217" (5512 mm)

(B) Width 98" (2489 mm)

(D) Wheelbase 113" (2870 mm)

(E) Tread 84" (2134 mm)

(F) Ground Clearance 16" (406 mm)

(G) Turning Radius, Curb to Curb 165" (4191 mm)

(H) Turning Radius, Clearance 165" (4191 mm)

(I) Maximum Lift Height, Boom Extended 36' 1" (11 m)

(J) Maximum Lift Height, Boom Retracted 20' 2" (6,1 mm)

(K) Maximum Below Grade Depth, Boom Extended 2' 1" (635 mm)

(L) Maximum Reach, from Front of Front Tires 22' 4" (6,8 m)

(M) Maximum Reach at Maximum Lift Angle,

Boom Extended

(N) Maximum Reach at Maximum Lift Angle,

Boom Retracted

(O) Maximum Reach at Minimum Lift Angle,

Boom Extended

(P) Maximum Boom Lift Angle 69°

(Q) Minimum Boom Lift Angle -8°

(R) Angle of Departure 28°

Fork Tilt Angle:

(S) At Minimum Boom Angle - UP 11°

(T) At Minimum Boom Angle - DOWN -101°

(U) At Maximum Boom Angle - UP 87°

(V) At Maximum Boom Angle - DOWN -25°

Frame Tilt Angle (Not Shown):

Right 10.0°

5' 6" (1676 mm)

-15" (-381 mm)

21' 3" (6,5 m)

Left 10.0°

2.8

Model 6036 Legacy

General Information and Specifications

0.0

24.0"

0.0

MA8250

Figure 2- 2 Vehicle Dimensions with Standard Tires

Model 6036 Legacy

2.9

General Information and Specifications

2.5.2 Vehicle Weights

Curb Weight (Open Cab) 20,095 lb (9115 kg)

Curb Weight (Enclosed Cab) 20,295 lb (9206 kg)

Operating Load 6,000 lb (2721 kg)

Working Weight (Machine working weight is figured with 72" [1829 mm] carriage, two 48" (1219 mm) pallet forks, 25%-full fuel tank, and standard bias ply tires [no hydrofill]):

Open Cab:

Front Axle 7,767 lb (3523 kg)

Rear Axle 12,328 lb (5592 kg)

Total (Open Cab) 20,095 lb (9115 kg)

Closed Cab:

Front Axle 7,866 lb (3568 kg)

Rear Axle 12,429 lb (5638 kg)

Total (Closed Cab) 20,295 lb (9206 kg)

2.10

Model 6036 Legacy

General Information and Specifications

2.5.3 Attachment Weights

Std 48" Carriage with Shaft 456 lb (205 kg)

Std 60" Carriage with Shaft 526 lb (239 kg)

Std 72" Carriage with Shaft 677 lb (307 kg)

48" Side Tilt Carriage with Shaft and Cylinder 687 lb (312 kg)

60" Side Tilt Carriage with Shaft and Cylinder 752 lb (341 kg)

72" Side Tilt Carriage with Shaft and Cylinder 770 lb (347 kg)

52" Swing Carriage with Shaft and Cylinder 950 lb (428 kg)

72" Swing Carriage with Shaft and Cylinder 1,135 lb (511 kg)

Bucket, 1.125 yd

(0,855 m3)

Broom, 8 foot (2,44 m) 1,100 lb (495 kg)

Pallet Forks, 2" x 4" x 48" (5,7 x 10 x 122 cm), quantity: 2278 lb (127 kg)

760 lb (342 kg)

Pallet Forks, 2.25" x 4" x 48" (5,7 x 10 x 122 cm), quan-

312 lb (141 kg)

tity: 2

Block Forks, 2" x 2" x 48" (5 x 5 x 122 cm), quantity: 6 480 lb (216 kg)

Lumber Forks, 1.75" x 7" x 60" (4 x 17,8 152,4 cm),

466 lb (210 kg)

quantity: 2

12 ft Truss Boom 470 lb (213 kg)

Auger Drive Unit 285 lb (128 kg)

Auger Mounting Frame 180 lb (81 kg)

Auger (Various Sizes Available) Varies

Auger Extension (Various Sizes Available) Varies

2.5.4 Performance Specifications

Note: Performance criteria is based on full throttle engine speed unless otherwise specified or not applicable.

