ANSI Operators and Safety Manual Model MARCH 2002 10054 8990394-001 S/N 13198 thru 19079 Legacy Series Legacy Series S/N 13198 thru 19079 10054 8990394-001 MARCH 2002 Model Operators and Safety Manual ANSI
. Read all the safety decals on the vehicle. 3. Clear the area of other persons. CALIFORNIA 1. Read this owner/operators manual. Proposition 65 Warning Before starting the engine, do the following: Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling. WARNING: Improper operation of this vehicle can cause injury or death.
ã 2002 OmniQuip Textron Inc. 1 General Maintenance ................108 Maintenance Schedule And Checklist .................................109 1. Lubrication Points.............114 2. Air Cleaner And Restriction Indicator.............................116 3. Engine Cooling System .....120 4. Engine Oil And Filter .........123 General Maintenance Towing A Disabled Vehicle..........93 Emergency Boom Lowering ........95 Emergency Operations Operator Controls ........................
2 Model 10054 Rev 3/02 Introduction Introduction The Manual IMPORTANT! A Warranty Registration form must be filled out by the OmniQuip Authorized Service Center (ASC), signed by the purchaser, and returned to OmniQuip once the product is sold and/or put into service. This report activates the warranty period, assuring that your claims during the warranty period will be processed promptly.
Model 10054 3 Rev 3/02 Safety Practices Safety Practices Disclaimer OmniQuip reserves the right to make changes on and to add improvements upon its products at any time without public notice or obligation. OmniQuip also reserves the right to discontinue manufacturing any product at its discretion at any time. NOTICE: Under OSHA rules, it is the responsibility of the employer to provide operator training. Successful completion and certification of Safety Training for Rough Terrain Forklifts is required.
4 Model 10054 Rev 3/02 Safety Practices Signal Word For safe maintenance of the vehicle, read, understand and follow all DANGER, WARNING and CAUTION information. A signal word is a distinctive word located on hazard decals and used throughout this manual that alerts the viewer to the existence of and relative degree of the hazard. The signal word “CAUTION”, used without the safety alert symbol, indicates a potentially hazardous situation which, if not avoided, may result in property damage.
Model 10054 5 Rev 3/02 Safety Practices Accident Prevention Tags Before beginning any maintenance or service, place an Accident Prevention Tag on both the starter key switch and the steering wheel (Figure 1), stating that the vehicle should not be operated. Actual Accident Prevention Tags, which can be punched out and used, are included as the last page of this manual. Retain these Accident Prevention Tags for reuse at a later date.
6 Model 10054 Rev 3/02 Safety Practices The following symbol definitions will help you understand all hazard related decals used on this vehicle. This Symbol Signifies That Specific Attachments Must Only Be Used On Vehicles Equipped With Auxiliary Hydraulics. Always Connect Couplers.
Model 10054 7 Rev 3/02 Safety Practices FALLING OFF ATTACHMENT Can Result In Death Or Serious Injury Hazard Symbols OH2110 OH2120 Lead Acid Batteries Generate Explosive Gases Rotating Fan Blades Can Cut Vehicle Tipover Can Crush OH2150 OH2140 OH2130 - OH2300 VEHICLE TIPOVER, Outriggers Over Holes Or Voids Can Cause Death Or Serious Injury.
8 Model 10054 Rev 3/02 Safety Practices OH3120 • • • • Travel Slowly Close Hitch Use Two Slings Use Two Tethers Avoidance Symbols To Avoid Vehicle Tipover ALWAYS: Maintain Proper Air Pressure In Tire Keep Flames and Ignition Sources Away OH2290 OH2270 Do Not Travel With Boom Raised OH2270 OH2290 Keep Flames and Ignition Sources Away OH2320 Maintain Proper Air Pressure In Tire Do Not Raise Boom While On A Slope Keep Lit Cigarettes Away OH2280 OH2310 Do Not Travel With Boom Raised Keep Away F
Model 10054 9 Rev 3/02 Safety Practices • Lean Away From The Point Of Impact Avoidance Symbols (cont’d) • Hold On Firmly • Keep Seat Belt Fastened ALWAYS Fully Lower Outriggers Onto Solid Surfaces OH3170 • Brace Yourself and Stay With Vehicle DO NOT JUMP OH2250 OH2220 OH2260 Keep Clear Of Power Lines Use Only Approved Work Platforms To Raise Or Lower Personnel Engage Parking Brake OH2170 Do Not Travel With Personnel In Work Platform OH2230 Carry No Riders OH2240 OH2240 Carry No Riders Do N
10 Model 10054 Rev 3/02 Safety Practices Personal Considerations • exit the vehicle using the hand holds. 1. Seat Belt • unbuckle the seat belt, Always fasten the seat belt before starting the engine. • turn the engine OFF, if appropriate, 2. Clothing and Safety Gear • engage the parking brake switch, • place the neutral lock lever in (N) NEUTRAL LOCK, • place the travel select lever in (N) NEUTRAL, DO NOT wear loose clothing or jewelry that can get caught on controls or moving parts.
Model 10054 11 Rev 3/02 Safety Practices 4. Chemical Hazards A. Exhaust Fumes Fumes from the engine exhaust can cause death or serious personal injury. DO NOT operate vehicle in an enclosed area without a ventilation system capable of routing the hazardous fumes outdoors. B. Explosive Fuel Engine fuel is flammable and can cause a fire and/or an explosion.
12 Model 10054 Rev 3/02 Safety Practices D. Battery The following WARNING is intended to supplement and does not replace the warnings and information provided on the battery by the battery manufacturer. IMPORTANT! In case of internal contact, DO NOT give fluids that would induce vomiting! When jump starting the vehicle, carefully follow instructions found under “Jump Starting” on page 60. • Internal Contact — Drink large quantities of water. Follow with Milk of Magnesia, beaten egg or vegetable oil.
Model 10054 13 Rev 3/02 Safety Practices 5. Moving Parts Hazard DO NOT place limbs near moving parts. Severing of any body part can result. Turn OFF engine and wait until fan and belts stop moving before servicing. NEVER allow anyone to walk or stand under the boom. A lowering boom or falling load can result in death or serious personal injury. DO NOT get under a raised boom unless it is blocked up safely.
14 Model 10054 Rev 3/02 Safety Practices Operational Considerations 1. Preparation and Prevention Know the location and function of all vehicle controls. Prevent accidents when you move the vehicle around the worksite. Know the rules for movement of people and vehicles on the worksite. Have a person act as a lookout for you. Follow the instructions of signals and signs. Always check for power lines when raising the boom. Beware of overhead wires.
Model 10054 15 Rev 3/02 Safety Practices 4. Underground Hazards Know the location of all underground hazards before operating this vehicle in a new area or worksite. Electrical cables, gas and water pipes, sewer, or other underground objects can cause death or serious personal injury. Contact your local underground utility service or diggers hotline to mark all underground hazards. 5.
16 Model 10054 Rev 3/02 Safety Practices 6. Carrying Personnel Keep the vehicle under control at all times. When negotiating turns, slow down and turn the steering wheel in a smooth sweeping motion. Avoid jerky turns, starts or stops. Reduce vehicle speed on rough ground and slopes. OS0086 MAINTAIN proper tire pressure at all times. FALLING OFF ATTACHMENT, can result in death or serious injury.
Model 10054 17 Rev 3/02 Safety Practices DO NOT exceed the rated lift capacity of the vehicle as structural damage and unstable conditions will result. To ensure that the vehicle is positioned in the most stable condition before operating an attachment, use the frame sway control (frame tilt) to level the vehicle. The vehicle is level when the frame level indicator gauge reaches (0°) zero degrees. If the vehicle cannot be leveled using the frame sway control, reposition the vehicle.
18 Model 10054 Rev 3/02 Safety Practices 8. Emergency Exit Rear Window The rear window in the enclosed cab can be used as an emergency exit by removing the latch pin (Figure 2) located on the window latch. The window is then free to swing open. Latch Pin 1. Rear Window 2. 3. Latch Handle 4109 791 OH1730 Figure 2 To ensure proper vehicle stability, check all four tire pressures before operating the vehicle. DANGER MAINTAIN proper tire pressures at all times.
Model 10054 19 Rev 3/02 Safety Practices 10. Do Not Jump DANGER • When operating on a downhill slope, reduce travel speed and downshift to a low gear to permit compression braking by the engine and aid the application of the service brakes. • On all slopes, the load must be tilted back and raised only as far as necessary to clear the ground. AVOID CRUSHING if vehicle tips. Jumping can result in death or serious injury.
20 Model 10054 Rev 3/02 Safety Practices 12. Falling Load Hazard DO NOT exceed the total rated load capacity of the specific type fork being used. Each fork is stamped with a maximum load capacity. If the capacity is exceeded, forks may break. See “Fork Ratings” on page 87. DO NOT downshift at a high ground speed. Sudden slowing can cause the load to drop off the forks. 13. Ventilation DO NOT operate this vehicle in an area with flammable dust or vapors unless good ventilation has removed the hazard.
Model 10054 21 Rev 3/02 Safety Practices Equipment Considerations WARNING: DO NOT modify or alter (weld, drill, etc.) any part of this vehicle without first consulting OmniQuip. Modifications can weaken the structure creating a hazard that can cause death or serious personal injury. DO NOT by-pass or disconnect any electrical or hydraulic circuits. Consult the OmniQuip Service Department or your OmniQuip Authorized Service Center (ASC) if any circuit is malfunctioning.
22 Model 10054 Rev 3/02 Safety Practices Figure 3 NOTE: Hazard/Emergency Information related decals, with part numbers, are available free of charge by calling OmniQuip Textron Parts Worldwide at (888) 872-5123 domestically or (262) 268-8958 internationally. 3 5 Decal Description 4107971 1 8 OH2732 AVOID CRUSHING, falling off vehicle can cause death or serious injury VEHICLE TIPOVER, outriggers ALWAYS fully lower outriggers over holes or voids can cause onto solid surfaces.
Model 10054 23 Rev 3/02 Safety Practices Figure 4 NOTE: Hazard/Emergency Information related decals, with part numbers, are available free of charge by calling OmniQuip Textron Parts Worldwide at (888) 872-5123 domestically or (262) 268-8958 internationally. 10 11 12 13 14 10 FALLING OFF ATTACHMENT, can result in death or serious injury.
24 Model 10054 Rev 3/02 Operation Operation Figure 5 Operator Controls OH1760 Service Brake Pedal Accelerator Pedal (Figure 5) Pressing down the accelerator pedal increases engine and hydraulic speed of the vehicle. The pedal is spring-loaded to return to idle speed. Service Brake Pedal Horn Button Steering Wheel Steering Wheel Pressing down the brake pedal decreases the speed of the vehicle by applying the service brakes located in the axles.
