Document Outline

• 8990465 SkyTrak 6042 Operators Manual
  • Introduction
    • The Manual
    • Replacement Parts
    • Reports
  • Safety Practices
    • Disclaimer
    • Hazard Classification System
      • Signal Word
    • Accident Prevention Tags
      • Figure 1
    • New or Additional Operators
    • Instructional Symbols
    • Hazard Symbols
    • Avoidance Symbols
    • Avoidance Symbols (cont’d)
    • Personal Considerations
      • 1. Seat Belt
      • 2. Clothing and Safety Gear
      • 3. Dismounting
      • 4. Chemical Hazards
        • A. Exhaust Fumes
        • B. Explosive Fuel
        • C. Hydraulic Fluid
        • D. Battery
      • Battery Electrolyte First Aid:
        • 5. Moving Parts Hazard
        • 6. Lowering Boom or Falling Load Hazard
    • Operational Considerations
      • 1. Preparation and Prevention
      • 2. Clearances
      • 3. Visual Obstruction
      • 4. Underground Hazards
      • 5. Electrocution Hazards
      • 6. Carrying Personnel
      • 7. Tip Over Hazard
      • 8. Emergency Exit Rear Window
      • 2
        • Figure 2
        • 9. Tire Pressure
        • 10. Do Not Jump
        • 11. Slopes
        • NOTE: The rear of the vehicle is normally considered the heavy end unless the carriage is fully l...
          • 12. Falling Load Hazard
          • 13. Ventilation
    • Equipment Considerations
      • 2
      • 3
      • 4
      • 5
      • 6
      • 7
      • NOTE: Hazard/Emergency Information related decals, with part numbers, are available free of charg...
        • Figure 3
        • 8
        • 9
        • 10
        • 11
        • 12
        • 13
      • NOTE: Hazard/Emergency Information related decals, with part numbers, are available free of charg...
        • Figure 4
  • Operation
    • Operator Controls
      • Accelerator Pedal
        • (Figure 5)
      • Service Brake Pedal
        • (Figure 5)
      • Steering Wheel
        • (Figure 5)
      • Horn Button
        • (Figure 5)
          • Figure 5
      • Ignition Switch
        • (Figure 6)
          • Figure 6
      • Steering Select Switch
        • (Figure 7)
          • Figure 7
      • Park Brake Switch
        • (Figure 8)
          • Figure 8
      • Neutral Lock Lever
        • (Figure 9)
          • Figure 9
      • Travel Select Lever
        • (Figure 10)
          • Figure 10
        • NOTE: The Travel Select Lever must be in the (N) NEUTRAL position to permit engine starting and w...
      • Gear Select Lever
        • (Figure 11)
          • Figure 11
      • Recommended Gear/Speed for Various Load/Travel Conditions
      • Load Size
      • Surface
      • Gear
      • Speed
        • No Load
        • Smooth
        • 4th*
        • 0 to 20 mph (0 to 32 km/h)
        • Improved
        • 3rd
        • 0 to 14 mph (0 to 23 km/h)
        • Rough
        • 2nd
        • 0 to 6 mph (0 to 9,7 km/h)
        • Load
        • Smooth
        • 3rd
        • 0 to 14 mph (0 to 23 km/h)
        • up to 3,500 lbs
        • Improved
        • 2nd
        • 0 to 6 mph (0 to 9,7 km/h)
        • (up to 1.588 kg)
        • Rough
        • 2nd
        • 0 to 6 mph (0 to 9,7 km/h)
        • Load
        • Smooth
        • 3rd
        • 0 to 14 mph (0 to 23 km/h)
        • 3,500 to 6,000 lbs
        • Improved
        • 2nd
        • 0 to 6 mph (0 to 9,7 km/h)
        • (1.588 to 2.721 kg)
        • Rough
        • 1st
        • 0 to 3.5 mph (0 to 5,6 km/h)
          • Boom Control Lever
            • (Figure 12)
              • Figure 12
          • Attachment Tilt and Frame Sway Control Lever
            • (Figure 13)
              • Figure 13
          • Seat Belt
            • (Figure 14)
              • 1. Grasp both free ends of the belt and make certain that the belt webbing is not twisted or enta...
              • 2. With your back straight in the seat, couple both ends of the belt.
              • 3. With the belt buckle as low on your body as possible, pull the free end of the belt to shorten...
              • Figure 14
                • 4. To release the belt latch, depress the red button (Figure 14, 1) on a 2 inch seat belt (2) or ...
