Operators and Safety Manual Operators and Safety Manual Model Model 8990298-004 8990298-004 November 1999 November 1999 3606 ANSI 3606 ANSI
WARNING WARNING Improper operation of this vehicle can cause injury or death. Improper operation of this vehicle can cause injury or death. Before starting the engine, do the following: Before starting the engine, do the following: 1. Read this owner/operators manual. 1. Read this owner/operators manual. 2. Read all the safety decals on the vehicle. 2. Read all the safety decals on the vehicle. 3. Clear the area of other persons. 3. Clear the area of other persons.
Table of Contents Introduction The Manual....................................2 Replacement Parts ........................2 Reports ..........................................2 Safety Practices Disclaimer......................................3 Hazard Classification System........3 New or Additional Operators .........4 Personal Considerations ...............4 Operational Considerations ...........8 Equipment Considerations ..........13 Operation Operator Controls ........................
Introduction Introduction Introduction Introduction The Manual The Manual This Owners/Operators Manual provides the information you need to correctly operate and maintain this vehicle. This Owners/Operators Manual provides the information you need to correctly operate and maintain this vehicle. IMPORTANT! Before you operate this vehicle, read this manual completely and carefully so you will understand the instructions and the proper operation of the controls and equipment.
Safety Practices Safety Practices Disclaimer Disclaimer Sky Trak reserves the right to make changes on and to add improvements upon its products at any time without public notice or obligation. Sky Trak also reserves the right to discontinue manufacturing any product at its discretion at any time. Sky Trak reserves the right to make changes on and to add improvements upon its products at any time without public notice or obligation.
Safety Practices Safety Practices ON0021 The signal word “DANGER” indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. ON0021 The signal word “DANGER” indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. ON0030 The signal word “WARNING” indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Safety Practices 2. Clothing and Safety Gear Safety Practices 2. Clothing and Safety Gear DO NOT wear loose clothing or jewelry that can get caught on controls or moving parts. Wear protective clothing and personal safety gear issued or called for by job conditions. 3. Dismounting DO NOT wear loose clothing or jewelry that can get caught on controls or moving parts. Wear protective clothing and personal safety gear issued or called for by job conditions. 3.
Safety Practices Safety Practices C. Hydraulic Fluid C. Hydraulic Fluid DO NOT attempt to repair or tighten any hydraulic hoses or fittings while the engine is running or when the hydraulic system is under pressure. Fluid in the hydraulic system is under enough pressure that it can penetrate the skin causing serious injuries or death. DO NOT attempt to repair or tighten any hydraulic hoses or fittings while the engine is running or when the hydraulic system is under pressure.
Safety Practices Battery Electrolyte First Aid: Safety Practices Battery Electrolyte First Aid: • External Contact — Flush with water. • External Contact — Flush with water. • Eyes — Flush with water for at least 15 minutes and get medical attention immediately. • Eyes — Flush with water for at least 15 minutes and get medical attention immediately. • Internal Contact — Drink large quantities of water. Follow with Milk of Magnesia, beaten egg or vegetable oil. Get medical attention immediately.
Safety Practices Safety Practices Operational Considerations Operational Considerations 1. Preperation and Prevention 1. Preperation and Prevention Know the location and function of all vehicle controls. Know the location and function of all vehicle controls. Make sure all persons are away from the vehicle and that the Travel Select Lever is in the (N) NEUTRAL position with the parking brake switch engaged before starting the engine.
Safety Practices 4. Electrocution Hazards Safety Practices 4. Electrocution Hazards NEVER operate this vehicle in an area where overhead power lines, overhead or underground cables, or other power sources may exist without first requesting that the appropriate power or utility company deenergize the lines, or take other suitable precautions.
Safety Practices Safety Practices 6. Tip Over Hazard 6. Tip Over Hazard OS1633 OS1633 MAINTAIN proper tire pressures at all times. Underpressurized tire(s) adversely affects vehicle stability. If proper tire pressures are not maintained, this vehicle can tip over. If a vehicle ever becomes unstable and starts to tip over: 10 MAINTAIN proper tire pressures at all times. Underpressurized tire(s) adversely affects vehicle stability.
Safety Practices Safety Practices OS0083 OS0083 Travelling with the boom raised is dangerous and can cause tipover. Keep the boom as low as possible. Travel with extreme caution and at the slowest possible speed. Travelling with the boom raised is dangerous and can cause tipover. Keep the boom as low as possible. Travel with extreme caution and at the slowest possible speed. Swaying (frame tilt) left or right with the boom raised above horizontal is dangerous.
Safety Practices Safety Practices 8. Falling Load Hazard 8. 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 Rating” on page 75. 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 Rating” on page 75.
Safety Practices Safety Practices Equipment Considerations Equipment Considerations WARNING WARNING DO NOT modify or alter (weld, drill, etc.) any part of this vehicle without consulting Sky Trak. Modifications can weaken the structure creating a hazard that can cause injury or death. DO NOT modify or alter (weld, drill, etc.) any part of this vehicle without consulting Sky Trak. Modifications can weaken the structure creating a hazard that can cause injury or death.
Safety Practices Safety Practices Vehicles Stamped with Work Order No. 06148 thru 45611 DANGER Vehicles Stamped with Work Order No. 06148 thru 45611 DANGER NEVER operate vehicle within 10 feet (3m) of electric power lines. CONTACTING ELECTRIC POWER LINES can result in electrocution. 3 6 LOW TIRE PRESSURE can result in tipover. DANGER 5 2 DANGER NEVER operate vehicle within 10 feet (3m) of electric power lines. CONTACTING ELECTRIC POWER LINES can result in electrocution.
Safety Practices Safety Practices Vehicles Stamped with Work Order No. 06148 thru 45611 Vehicles Stamped with Work Order No.
Safety Practices Safety Practices Vehicles Stamped with Work Order No. 45612 and After DANGER NEVER operate vehicle within 10 feet (3m) of electric power lines. CONTACTING ELECTRIC POWER LINES can result in electrocution. VEHICLE TIPOVER can result in death or serious injury. Vehicles Stamped with Work Order No. 45612 and After DANGER DANGER DO NOT raise boom while on a slope unless load is level. DO NOT travel with the boom raised.
Safety Practices Safety Practices Vehicles Stamped with Work Order No. 45612 and After Vehicles Stamped with Work Order No.
Operation Operation Operation Operation Operator Controls Operator Controls Accelerator Pedal Accelerator Pedal (Figure 5) (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. Pressing down the accelerator pedal increases engine and hydraulic speed of the vehicle. The pedal is spring-loaded to return to idle speed.
Operation Operation Steering Wheel - Ref. Steering Wheel - Ref. Tilt Steering Wheel Lever Tilt Steering Wheel Lever OS1120 OS1120 Figure 6 Figure 6 Ignition Switch Ignition Switch (Figure 7) (Figure 7) Using the ignition switch key, the switch may be turned clockwise from the OFF position to the RUN, PREHEAT and START positions. The PREHEAT and START positions are spring-loaded to return to the RUN position and must be manually held in place for starting.
Operation Operation Travel and Gear Select Lever Travel and Gear Select Lever Steering Selection Indicators Steering Selection Indicators Attachment Tilt Mode Switch Attachment Tilt Mode Switch Parking Brake Switch Parking Brake Switch Steering Select Switch (Either of two locations) Steering Select Switch (Either of two locations) OS0403 OS0403 Figure 8 Figure 8 Steering Select Switch Steering Select Switch (Figure 8) (Figure 8) The switch has three positions: The switch has three posit
Operation Operation Parking Brake Switch Parking Brake Switch (Figure 8) (Figure 8) The parking brake switch has two positions: The parking brake switch has two positions: Engaged................................ toggle switch downward P Disengaged................................toggle switch upward P OS1323 Engaged................................ toggle switch downward Disengaged................................