Model 10054 25 Rev 3/02 Operation Ignition Switch (Figure 6) Using the ignition switch key, the switch may be turned clockwise from the OFF position to the RUN and START positions. The START position is spring-loaded to return to the RUN position and must be manually held in place for starting. OFF position — The entire electrical system is shut down. RUN position — All controls and indicators are operable.
26 Model 10054 Rev 3/02 Operation Steering Select Switch (Figure 7) This vehicle has one steering select switch with three positions (Figure 7). The switch is located in the lower switch bank on right side dash panel. Refer to “Steering Modes” on page 70 for detailed information. Lower Switch Bank Figure 7 Steering Select Switch OH1772 Steering Select Switch OH1772 Figure 7 Lower Switch Bank Refer to “Steering Modes” on page 70 for detailed information.
Model 10054 27 Rev 3/02 Operation Park Brake Switch (Figure 8) The Parking Brake Switch has two positions: Figure 8 OH1772 OS0121 P ENGAGED ............toggle switch downward P DISENGAGED............toggle switch upward OS1323 The Parking Brake Switch must be ENGAGED to permit engine starting. A red LED, on the parking brake switch, and a light in the instrument cluster will indicate the brake is ENGAGED. The parking brake may be used to stop in an EMERGENCY situation.
28 Model 10054 Rev 3/02 Operation Neutral Lock Lever (Figure 9) OT0580 The Travel Select Lever is equipped with a neutral lock. The Neutral Lock Lever locks the Travel Select Lever in NEUTRAL or unlocks the Travel Select Lever so that it can be moved into the FORWARD or REVERSE drive position. D = DRIVE ...................................all the way RIGHT OT0570 N = NEUTRAL LOCK .................. all the way LEFT To unlock, move the Neutral Lock Lever to the (D) DRIVE position.
Model 10054 29 Rev 3/02 Operation Travel Select Lever (Figure 10) The Travel Select Lever has three positions to select direction of travel: F = FORWARD............... all the way FORWARD NOTE: The Travel Select Lever must be in the (N) NEUTRAL position to permit engine starting and when boom angles are greater than 40°, shifting into NEUTRAL activates the locked mode of the Stabil-TRAK system. When the Travel Select Lever is shifted to REVERSE, the back-up alarm will automatically sound. N = NEUTRAL..
30 Model 10054 Rev 3/02 Operation Gear Select Lever *NEVER travel in 4th gear when carrying a load. 1st Improved 8000 to 10,000 lbs 2nd Smooth Load 1st 1st Rough (2041 to 3629 kg) Improved 4500 to 8000 lbs 3rd Smooth Load 2nd Rough (up to 2041 kg) Improved up to 4500 lbs Load 2nd 2nd 3rd Smooth 2nd Rough 3rd Improved Smooth No Load Surface Load Size 4th* Gear 0 to 3.5 mph (0 to 5,6 km/h) 0 to 3.5 mph (0 to 5,6 km/h) 0 to 6 mph (0 to 9,7 km/h) 0 to 3.
Model 10054 31 Rev 3/02 Operation Boom Control Lever Figure 12 (Figure 12) The boom control lever is a joystick with variable motion from the center to control the boom functions: OH1700 Boom Raise ........................ move lever backward Boom Lower........................ move lever forward Boom Extend .......................move lever to the right Boom Retract .......................
32 Model 10054 Rev 3/02 Operation Attachment Tilt and Frame Sway Control Lever (Figure 13) The attachment tilt and frame sway control is a joystick with four perpendicular motions from the center to control two attachment tilt functions and two frame sway functions: Figure 13 OH1700 Frame Sway Left .................move lever to the left Frame Sway Right ...............move lever to the right Attachment Tilt And Frame Sway Control Lever Attachment Tilt Down ..........
Model 10054 33 Rev 3/02 Operation Outrigger Control Switches (Figure 14) The left and right outrigger control switches raise or lower the corresponding outriggers. The rocker switches are spring loaded to return to the center (stop) position when released. NOTE: Outrigger position is critical to allow full extension of the boom. Refer to “Understanding the Boom/Outrigger Interlock System” on page 66 for a detailed explanation of the interlock. Figure 14 Raise Left Outrigger............
34 Model 10054 Rev 3/02 Operation IMPORTANT! Outrigger equipped vehicles can be used with the outriggers in either the raised or lowered position. The operator must operate the vehicle within the limits specified on the appropriate capacity chart for the outrigger position (up or down). Procedure for Lowering of Outriggers Secure and proper outrigger placement is critical for stability of the vehicle. Avoid holes or drop-offs and soft or excessively uneven terrain.
Model 10054 35 Rev 3/02 Operation Seat Belt (Figure 15) WARNING: Serious bodily injury or death may result from failure to wear the seat belt installed on this vehicle. The seat belt is a critical component of the Operator’s protective Structure, and is provided for the operator’s protection in case of vehicle upset. The seat belt MUST be worn whenever this vehicle is operated. An optional 3 inch wide seat belt is available for those locations that require a 3 inch seat belt. 4.
36 Model 10054 Rev 3/02 Operation Operator’s Seat Adjustment Figure 16 The operator’s seat can be adjusted three ways: OH1820 A. Fore and Aft Adjustment Fore and Aft Adjustment (Figure 16) Pull the handle outward to adjust the seats forward and backward. Release the handle to lock the seat in the desired position. B. Suspension Adjustment Backrest Angle Adjustment Turn the knob on the front of the seat to adjust the suspension to correspond with the operator’s weight.
Model 10054 37 Rev 3/02 Operation Instruments and Indicators Hourmeter (Figure 17) OS0260 Figure 17 The hourmeter records engine operating hours and has a total readout of 9,999.99 hours. It is located at the lower portion of the instrument cluster on the right side of the dash. Fuel Gauge OH1810 Hourmeter (Figure 17) 0000 00 OH2470 The fuel gauge indicates the quantity of fuel in the fuel tank. The gauge is located in the center of the instrument cluster on the right side of the dash.
38 Model 10054 Rev 3/02 Operation Instrument Cluster Light Test • Turn Signal Light (9) (Figure 18) • Stabil-TRAK Light (8) Test the bulbs in the instrument cluster before starting the engine. • High Beam Light (7) Turn the ignition switch to the RUN position, ALL nine lights in the instrument cluster will come ON for a few seconds and then go out. Replace any bulbs that DO NOT come ON during this test.
Model 10054 39 Rev 3/02 Operation Figure 19 Function Indicator Lights A. Stabil-TRAK Indicator Light (Figure 19) OH2500 OH1810 Stabil-TRAK Light 0000 00 The Stabil-TRAK light will come ON when the system has been activated. The rear axle will lock when one or more of the following conditions exist with the boom above a 40° angle.
40 Model 10054 Rev 3/02 Operation OH2480 C. High Beam Light 0000 00 This light illuminates any time the park brake is applied and the ignition switch is in the RUN position. OH1810 P (Figure 20) Figure 20 B. Park Brake Light Turn Signal Light (used with optional road light package only) OH2490 (Figure 20) High Beam Light This light illuminates when the road option headlights are on full (high) beam and will turn OFF when the headlights are switched to low beam. P D.
Model 10054 41 Rev 3/02 Operation Warning Indicator Lights There are five additional indicator lights in the instrument cluster that will illuminate during critical circumstances. All five warning indicator lights demand immediate attention and vehicle servicing. In many cases, the vehicle should be shut down AS SOON AS PRACTICAL to prevent serious mechanical failure. Figure 21 OH1810 Transmission Temperature Warning Light 0000 00 The five warning indicator lights are: A.
42 Model 10054 Rev 3/02 Operation C. Hydraulic Oil Temperature Warning Indicator Light (Figure 22) Figure 22 OH2540 OH1810 This light illuminates when the hydraulic oil temperature is too high; above 195° F (91° C). Stop and idle the engine, allowing time for cooling. If the light does not go out after five minutes, shut the vehicle down. 0000 00 D.
Model 10054 43 Rev 3/02 Operation E. Alternator Charging Warning Indicator Light (Figure 22) OH2560 This light illuminates when the charging system is not working properly. Service the engine alternator. Frame Level Indicator (Figure 23) The indicator is mounted on the top inside of the Operator's Protective Structure (cab). This is a bubble type indicator which allows the operator to tell if the vehicle has been positioned in a level condition.
44 Model 10054 Rev 3/02 Operation Figure 25 Boom Angle Indicator OH1830 (Figure 24) The boom angle indicator is a plumb arrow with angular graduations from minus 10° to plus 80°. It is located on the left side of the boom and is visible from the operator’s position. Use this indicator to determine the boom angle when reading the capacity chart (see “Using The Capacity Chart”).
Model 10054 45 Rev 3/02 Operation Figure 26 Optional Controls OH1710 Auxiliary Attachment Control Lever (Figure 26) The auxiliary attachment control lever controls the functions of an optional attachment that is mounted to the vehicle and requires a hydraulic supply for operation. Some of the optional attachments that require auxiliary hydraulics are: Side Tilt Carriage, Auger, and Swing Carriage.
46 Model 10054 Rev 3/02 Operation Worklight Switch (Front, Rear & Boom Worklights) (Figure 27) OH2570 This three position rocker switch controls the front, rear and boom worklights. The switch is located in the upper switch bank on the right side dash panel. These lights will only operate when the ignition switch is in the RUN position. Figure 27 • Push the top of the switch in to turn all the worklights OFF.
Model 10054 47 Rev 3/02 Operation Beacon Light Switch (Figure 28) OH2580 This rocker switch turns the beacon light ON and OFF. The switch is located in the upper switch bank on the right side dash panel. This light will only operate when the ignition switch is in the RUN position. • Push the bottom of the switch in to turn the beacon light ON. Figure 28 • Push the top of the switch in to turn the beacon light OFF.
48 Model 10054 Rev 3/02 Operation Figure 29 Worklight Switch (with Optional Road Lights) (Figure 29) OH1862 OH2620 This rocker switch activates the worklight system. The switch is located in the upper switch bank on the right side dash panel. This system will only operate when the ignition switch is in the RUN position. See “Parking Lights, Headlights & High/Low Beam Switch” on page 50 for operation of the road lights. • Push the top of the switch IN to DEACTIVATE the entire the worklight system.
Model 10054 49 Rev 3/02 Operation Emergency Flashers (Figure 30) OS1920 This switch is located in the upper switch bank on the right side dash panel. • To ACTIVATE the emergency flashers, push the bottom of the switch IN. OH2611 • To DEACTIVATE the emergency flashers push the top of the switch IN. OH2591 Figure 30 OH1862 Emergency Flasher Switch Emergency Flasher Switch • To DEACTIVATE the emergency flashers push the top of the switch IN.