          • Operator’s Seat Adjustment
            • (Figure 15)
              • A. Fore and Aft Adjustment
              • B. Suspension Adjustment
              • C. Backrest Angle Adjustment
                • Figure 15
    • Instruments and Indicators
      • Hourmeter
        • (Figure 16)
      • Fuel Gauge
        • (Figure 16)
          • Figure 16
      • Instrument Cluster Light Test
        • (Figure 17)
          • Figure 17
      • Function Indicator Lights
        • A. Stabil-TRAK Indicator Light
          • Figure 18
        • B. Park Brake Light
        • C. High Beam Light
        • D. Turn Signal Light
          • Figure 19
      • Warning Indicator Lights
        • A. Engine Coolant Temperature Warning Indicator Light
        • B. Transmission Temperature Warning Indicator Light
          • Figure 20
        • C. Hydraulic Oil Temperature Warning Indicator Light
          • Figure 21
        • D. Engine Oil Pressure Warning Indicator Light
        • E. Alternator Charging Warning Indicator Light
          • Figure 22
      • Frame Level Indicator
        • (Figure 23)
        • NOTE: Maximum frame sway is 10˚ in either direction.
          • Figure 23
      • Boom Angle Indicator
        • (Figure 24)
          • Figure 24
      • Rear View Mirrors
        • (Figure 25)
          • Figure 25
    • Optional Controls
      • Auxiliary Attachment Control Lever
        • (Figure 26)
          • Figure 26
      • Worklight Switch (Front, Rear & Boom Worklights)
        • (Figure 27)
          • Figure 27
      • Beacon Light Switch
        • (Figure 28)
          • Figure 28
      • Worklight Switch (with Optional Road Lights)
        • (Figure 29)
          • Figure 29
      • Emergency Flashers
        • (Figure 30)
          • Figure 30
      • Turn Signals
        • (Figure 31)
      • Parking Lights, Headlights & High/Low Beam Switch
        • (Figure 31)
          • Figure 31
      • Windshield Wiper Control
        • (Figure 32)
      • 1
        • Figure 32
        • Roof Wiper Control
          • (Figure 33)
      • 1
        • Figure 33
        • Windshield & Roof Washer Control
          • (Figure 33)
        • Cab Heater & Fan Control
          • (Figure 34)
        • To heat the cab:
        • To defrost the cab:
      • 3
        • Figure 34
        • Rear Window Latch
          • (Figure 35)
          • NOTE: In an emergency situation, the operator can exit through the rear window opening by removin...
            • Figure 35
        • Door Latches
          • (not pictured)
        • Door Window Latch
          • (not pictured)
    • Pre-Operation Inspection
      • 1. Check safety belt for damage. Check for frayed or cut seat belt webbing, damaged buckles or lo...
      • 2. Check all four tires and rims for damage. Check for proper tire pressure, add air if required....
      • 3. Check and add engine oil if required. This procedure is explained in greater detail on page121.
      • 4. Check and add transmission oil if required. This procedure is explained in greater detail on p...
      • 5. Check the cooling system overflow bottle for coolant. Add coolant if required. This procedure ...
      • 6. Check the hydraulic oil level sight glass and add hydraulic oil if required. This procedure is...
      • 7. Visually inspect the battery for cleanliness. Check the terminals for corrosion. Check the cab...
      • 8. Walk around the vehicle and check for oil leakage as well as damaged or missing parts. Make an...
      • 9. Check ALL lighting systems (if so equipped) for proper operation.
      • 10. Adjust rear view mirrors as required to obtain proper field of vision to the rear.
      • 11. Test the back-up alarm and horn for proper operation.
      • 12. Check condition of cab glass (if so equipped), looking for cracks or other damage.
    • 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.
      • 3. Fasten the seat belt.
      • 4. Make sure the parking brake switch is ENGAGED.
      • 5. Place the travel select lever in (N) NEUTRAL and move the neutral lock lever to NEUTRAL LOCK p...
      • 6. Turn the ignition switch to the START position (fully clockwise) to crank the engine. Release ...
      • 7. After the engine starts, run engine at partial throttle for 30 to 60 seconds before operating ...
      • 8. Move the Neutral Lock Lever to the (D) DRIVE position before you start operating.
      • 9. Disengage the parking brake switch before you start operating.
    • Cold 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.
      • 3. Fasten the seat belt.
      • 4. Make sure the parking brake switch is ENGAGED.
      • 5. Place the travel select lever in (N) NEUTRAL and move the neutral lock lever to NEUTRAL LOCK p...
      • 6. Turn the ignition switch to the START position to crank the starter.
      • 7. As the engine starts, release the ignition switch to the RUN position. Depress the accelerator...