Operation Operation Travel Select Lever Travel Select Lever (Figure 9) (Figure 9) The travel select lever has three positions to select direction of travel: The travel select lever has three positions to select direction of travel: F = FORWARD ...................................all the way UP F = FORWARD ...................................all the way UP N = NEUTRAL ....................................CENTER position N = NEUTRAL ....................................CENTER position R = REVERSE.....
Operation Operation Gear Select Lever Gear Select Lever (Figure 10) (Figure 10) The gear select lever has a twist grip handle with four positions. Vehicles equipped with either Cummins or Perkins turbocharged engine have four (4) forward gears and three (3) reverse. Vehicles equipped with a naturally aspirated Perkins engine have three (3) forward gears and three (3) reverse. Use first gear for highest torque and pulling power. Use higher gears for higher ground speed.
Operation Operation Multi-Function Joystick Multi-Function Joystick (Figure 11) (Figure 11) Multi-Function Joystick Multi-Function Joystick Logic Panel Logic Panel OS0152 OS0152 Figure 11 Figure 11 The joystick is equipped with four buttons that enable the joystick to operate in four specific modes. The joystick controls boom movement, attachment tilt, sway control and optional auxiliary hydraulics.
Operation MODE 1 Operation MODE 1 Boom Control (Default) (No buttons depressed) OS2050 Boom Control (Default) logic panel symbol (No buttons depressed) Boom Lift ................... move handle backward Boom Lift ................... move handle backward Boom Lower .............. move handle forward Boom Lower .............. move handle forward Boom Extend ............. move handle to the right Boom Extend ............. move handle to the right Boom Retract .............
Operation Operation MODE 2B MODE 2B Boom Lift/Lower & Attachment Tilt Up/Down Boom Lift/Lower & Attachment Tilt Up/Down (Right button depressed) (Right button depressed) Attachment Tilt Mode Switch In MODE 2B Attachment Tilt Mode Switch In MODE 2B display panel symbol display panel symbol Attachment Tilt with Lift & Lower Attachment Tilt with Lift & Lower logic panel symbol OS2070 logic panel symbol Boom Lift ...................... move handle backward Boom Lift ......................
Operation MODE 3 Operation MODE 3 Boom Lift/Lower & Frame Sway Right/Left (Depress left & front button simultaneously, then hold either button) Boom Lift/Lower & Frame Sway Right/Left (Depress left & front button simultaneously, then hold either button) logic panel symbol OS2080 logic panel symbol Boom Lift ................... move handle backward Boom Lift ................... move handle backward Boom Lower .............. move handle forward Boom Lower ..............
Operation Operation MODE 4 MODE 4 Auxiliary Hydraulic Control - Optional Auxiliary Hydraulic Control - Optional The auxiliary hydraulic control regulates the functions of an optional attachment. Some of the optional attachments that require auxiliary hydraulics are: Side Tilt Carriage, Swing Carriage. The auxiliary hydraulic control regulates the functions of an optional attachment. Some of the optional attachments that require auxiliary hydraulics are: Side Tilt Carriage, Swing Carriage.
Operation Operation Seat Belt Seat Belt (Figure 12) (Figure 12) The seat belt has one retractable strap for easy installation and removal. Insert the seat belt tang into the receptacle to fasten. Press the center button to unfasten the seat belt. Always wear the seat belt when operating the vehicle. An optional 3 inch wide seat belt is available for those locations that require a 3 inch seat belt. The seat belt has one retractable strap for easy installation and removal.
Operation Operation Operators Seat Adjustments Operators Seat Adjustments (Figure 13) (Figure 13) The operator’s seat can be adjusted three ways: The operator’s seat can be adjusted three ways: A. Fore and Aft Adjustment - A. Fore and Aft Adjustment - Pull the handle outward to adjust the seats forward and rearward position. Release the handle to lock the seat in the desired position. Pull the handle outward to adjust the seats forward and rearward position.
Operation Operation Operators Display Panel Operators Display Panel The display panel provides the operator with important information. It is “user friendly” and only provides the operator with the information needed at any given time. The display panel provides the operator with important information. It is “user friendly” and only provides the operator with the information needed at any given time.
Operation Operation Normal Operating Lights Normal Operating Lights (Figure 15) (Figure 15) After the engine has started, the display panel provides the operator with information about: After the engine has started, the display panel provides the operator with information about: A. Fuel Level Indicators A. Fuel Level Indicators Make sure the vehicle is level to ensure an accurate fuel level reading. Each bar represents 1/4 of the tank.
Operation Operation Function Indicator Lights Function Indicator Lights (Figure 16) (Figure 16) There are three “hidden” function indicator lights in the display panel that become illuminated only when a specific function has been activated. They are: There are three “hidden” function indicator lights in the display panel that become illuminated only when a specific function has been activated. They are: A. Engine Preheat Indicator (Optional) A.
Operation Operation Warning Indicator Lights Warning Indicator Lights (Figure 17) (Figure 17) There are eight additional “hidden” indicator lights in the display panel that become illuminated during critical circumstances. All eight 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.
Operation Operation will also sound. Stop and idle the vehicle, allowing time for cooling. If the light does not go out after five minutes, shut the vehicle down. will also sound. Stop and idle the vehicle, allowing time for cooling. If the light does not go out after five minutes, shut the vehicle down. Reset Button for Engine Maintenance/ Vehicle Lubrication Indicator Reset Button for Engine Maintenance/ Vehicle Lubrication Indicator OS0251 OS0251 Figure 18 Figure 18 D.
Operation Operation Instruments and Indicators Instruments and Indicators Hourmeter (Figure 19) Hourmeter (Figure 19) OS0260 The hourmeter records engine operating hours and has a total readout of 99,999.9 hours. It is located on the left side of the operators console and is best viewed from outside the vehicle. OS0260 The hourmeter records engine operating hours and has a total readout of 99,999.9 hours.
Operation Operation Boom Angle Indicator Boom Angle Indicator (Figure 21) (Figure 21) The boom angle indicator is a plumb arrow with angular graduations from -10° to + 80° . It is located on the left side of the boom and is visible from the operators position. Use this indicator to determine the boom angle when reading the capacity chart (see “Using the Capacity Chart”). The boom angle indicator is a plumb arrow with angular graduations from -10° to + 80° .
Operation Operation Optional Controls Optional Controls Manually Operated Pressure Release Valve (Figure 23) Manually Operated Pressure Release Valve OS2140 (Figure 23) OS2140 The pressure release valve is located in the rear of the vehicle and is used to release pressure before connecting or disconnecting the optional Auxiliary Hydraulic Couplings.
Operation Directional Signals (Figure 25) Operation Directional Signals (Figure 25) OS1910 OS1910 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. To deactivate either directional signal, the lever must be manually returned to the center position, the lever will not cancel automatically after a turn.
Operation Operation Power Window Power Window (Figure 26) (Figure 26) OS1850 OS1850 The power window control is a momentary toggle switch that will raise or lower the cab door window when the ignition is in the RUN position. To lower the window, toggle the switch downward to the desired position then release the switch. The power window control is a momentary toggle switch that will raise or lower the cab door window when the ignition is in the RUN position.
Operation Operation Latch Pin (Ref.) Latch Pin (Ref.) Rear Window Rear Window Latch Handle Latch Handle OS1830 OS1830 Figure 27 Front Windshield Wiper Front Windshield Washer (Figure 28) OS1930 Figure 27 Front Windshield Wiper Front Windshield Washer OS1940 (Figure 28) OS1930 OS1940 The front wiper switch and the front washer switch are separate switches located in the right-hand bank of switches on the dash.
Operation Operation Cab Heater/ Cab Air Conditioning Controls Cab Heater/ Cab Air Conditioning Controls (Figure 29) OS1950 OS1960 The cab heater and air conditioning controls are located directly below the vehicles Capacity Chart Booklet. From left to right the control panel consists of: a stepped fan control knob, an A/C on-off rocker switch (A/C units only), and a temperature control knob.