50 Model 10054 Rev 3/02 Operation Turn Signals (Figure 31) Figure 31 Turn Signal Switch OH1872 1st Position Parking Lights Only Turn Left Parking Lights, Headlights & High/Low Beam Switch 2nd Position Parking Lights & Headlights The directional signals are ACTIVATED from the lever on the right side of the steering wheel. To activate the left turn signal, raise the lever. To activate the right turn signal, lower the lever.
Model 10054 51 Rev 3/02 Operation Windshield Wiper Control (Figure 32) OS1930 This three position rocker switch controls the speed of the windshield wiper. This switch is located in the lower switch bank on the right side dash panel. Figure 32 Windshield Wiper Control • To OPERATE the windshield wiper at HIGH speed, push the top of the switch IN. OH2591 • To STOP the windshield wiper, position the switch in the CENTER POSITION.
52 Model 10054 Rev 3/02 Operation Roof Wiper Control Figure 33 (Figure 33) Roof Wiper Control Windshield & Roof Washer Control OH1852 OH1900 This rocker switch turns the roof wiper ON and OFF. This switch is located in the lower switch bank on the right side dash panel. • Push the bottom of the switch IN to turn the roof wiper ON. OH2611 • Push the top of the switch IN to turn the roof wiper OFF.
Model 10054 53 Rev 3/02 Operation Cab Heater & Fan Control Figure 34 (Figure 34) OS1950 Fan Control Temperature Control The cab heater controls are located directly below the switch banks on the right side dash panel. The control panel consists of: a variable speed fan control knob and a temperature control knob. OH1884 Controls After Jan. 2001 Controls Prior To Jan. 2001 Control of air flow to the windshield is made by opening, closing or redirecting the air vent louver on the front dash.
54 Model 10054 Rev 3/02 Operation Rear Window Latch (Figure 35) The rear window can be partially opened and secured in place with the rear window latch. To open the window, grab the latch handle and pull up and then push the window outward. To close and secure the window, pull the latch handle forward and down. The door window can be swung open by releasing the window from inside the cab. Swing the window all the way open and lock in place on the outside of the cab.
Model 10054 55 Rev 3/02 Operation Pre-Operation Inspection 1. Check safety belt for damage. Check for frayed or cut seat belt webbing, damaged buckles or loose mounting brackets. Make any necessary repairs before operating the vehicle. 2. Check all four tires and rims for damage. Check for proper tire pressure, add air if required. Observe the condition of each tire looking specifically for punctures, cracks, cuts, gouges, bulges or any other damage.
56 Model 10054 Rev 3/02 Operation Normal Starting 1. Enter the cab using the hand holds and adjust the seat for comfortable operation. 2. Adjust the mirrors to obtain the best rear view from the operator’s position. WARNING: DO NOT start the engine unless you are in the seat with the seat belt fastened around you. Death or serious personal injury could result if the belt is not securely fastened. 9. Disengage the parking brake switch before you start operating. 3. Fasten the seat belt. 8.
Model 10054 57 Rev 3/02 Operation Cold Starting The engine is equipped with a 120 volt 750 watt block heater. Block heaters are recommended when temperatures drop below 10° F (-12° C). (Temperature ranges will vary when using different oil weights. Consult the engine manufacturer’s manual for other variables.) At temperatures below 10° F (-12° C), operate the engine at moderate speeds for 5 minutes before full loads are applied. 1.
58 Model 10054 Rev 3/02 Operation 9. If using starting fluid with mechanical or electrical metering equipment: • Turn the ignition switch to the START position to engage the starter motor and inject metered amounts of starting fluid. • As the engine starts, stop injection of starting fluid and release the ignition key to the RUN position. Release the accelerator pedal enough to provide a smooth idle speed. DO NOT use excessive amounts of starting fluid.
Model 10054 59 Rev 3/02 Operation • Turn the ignition switch (Figure 36) to the START position to engage the starter motor. After the engine has started to crank, not before, the other person can begin spraying starting fluid into the air cleaner intake (Figure 37). IMPORTANT! DO NOT crank the starting motor continuously for more than 30 seconds. Stop cranking the starter and allow the starter to cool for 2 minutes before engaging the starter again.
60 Model 10054 Rev 3/02 Operation Jump Starting Jump starting at the battery or battery replacement is required when the battery is discharged to the point where the battery will not crank the starter. 5. Follow the steps in “Normal Starting” on page 56. NEVER jump start the vehicle directly to the starter solenoid. Death or serious personal injury could result from the vehicle lurching forward or backward and running over the person attempting to jump start the vehicle directly to the starter. 6.
Model 10054 61 Rev 3/02 Operation Refueling Make sure the vehicle is level to assure an accurate fuel level reading. The fuel tank is capable of holding 37 gallons (140 liters) of diesel fuel. The usable capacity of the fuel tank is 35.6 gallons (135 liters). Fuel Types OH0480 Use ASTM #2 diesel fuel with a minimum Cetane rating of 40. #2 diesel fuel gives the best fuel economy and performance under most operating conditions.
62 Model 10054 Rev 3/02 Operation Fuel Cap (Figure 38) Unlock the fuel cap through the fuel cap access hole. Slowly remove the fuel cap from the fuel fill neck. Fuel Cap Access Hole Hydraulic Oil/Diesel Fuel Reservoir Fuel Cap Reassemble the fuel cap onto the fill neck and turn to lock in place. Line up the locking tabs to reassemble a lock if desired. Fill fuel tank. Figure 38 OH1920 OH1920 Figure 38 Fill fuel tank. Reassemble the fuel cap onto the fill neck and turn to lock in place.
Model 10054 63 Rev 3/02 Operation Figure 39 Operating OH0603 Understanding the Stabil-TRAK System OS1970 The following describes the three basic modes of the patented Stabil-TRAK system. The vehicle may operate in any one of these three modes. FREE PIVOT MODE With the OUTRIGGERS RAISED, the unit may operate in any one of these three modes at any given time while the boom is within the OUTRIGGER UP extension limit.
64 Model 10054 Rev 3/02 Operation Locked Mode (Figure 40) Figure 40 OH0613 With the boom above 40° and by activating one or more of the functions (as follows), the Stabil-TRAK system is in the LOCKED MODE. The rear axle is locked so it is rigid with the frame. The Stabil-TRAK light will be ON.
Model 10054 65 Rev 3/02 Operation Final Positioning Mode (Figure 41) With the boom above 40°, the Stabil-TRAK System is now in the final positioning mode. In this mode the rear axle is UNLOCKED and is allowed to pivot but will respond SLOWLY to changes in terrain. The frame sway will function normally in this mode. Figure 41 To check that the Stabil-TRAK System is functioning properly, refer to the test procedure on page 178 for the proper system function.
66 Model 10054 Rev 3/02 Operation (Figure 43) The ultimate purpose of this interlock system is to add an extra measure of stability allowing the boom to be extended to its maximum limits. There are two modes to this interlock, the Extend Interlock and the Outrigger Interlock. The Outrigger Interlock Mode (Figure 43), allows for full boom extension only as long as both outriggers have been lowered onto firm terrain (Figure 43) (OUTRIGGERS DOWN).
Model 10054 67 Rev 3/02 Operation IMPORTANT! As an added measure of safety, ALWAYS remember to shift the Travel Select Lever into (N) NEUTRAL, move the neutral lock lever to NEUTRAL LOCK position and engage the parking brake when outriggers are lowered. With the outrigger interlock engaged additional systems are automatically activated which enhance the stability of the vehicle: It is important that you regularly check that this system is functioning properly.
68 Model 10054 Rev 3/02 Operation Figure 45 OH1792 1. Enter the operator cab, fasten the seat belt, start the engine, apply the service brake pedal and disengage the parking brake switch. Travel Select Lever Starting Travel 2. Rotate the twist grip of the range select lever to 1st gear (Figure 44). 3. Move the travel select lever to (F) FORWARD to travel in a forward direction or to (R) REVERSE to travel backward. 4.
Model 10054 69 Rev 3/02 Operation Shifting Gears 1. Rotate the twist grip of the gear select lever to the next desired gear. The transmission has four (4) forward gears and three (3) reverse gears. 2. Use first gear for highest torque and pulling power. Use higher gears for higher ground speed. The recommendations listed in the table that follows are guidelines only. Always use good judgement when traveling with a load.
70 Model 10054 Rev 3/02 Operation Steering Modes (Figure 46) Figure 46 IMPORTANT! DO NOT change steering modes unless you are at a complete stop and all four tires are in the “straight-ahead” position. OH19421 The three steering modes are: • Four Wheel Steering Four Wheel Steering • Front Wheel Steering • Crab Steering Front Wheel Steering The steering modes can be changed using a single rocker switch located in the lower switch bank on the right side dash panel.
Model 10054 71 Rev 3/02 Operation Four Wheel Steer Indexing If the vehicle does not drive “straight,” the steering could be ”out of phase.” Perform the “Four Wheel Steer Indexing Procedure” on page 186 to synchronize the front and rear steering. 1. Four Wheel Steering (Figure 47) WARNING: NEVER use the Four Wheel Steering Mode when traveling at high speed. Rapid turning in this mode can cause tipover. Use only the Front Wheel Steering Mode at higher speeds and slow the vehicle when turning.
72 Model 10054 Rev 3/02 Operation Figure 49 2. Front Wheel Steering (Figure 48) OH1680 The front wheels will steer in the direction that the steering wheel is turned. The rear wheels will remain in a fixed forward position. This steering mode should be used when loading or unloading the vehicle from a trailer and for on-highway travel at higher speeds. OH1670 All wheels will steer in the same direction that the steering wheel is turned.
Model 10054 73 Rev 3/02 Operation 4. Maximum Fork Sweep (Figure 50) CAUTION: Allow for adequate clearance between the attachment and other objects when turning. The attachment extends beyond the end of the vehicle. The operator must be aware of the maximum sweep of the attachment when turning in order to avoid hitting personnel and other objects in the area. Use of the frame sway control with the boom raised above horizontal can cause tipover resulting in death or serious personal injury.
74 Model 10054 Rev 3/02 Operation 1. Place the travel select lever in (N) NEUTRAL, come to a complete stop, move the neutral lock lever to NEUTRAL LOCK position and engage the parking brake switch. OS0331 Be sure you are performing this procedure on level ground. Figure 51 Attachment Removal 5. Return to the operators compartment, fasten the seat belt and lower the attachment to the ground in a level position. Tilt the attachment forward.
Model 10054 75 Rev 3/02 Operation Attachment Reconnect Be sure you are performing this procedure on level ground. 1. Position the vehicle directly behind the attachment to be mounted. 2. Tilt the quick attach backward. 3. Extend the boom approximately 10 feet (3 meters) and drive the vehicle forward until the attachment pivot pins are below and between the two hooks on the attachment. 4. Raise the boom until the attachment pivot pins have seated fully in the hooks of the attachment. 5.