      • 8. The engine oil pressure warning indicator light should go OFF within five seconds after starti...
      • 9. If using starting fluid with mechanical or electrical metering equipment:
      • 10. If using starting fluid without metering equipment:
      • Figure 36
      • Figure 37
        • 11. The engine oil pressure warning indicator light should go OFF within 5 seconds after starting...
    • Jump Starting
      • 1. Connect the positive (+) jumper cable to the positive (+) post of the discharged battery.
      • 2. Connect the other end of the positive (+) jumper cable to the positive (+) post of the booster...
      • 3. Connect one end of the negative (-) jumper cable to the negative (-) post of the booster battery.
      • 4. Make the final cable connection to the furthest point from the battery.
      • 5. Follow the steps in “Normal Starting” on page55.
      • 6. Remove the jumper cables in the reverse order of their connection (i.e. negative cable ground ...
    • Refueling
      • Fuel Types
      • Fuel Cap
        • (Figure 38)
          • Figure 38
    • Operating
      • Understanding the Stabil-TRAK System
      • Free Pivot Mode
        • (Figure 39)
          • Figure 39
      • Locked Mode
        • (Figure 40)
          • Figure 40
      • Final Positioning Mode
        • (Figure 41)
          • Figure 41
      • Starting Travel
        • 1. Enter the operator cab, fasten the seat belt, start the engine, apply the service brake pedal ...
        • 2. Rotate the twist grip (Figure 42, 1) of the range select lever to 1st gear.
        • 3. Move the travel select lever (Figure 43, 1) to (F) FORWARD to travel in a forward direction or...
        • 4. Slowly remove your foot from the service brake pedal and press the accelerator pedal to start ...
        • Figure 42
        • Figure 43
      • Changing Travel Direction
        • 1. Stop the vehicle by applying the service brakes.
        • 2. Grasp the travel select lever (Figure 44, 1), pull it toward the steering wheel (2), then move...
        • Figure 44
      • Shifting Gears
        • 1. Rotate the twist grip of the gear select lever to the next desired gear. The transmission has ...
        • 2. Use first gear for highest torque and pulling power. Use higher gears for higher ground speed....
      • Recommended Gear/Speed for Various Load/Travel Conditions
      • Load Size
      • Surface
      • Gear
      • Speed
        • No Load
        • Smooth
        • 4th*
        • 0 to 20 mph (0 to 32 km/h)
        • Improved
        • 3rd
        • 0 to 14 mph (0 to 23 km/h)
        • Rough
        • 2nd
        • 0 to 6 mph (0 to 9,7 km/h)
        • Load
        • Smooth
        • 3rd
        • 0 to 14 mph (0 to 23 km/h)
        • up to 3,500 lbs
        • Improved
        • 2nd
        • 0 to 6 mph (0 to 9,7 km/h)
        • (up to 1.588 kg)
        • Rough
        • 2nd
        • 0 to 6 mph (0 to 9,7 km/h)
        • Load
        • Smooth
        • 3rd
        • 0 to 14 mph (0 to 23 km/h)
        • 3,500 to 6,000 lbs
        • Improved
        • 2nd
        • 0 to 6 mph (0 to 9,7 km/h)
        • (1.588 to 2.721 kg)
        • Rough
        • 1st
        • 0 to 3.5 mph (0 to 5,6 km/h)
          • NOTE: Shifting to the next higher gear may be done while the vehicle is in motion.
          • Stopping Travel
            • 1. Apply the service brake pedal and downshift the vehicle to a lower gear if necessary to slow t...
            • 2. Move the travel select lever to (N) NEUTRAL and engage the parking brake switch. For longer st...
          • Steering Modes
            • (Figure 45)
              • Figure 45
          • Four Wheel Steer Indexing
          • 1. Four Wheel Steering
            • (Figure 46)
              • Figure 46
          • 2. Front Wheel Steering
            • (Figure 47)
              • Figure 47
          • 3. Crab Steering
            • (Figure 48)
              • Figure 48
          • 4. Maximum Fork Sweep
            • (Figure 49)
              • Figure 49
          • Leveling Frame
          • Quick Attach
          • Attachment Removal
            • 1. Place the travel select lever in (N) NEUTRAL, come to a complete stop, move the neutral lock l...
            • 2. Extend the boom approximately 10 feet (3 meters) and tilt the carriage backward.
            • 3. Exit the vehicle using the hand holds.
            • NOTE: If you are removing a standard carriage with forks, spread the forks apart on the carriage ...
              • 4. Raise the quick attach pin lock lever (Figure 50, 1) and pull out the pin (2) at the bottom of...