Operation To defrost the cab: Operation To defrost the cab: • turn temperature control knob to far right position (RED=HOT), • turn temperature control knob to far right position (RED=HOT), • direct desired air flow by adjusting vent louvers, • direct desired air flow by adjusting vent louvers, • turn fan control to “3” to assure rapid defrost. • turn fan control to “3” to assure rapid defrost.
Operation Operation Normal Starting Normal Starting 1. Enter the cab and adjust the seat for comfortable operation. 1. Enter the cab and adjust the seat for comfortable operation. 2. Adjust the mirrors to obtain the best rear view from the operators position. 2. Adjust the mirrors to obtain the best rear view from the operators position. WARNING WARNING DO NOT start the engine unless you are in the seat with the seat belt fastened around you.
Operation Cold Starting (Perkins Engines Only) Operation Cold Starting (Perkins Engines Only) Use the PREHEAT cold starting aid when the temperature is below 32° F (0° C) with 10W30 oil in the engine crankcase. Using the block heater is recommended when temperatures fall below 10° F (-12° C). (Temperature ranges will vary when using different oil weight. Consult the engine manufacturer’s manual for other variables.
Operation Operation 5. Turn and hold the ignition switch to the PREHEAT position until the preheat indicator light on the display panel stops flashing and glows steadily. Release the switch immediately after the light goes out. For location of the preheat indicator light on the display panel see page 33. OFF 5. Turn and hold the ignition switch to the PREHEAT position until the preheat indicator light on the display panel stops flashing and glows steadily.
Operation Operation Cold Starting (Cummins Engines Only) Cold Starting (Cummins Engines Only) The Cummins engine is equipped with a 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.) The Cummins engine is equipped with a block heater. Block heaters are recommended when temperatures drop below 10° F (-12° C).
Operation Operation 7. If using starting fluid without metering equipment: 7. If using starting fluid without metering equipment: WARNING WARNING NEVER use starting fluid near an open flame. NEVER use starting fluid near an open flame. NEVER use starting fluid in a vehicle equipped with an electrical preheat option or flame air heating equipment. NEVER use starting fluid in a vehicle equipped with an electrical preheat option or flame air heating equipment. DO NOT breathe starting fluid fumes.
Operation Operation • as the engine starts, stop spraying the starting fluid and release the ignition switch to the RUN position. Release the accelerator pedal enough to provide a smooth idle speed. • as the engine starts, stop spraying the starting fluid and release the ignition switch to the RUN position. Release the accelerator pedal enough to provide a smooth idle speed. 8. The engine oil pressure warning indicator light should go off within 5 seconds after starting.
Operation Operation Jump Starting Jump Starting WARNING WARNING NEVER jump start the vehicle directly to the starter or starter solenoid. Serious injury or death could result from the vehicle lurching forward or backward and running over the person attempting to jump start the vehicle directly to the starter. NEVER jump start the vehicle directly to the starter or starter solenoid.
Operation 7. Remove the jumper cables in the reverse order of their connection (i.e. negative cable ground connection first, etc.) Operation 7. Remove the jumper cables in the reverse order of their connection (i.e. negative cable ground connection first, etc.) Refueling Refueling Make sure the vehicle is level to assure an accurate fuel level reading. The fuel tank is capable of holding 35.1 gallons (132,8 liters) of diesel fuel. Make sure the vehicle is level to assure an accurate fuel level reading.
Operation Operation To unlock the fuel cap: To unlock the fuel cap: 1. Level the vehicle, ground the carriage, place the travel select lever in (N) NEUTRAL, engage the parking brake switch and turn the ignition switch to the OFF position. Remove the keys from the ignition. 1. Level the vehicle, ground the carriage, place the travel select lever in (N) NEUTRAL, engage the parking brake switch and turn the ignition switch to the OFF position. Remove the keys from the ignition.
Operation Operation Operating Operating Understanding the Stabil-TRAK™ System Understanding the Stabil-TRAK™ System OS1970 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. The following describes the three basic modes of the patented Stabil-TRAK system. The vehicle may operate in any one of these three modes.
Operation Operation Locked Mode Locked Mode (Figure 35) (Figure 35) With the boom above 40° and by activating one or more of the following functions listed below, the Stabil-TRAK system is in the locked mode and the rear axle is locked so it is rigid with the frame. The Stabil-TRAK light will be ON. With the boom above 40° and by activating one or more of the following functions listed below, the Stabil-TRAK system is in the locked mode and the rear axle is locked so it is rigid with the frame.
Operation Above 40° Operation Above 40° FINAL POSITIONING MODE FINAL POSITIONING MODE Stabil-TRAK Light "OFF" Stabil-TRAK Light "OFF" OS1492 OS1492 Figure 36 Figure 36 Stabil-TRAK™ System Test Stabil-TRAK™ System Test IMPORTANT! It is important for the operator to know that the Stabil-TRAK system is active and functioning properly. IMPORTANT! It is important for the operator to know that the Stabil-TRAK system is active and functioning properly.
Operation Operation • DO NOT raise the boom above 60° for steps 3 through 6. • DO NOT raise the boom above 60° for steps 3 through 6. • DO NOT raise the boom above 45° for steps 7 through 9. • DO NOT raise the boom above 45° for steps 7 through 9. • Follow steps 1 through 9 of the Stabil-TRAK system test procedure exactly as written. • Follow steps 1 through 9 of the Stabil-TRAK system test procedure exactly as written.
Operation Operation brake pedal and increase the engine RPM slightly if necessary just enough to back the vehicle off the block, while keeping the service brake pedal partially depressed so the Stabil-TRAK light remains ON. The rear axle should remain locked while backing off the block and the front left tire should remain off the ground.
Operation Operation 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 Sky Trak Distributor immediately to repair the system. If steps 1 through 9 prove positive, the Stabil-TRAK system is functioning properly and the vehicle can be returned to service.
Operation Stopping Travel Operation Stopping Travel 1. Apply the service brake pedal and downshift the vehicle to a lower gear if necessary to slow the vehicle until it comes to a complete stop. 1. Apply the service brake pedal and downshift the vehicle to a lower gear if necessary to slow the vehicle until it comes to a complete stop. 2. Move the travel select lever to (N) NEUTRAL and engage the parking brake switch. 2. Move the travel select lever to (N) NEUTRAL and engage the parking brake switch.
Operation Operation Four Wheel Steer Indexing Four Wheel Steer Indexing 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. 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.
Operation Operation WARNING WARNING NEVER use the Four Wheel Steering Mode when traveling at high speed. Rapid turning in the mode will cause tipover. Use only the Front Wheel Steering Mode at higher speeds and slow the vehicle when turning. NEVER use the Four Wheel Steering Mode when traveling at high speed. Rapid turning in the mode will cause tipover. Use only the Front Wheel Steering Mode at higher speeds and slow the vehicle when turning. 2. Front Wheel Steering 2.
Operation Operation 3. Crab Steering 3. Crab Steering (Figure 40) (Figure 40) All wheels will steer in the same direction that the steering wheel is turned. This steering mode allows the operator to move the vehicle “sideways” toward the landing point of a load. This is especially useful on a congested worksite, in order to line up at the exact spot in front of the loading location. All wheels will steer in the same direction that the steering wheel is turned.
Operation Operation Maximum Fork Sweep Maximum Fork Sweep (Figure 41) (Figure 41) CAUTION CAUTION Allow for adequate clearance between the attachment and other objects when turning. 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.
Operation Operation Leveling the Vehicle Leveling the Vehicle When placing a load on a slope, use the Frame Sway Control (see MODE 3 on page 27) to keep the vehicle level. The operator should observe the frame level indicator to assure that the vehicle is level at all times. When placing a load on a slope, use the Frame Sway Control (see MODE 3 on page 27) to keep the vehicle level. The operator should observe the frame level indicator to assure that the vehicle is level at all times.
Operation Operation Quick Attach Pin Lock Lever Quick Attach Pin Quick Attach Pin Lock Lever OS0331 Quick Attach Pin Figure 42 OS0331 Figure 42 6. Return to the operators compartment, fasten the seat belt and lower the attachment to the ground in a level position. Tilt the attachment forward. This will rotate the quick attach link back away from the attachment. 6. Return to the operators compartment, fasten the seat belt and lower the attachment to the ground in a level position.