76 Model 10054 Rev 3/02 Operation Figure 53 OH2750 Boom Extend Letters Outer Boom B C Capacity Chart Booklet 10054 Primary Intermediate Boom The individual capacity charts are located inside a booklet on the right side of the front dash (Figure 52). Capacity charts are provided to assist the operator in determining how far in front, how high and at what angle a specific load can be safely handled with this vehicle.
Model 10054 77 Rev 3/02 Operation As the boom is extended, boom extend letters will appear on the left side of the boom visible to the operator. The letters are graduated in four foot increments. These letters indicate the point of boom extension and correspond to the capacity chart. For example, when the letter “A” first appears, the boom is at the point of boom extension corresponding to the arc of line “A” throughout the entire capacity charts (Figure 54) through (Figure 61).
78 Model 10054 Rev 3/02 Operation Reading The Capacity Chart Example: 1. The operator has placed the load onto the forks, fully retracted the boom, positioned the vehicle perpendicular to the structure and leveled the vehicle with the outriggers up. 2. The operator then determines that: • The load weight is 4000 pounds (1814 kg). • The height of the structure the load is to be placed upon is 27 feet (8,2 meters) from ground level.
Model 10054 79 Rev 3/02 Operation Figure 54 Standard Carriage Capacity Chart - Outriggers Up OH2760 10054 WITH SKY TRAK MANUFACTURED STANDARD CARRIAGES ONLY 26 -4 4 60 psi 20 2 0 1 0 4 0 0 0 l b l s b s 0° 8 10° 16 20 23 17 12 9 4110204 7 ASME B56.6b -1998 -8° 0 ft 12 = 17.
80 Model 10054 Rev 3/02 Operation Figure 55 Standard Carriage Capacity Chart - Outriggers Down OH2770 -8° l b s D E F G 60° 52 68° 56 40 36 32 28 = 17.5-25, 12 PLY 24 20 16 12 8 H 4 0 ft 60 psi 24 WITH SKY TRAK MANUFACTURED STANDARD CARRIAGES ONLY 22 9 7 ASME B56.
Model 10054 81 Rev 3/02 Operation Figure 56 Side Tilt Carriage - Outriggers Up OH2780 10054 WITH SKY TRAK MANUFACTURED SIDE TILT CARRIAGES ONLY 4110206 27.4 -4 2 1 0 4 0 0 0 0 l l b b s s 0 ft 4 12 0° 10° 16 20 23 20 12 17 ASME B56.6b -1998 9 -8° 8 = 17.
82 Model 10054 Rev 3/02 Operation Figure 57 Side Tilt Carriage - Outriggers Down OH2790 -8° G H 60° 52 68° 56 40 36 32 28 = 17.5-25, 12 PLY 24 20 16 12 8 SAFETY INSTRUCTIONS 4 0 ft 60 psi WITH SKY TRAK MANUFACTURED SIDE TILT CARRIAGES ONLY ASME B56.6b -1998 4110207 10054 9 50° 22 48 31 44 39 Use only with vehicles equipped with auxiliary hydraulics. Always connect couplers.
Model 10054 83 Rev 3/02 Operation Figure 58 Swing Carriage - Outriggers Up OH2800 10054 WITH SKY TRAK MANUFACTURED SWING CARRIAGES ONLY 1000 lbs 2000 lbs 3000 lbs 28 -4 0 ft = 17.5-25, 12 PLY 4 12 4000 lbs 4000 lbs ASME B56.6b -1998 0° 24 10° 1 2 3 4 5 20° 24 28 D C B A 30° 32 36 40° 40 Use only with vehicles equipped with auxiliary hydraulics. Always connect couplers. E 44 50° 48 SAFETY INSTRUCTIONS 60° 52 56 4110208 -8° 16 20 6000 lbs 8000 lbs 20 16.
84 Model 10054 Rev 3/02 Operation Figure 59 Swing Carriage - Outriggers Down OH2810 36 E D 40° H G F 50° 52 68° 24 = 17.5-25, 12 PLY 20 16 12 8 4 0 ft 60 psi WITH SKY TRAK MANUFACTURED SWING CARRIAGES ONLY 10054 4110209 28 6000 lbs 8000 lbs 32 4000 lbs 4000 lbs 36 2000 lbs 3000 lbs 4000 lbs ASME B56.6b -1998 40 9 56 SAFETY INSTRUCTIONS 11 48 29 44 32 40 -8° 32 24 0° 39 Use only with vehicles equipped with auxiliary hydraulics. Always connect couplers.
Model 10054 85 Rev 3/02 Operation Figure 60 15 Foot Truss Boom - Outriggers Up OH2820 10054 15 WITH SKY TRAK MANUFACTURED 15 TRUSS BOOMS ONLY 4110210 39 35 31 -4 0 ft 4 8 12 = 17.5-25, 12 PLY 60 psi 16 20 40 44 24 72 28 68 32 64 36 60 40 56 44 52 48 48 52 44 56 40 60 36 64 32 68 28 72 24 ASME B56.
86 Model 10054 Rev 3/02 Operation Figure 61 15 Foot Truss Boom - Outriggers Down OH2830 4110211 10054 ASME B56.6b -1998 15 51 -4 -8° WITH SKY TRAK MANUFACTURED 15 TRUSS BOOMS ONLY 0 ft 0° 4 10° 12 8 68° 72 52 48 44 40 36 32 = 17.
Model 10054 87 Rev 3/02 Operation Fork Ratings All approved forks for this vehicle are marked with a maximum load capacity rating. This rating is stamped on the left edge of the fork just below the fork pivot shaft (Figure 62). The rating is listed in U.S. pounds and based upon a 24" (610 mm) load center. This rating specifies the maximum load capacity that the individual fork can safely carry at a maximum load center of 24" (610 mm).
88 Model 10054 Rev 3/02 Operation How To Pick, Carry & Place A Load To pick a load, tilt the carriage forward so the forks hang freely on the fork shaft. Move the forks inward or outward on the fork shaft so that they are aligned with the openings in the pallet. Tilt the carriage back and extend the boom slowly so the forks slide into the openings in the pallet. Raise the boom so that the load is lifted.
Model 10054 89 Rev 3/02 Operation Elevating Personnel This vehicle is designed to lift and transport materials and should not be used to elevate personnel except as explained in this section. Only equipment designed and approved for elevating personnel should be used. If the vehicle must be used to elevate personnel, use only an approved work platform. When using a work platform, the following precautions must be taken: WARNING: Use only an approved work platform to lift or lower personnel.
90 Model 10054 Rev 3/02 Operation DANGER: Never operate this or any equipment in an area in which overhead or underground cables or power sources exist without first requesting that the appropriate power company or utility company de-energize the lines or take other suitable precautions. Elevating Personnel 1. Make sure there are no overhead obstructions or electrical wires above the platform before lifting. 2.
Model 10054 91 Rev 3/02 Operation Using Other Attachments Numerous attachments, marketed by OmniQuip are available for this vehicle. The capacity charts attached to this vehicles dash are to be used with OmniQuip approved attachments only. Hydraulically powered attachments must only be used on vehicles equipped with auxiliary hydraulics. IMPORTANT! This vehicle is intended for the function of lifting only. This vehicle is not designed to PULL, TOW or DRAG other objects.
92 Model 10054 Rev 3/02 Operation Shut-Off 1. Bring the vehicle to a complete stop using the service brakes. 2. Park the vehicle on level ground. WARNING: To prevent death or serious personal injury, be certain to lower the boom, engage the parking brake switch, and shut off the engine prior to exiting the vehicle. 3. Place the travel select lever in (N) NEUTRAL, move the neutral lock lever to NEUTRAL LOCK position and engage the parking brake switch. 4. Lower the boom and ground the carriage. 5.
Model 10054 93 Rev 3/02 Emergency Operations Emergency Operations Figure 63 Towing A Disabled Vehicle OH2372 Towing a disabled vehicle should only be attempted after exhausting all other options. Every effort should be made to repair the vehicle and move it under its own power. Towing the vehicle improperly can result in damage to the vehicle drivetrain.
94 Model 10054 Rev 3/02 Emergency Operations 7. Pressurize the park brake with the pressurizing unit. Close the pump needle valve. DO NOT exceed 575 psi (40 bar) when pressurizing the park brake. Applying too much pressure may damage the brake seals. Front Of Vehicle 8. Clear the area of all unnecessary personnel. Frame Wall Left Side Of Vehicle 9. Carefully remove the wheel blocks from each of the four tires. Tow the vehicle to a secure location. 5.
Model 10054 95 Rev 3/02 Emergency Operations Emergency Boom Lowering This section discusses emergency boom lowering procedures: Part I In case of loss of engine power or hydraulic pump failure. 7. Place an accident prevention tag on both the ignition switch and steering wheel. Refer to “Accident Prevention Tags” on page 5. Actual accident prevention tags can be found as the last page of this manual. If you do not have a safety tag, tape over the ignition switch. 6.
96 Model 10054 Rev 3/02 Emergency Operations Figure 65 Boom Lower Line Boom Lift Line Boom Extend Line In any case of hydraulic line failure, it is critical to correctly identify which hydraulic line has failed. Identify the hydraulic line that has failed (Figure 65) and use the table on page 97 to determine which Step to follow to retract and lower the boom. Boom Lower Line IMPORTANT! Be aware that the boom must first be retracted and then lowered to avoid vehicle tipover.
Model 10054 97 Rev 3/02 Emergency Operations able HYDRAULIC LINE THAT FAILED NORMAL STEPS EMERGENCY STEPS FOLLOW FOLLOW THIS STEP THIS STEP IF PARTS IF PARTS ARE ARE NOT AVAILABLE AVAILBLE FOLLOW THIS STEP AS A LAST RESORT BOOM LIFT LINES (LIFT CYLINDERS TO CONTROL VALVE) STEP 1 BOOM LOWER LINES (LIFT CYLINDERS TO CONTROL VALVE) STEP 1 BOOM RETRACT LINE BOOM EXTEND LINE STEP 1 STEP 1 BOOM EXTEND LINE BOOM RETRACT LINE STEP 1 OP0330 STEP 2 STEP 3 STEP 2 STEP 4 STEP 1 BOOM LOWER LINE
98 Model 10054 Rev 3/02 Emergency Operations 15. Return to the cab, fasten your seat belt and start the engine. STEP 1 14. Completely remove the load from the carriage and/or attachment if you haven’t already done so. 13. Shut off the engine. 10. Tilt the carriage and/or attachment upward if necessary for clearance before retracting the boom. 3. Block all four wheels. 11. Slowly retract the boom. 2.