              • Figure 50
                • 5. Return to the operators compartment, fasten the seat belt and lower the attachment to the grou...
                • 6. Lower and then retract the boom until the attachment pivot pins have disconnected from the att...
          • Attachment Reconnect
            • 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 attac...
            • 4. Raise the boom until the attachment pivot pins have seated fully in the hooks of the attachment.
            • 5. Tilt the attachment up slightly. The quick attach link should be tight against the rear of the...
            • 6. Place the travel select lever in (N) NEUTRAL, move the neutral lock lever to NEUTRAL LOCK posi...
            • 7. Lift the quick attach lever. Insert the quick attach pin completely through the attachment and...
            • 8. Return to the cab, fasten the seat belt and resume operation.
    • Using The Capacity Chart
      • Figure 51
      • Figure 52
        • 1. Weight of the load being lifted.
        • 2. Height of the structure where the load is to be placed.
        • 3. Distance where the load will ultimately be placed in front of the front tires.
      • Reading The Capacity Chart
        • 1. The operator has placed the load onto the forks, fully retracted the boom, positioned the vehi...
        • 2. The operator then determines that:
        • 3. After applying the height of the structure and the distance of load placement away from the ve...
      • Standard Carriage Capacity Chart
        • Figure 53
      • Side Tilt Carriage Capacity Chart
        • Figure 54
      • Swing Carriage Capacity Chart
        • Figure 55
      • 12 Foot Truss Boom Capacity Chart
        • Figure 56
    • Fork Ratings
      • Figure 57
    • How To Pick, Carry & Place A Load
    • Elevating Personnel
      • Preparation and Setup
        • 1. Make sure that the work platform is securely attached to the quick attach or forks. Follow the...
        • 2. Make sure the platform, carriage and forks are secured to prevent them from pivoting from side...
        • 3. Ensure the vehicle has a firm footing and is level.
        • 4. Place the travel select lever in (N) NEUTRAL and move the neutral lock lever to the (N) NEUTRA...
        • 5. Engage the parking brake switch. Blocking the wheels is also recommended.
        • 6. Level the platform in both the side-to-side and front-to-back directions before use.
      • Elevating Personnel
        • 1. Make sure there are no overhead obstructions or electrical wires above the platform before lif...
        • 2. A trained operator must operate the controls from the operators compartment and must remain wi...
        • 3. Always position the platform in the travel position (approximately one foot above ground level...
      • Capacity Limitations
    • Using Other Attachments
    • Shut-Off
      • 1. Bring the vehicle to a complete stop using the service brakes.
      • 2. Park the vehicle on level ground.
      • 3. Place the travel select lever in (N) NEUTRAL, move the neutral lock lever to NEUTRAL LOCK posi...
      • 4. Lower the boom and ground the carriage.
      • 5. Turn the ignition key to the OFF position and remove the key.
  • Emergency Operations
    • Towing A Disabled Vehicle
      • 1. Remove the load from the vehicle.
      • 2. Block all four wheels to help prevent the vehicle from moving after the parking brake is disab...
      • 3. Remove the six capscrews (Figure 58, 1) securing the transmission covers (2) to the frame. Rem...
      • Figure 58
        • 4. Position the towing vehicle in place. Attach any chains needed to secure the disabled vehicle.
        • 5. Attach a remote portable hydraulic pressurizing unit to the parking brake gauge port (Figure 5...
      • 2
        • Figure 59
          • 6. Turn the key switch to the ON position (with the engine not running), release the park brake s...
          • 7. Pressurize the park brake with the pressurizing unit. Close the pump needle valve.
          • 8. Clear the area of all unnecessary personnel.
          • 9. Carefully remove the wheel blocks from each of the four tires. Tow the vehicle to a secure loc...
    • Emergency Boom Lowering
      • Part I
      • Loss of Engine Power or Hydraulic Pump Failure
        • 1. Clear the area around the vehicle of all personnel.
        • 2. Place the travel select lever in (N) NEUTRAL, move the neutral lock lever to NEUTRAL LOCK posi...
        • 3. Block all four wheels.
        • 4. Section off a large area under the boom with string or tape to restrict any personnel from ent...
        • 5. Temporarily block up or support the outer boom so it cannot be lowered.
        • 6. If the load is in a position where it can be removed safely, completely remove the load from t...
        • 7. Place an accident prevention tag on both the ignition switch and steering wheel. Refer to “Acc...
      • Part ll - Hydraulic Line Failure
      • 2
        • Figure 60
        • STEP 1
          • 1. Clear the area of any unnecessary personnel.
          • 2. Place the travel select lever in (N) NEUTRAL, move the neutral lock lever to NEUTRAL LOCK posi...