Operation Operation 6. Place the travel select lever in (N) NEUTRAL, engage the parking brake switch and exit the vehicle using both hand holds. 6. Place the travel select lever in (N) NEUTRAL, engage the parking brake switch and exit the vehicle using both hand holds. 7. Lift the quick attach lever. Insert the quick attach pin completely through the attachment and the quick attach link. Be sure that the quick attach lock lever has lowered and seated itself into the groove in the quick attach pin. 7.
Operation Operation Manually Operated Pressure Release Manually Operated Pressure Release OS0360 OS0360 Figure 43 Figure 43 8. Pull the knob toward you to release pressure trapped in the auxiliary hydraulic system. The valve is spring loaded and the knob will return to its original position. 8. Pull the knob toward you to release pressure trapped in the auxiliary hydraulic system. The valve is spring loaded and the knob will return to its original position. 9. Close the rear cover. 9.
Operation Operation Using the Capacity Chart Using the Capacity Chart The individual capacity charts are located inside a booklet on the right side of the operator’s compartment. 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. The individual capacity charts are located inside a booklet on the right side of the operator’s compartment.
Operation Operation Boom Extend Stripes A Boom Extend Stripes B A Intermediate Boom B Intermediate Boom OS1710 OS1710 Figure 45 Figure 45 The boom angle indicator, located on the left side of the outer boom, indicates the angle of the boom and also corresponds with the angles indicated on the capacity chart.
Operation Operation Reading the Standard Capacity Chart Reading the Standard Capacity Chart Example: 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. 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. 2. The operator determines that: 2.
Operation Standard Carriage Capacity Chart Operation Standard Carriage Capacity Chart Load Placement Example Load Placement Example OS0351 OS0351 Figure 47 3606 Rev 11/99 Figure 47 71 3606 Rev 11/99 71
Operation Operation Truss Boom Capacity Chart Truss Boom Capacity Chart OS0382 OS0382 Figure 48 72 Figure 48 3606 Rev 11/99 72 3606 Rev 11/99
Operation Swing Carriage Capacity Chart Operation Swing Carriage Capacity Chart OS1661 OS1661 Figure 49 3606 Rev 11/99 Figure 49 73 3606 Rev 11/99 73
Operation Operation Side Tilt Carriage Capacity Chart Side Tilt Carriage Capacity Chart OS1670 OS1670 Figure 50 74 Figure 50 3606 Rev 11/99 74 3606 Rev 11/99
Operation Operation Fork Rating Fork Rating 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 51). 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).
Operation Operation The maximum load capacity for this vehicle is 6,600 pounds (2994 Kg). The matched pair or set of forks used on this vehicle should have total load ratings which equal or exceed 6,600 pounds (2994 Kg). When the load rating of the vehicle differs from the load capacity of the forks, the lower value becomes the overall load capacity. The maximum load capacity for this vehicle is 6,600 pounds (2994 Kg).
Operation Preperation and Set-up Operation Preperation and Set-up 1. Make sure that the work platform is securely attached to the quick attach or forks. Follow the platform manufacturer’s instructions. 1. Make sure that the work platform is securely attached to the quick attach or forks. Follow the platform manufacturer’s instructions. 2. Make sure the platform, carriage and forks are secured to prevent them from pivoting from side to side. 2.
Operation Operation 3. Always position the platform in the travel position (approximately one foot above ground level) before moving the vehicle. 3. Always position the platform in the travel position (approximately one foot above ground level) before moving the vehicle. IMPORTANT! Make sure that required restraining equipment such as railings, chains, cable, body belts with lanyards, etc. are in place and properly used. Never use railings, planks, ladders, etc.
Operation Operation The attachments listed below are supplied with their own individual capacity chart: The attachments listed below are supplied with their own individual capacity chart: • 12’ Truss Boom • 12’ Truss Boom • 48, 60 & 72” Side Tilt Carriage • 48, 60 & 72” Side Tilt Carriage • 52 & 72” Swing Carriage • 52 & 72” Swing Carriage Hydraulically actuated attachments also have a maximum hydraulic pressure rating.
Operation 80 Operation 3606 Rev 11/99 80 3606 Rev 11/99
Accident Prevention Tags Accident Prevention Tags Accident Prevention Tags Accident Prevention Tags OS2180 3606 Rev 11/99 OS2180 81 3606 Rev 11/99 81
Accident Prevention Tags Accident Prevention Tags OS2180 82 3606 Rev 11/99 OS2180 82 3606 Rev 11/99
Emergency Operations Emergency Operations Emergency Operations Emergency Operations Towing a Disabled Vehicle Towing a Disabled Vehicle Towing a disabled vehicle should only be attempted after exhausting all other options. Every effort should be made to repair the vehicle, and move it under its own power before using the following emergency towing procedures. Towing a disabled vehicle should only be attempted after exhausting all other options.
Emergency Operations Emergency Operations 2. Block all four wheels to prevent the vehicle from moving once the parking brake is disabled. 2. Block all four wheels to prevent the vehicle from moving once the parking brake is disabled. 3. Position the towing vehicle in place. Attach any chains needed to secure the disabled vehicle. 3. Position the towing vehicle in place. Attach any chains needed to secure the disabled vehicle. 4.
Emergency Operations Steering Cylinder (Ref.) A Turn Clockwise to Release Brake Emergency Operations Steering Cylinder (Ref.) A Turn Clockwise to Release Brake FRONT FRONT B B C Brake Release Bolt EARLY PRODUCTION LEFTSIDE CROSS SECTION OF FRONT AXLE EARLY PRODUCTION A Turn Clockwise to Release Brake C Brake Release Bolt LEFTSIDE CROSS SECTION OF FRONT AXLE Steering Cylinder (Ref.) A Turn Clockwise to Release Brake Steering Cylinder (Ref.
Emergency Operations Emergency Operations 13. After you have blocked all four wheels, crawl under the front axle. Using the torque wrench, alternately turn brake release bolts A, B & C outward (counterclockwise) 1/2 turn until the torque drops to 22 lb/ft (30 Nm). 13. After you have blocked all four wheels, crawl under the front axle. Using the torque wrench, alternately turn brake release bolts A, B & C outward (counterclockwise) 1/2 turn until the torque drops to 22 lb/ft (30 Nm). 14.
Emergency Operations Emergency Operations Emergency Boom Lowering Emergency Boom Lowering This section discusses emergency boom lowering procedures: This section discusses emergency boom lowering procedures: Part I In case of loss of engine power or hydraulic pump failure. Part I In case of loss of engine power or hydraulic pump failure. Part II In case of hydraulic line failure. Part II In case of hydraulic line failure.
Emergency Operations Emergency Operations Part II - Hydraulic Line Failure Part II - Hydraulic Line Failure In case of hydraulic line failure there are step by step procedures available to assist you in safely retracting and then lowering the boom. Read Part II from start to finish before performing any of these procedures so you fully understand the process and the danger involved.
Emergency Operations Emergency Operations 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 56) and use the table below to determine which Step to follow to retract and lower the boom. In any case of hydraulic line failure, it is critical to correctly identify which hydraulic line has failed.
Emergency Operations Emergency Operations STEP 1 STEP 1 1. Clear the area of any unneccessary personnel. 1. Clear the area of any unneccessary personnel. 2. Block all four wheels. 2. Block all four wheels. WARNING 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. 3.
Emergency Operations Boom Extend Line Boom Extend Line Boom Retract Line Boom Lift Line (Lift Cylinder to Bulkhead) Boom Lower Line (Lift Cylinder to Bulkhead) Bulkhead (Ref.) Boom Retract Line Boom Lift Line (Lift Cylinder to Bulkhead) Boom Lower Line (Lift Cylinder to Bulkhead) Bulkhead (Ref.