Model 10054 99 Rev 3/02 Emergency Operations 16. Cycle the lift and extend cylinders several times to bleed air from the system. Check for leaks. 17. Recheck the hydraulic oil level. Add oil if necessary.
100 Model 10054 Rev 3/02 Emergency Operations STEP 2 13. Cycle the lift cylinder several times to bleed air from the system. Check for leaks. USE IN CASE OF: 12. Return to the cab, fasten your seat belt and start the engine. BOOM LIFT LINE FAILURE (Lift Cylinders to Control Valve) 11. Have the vehicle serviced immediately. Replace any failed hydraulic lines with new parts (Figure 67). 1. Clear the area of any unnecessary personnel. 2.
Model 10054 101 Rev 3/02 Emergency Operations 14. Recheck the hydraulic oil level. Add oil if necessary. 15. Transfer any waste oil to a container with a cover and label as used oil. Dispose of properly.
102 Model 10054 Rev 3/02 Emergency Operations 9. Check the hydraulic oil level and add oil if needed. STEP 3 IMPORTANT! Once either boom lift line is removed and the boom is retracted during the remaining steps, hydraulic oil will drain out of the base end of the boom cylinder. The escaping oil should be deflected by some means (the failed hose could be used) directing the oil into the drain container. 1. Clear the area of any unnecessary personnel.
Model 10054 103 Rev 3/02 Emergency Operations 10. Remove the blocking or support from the outer boom. 11. Return to the cab, fasten your seat belt and start the engine. IMPORTANT! Have the vehicle serviced and hoses replaced as soon as the boom has been lowered and the vehicle is in a secure location.
104 Model 10054 Rev 3/02 Emergency Operations 12. Tilt the carriage and/or attachment upward if necessary for clearance before retracting the boom. 13. SLOWLY RETRACT the boom. 14. SLOWLY LOWER the boom and ground the carriage. 15. Completely remove the load from the carriage and/or attachment if you haven’t already done so. 16. Have the vehicle serviced immediately. 17. Replace any faulty hydraulic lines. 18. Return to the cab, fasten your seat belt and start the engine. 19.
Model 10054 105 Rev 3/02 Emergency Operations STEP 4 BOOM RETRACT LINE FAILURE 1. Clear the area of any unnecessary personnel. 2. Place the travel select lever in (N) NEUTRAL, move the neutral lock lever to NEUTRAL LOCK position and engage the parking brake switch. 3. Block all four wheels. WARNING: DO NOT get under a raised boom unless the boom is blocked up. Always block the boom before doing any servicing that requires the boom to be up. 4.
106 Model 10054 Rev 3/02 Emergency Operations WARNING: NOTE: If a replacement hose is not available, the adjacent boom extend line (Figure 69) can be used to replace the failed boom retract line. 18. Transfer the waste oil to a container with a cover and label as used oil. Dispose of properly. 6. Remove the failed boom retract line (Figure 69) from the circuit. 17. Cycle the extend cylinder several times to bleed air from the system. Check for leaks. 7.
Model 10054 107 Rev 3/02 Emergency Operations Boom Extend Line Boom Extend Line Figure 69 Boom Retract Line Boom Retract Line Boom Extend Line OH1931 Boom Extend Line Boom Retract Line OH1931 Boom Retract Line Figure 69 Boom Extend Line Boom Extend Line Emergency Operations Model 10054 Rev 3/02 107
108 Model 10054 Rev 3/02 General Maintenance General Maintenance General Maintenance WARNING: Figure 70 Maintenance Chart NOTE: The Lubrication and Maintenance Chart decals are located inside the right side engine cover (Figure 70). They contain a general maintenance schedule that should be followed to maintain the vehicle in good operating condition.
Model 10054 109 Rev 3/02 General Maintenance Maintenance Schedule And Checklist 10 Hour Intervals OH1980 10 Drain Fuel/ Water Separator Paragraph Ref. 5A Check Check Check Engine Check Engine Hydraulic Oil Transmission Coolant Level Oil Level Oil Level Level 3A 4A 7B 8A Check Tire Pressure 12A OF1190 Paragraph Ref. 2A Air Filter Restriction Indicator Air Filter Restriction Indicator Paragraph Ref. 2A Model 10054 Rev 3/02 OF1190 Paragraph Ref.
110 Model 10054 Rev 3/02 General Maintenance At First 50 Hours of Use OM1460 430-470 (583-637) LB/F T (N m) 4B 8B 7C 12B Paragraph Ref. Lubricate Pivot Points Check Wheel Lug Nut Torque Inspect Wear Pads Change Hydraulic Filter 1 Change Transmission Filter 15G Change Engine Oil and Filter Paragraph Ref. 50 OH2000 Change Wheel End Oil Check Boom Chain Tension 9B 11B 15A & 15C 50 Change Axle Oil OH2010 Paragraph Ref.
Model 10054 111 Rev 3/02 General Maintenance 250 Hour Intervals OH2021 250 Paragraph Ref. Change Air Filter Lubricate Pivot Points Change Engine Oil and Filter 2B 1 4B Paragraph Ref. OA1460 5B & 5C Change Fuel Filter Check Wheel End Oil Level Check Axle Oil Level Inspect Extend chains 11A 9A 15E Paragraph Ref. 500 Hour Intervals OH3150 500 500 OH3150 500 Hour Intervals Paragraph Ref.
112 Model 10054 Rev 3/02 General Maintenance 1000 Hour Intervals OH2040 Paragraph Ref. 1000 15F Lubricate Boom Chains Check Boom Chain Tension Inspect Wear Pads Change Transmission Oil And Filter 15A & 15C 15G 8B OA1470 OH2050 10A Check Axle Brake Discs Change Hydraulic Oil And Filter Check Axle Brake Discs 10A OH2050 15G 15A & 15C Inspect Wear Pads Check Boom Chain Tension 8B Change Transmission Oil And Filter Lubricate Boom Chains Paragraph Ref. OA1470 1000 Paragraph Ref.
Model 10054 113 Rev 3/02 General Maintenance 2000 Hour Intervals OH2070 2000 Change Engine Coolant Paragraph Ref. 3B Model 10054 Rev 3/02 Paragraph Ref.
114 Model 10054 Rev 3/02 General Maintenance NOTE: Shorten the lubrication interval on all lube points when operating in severe conditions. (2 points) OS1750 OS1750 (2 points) (3 points) F. Retract Chain Sheave ..................................... H. Drive shaft slip joints ...................................... (2 points) (2 points) E. Extend Chain Sheave...................................... I. Boom pivot pin ................................................ D. Boom attachments ..............
Model 10054 115 Rev 3/02 General Maintenance Figure 71 Lubrication Points OH2840 H H C G G J G B K A J C 2/ 2/ D K H G B F (Qty. 2) I G L E E L G I F (Qty.
116 Model 10054 Rev 3/02 General Maintenance 2. Air Cleaner And Restriction Indicator Figure 72 NEVER operate the vehicle without the air cleaner assembly and both filters in place. OA0203 A. Filter Check 10 OH2660 OF1190 1. Ground the carriage, place the travel select lever in (N) NEUTRAL, move the neutral lock lever to NEUTRAL LOCK position, engage the parking brake switch and shut off the engine. 2.
Model 10054 117 Rev 3/02 General Maintenance 3. Remove dust from vacuator valve (Figure 73) by squeezing bottom of vacuator to allow loose particles to fall out. Replace elements, if required, as described in paragraph 2B. NEVER run the engine with only the inner safety element installed. CAUTION: Air Cleaner An inner element should never be washed or reused. Always install a new element. Replace inner elements after every third primary element change.
118 Model 10054 Rev 3/02 General Maintenance To change elements: 1. Loosen cover wing nut and remove cover from air cleaner canister (Figure 74). Cannister Wing Nut with O-Ring Primary Element Cover With Wing Nut 3. Thoroughly clean the interior of the air filter canister and vacuator valve. OF0110 2. Remove wing nut and primary element. Inspect element for damage. Damaged elements should not be reused. Figure 74 2. Remove wing nut and primary element. Inspect element for damage.
Model 10054 119 Rev 3/02 General Maintenance 4. If replacing safety element at this time (Figure 75), remove wing nut and carefully slide safety element out. Always discard this element and replace with a new element and secure with wing nut. 5. Install the new primary element and secure with wing nut. 6. Position canister cover in place and secure with cover wing nut.
120 Model 10054 Rev 3/02 General Maintenance 3. Engine Cooling System Figure 76 10 MA2021 OH2660 Coolant Overflow Bottle A. Engine Coolant Level Check OS0800 1. Level the vehicle, ground the carriage, place the travel select lever in (N) NEUTRAL, move neutral lock lever to NEUTRAL LOCK position, engage the parking brake switch and shut off the engine. 2. Unlock and open the right rear engine access door. Check level of coolant in overflow bottle (Figure 76).
Model 10054 121 Rev 3/02 General Maintenance B. Drain And Flush Radiator OS0810 Figure 77 2000 OH2640 Petcock OH2700 1. Level the vehicle, ground the carriage, place the travel select lever in (N) NEUTRAL, move neutral lock lever to NEUTRAL LOCK position, engage the parking brake switch and shut off the engine. WARNING: DO NOT attempt this procedure when the engine is hot. Wait for the engine, muffler and tailpipes to cool down before proceeding. Failure to do so could result in severe burns. 2.
122 Model 10054 Rev 3/02 General Maintenance Figure 79 NOTE: Attach a hose to the petcock to allow draining directly into a container. OH2650 4. Allow coolant to drain from the radiator. Detach line from bottom of coolant overflow bottle and drain bottle. Petcock Turbo Aftercooler 5. Flush system with clean water and drain again. NOTE: On vehicles equipped with a cab heater option, a shut off valve is installed at the engine inlet. Disconnect hose from shut off valve to drain the heater. 9.
Model 10054 123 Rev 3/02 General Maintenance 10. Fill radiator completely with 50/50 mixture of ethylene glycol and water. Total System Capacity is 4 gallons (15 liter). Add coolant to overflow bottle until bottle is about 1/2 to 3/4 full. This “overfilling” will compensate for any air in the cooling system. 11. Close the petcock on the turbo aftercooler. 12. Clean dirt and debris from radiator fins and core, if required. 13.
124 Model 10054 Rev 3/02 General Maintenance 3. Remove dipstick and check mark on dipstick (Figure 80). Oil should be within the crosshatched area. Figure 81 MA2021 Oil Fill Cap Crosshatched Area Engine Oil Dipstick L L U F T D 1 Q D A OG0290 Figure 80 4. If oil is low, remove oil fill cap (Figure 81) and add 15W40 motor oil that is equal to API, CD or CE (severe duty diesel engine) specifications to bring oil up to the FULL mark in the crosshatched area.