Travel Speed (Standard Tires, No Load)

First Gear 0-3.5 mph (0-5,6 km/hr)

Second Gear 0-6 mph (0-9,7 km/hr)

Third Gear 0-14 mph (0-23 km/hr)

Fourth Gear 0-20 mph (0-32 km/hr)

Model 6036 Legacy

2.11

General Information and Specifications

2.5.5 Hydraulic Cylinder Performance Specifications

Note: Vehicle with no load, engine at full throttle, hydraulic oil above 130° F (54° C) minimum, engine at operating

temperature

Boom Extend Less than 15 seconds

Boom Retract Less than 15 seconds

Boom Lift Retracted Less than 15 seconds

Boom Lower Retracted Less than 10 seconds

Attachment Tilt - UP 4-6

Attachment Tilt - DOWN 3.5-5.5

Frame Sway Left to Right 3-6

Frame Sway Right to Left 4-8

Function Approximate Times, in Seconds

2.5.6 Electrical System

Battery:

Type, Rating 12 VDC, Negative (-) Ground, Maintenance-Free

Quantity 1

Reserve Capacity 1,000 Cold Cranking Amps @ 0° F (-18° C)

Group/Series C31XH

Alternator 12V, 65 Amps

Fuses - Standard Blade Style:

7.5 Amps Light Switch Relay, Transmission

10 Amps Instrument Panel, Horn/Heater, Steer Select Switch,

Washer/Wipers (Optional)

30 Amps Lights

40 Amps Main

Relays:

Neutral Start Relay 12 Volt

Park Brake Disengage Relay 12 Volt

Headlight Switch Relay 12 Volt

Back-up Relay 12 Volt

Light Switch Relay 12 Volt

2.12

Model 6036 Legacy

General Information and Specifications

2.5.7 Engine Performance Specifications

Note: Engine manufacturer's maximum “high idle” setting is lockwired and sealed. DO NOT disturb this setting.

Engine Make/Model Cummins Turbo/4BT3.9

Displacement

Horsepower 110 HP @ 2,500 rpm

Number of Cylinders 4

Engine High Idle with No Load 2,750 ±100 rpm

Engine Low Idle 1,050 ±50 rpm

Fuel Delivery Fuel Injection

Air Cleaner Dry Type, Replaceable Primary and Safety Elements

Peak Torque 278 lb/ft @ 1,500 rpm (377 Nm @ 1,500 rpm)

Average Fuel Consumption, Depending on Load/Duty 2 gal/hr (1,67 Imp gal/hr, or 7,57 liters/hr)

239 in

(3,9 liters)

Model 6036 Legacy

2.13

General Information and Specifications

2.5.8 Fluid and Lubricant Capacities

Engine Crankcase Oil:

Capacity with Filter Change 11.0 qt (10,4 liters)

Filter Capacity 1.0 qt (0,9 liters)

Oil Type SAE 15W40 Diesel Engine Oil

(Refer to Section 2.6.6, “Engine.”)

Fuel Tank:

Total Capacity 37.0 gal (140 liters)

Usable Capacity 35.0 gal (132,5 liters)

Type of Fuel Above 32° F (0° C) Standard No. 2 Diesel. (Refer to Section 2.6.6, “Engine.”)

Type of Fuel Below 32° F (0° C) 50/50 Mix of #1 and #2 Diesel Fuels

(Refer to Section 2.6.6, “Engine.”)

Cooling System:

Capacity w/o Heater

4.0 gal (15 liters)

(including 1.5 qt [1,4 liters] for overflow bottle)

Overflow Bottle Capacity 3.0 qt (2,8 liters)

Type of Fluid 50/50-mix of ethylene glycol and water

(Refer to Section 2.6.6, “Engine.”)

Transmission:

Capacity w/Filter Change 12.5 qt (11,8 liters)

Filter Capacity 1.5 qt (1,4 liters)

Type of Oil Universal Tractor Fluid

(Refer to Section 2.6.3, “Transmission.”)

Axle (Differential Housing):

Capacity 12.2 qt (11,5 liters)

Type of Oil Universal Tractor Fluid. Refer to Section 2.6.1, “Axles

(Differential Housings).”

Axle (Wheel Ends):

Capacity .95 qt (0,9 liters)

Type of Oil Universal Tractor Fluid. Refer to Section 2.6.1, “Axles

(Differential Housings).”

Hydraulic System:

System Capacity 57.5 gal (217,6 liters)

Reservoir Capacity 32.2 gal (122 liters)

Type of Oil ISO Grade 46 Anti-Wear Hydraulic Oil

(Refer to Section 2.6.5, “Hydraulic System.”)

2.14

Model 6036 Legacy

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SkyTrak 6036 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

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