Emergency Operations Emergency Operations STEP 2 STEP 2 USE IN CASE OF: USE IN CASE OF: BOOM LIFT LINE FAILURE (Lift Cylinder to Bulkhead) BOOM LIFT LINE FAILURE (Lift Cylinder to Bulkhead) BOOM LIFT LINE FAILURE (Bulkhead to Control Valve) BOOM LIFT LINE FAILURE (Bulkhead to Control Valve) BOOM EXTEND LINE FAILURE BOOM EXTEND LINE FAILURE 1. Clear the area of any unneccessary personnel. 1. Clear the area of any unneccessary personnel. 2. Block all four wheels. 2. Block all four wheels.
Emergency Operations Emergency Operations Boom Lift Line (Lift Cylinder to Bulkhead) Boom Extend Line Boom Lift Line (Lift Cylinder to Bulkhead) Boom Extend Line Bulkhead (Ref.) Bulkhead (Ref.) Boom Lift Line (Bulkhead to Control Valve) Boom Lift Line (Bulkhead to Control Valve) Control Valve (Ref.) Control Valve (Ref.) OS0430 OS0430 Figure 58 Figure 58 11. Return to the cab, fasten your seat belt and start the engine. 11. Return to the cab, fasten your seat belt and start the engine. 12.
Emergency Operations Emergency Operations STEP 3 STEP 3 BOOM LOWER LINE FAILURE (Lift Cylinder to Bulkhead) BOOM LOWER LINE FAILURE (Lift Cylinder to Bulkhead) BOOM LOWER LINE FAILURE (Bulkhead to Control Valve) BOOM LOWER LINE FAILURE (Bulkhead to Control Valve) 1. Clear the area of any unnecessary personnel. 1. Clear the area of any unnecessary personnel. 2. Block all four wheels. 2. Block all four wheels. WARNING WARNING DO NOT get under a raised boom unless the boom is blocked up.
Emergency Operations Emergency Operations Bulkhead (Ref.) Bulkhead (Ref.) Faulty Line Removed Faulty Line Removed Faulty Line Removed Faulty Line Removed OS2160 Figure 59 Figure 59 Bulkhead (Ref.) Bulkhead (Ref.) Boom Lift Line Boom Lift Line Boom Lift Line Boom Lift Line OS2170 Figure 60 OS2170 Figure 60 IMPORTANT! Have the vehicle serviced and hoses replaced as soon as the boom has been lowered and the vehicle is in a secure location.
Emergency Operations Emergency Operations 9. Reattach the faulty hose and direct the line so any oil that escapes will be caught by the container. 96 9. Reattach the faulty hose and direct the line so any oil that escapes will be caught by the container. 10. Close the rear cover. 10. Close the rear cover. 11. Check the hydraulic oil level and add oil if needed. 11. Check the hydraulic oil level and add oil if needed. 12. Remove the blocking or support from the outer boom. 12.
Emergency Operations STEP 4 Emergency Operations STEP 4 BOOM RETRACT LINE FAILURE BOOM RETRACT LINE FAILURE 1. Clear the area of any unnecessary personnel. 1. Clear the area of any unnecessary personnel. 2. Block all four wheels. 2. Block all four wheels. WARNING 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. DO NOT get under a raised boom unless the boom is blocked up.
Emergency Operations Emergency Operations 5. Remove the faulty boom retract line (Figure 61). 5. Remove the faulty boom retract line (Figure 61). 6. Temporarily remove the adjacent boom extend line on the opposite side of the extend cylinder. This line can then be used in an emergency situation to lower the boom. 6. Temporarily remove the adjacent boom extend line on the opposite side of the extend cylinder. This line can then be used in an emergency situation to lower the boom. 7.
Emergency Operations Base of Extend Cylinder (Ref.) Boom Extend Line Emergency Operations Base of Extend Cylinder (Ref.) Boom Extend Line OS1140 OS1140 Figure 62 Figure 62 10. Check the hydraulic oil level and add oil if needed. 10. Check the hydraulic oil level and add oil if needed. 11. Return to the cab, fasten your seat belt and start the engine. 11. Return to the cab, fasten your seat belt and start the engine. 12.
General Maintenance General Maintenance General Maintenance General Maintenance Introduction Introduction This section of the manual contains a maintenance schedule and checklist with references to pertinent procedures and instructions. To prevent problems before they occur, follow the maintenance schedule. This section of the manual contains a maintenance schedule and checklist with references to pertinent procedures and instructions.
General Maintenance General Maintenance Maintenance Schedule and Checklist Maintenance Schedule and Checklist 10 Hour Intervals 10 Hour Intervals 10 10 H 20 Drain Fuel/Water Separator Check Engine Coolant Level Check Engine Oil Level Check Hydraulic Oil Level 6A 4A 5A 8A Ref: Check Transmission Oil Level 9A Check Tire Pressure 13A H 20 Drain Fuel/Water Separator Check Engine Coolant Level Check Engine Oil Level Check Hydraulic Oil Level 6A 4A 5A 8A Ref: Inspect Wear Pads Ref:
General Maintenance General Maintenance 250 Hour Intervals 250 Hour Intervals 250 250 Change Engine Oil & Filter (Cummins) Ref: Check Axle Oil Level Check Wheel End Oil Level 11A Lubricate Fittings 1 Change Engine Oil & Filter (Cummins) 10A 12A 5B Ref: Check Transfer Case Oil Level Ref: OS1191 Check Wheel End Oil Level 11A 500 Hour Intervals 102 10A Lubricate Fittings 1 OS1191 500 Hour Intervals 500 Ref: Check Axle Oil Level 12A 5B Ref: Check Transfer Case Oil Level 500 Chang
General Maintenance General Maintenance 1000 Hour Intervals 1000 Hour Intervals 1000 1000 Check Boom Chain Tension Check Fan Belt Ref: 16A / 16B 7A Ref: Change Transfer Case Oil 12B Change Transmission Oil and Filter Change Axle Oil 10B 9B Change Hydraulic Oil and Filter 8B Change Wheel End Oil 11B OS1211 Check Boom Chain Tension Check Fan Belt Ref: 16A / 16B 7A Ref: Change Transfer Case Oil 12B 2000 Hour Intervals Change Transmission Oil and Filter Change Axle Oil 10B 9B Change
General Maintenance General Maintenance 1. Lubrication Points 1. Lubrication Points Lubricate the following grease fittings using Multi-Purpose Grease (MPG) every 250 hours: Lubricate the following grease fittings using Multi-Purpose Grease (MPG) every 250 hours: OS1750 OS1750 A. Hydraulic cylinder pins ...................................... (7 points) A. Hydraulic cylinder pins ...................................... (7 points) B. Drive shaft slip joints & U-Joints B.
General Maintenance General Maintenance 3606 LUBRICATION POINTS 3606 LUBRICATION POINTS (2) PLACES (2) PLACES A A C C F H A E 3 A E 1 B A B 4 E H A 2 (2) PLACES F 2 (2) PLACES D E A E 3 E H B B B B 1 B Current Production Vehicles B A A B Current Production Vehicles B B B B H B B B B B B H OF ARROW VIEW IN DIRECTION B 2 Early Production Vehicles VIEW IN DIRECTION OF ARROW 1 B VIEW IN DIRECTION OF ARROW G OF ARROW 2 VIEW IN DIRECTION OF ARROWS 3 &
General Maintenance General Maintenance 2. Air Cleaner 2. Air Cleaner The operator’s display panel illuminates an indicator light that will alert the operator when it senses restricted air flow to the engine. This indicates the air filter(s) need servicing. NEVER operate the vehicle without the air cleaner assembly and both filters in place. The operator’s display panel illuminates an indicator light that will alert the operator when it senses restricted air flow to the engine.
General Maintenance General Maintenance Carefully cleaning or washing, if done correctly, can extend the life of an element. But you must realize that each time an element is cleaned the dirt holding capacity is reduced and the risk of dirt reaching the clean side of the filter is increased. Filters should never be washed more than six times or retained for more than one years service - whichever comes first. Carefully cleaning or washing, if done correctly, can extend the life of an element.