Model 10054 125 Rev 3/02 General Maintenance B. Oil And Filter Change 50 OH2670 7. Clean filter sealing surface. Make sure the o-ring seal from the filter comes off the sealing surface. Figure 82 250 OH2710 OS0830 OG0031 1. Operate the engine until warm (approximately 5 minutes). 390 3102 2. Level the vehicle, ground the carriage, place the travel select lever in (N) NEUTRAL, move neutral lock lever to NEUTRAL LOCK position, engage the parking brake switch and shut off the engine. 0 072465 3.
126 Model 10054 Rev 3/02 General Maintenance NOTE: The filter o-ring may stick to the filter head. Make sure the old o-ring is removed before installing the new filter. Figure 83 MA2021 8. Apply a thin coat of clean engine oil to seal on new filter. 9. Install the new oil filter and hand tighten 1/2 turn after initial contact. 10. Clean and re-install oil pan drain plug. 11. Unlock and open right rear access door. Oil Fill Cap Engine Oil Dipstick 12.
Model 10054 127 Rev 3/02 General Maintenance 5. Engine Fuel System A. Drain Water From Fuel Water Separator/Filter 10 OH2660 H 20 OS0851 Figure 84 Unlock and open the right rear engine access door. Loosen drain valve on under side of the water separator/filter (Figure 84) and allow all water to drain into a glass until clear fuel is visible. Tighten drain valve after draining. Close and lock access door.
128 Model 10054 Rev 3/02 General Maintenance Controlled venting is provided at the injection pump through the fuel drain manifold. Small amounts of air introduced by changing the fuel filter element will be vented automatically as long as the element was filled with fuel prior to installation. B. Change Fuel Filter 500 OS0870 NOTE: Mechanical over-tightening may distort the threads or damage the sealing ring.
Model 10054 129 Rev 3/02 General Maintenance C. Replace In-line Fuel Strainer 500 OT1150 Figure 86 1. Unlock and open the right rear engine access door. 2. The in-line fuel strainer is located down line from the engines lift pump (Figure 86). Loosen the two hose clamps that secure the strainer in place. OH2200 Lift Pump In-line Fuel Strainer 3. Remove the old in-line fuel strainer and dispose of properly. 4. Install the new in-line fuel strainer with arrow pointing toward the lift pump. 5.
130 Model 10054 Rev 3/02 General Maintenance D. Bleeding Fuel System Air must be vented from the fuel system whenever any component between the fuel tank and the injection pump has been disconnected, or when the system has been emptied or run out of fuel. Figure 87 OH2200 Lift Pump WARNING: Hand Plunger DO NOT bleed the fuel system of a hot engine. Doing so could create a fire hazard. Allow the engine to cool before bleeding the fuel system.
Model 10054 131 Rev 3/02 General Maintenance The process to vent the high pressure fuel lines (Figure 88) involves energizing the starter motor to rotate the crankshaft which will, in turn, pump any unwanted air from the fuel lines. Figure 88 MA1870 Injector CAUTION: When using the starting motor to vent the fuel system, DO NOT energize the starter solenoid or crank the engine for more than 15 seconds at a time; wait two minutes between engagements. WARNING: KEEP CLEAR of spraying fuel.
132 Model 10054 Rev 3/02 General Maintenance Figure 89 6. Engine Fan Belt OT04002 A. Engine Fan Belt Check Crankshaft Pulley OH2690 Water Pump Pulley 1000 OS08802 1. Ground the carriage, place the travel select lever in (N) NEUTRAL, move the neutral lock lever to NEUTRAL LOCK position, engage the parking brake switch and shut off the engine. Alternator Pulley Fan Belt 2. Unlock and open the left rear engine access door. 3. Inspect the fan belt (Figure 89). Replace if cracked or frayed.
Model 10054 133 Rev 3/02 General Maintenance 7. Hydraulic Oil and Filter A. Hydraulic System Oil OH2630 Hydraulic system oil can be either a hydraulic oil meeting the requirements of ISO Grade 46 or a 10W motor oil meeting the requirements of U.S. Ordinance Specifications MIL-L-2104C. See table below.
134 Model 10054 Rev 3/02 General Maintenance B. Hydraulic Oil Level Check 10 Figure 90 OH2340 OS0660 Capscrews OH2660 1. Be sure all cylinders are fully retracted and oil is at room temperature. Hydraulic Oil Tank Cover 4. The oil level should be visible in the gauge window. Hydraulic Oil Tank 3. Check level of hydraulic oil in tank at the sight gauge on the back side of the hydraulic tank (Figure 90). Hydraulic Oil Sight Gauge 2.
Model 10054 135 Rev 3/02 General Maintenance C. Hydraulic Oil & Filter Change Figure 91 (Filter Only) OH1920 50 Capscrews (Oil & Filter) OT08402 OH2670 1000 OH2690 OS08402 Change the hydraulic oil filter after the first 50 hours of operation and change the hydraulic oil and filter every 1000 hours of operation thereafter. Other than the 1000 hour interval, the hydraulic oil must be changed when a hydraulic component has contaminated the system. 1.
136 Model 10054 Rev 3/02 General Maintenance Figure 92 Seal OH2350 4. Clean area around filter head (Figure 92). Loosen but do not remove the nuts that secure the filter head to the hydraulic tank. 5. Rotate and remove the filter head (Figure 92). 6. Remove the seal and the element (Figure 92) from the filter head. Dispose of properly. Element Hydraulic Oil Tank 8. Place a receptacle under the hydraulic reservoir magnetic drain plug.
Model 10054 137 Rev 3/02 General Maintenance Figure 93 8. Transmission Oil and Filter OH23622 Transmission Dipstick APPROVED UNIVERSAL TRACTOR FLUIDS JOHN DEERE JDM J20C (HY-GARD) FORD / NEW HOLLAND ESN-M2C134-D (HYDRAULIC OIL134) MASSEY FERGUSON M-1141 (PERMATRAN III) CHEVRON CHEVRON 1000 THF Access Hole A. Transmission Oil Level Check 10 OS0890 Transmission Covers OH2660 1.
138 Model 10054 Rev 3/02 General Maintenance B. Transmission Oil & Filter Change (Filter Only) 50 OH2670 OT08302 Figure 94 1000 OH2690 OH2372 (Oil & Filter) OS09502 Change the transmission oil filter after the first 50 hours of operation and change the transmission oil and filter every 1000 hours of operation thereafter. 1.
Model 10054 139 Rev 3/02 General Maintenance 3. Allow the transmission to cool. 4. Place a receptacle under the transmission drain plug (Figure 95). Remove the drain plug and allow the Universal Tractor Fluid to drain into the receptacle. Transfer the used oil into a suitable container with a cover and label the container as used oil. Dispose of properly. 5. Clean and re-install the drain plug into the transmission housing. 6.
140 Model 10054 Rev 3/02 General Maintenance Figure 96 9. Axle Oil OH2410 OH2710 Axle Level Plugs (Located On Opposite Side Of Housing) 250 Axle Drain Plug A. Axle Oil Level Check OT0460 APPROVED UNIVERSAL TRACTOR FLUIDS ESN-M2C134-D (HYDRAULIC OIL134) MASSEY FERGUSON M-1141 (PERMATRAN III) CHEVRON CHEVRON 1000 THF 1.
Model 10054 141 Rev 3/02 General Maintenance B. Axle Oil Change 50 OH2670 1000 OH2690 OT0440 NOTE: At the 1000 Hour Interval Oil Change also inspect the brake disk wear. Refer to “Brake Disk Inspection” on page 142 and follow the inspection procedure. After brake disk inspection is complete, reassemble the level plugs using new o-rings. 1.
142 Model 10054 Rev 3/02 General Maintenance 10. Brake Disk Inspection Check the brake disks for wear every 1,000 hours of operation or yearly. 1000 P OH2690 OH2372 (1000 Hour Intervals) Figure 97 A. Brake Disk Wear Check MT2830 If the brake disks require service due to wear, the axle should be checked, serviced and repaired only by experienced service technicians who are aware of all safety instructions and particular component features. Transmission Covers A.
Model 10054 143 Rev 3/02 General Maintenance 3. Attach a remote portable hydraulic pressurizing unit to the parking brake gauge port on the secondary function manifold mounted on the inside wall of the frame on the left side next to the transmission (Figure 98). Frame Wall Left Side Of Vehicle Front Of Vehicle DO NOT exceed 575 psi (40 bar) when pressurizing the park brake. Applying too much pressure may damage the brake seals.
144 Model 10054 Rev 3/02 General Maintenance 5. Pressurize the park brake with the pressurizing unit. Close the pump needle valve. 6. Working through the level plug hole (Figure 99), carefully use a screwdriver to spread the brake disks apart. IMPORTANT! DO NOT damage the surfaces of the brake disks when spreading the brake disks. 9. Continue with step 6 of “B. Axle Oil Change” on page 141. 8. Repeat step 6 and step 7 for the other side of the axle.
Model 10054 145 Rev 3/02 General Maintenance 4. Continue with step 6 of “B. Axle Oil Change” on page 141. 3. Repeat step 1 and step 2 for the other side of the axle. NOTE: If the brake disks are worn beyond .167" (4,25 mm), the brake disk must be replaced on both sides of the axle at the same time. 2. Using a feeler gauge, check the gap (Figure 100) between the brake disks. If the gap is greater than .167" (4,25 mm), replace the brake disks.
146 Model 10054 Rev 3/02 General Maintenance Figure 101 11. Wheel End Oil OT0280 Wheel End Fill/Drain Plug WARNING: DO NOT perform service or maintenance on this vehicle with the engine running. Contact with moving parts can cause death or serious personal injury. Horizontal Wheel End APPROVED UNIVERSAL TRACTOR FLUIDS JDM J20C (HY-GARD) FORD / NEW HOLLAND ESN-M2C134-D (HYDRAULIC OIL134) MASSEY FERGUSON M-1141 (PERMATRAN III) CHEVRON CHEVRON 1000 THF 3.
Model 10054 147 Rev 3/02 General Maintenance B. Wheel End Oil Change 7. Clean and re-install the wheel end fill/drain plug. 6. Fill the wheel end with Universal Tractor Fluid to the level of the drain plug. See chart of approved fluids on page 146. Wheel end capacity is approximately 1.7 quarts (1,6 liters). 50 OH2670 1000 OH2690 OT0450 5. Reposition the vehicle so the wheel end fill/drain plug is positioned horizontally (refer back to Figure 101). 1.
148 Model 10054 Rev 3/02 General Maintenance 12. Wheels and Tires A. Tire Air Pressure Check 10 OS0900 OH2660 DANGER: LOW TIRE PRESSURE can result in tipover. MAINTAIN proper tire pressure at all times. Check all four tires: 1. Remove the valve stem cap. 2. Check tire pressure using a good quality gauge. You cannot tell if a tire is properly inflated simply by looking at it. 3. Add air if required. Fill the tire(s) to 60 psi (414 kPa). DO NOT overinflate. 4. Replace the valve stem cap. 4.
Model 10054 149 Rev 3/02 General Maintenance B. Wheel Lug Nut Torque Check 430-470 (583-637) LB/F T (N m) 50 OM14001 OH2670 1. Wire brush the area around the lug nuts if necessary.There are separate lockwashers under the lug nuts (Figure 103). Be sure the lockwashers are installed under each lug nut. 2. Using the torque sequence (A thru K) shown below (Figure 103), alternately check the torque of each of the ten lug nuts. The recommended torque should be 430-470 lb-ft (583-637 Nm).
150 Model 10054 Rev 3/02 General Maintenance Figure 104 13. Battery OH2420 WARNING: Battery Lead-acid batteries produce flammable and potentially explosive gases. To avoid personal injury when checking, testing or charging batteries: • DO NOT use smoking materials near batteries. • Keep arcs, sparks and open flames away from batteries. • Provide ventilation and wear safety glasses. The battery in this vehicle is a maintenance free type battery.
Model 10054 151 Rev 3/02 General Maintenance WARNING: Fluid in electric storage batteries contains sulfuric acid which is POISON and can cause SEVERE CHEMICAL BURNS. Avoid all contact of fluid with eyes, skin or clothing. Use protective gear when handling batteries. DO NOT tip a battery beyond a 45° angle in any direction. If contact does occur, follow the First Aid suggestions that follows. Battery Electrolyte First Aid: • External Contact — Flush with water.
152 Model 10054 Rev 3/02 General Maintenance 14. Fuse and Relay Replacement The fuses and relays in this vehicle protect the electrical system. The fuses most often fail if there is a short or grounded wire in the applicable circuit. The fuses will have to be replaced if they fail. If fuses continually fail, check the system for shorts, grounds or defective electrical components. The fuses and relays are mounted inside the right side console in the operators cab (Figure 105).
Model 10054 153 Rev 3/02 General Maintenance 2 3 4 5 6 7 8 9 10 11 12 13 10 11 9 12 7.5 7.5 20 10 8 7 10 10 10 4 10 7.5 7.5 40 7.5 3 2 1 No. 1 7.5 Amp 7.5 Amp 40 Amp 7.5 Amp 10 Amp 10 Amp 10 Amp 10 Amp 10 Amp 7.5 Amp 7.
154 Model 10054 Rev 3/02 General Maintenance 11 10 5 7 4 8 3 10 10 14 10 10 7.5 7.5 40 7.5 2 Figure 107 9 Circuit Controlled 15 Volt 13 6 No.
Model 10054 155 Rev 3/02 General Maintenance 15. Boom Chains and Wear Pads A. Intermediate Boom Chains Tension Check 50 OH2670 1000 OH2390 OH2690 Check the intermediate boom chain tension by measuring the intermediate boom extend chain sag. 1. Park the vehicle on level ground. Place the travel select lever in (N) NEUTRAL, move neutral lock lever to NEUTRAL LOCK position, engage the parking brake switch and raise the boom to a horizontal (level) position. 2. Lower both outriggers completely.
156 Model 10054 Rev 3/02 General Maintenance 3. Measure the sag in the intermediate boom extend chains between the bottom of the chains and the top of the primary intermediate boom at their closest point (Figure 108). Acceptable intermediate boom chain sag is between 1.5" (38 mm) and 2.5" (64 mm). If the measurement is not within the dimensions listed above, the boom chains need to be adjusted. Intermediate Boom Chain Sag 4. Start the vehicle, retract the boom completely and turn the vehicle OFF.
Model 10054 157 Rev 3/02 General Maintenance 5. Go to the back of the vehicle and remove the rear cover from the back of the boom. 6. Check the measurement “A” from the top rear edge of the primary intermediate boom to the top rear edge of the secondary intermediate boom (Figure 109). Measurement “A” should be in the range of: • 4x6 chain - 8.5" (216 mm) to 9" (229 mm) • 6x6 chain - 9.31" (236 mm) - 9.
158 Model 10054 Rev 3/02 General Maintenance • 4x6 chain - 8.5" (216 mm) to 9" (229 mm) • 6x6 chain - 9.31" (236 mm) - 9.81" (249 mm) 10. Start the vehicle, with the outriggers lowered completely, cycle the boom in and out several times. With the boom horizontal, fully extend the boom and then retract it 2" (51 mm). Turn the vehicle OFF. 7. If the measurement is more than measurement listed below, tighten the retract chain locknut (Figure 110) located on the bottom of the outer boom.
Model 10054 159 Rev 3/02 General Maintenance 11. Measure the sag in the intermediate boom extend chains between the bottom of the chains and the top of the primary intermediate boom at their closest point (Figure 111). Acceptable boom chain sag is between 1.5" (38 mm) and 2.5" (64 mm). If the measurement is less than 1.5" (38 mm), the intermediate boom chains need to be adjusted. See “Intermediate Boom Chain Tension Adjustment” on page 160.
160 Model 10054 Rev 3/02 General Maintenance B. Intermediate Boom Chain Tension Adjustment (As required) Figure 112 OH0551 Yoke NOTE: Always perform the “Intermediate Boom Chain Tension Check” starting on page 155 before adjusting the boom chain tension. 1. Park the vehicle on level ground. Place the travel select lever in (N) NEUTRAL, move neutral lock lever to NEUTRAL LOCK position, engage the parking brake switch and raise the boom to a horizontal position.
Model 10054 161 Rev 3/02 General Maintenance Wear Pads Intermediate Boom Extend Chains Locknuts 6. Replace the rear outer boom cover. NOTE: If the intermediate boom extend chain sag cannot be adjusted within the acceptable range of 1.5" (38 mm) to 2.5" (64 mm), the boom may require extensive adjustment and/or repair. Contact your OmniQuip Authorized Service Center (ASC). 5. Measure the intermediate boom chain sag. Acceptable intermediate boom chain sag is between 1.5" (38 mm) and 2.5" (64 mm).
162 Model 10054 Rev 3/02 General Maintenance C. Inner Boom Chain Tension Check OH2390 OH2690 OA0491 Check the inner boom chain tension by measuring the inner boom extend chain sag. Center Section Of Secondary Intermediate Boom OH2670 1000 Figure 114 50 1. Park the vehicle on level ground. Place the travel select lever in (N) NEUTRAL, move neutral lock lever to NEUTRAL LOCK position, engage the parking brake switch and raise the boom to a horizontal (level) position. 2.
Model 10054 163 Rev 3/02 General Maintenance Before making any adjustments to the inner boom extend chain, check the following measurement at the rear of the boom. 4. Start the vehicle, retract the boom completely and turn the vehicle OFF. 5. Go to the back of the vehicle and remove the rear cover from the back of the boom. Figure 115 6. Check the measurement “B” from the top rear edge of the secondary intermediate boom to the top rear edge of the inner boom (Figure 115).
164 Model 10054 Rev 3/02 General Maintenance • 6x6 chain - 13.75" (349 mm) - 14.25" (362 mm) Primary Intermediate Boom Inner Boom Retract Chain Locknut 9. Recheck the measurement at the rear of the boom between the top rear edge of the secondary intermediate boom and the top rear edge of the inner boom. If the measurement is still more than the ranges listed above, repeat steps 7 through 8. • 4x6 chain - 13" (330 mm) to 13.
Model 10054 165 Rev 3/02 General Maintenance If the measurement is within the specified ranges measure the inner boom extend chain sag again. 10. Start the vehicle, with the outriggers lowered completely, cycle the boom in and out several times. With the boom horizontal, fully extend the boom and then retract it 2" (51 mm). Turn the vehicle OFF. 11.
166 Model 10054 Rev 3/02 General Maintenance Figure 119 2. Adjust the inner boom extend chain (Figure 118) by tightening the locknut (Figure 119) OH0531 Inner Boom Extend Chain Inner Boom Extend Chain Locknut Figure 118 OH0551 OH0551 Figure 118 Inner Boom Extend Chain Locknut Inner Boom Extend Chain OH0531 2.
Model 10054 167 Rev 3/02 General Maintenance 3. Start the vehicle, with the outriggers lowered completely, cycle the boom in and out several times. With the boom horizontal, fully extend the boom and then retract it 2" (51 mm). Turn the vehicle OFF. 4. Measure the inner boom chain sag. Acceptable inner boom chain sag is between 1.5" (38 mm) and 2.5" (64 mm). If the chain sag is less than 1.5" (38 mm), repeat steps 1 through 4 until the sag is within the acceptable range.
168 Model 10054 Rev 3/02 General Maintenance 250 OA1490 (250 Hour Intervals) E. Boom Chain Inspection The boom chain’s normal life expectancy can be expressed as a maximum percent of elongation. This is generally 3% of pitch. As the chain flexes back and forth over the sheave, the bearing joints (pins and inside link plates) gradually incur wear due to articulation. OH2710 The above load cycles and environmental conditions make it impossible to predict chain life.
Model 10054 169 Rev 3/02 General Maintenance Figure 120 Inspection Guidelines MM2051 1. Park the vehicle on level ground. Place the travel select lever in (N) NEUTRAL, place the neutral lock lever in the (N) NEUTRAL LOCK position, engage the parking brake switch and raise the boom to a horizontal (level) position. “B” “A” 2. Fully extend the boom until the extend chain is taut. Shut the engine off. The extend chains will be visible for inspection with the vehicle in this state.
170 Model 10054 Rev 3/02 General Maintenance Figure 121 Elongation Double Extend Chains or Retract Chains: MM2120 When the original length (Figure 121, “A”) of 12.00" (305 mm) per foot of new chain has elongated from wear to a length (“B”) of 12.36" (313 mm), the chain should be discarded and replaced. Single Extend Chains: When the original length (Figure 121, “A”) of 12.00" (305 mm) per foot of new chain has elongated from wear to a length (“B”) of 12.
Model 10054 171 Rev 3/02 General Maintenance Figure 123 Turning or Protruding Pins (Figure 122) Highly loaded chain, operating with inadequate lubrication can generate abnormal frictional forces between pin and link plates. When chain is allowed to operate in this condition, a pin or series of pins, can begin to twist out of a chain, resulting in failure. MA9340 Examine the pin head rivets to determine if the “VEE” flats are still in correct alignment.