General Maintenance General Maintenance 6. Position the air cleaner cover in place and secure it by latching the three retaining clips. 6. Position the air cleaner cover in place and secure it by latching the three retaining clips. Air Cleaner Cover Air Cleaner Cover Primary Element Safety Element Air Cleaner Canister Vactuator Valve (Ref.) Safety Element Air Cleaner Canister Vactuator Valve (Ref.
General Maintenance General Maintenance 5. Dry the filter before re-using. Circulate warm air at less than 160° F (57° C). DO NOT use a light bulb to dry the filter. 5. Dry the filter before re-using. Circulate warm air at less than 160° F (57° C). DO NOT use a light bulb to dry the filter. 6. Inspect for holes or tears by looking through the filter toward a bright light. Check for damaged gaskets or metal parts. DO NOT reuse a damaged filter. 6.
General Maintenance General Maintenance Fresh Air Intake Filter Fresh Air Intake Filter Periodically remove the cabs rear panel and inspect the fresh air intake filter (Figure 68). The filter must be cleaned sometimes as often as twice a day, depending on the operating environment. This is done by removing the filter and shaking it. Pressurized air can also be used to blow out dust. The filter will clean outside air when pressurizing the cab. The filter should be replaced when required.
General Maintenance General Maintenance 4. Engine Cooling System 4. Engine Cooling System A. Engine Coolant Level Check (10 Hour Intervals) A. Engine Coolant Level Check (10 Hour Intervals) OS0800 OS0800 1. Level the vehicle, ground the carriage, place the travel select lever in (N) NEUTRAL, engage the parking brake switch and shut off the engine. 1. Level the vehicle, ground the carriage, place the travel select lever in (N) NEUTRAL, engage the parking brake switch and shut off the engine. 2.
General Maintenance General Maintenance B. Drain and Flush Radiator B. Drain and Flush Radiator (2000 Hour Intervals) (2000 Hour Intervals) OS0810 OS0810 1. Level the vehicle, ground the carriage, place the travel select lever in (N) NEUTRAL, engage the parking brake switch and shut off the engine. 1. Level the vehicle, ground the carriage, place the travel select lever in (N) NEUTRAL, engage the parking brake switch and shut off the engine. 2. Unlatch, unlock and open the engine cover.
General Maintenance General Maintenance WARNING WARNING NEVER remove radiator cap while the engine is hot. The cooling system is under pressure. Hot coolant can cause severe burns or eye injury. Wear protective clothing and safety glasses. NEVER remove radiator cap while the engine is hot. The cooling system is under pressure. Hot coolant can cause severe burns or eye injury. Wear protective clothing and safety glasses. 3.
General Maintenance General Maintenance 10. Fill the radiator completely with a 50/50 mixture of ethylene glycol and water. Replace the radiator cap. Add coolant to the overflow bottle until the bottle is 1/2 to 3/4 full. This “overfilling” will compensate for any air in the cooling system. 10. Fill the radiator completely with a 50/50 mixture of ethylene glycol and water. Replace the radiator cap. Add coolant to the overflow bottle until the bottle is 1/2 to 3/4 full.
General Maintenance FULL FULL General Maintenance ADD ADD (PERKINS ENGINE) FULL FULL ADD ADD (CUMMINS ENGINE) (PERKINS ENGINE) (CUMMINS ENGINE) OS0522 OS0522 Figure 72 Figure 72 B. Oil and Filter Change B. Oil and Filter Change (Cummins & Perkins Engine First 50 Hours) (Cummins Engine 250 Hour Intervals) (Perkins Engine 500 Hour Intervals) (Cummins & Perkins Engine First 50 Hours) (Cummins Engine 250 Hour Intervals) (Perkins Engine 500 Hour Intervals) OS0830 OS0830 1.
General Maintenance General Maintenance Oil Fill Cap Oil Fill Cap Dipstick Dipstick Oil Filter Oil Filter Oil Drain Plug Oil Fill Cap Oil Fill Cap Oil Fill Cap (PERKINS ENGINE) Dipstick Oil Filter Dipstick Dipstick Oil Filter Oil Drain Plug (CUMMINS ENGINE) S/N 9179 and Before Oil Fill Cap (PERKINS ENGINE) Oil Filter (Opposite Side of Engine) Oil Drain Plug Oil Drain Plug Oil Filter (Opposite Side of Engine) Dipstick Oil Drain Plug Oil Drain Plug (CUMMINS ENGINE) S/N 9180 and After
General Maintenance General Maintenance 12. Reinstall oil fill cap. Start engine and allow to run for several minutes. 12. Reinstall oil fill cap. Start engine and allow to run for several minutes. 13. Shut off engine. Wait several minutes and check the oil level on the dipstick. Add oil if necessary. DO NOT overfill. 13. Shut off engine. Wait several minutes and check the oil level on the dipstick. Add oil if necessary. DO NOT overfill. 14.
General Maintenance General Maintenance CUMMINS ENGINE: CUMMINS ENGINE: Unlatch, unlock and open the engine cover. Loosen the drain cock (Figure 75) on the underside of the fuel filter and allow all the water to drain into a container until clear fuel is visible. Dispose of properly. Tighten drain cock after draining. Close, latch and lock engine cover. Unlatch, unlock and open the engine cover.
General Maintenance General Maintenance B. Change Fuel Filter B. Change Fuel Filter (500 Hour Intervals) (500 Hour Intervals) OS0870 OS0870 The fuel filter must be changed at shorter intervals with water evidence or contaminated fuel. PERKINS ENGINE: The fuel filter must be changed at shorter intervals with water evidence or contaminated fuel. PERKINS ENGINE: 1. Unlatch, unlock and open the engine cover. 1. Unlatch, unlock and open the engine cover. 2.
General Maintenance General Maintenance CUMMINS ENGINE: CUMMINS ENGINE: 1. Unlatch, unlock and open the engine cover. 1. Unlatch, unlock and open the engine cover. 2. Clean around the fuel filter head (Figure 77). 2. Clean around the fuel filter head (Figure 77). 3. Unscrew the fuel filter and dispose of properly. 3. Unscrew the fuel filter and dispose of properly. 4. Clean the gasket surface of the filter head and replace the o-ring. 4.
General Maintenance General Maintenance C. Replace In-line Fuel Strainer C. Replace In-line Fuel Strainer (500 Hour Intervals) (500 Hour Intervals) 1. Unlatch, unlock and open the engine cover. 1. Unlatch, unlock and open the engine cover. 2. On both Perkins and Cummins engines, the strainer is located down line from the engines lift pump (Figure 78). Loosen the two hose clamps that secure the strainer in place. 2.
General Maintenance General Maintenance D. Bleeding Fuel System 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. 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.
General Maintenance Vent Plug Filter Head High Pressure Line General Maintenance Vent Plug Filter Head Injector OS0731 High Pressure Line Injector OS0731 (PERKINS ENGINE) (PERKINS ENGINE) Figure 79 Figure 79 2. If the fuel system or a component in the system has been drained or run out of fuel continue with Step 2, otherwise skip to Step 3. Ensure that the ignition switch is in the OFF position. Loosen one of the high pressure connections at the injector.
General Maintenance General Maintenance CUMMINS ENGINE: CUMMINS ENGINE: 1. To vent the low pressure lines and fuel filter, open the vent screw located on the filter head. Operate the hand plunger on the lift pump, until fuel flowing from the fitting is free of air. Tighten the vent screw and torque to 7 lb/ft (9 Nm). 1. To vent the low pressure lines and fuel filter, open the vent screw located on the filter head.
General Maintenance General Maintenance WARNING WARNING KEEP CLEAR of spraying fuel. Fuel will spray when venting high pressure fuel lines. The fuel pressure is sufficient to penetrate the skin and cause serious bodily injury. Wear protective clothing and safety glasses. KEEP CLEAR of spraying fuel. Fuel will spray when venting high pressure fuel lines. The fuel pressure is sufficient to penetrate the skin and cause serious bodily injury. Wear protective clothing and safety glasses.