172 Model 10054 Rev 3/02 General Maintenance Cracked Plates The types of cracks are: MM2070 2 MM2100 MM2080 MM2090 • Corrosion Fatigue Cracking - Corrosion fatigue cracks are very similar to fatigue cracks in appearance. Corrosion fatigue is the combined action of an aggressive environment and cyclic stress. 4 3 Other Modes of Failure Other Modes of Failure 3 4 MM2090 • Corrosion Fatigue Cracking - Corrosion fatigue cracks are very similar to fatigue cracks in appearance.
Model 10054 173 Rev 3/02 General Maintenance F. Chain Lubrication (1000 Hour Intervals) 1000 OA1510 After inspection and before OH2690 being returned to service, chains must be lubricated with a quality chain lubricant (“LUBRIPLATE” Chain & Cable Fluid, “LPS3” or equivalent). The lubricant must penetrate the chain joint to prevent wear.
174 Model 10054 Rev 3/02 General Maintenance G. Wear Pad Inspection (50 Hour Intervals) 50 Visually inspect boom wear OH2680 pads between the boom sections at the rear and front of the boom for excessive wear at every 50 hour interval. OH2400 The average expected life of boom pads will vary depending upon vehicle use, weight of loads, operating conditions, and the location of boom pads inside the boom.
Model 10054 175 Rev 3/02 General Maintenance H. Wear Pad Replacement Figure 124 (As Wear Pad Indicators Indicate) Each boom pad is manufactured with a convenient wear pad indicator. This is the angled cut at each end of all wear pads (Figure 124). The total thickness of a new wear pad is .625" (16 mm). The angled cut will provide a total wear thickness of .25" (6 mm). This will leave approximately .375" (10 mm) of total unused base material. Wear Pad Spacer Boom Plate SC0030 .
176 Model 10054 Rev 3/02 General Maintenance 5. Refer to “Maintenance Schedule And Checklist” on page 109. Perform all the maintenance checks listed under the 10 Hour Intervals. Storage and Transport Storage 4. Wipe off any rust inhibiting lubricant that was applied to vehicles hydraulic cylinder rods prior to storing. 3. If the vehicle has been stored for two years or more, drain the coolant from the engine block and radiator and refill with a 50/50 mixture of fresh anti-freeze and water.
Model 10054 177 Rev 3/02 General Maintenance 6. Review and familiarize yourself and any other operator with all the safe and proper operating procedures contained in this manual. Transport When transporting the vehicle, make use of all four tiedown/lift point locations on the vehicles frame (Figure 125).
178 Model 10054 Rev 3/02 Test Procedures Test Procedures Stabil-TRAK System Test To test the function of the Stabil-TRAK system, read the Stabil-TRAK system test instructions on this page and follow steps 1 thru 9 of the StabilTRAK System Test Procedure starting on page 179. Stabil-TRAK System Test Instructions • Test the Stabil-TRAK system with the vehicle on a level surface. • Remove any attachment from the quick attach before performing the test.
Model 10054 179 Rev 3/02 Test Procedures WARNING: DO NOT operate this vehicle unless you are in the seat with the seat belt fastened around you. Serious injury or death could result if the belt is not securely fastened. Stabil-TRAK System Test Procedures Step 1: c. Raise the boom to exactly 60°. The Stabil-TRAK light should come ON when the boom angle is at about 40° and remain ON. a. Place the vehicle on a level surface with 0° sway. b. Have the boom fully retracted and horizontal. b.
180 Model 10054 Rev 3/02 Test Procedures Step 4: d. Frame sway the vehicle back to 0°. IMPORTANT! Perform procedures 5 through 9 with the engine rpm at idle. e. Frame sway the vehicle no more than 5° to the right. d. With your right foot, increase the engine RPM slightly, as necessary, just enough to back the vehicle off the block. While backing off the block, the front left tire should remain off the ground. NOTE: Observe that frame sway will be slower than normal during this test. c.
Model 10054 181 Rev 3/02 Test Procedures Step 8: a. Depress the service brake pedal. b. Disengage the parking brake switch. If steps 1 through 9 prove positive, the Stabil-TRAK system is functioning properly and the vehicle can be returned to service. If any of these steps indicate that the Stabil-TRAK system is not functioning properly, contact your local OmniQuip Authorized Service Center (ASC) immediately to repair the system. c.
182 Model 10054 Rev 3/02 Test Procedures Boom/Outrigger Interlock System Test b. Fasten your seat belt. Step 3 a. Place the vehicle with no load on a flat, level hard surface such as blacktop or concrete. a. Lower both outriggers to the ground (DO NOT lift the front wheels of the vehicle off the ground at this time). Step 1 b. With the boom still in a horizontal position extend the boom.
Model 10054 183 Rev 3/02 Test Procedures Step 4 a. Put the travel select lever in the (F) FORWARD position and the gear select lever in the first gear position. b. Attempt to accelerate the vehicle. The vehicle should not move. c. If the vehicle attempts to move, STOP and have the system repaired before using the vehicle again. Step 5 a. Attempt to frame sway the vehicle to the right and left, it should frame sway but at a slower speed than normal. b. The Stabil-TRAK light should remain ON. c.
184 Model 10054 Rev 3/02 Test Procedures d. Engage the parking brake. The unit should stop abruptly. Parking Brake/Transmission De-Clutch Test Procedures c. Move the unit slowly in a forward direction (approximately 1 mph [1,6 kmh]). To check that the parking brake/transmission de-clutch system is functioning properly, perform the following tests. b. Move the travel select lever to (F) FORWARD. a. Disengage the parking brake.
Model 10054 185 Rev 3/02 Test Procedures Figure 126 Test 3 - Park Brake Hold Performance a. With the rated load of 10,000 lbs (4.536 Kg) on the forks, drive the vehicle forward up a 15% grade (15 ft. rise over 100 ft. run). OH1720 b. Stop the vehicle using the service brakes, apply the park brake, shift the transmission into NEUTRAL (N). DANG ER c. Take your foot off the service brake pedal. The vehicle should not move. DANGER d.
186 Model 10054 Rev 3/02 Test Procedures Figure 127 Four Wheel Steer Indexing Procedure OH3200 Four Wheel Steer If the vehicle does not drive “straight,” the steering could be out-of-phase. Perform the following Four Wheel Steer Indexing Procedure to synchronize the front and rear steering. 1. With the steering select (Figure 127) switch in the Four Wheel Steer position, turn the steering wheel full left. Steer Select Switch Front Wheel Steer 2.
Model 10054 187 Rev 3/02 Specifications Type of Fluid.....................Universal Tractor Fluid (see chart on page 137) Specifications Capacity with filter change ........................................ 3 gallons (11,8 liters) Fluid & Lubrication Capacities Engine Crankcase Oil: Transmission: Capacity with Filter Change ......................................11 quarts (10,4 liters) (See Chart On page 133) Filter Capacity ................................................................
188 Model 10054 Rev 3/02 Specifications Axles: Differential Housing Capacity .................................... 9.5 quarts (9,0 liters) Type of Fluid .................... Universal Tractor Fluid (see chart on page 140) Wheel Ends: Wheel End Capacity.................................................. 1.7 quarts (1,6 liters) Type of Fluid .................... Universal Tractor Fluid (see chart on page 146) Model 10054..............................................................
Model 10054 189 Rev 3/02 Specifications Vehicle Dimensions With Standard 17.5 - 25 Tires: Length (less forks) .................................................. 239 inches (6071 mm) Width (outriggers up) .............................................. 102 inches (2591 mm) Series of Batteries:............................................................. Series 31 Width (outriggers down)..................................... 156.75 inches (3981 mm) Height....................................................
190 Model 10054 Rev 3/02 Specifications Fuse Ratings: Neutral Start .........................................................................................12V Optional Road/Work Lights ............................................................40 Amp Stabilizer Lock ......................................................................................12V Boom/Outrigger Interlock ..............................................................7.5 Amp Boom Switch .....................................
Index Index Model 10054 A Accelerator Pedal ...........................24 Accident Prevention Tags ................5 Air Cleaner ...................................116 Air Intake System .........................119 Air Pressure .................................188 Alternator Charging Warning Indicator Light ............................43 Attachment Reconnect ...................75 Attachment Removal ......................74 Attachment Tilt ...............................32 Auger Operation .................
192 Model 10054 Rev 3/02 Index Gear Select Lever ......................... 30 G Falling Load Hazard ................ 13, 20 Fan Control .................................... 53 Filter Change ............................... 125 Filter Check ................................. 116 Final Positioning Mode .................. 65 Fork Ratings .................................. 87 Fork Sweep ................................... 73 Four Wheel Steer Indexing ............ 71 Four Wheel Steer Indexing Procedure ......
Index Model 10054 O S Oil Level Check ............................123 Operating .......................................63 Operator’s Seat Adjustment ...........36 Outer Primary Element .................117 Outrigger Control Switches ............33 Outrigger Interlock Mode ................66 Safety Element ............................. 117 Seat Belt .................................. 10, 35 Serial Number Plate ......................... 2 Service Brake Pedal ...................... 24 Shifting Gears ......
194 Model 10054 Rev 3/02 Index V Underground Hazards ................... 15 Understanding the Boom/Outrigger Interlock System ...................... 66 Using Other Attachments .............. 91 Using The Capacity Chart ............. 76 W Warning Indicator Lights ................41 Wear Pad Inspection ....................174 Wear Pad Replacement ...............175 Wear Pads ...................................155 Weights ........................................188 Wheel End Oil ..........................
Accident Prevention Tags 8990401 Origin 5/00 OS2180 Accident Prevention Tags Accident Prevention Tags 8990401 Origin 5/00 OS2180 Accident Prevention Tags
Accident Prevention Tags 8990401 Origin 5/00 OS2180 OS2180 Accident Prevention Tags 8990401 Origin 5/00
Replacement Manuals Visit our Web Site at: http://www.jlg.com If the owner/operator or safety manuals that were originally shipped with your vehicle are lost, stolen or need replacement, contact your local distributor for replacement manuals. If for any reason your distributor cannot supply the manuals you need; write, call or send a fax to the following address for ordering information. JLG Industries Inc. 1 JLG Drive McConnellsburgh,PA 17233-9533 Domestic: (717) 485-5161 Parts Fax: (717) 485-6417 3.
Plataformas Elevadoras JLG Iberica, S.L. Trapadella, 2 P.I. Castellbisbal Sur 08755Castellbisbal Spain Phone: (34) 93 77 24700 Fax: (34) 93 77 11762 JLG Industries (Pty) Ltd. Unit 1, 24 Industrial Complex Herman Street Meadowdale Germiston South Africa Phone: (27) 11 453 1334 Fax: (27) 11 453 1342 JLG Industries (Europe) Kilmartin Place, Tannochside Park Uddingston G71 5PH Scotland Phone: (44) 1 698 811005 Fax: (44) 1 698 811055 JLG Polska UI.