General Maintenance General Maintenance 7. Engine Fan Belt 7. Engine Fan Belt A. Engine Fan Belt Check A. Engine Fan Belt Check (1000 Hour Intervals) (1000 Hour Intervals) OS0880 OS0880 PERKINS ENGINE: PERKINS ENGINE: 1. Ground the carriage, place the travel select lever in (N) NEUTRAL, engage the parking brake switch and shut off the engine. 1. Ground the carriage, place the travel select lever in (N) NEUTRAL, engage the parking brake switch and shut off the engine. 2.
General Maintenance CUMMINS ENGINE: General Maintenance CUMMINS ENGINE: 1. Ground the carriage, place the travel select lever in (N) NEUTRAL, engage the parking brake switch and shut off the engine. 1. Ground the carriage, place the travel select lever in (N) NEUTRAL, engage the parking brake switch and shut off the engine. 2. Unlatch, unlock and open the engine cover. 2. Unlatch, unlock and open the engine cover. 3. Inspect the fan belt. Replace if cracked or frayed. 3. Inspect the fan belt.
General Maintenance General Maintenance 8. Hydraulic Oil and Filter 8. Hydraulic Oil and Filter A. Hydraulic Oil Level Check (10 Hour Intervals) A. Hydraulic Oil Level Check (10 Hour Intervals) OS0660 1. Level the vehicle, ground the carriage, place the travel select lever in (N) NEUTRAL, engage the parking brake switch. 2. Fully retract all hydraulic cylinders and shut off the engine. 2. Fully retract all hydraulic cylinders and shut off the engine. 3. Unlatch, unlock and open the engine cover.
General Maintenance General Maintenance B. Hydraulic Oil & Filter Change B. Hydraulic Oil & Filter Change (First 50 Hours - Filter Only) (1000 Hour Intervals - Oil & Filter) (First 50 Hours - Filter Only) (1000 Hour Intervals - Oil & Filter) OS0840 OS0840 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.
General Maintenance General Maintenance 5. Rotate and remove the filter head (Figure 86). 5. Rotate and remove the filter head (Figure 86). 6. Remove the seal, and the element from the filter head (Figure 86). Dispose of element and seal properly. 6. Remove the seal, and the element from the filter head (Figure 86). Dispose of element and seal properly. 7. Clean the filter head sealing surface. 7. Clean the filter head sealing surface.
General Maintenance General Maintenance 13. Run vehicle and operate all hydraulic functions. Cycle all modes of controls to purge air from the system. 13. Run vehicle and operate all hydraulic functions. Cycle all modes of controls to purge air from the system. 14. Check for leaks. 14. Check for leaks. WARNING WARNING DO NOT run or otherwise operate the vehicle if any hydraulic hose or fitting is found to be leaking or visibly damaged.
General Maintenance General Maintenance B. Transmission Oil & Filter Change B. Transmission Oil & Filter Change (1000 Hour Intervals) (1000 Hour Intervals) OS0950 OS0950 1. Level the vehicle, ground the carriage, place the travel select lever in (N) NEUTRAL and engage the parking brake switch and shut off the engine. 1. Level the vehicle, ground the carriage, place the travel select lever in (N) NEUTRAL and engage the parking brake switch and shut off the engine. 2.
General Maintenance General Maintenance 8. Check the transmission level and add 10W Motor Oil as required following the procedures outlined in “Transmission Oil Level Check” on page 131. 8. Check the transmission level and add 10W Motor Oil as required following the procedures outlined in “Transmission Oil Level Check” on page 131. 9. Close, latch and lock the engine cover. 9. Close, latch and lock the engine cover. 10. Axle Oil 10. Axle Oil A. Axle Oil Level Check A.
General Maintenance B. Axle Oil Change General Maintenance B. Axle Oil Change OS0970 (1000 Hour Intervals) 1. Level the vehicle, ground the carriage, place the travel select lever in (N) NEUTRAL, engage the parking brake switch and shut off the engine. 1. Level the vehicle, ground the carriage, place the travel select lever in (N) NEUTRAL, engage the parking brake switch and shut off the engine. 2. Clean the area around the axle drain plug and the axle fill/level plug (see Figure 89 on previous page).
General Maintenance 4. Add SAE 80W90 or SAE80W140 Oil to bring the oil level up and even with the plug hole. Wheel End Fill/Drain Plug Wheel End General Maintenance 4. Add SAE 80W90 or SAE80W140 Oil to bring the oil level up and even with the plug hole. Wheel End Fill/Drain Plug Wheel End Oil Level Line Oil Level Line OS0710 OS0710 Figure 90 Figure 90 5. Clean and re-install the wheel end fill/drain plug. 5. Clean and re-install the wheel end fill/drain plug. B. Wheel End Oil Change B.
General Maintenance General Maintenance 2. Ground the carriage, place the travel select lever in (N) NEUTRAL, engage the parking brake switch and shut off the engine. 2. Ground the carriage, place the travel select lever in (N) NEUTRAL, engage the parking brake switch and shut off the engine. 3. Clean the area around the wheel end fill/drain plug. Slowly loosen the plug. Hold a receptacle under the wheel end and remove the plug from the wheel end. 3. Clean the area around the wheel end fill/drain plug.
General Maintenance General Maintenance 4. Add SAE 80W90 or 80W140 Oil as required through the oil level hole or oil fill hole. Bring the oil level up and even with the oil level plug hole. 4. Add SAE 80W90 or 80W140 Oil as required through the oil level hole or oil fill hole. Bring the oil level up and even with the oil level plug hole. 5. Clean and re-install the oil level plug and oil fill plug if removed. 5. Clean and re-install the oil level plug and oil fill plug if removed. B.
General Maintenance General Maintenance 13. Wheels and Tires 13. Wheels and Tires A. Tire Air Pressure Check A. Tire Air Pressure Check (10 Hour Intervals) (10 Hour Intervals) OS0900 OS0900 DANGER DANGER LOW TIRE PRESSURE can result in tipover. MAINTAIN proper tire pressure at all times. LOW TIRE PRESSURE can result in tipover. MAINTAIN proper tire pressure at all times. Check all four tires: Check all four tires: 1. Remove the valve stem cap. 1. Remove the valve stem cap. 2.
General Maintenance C. Replacing Tires General Maintenance C. Replacing Tires WARNING WARNING Mis-matched tire sizes may compromise vehicle stability and may result in vehicle tipover. Mis-matched tire sizes may compromise vehicle stability and may result in vehicle tipover. The specified size and ply rating (star rating for radial tires) for this vehicle is 13.00 - 24, 12 PLY. Make sure the replacement tire is of the same size and ply rating (star rating for radial tires) as all the other tires.
General Maintenance General Maintenance 2. Unlatch, unlock and open the engine cover. The battery is located directly underneath the radiator assembly (Figure 95). 2. Unlatch, unlock and open the engine cover. The battery is located directly underneath the radiator assembly (Figure 95). 3. Wearing safety glasses, visually inspect the battery. Check terminals for corrosion. Replace the battery if it has a cracked, melted or damaged case. 3. Wearing safety glasses, visually inspect the battery.
General Maintenance Battery Electrolyte First Aid: General Maintenance Battery Electrolyte First Aid: • External Contact — Flush with water. • External Contact — Flush with water. • Eyes — Flush with water for at least 15 minutes and get medical attention immediately. • Eyes — Flush with water for at least 15 minutes and get medical attention immediately. • Internal Contact — Drink large quantities of water. Follow with Milk of Magnesia, beaten egg or vegetable oil. Get medical attention immediately.
General Maintenance General Maintenance 15. Fuse & Relay Replacement 15. Fuse & Relay Replacement The fuses and relays in this vehicle protect the electrical system. The fuses most often blow if there is a short or grounded wire in the applicable circuit. The fuses will have to be replaced if they blow. If fuses continually blow, check the system for shorts, grounds or defective electrical components. The fuses and relays in this vehicle protect the electrical system.
General Maintenance Vehicles Stamped with S/N 8249 and Before: General Maintenance Vehicles Stamped with S/N 8249 and Before: Hourmeter Hourmeter *Cold Start Neutral Relay/Starter *Cold Start Neutral Relay/Starter Fuel Shut-off Fuel Shut-off Display Panel Display Panel Neutral Sense Main Main Logic Panel Switch Lamps Stabil-TRAK Solenoid *Optional Stabil-TRAK Solenoid Transm. Relay Stabilizer Lock Relay *Optional Horn Steer Solenoids Transm.
General Maintenance General Maintenance Vehicles Stamped with S/N 8250 thru 9398: Vehicles Stamped with S/N 8250 thru 9398: Neutral Relay/Starter Display Panel Logic Panel Neutral Sense *Cold Start Main Neutral Relay/Starter 15 7.5 Main 7.5 7.5 Park Brake Sense Relay 15 7.5 *Switch Lamps 7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5 Park Brake Sense Relay *Aux. Detent Mode Transm. Solenoids 7.5 7.5 7.5 7.5 7.5 7.5 Horn 7.5 7.5 *Aux.
General Maintenance Vehicles Stamped with S/N 9399 and After: Neutral Relay/Starter Vehicles Stamped with S/N 9399 and After: *Headlights & Taillights *Window Motor Logic Panel *Work Lights *Cold Start Main 15 Display Panel 30 Fuel Shut-off Park Brake Sense Relay 20 20 7.5 7.5 7.5 7.5 25 7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5 15 7.5 7.5 15 7.
General Maintenance General Maintenance 16. Boom Chains and Wear Pads 16. Boom Chains and Wear Pads A. Boom Chain Tension Check A. Boom Chain Tension Check (1000 Hour Intervals) (1000 Hour Intervals) OS0940 OS0940 1. Park the vehicle on level ground. Place the travel select lever in (N) NEUTRAL, engage the parking brake switch and raise the boom to a horizontal position. Retract the boom completely and shut the vehicle OFF. 1. Park the vehicle on level ground.
General Maintenance General Maintenance B. Boom Chain Adjustment B. Boom Chain Adjustment (As Required) (As Required) 1. Park the vehicle on level ground. Place the travel select lever in (N) NEUTRAL, engage the parking brake switch and raise the boom to a horizontal position. Retract the boom completely and shut the vehicle OFF. 1. Park the vehicle on level ground. Place the travel select lever in (N) NEUTRAL, engage the parking brake switch and raise the boom to a horizontal position.
General Maintenance General Maintenance 5. Periodically measure the distance between the inner boom and the intermediate boom. Repeat step 4 until the measurement between the inner boom and the intermediate boom (Figure 103) increases to 2.5” (63,5mm). 5. Periodically measure the distance between the inner boom and the intermediate boom. Repeat step 4 until the measurement between the inner boom and the intermediate boom (Figure 103) increases to 2.5” (63,5mm).
General Maintenance General Maintenance D. Wear Pad Replacement D. Wear Pad Replacement (As Wear Pad Indicators Indicate) (As Wear Pad Indicators Indicate) Each boom wear pad is manufactured with a convenient wear pad indicator. This is the angled cut at each end of all wear pads (Figure 104). Each boom wear pad is manufactured with a convenient wear pad indicator. This is the angled cut at each end of all wear pads (Figure 104). Angular Cut (Wear Pad Indicator) .
General Maintenance General Maintenance Storage and Transport Storage Storage and Transport Storage A. Before Storing A. Before Storing Perform the following steps prior to placing the vehicle in storage: Perform the following steps prior to placing the vehicle in storage: 1. Clean the entire vehicle. 1. Clean the entire vehicle. 2. Lubricate all grease fittings as described in “Lubrication Points” on pages 104 & 105. 2.
General Maintenance General Maintenance 5. Refer to “Maintenance Schedule and Check List” on page 101. Perform all the maintenance checks listed under the 10 Hour Intervals. 5. Refer to “Maintenance Schedule and Check List” on page 101. Perform all the maintenance checks listed under the 10 Hour Intervals. 6. Review and familiarize yourself and any other operator with all the safe and proper operating procedures contained in this manual. 6.
Specifications Specifications Specifications Specifications Fluid & Lubrication Capacities Fluid & Lubrication Capacities Engine Crankcase Oil: Engine Crankcase Oil: Capacity with Filter Change Capacity with Filter Change Perkins Turbo............................................................. 9.0 quarts (8,5 liters) Perkins Turbo............................................................. 9.0 quarts (8,5 liters) Cummins Turbo ..................................................... 11.
Specifications Specifications Transmission: Transmission: Capacity with filter change ..................................... 3.4 gallons (12,9 liters) Capacity with filter change ..................................... 3.4 gallons (12,9 liters) Type of Oil ............................................................................10W Motor Oil Type of Oil ............................................................................10W Motor Oil Axles: Axles: Differential Housing Capacity.............
Specifications Specifications Weights Weights Basic Vehicle: Basic Vehicle: Curb Weight...............................................................20,195 lbs (9160 Kg) Curb Weight...............................................................20,195 lbs (9160 Kg) Maximum Rated Capacity: Maximum Rated Capacity: ....................................................................................6,600 lbs (2994 Kg) ....................................................................................
Specifications Specifications Electrical System Electrical System Rating: Rating: ........................................................................... 12V DC Negative Ground ........................................................................... 12V DC Negative Ground Number of Batteries: Number of Batteries: ............................................................................................................. One .................................................................
Specifications Specifications Closed Cab Option - Rear Wiper Motor ........................................7.5 Amp Closed Cab Option - Rear Wiper Motor ........................................7.5 Amp Closed Cab Option - Blower Motor.................................................25 Amp Closed Cab Option - Blower Motor.................................................25 Amp Closed Cab Option - Power Window Motor ....................................30 Amp Closed Cab Option - Power Window Motor ........
Notes Notes Notes 3606 Rev 11/99 Notes 157 3606 Rev 11/99 157
Index Index A D A D Accelerator ...................................... 18 Additional Operators ......................... 4 Air Cleaner .................................... 106 Air Conditioning ............................... 42 Air Pressure .................................. 138 Attachment Reconnect .................... 65 Attachment Removal ....................... 64 Attachment Tilt Mode Switch .......... 21 Axle Oil .......................................... 133 Axle Oil Change .....................
Index H Hazard Classification System ........... 3 Heater ............................................. 42 Horn ................................................ 18 Hourmeter ....................................... 36 How To Pick, Carry & Place A Load .................................. 76 Hydraulic Fluid .......................... 6, 128 Hydraulic Oil & Filter Change ........ 129 Hydraulic Oil Level ........................ 128 I Ignition Switch ................................. 19 Indexing Procedure .....
Index Index Side Tilt Carriage ............................ 74 Slopes ............................................. 11 Stabil-TRAK .................................... 53 Std. Carriage Capacity Chart .......... 71 Starting Travel ................................. 58 Steering Modes ............................... 59 Steering Select Switch .................... 20 Steering Wheel ............................... 18 Stopping Travel ............................... 59 Storage .....................................
Notes Notes Notes Notes
JLG Industries, Inc. JLG Industries, Inc. TRANSFER OF OWNERSHIP TRANSFER OF OWNERSHIP To: JLG, Gradall, Lull and Sky Trak product owner: If you now own, but ARE NOT the original purchaser of the product covered by this manual, we would like to know who you are. For the purpose of receiving safety-related bulletins, it is very important to keep JLG Industries, Inc. updated with the current ownership of all JLG products.
Replacement Manuals Replacement Manuals If the owner/operator or safety manuals that were originally shipped with your vehicle are lost, stolen or need replacement, contact your local distributor for replacement manuals. If 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.
Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA Phone: (717) 485-5161 Customer Support Toll Free: (877) 554-5438 Fax: (717) 485-6417 JLG Worldwide Locations Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA Phone: (717) 485-5161 Customer Support Toll Free: (877) 554-5438 Fax: (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W.