          • 3. Block all four wheels.
          • 4. If the load is in a position where it can be removed safely, completely remove the load from t...
          • 5. Temporarily block up or support the outer boom.
          • 6. Replace the failed hydraulic line (Figure 61) with a new part.
          • 7. Check the hydraulic oil level, add oil if needed.
          • 8. Remove the blocking or support from the outer boom.
          • 9. Return to the cab, fasten your seat belt and start the engine.
          • 10. Tilt the carriage and/or attachment upward if necessary for clearance before retracting the b...
          • 11. Slowly retract the boom.
          • 12. Slowly lower the boom and ground the carriage and/or attachment.
          • 13. Shut off the engine.
          • 14. Completely remove the load from the carriage and/or attachment if you haven’t already done so.
          • 15. Return to the cab, fasten your seat belt and start the engine.
          • 16. Cycle the lift/lower and extend/retract cylinders several times to bleed air from the system....
          • 17. Recheck the hydraulic oil level. Add oil if necessary.
      • 2
        • Figure 61
        • STEP 2
          • 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 posi...
          • 3. Block all four wheels.
          • 4. Place a container under the failed hose to catch any hydraulic oil that may escape during this...
          • 5. Return to the cab, fasten your seat belt and start the engine.
          • 6. Slowly retract the boom.
          • 7. Slowly lower the boom and ground the carriage and/or attachment.
          • 8. Shut off the engine.
          • 9. Completely remove the load from the carriage and/or attachment.
          • 10. Place an accident prevention tag on both the ignition switch and steering wheel. Refer to “Ac...
          • 11. Have the vehicle serviced immediately. Replace any failed hydraulic lines (Figure 62) with ne...
          • 12. Return to the cab, fasten your seat belt and start the engine.
          • 13. Cycle the lift/lower cylinder several times to bleed air from the system. Check for leaks.
          • 14. Recheck the hydraulic oil level. Add oil if necessary.
          • 15. Transfer any waste oil to a container with a cover and label as used oil. Dispose of properly.
      • 2
        • Figure 62
        • STEP 3
          • 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 posi...
          • 3. Block all four wheels.
          • 4. Temporarily block up or support the outer boom.
          • 5. If the load is in a position where it can be removed safely, completely remove the load from t...
          • 6. Place a 10 gallon (40 liter) container under the vehicle to catch any hydraulic oil that will ...
          • NOTE: If a replacement hose is not available, the adjacent boom lift line (Figure 63) can be used...
            • 7. Remove the individual failed boom lower line (Figure 63, 1) from the circuit.
            • 8. Remove and temporarily reposition the adjacent boom lift line (Figure 63, 2) in place of the f...
            • 9. Check the hydraulic oil level and add oil if needed.
            • 10. Remove the blocking or support from the outer boom.
            • 11. Return to the cab, fasten your seat belt and start the engine.
            • Figure 63
              • 12. Tilt the carriage and/or attachment upward if necessary for clearance before retracting the b...
              • 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. Cycle the lift/lower cylinder several times to bleed air from the system. Check for leaks.
              • 20. Transfer the waste oil to a container with a cover and label as used oil. Dispose of properly.
              • 21. Recheck the hydraulic oil level. Add oil if necessary.
        • STEP 4
          • 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 posi...
          • 3. Block all four wheels.
          • 4. If the load is in a position where it can be removed safely, completely remove the load from t...
          • 5. Place a 10 gallon (40 liter) container under the vehicle to catch any hydraulic oil that will ...
          • NOTE: If a replacement hose is not available, the adjacent boom extend line (Figure 64) can be us...
            • 6. Remove the failed boom retract line (Figure 64, 1) from the circuit.
            • 7. Remove and temporarily reposition the adjacent boom extend line (Figure 64, 2) in place of the...
            • 8. Check the hydraulic oil level and add oil if needed.
            • 9. Return to the cab, fasten your seat belt and start the engine.
            • 10. Tilt the carriage and/or attachment upward if necessary for clearance before retracting the b...
            • 11. SLOWLY RETRACT the boom.
            • 12. SLOWLY LOWER the boom and ground the carriage and/or attachment.
            • 13. Completely remove the load from the carriage and/or attachment if you haven’t already done so.
            • 14. Have the vehicle serviced immediately.
            • 15. Replace any faulty hydraulic lines.
            • 16. Return to the cab, fasten your seat belt and start the engine.
            • 17. Cycle the extend/retract cylinder several times to bleed air from the system. Check for leaks.
            • 18. Transfer the waste oil to a container with a cover and label as used oil. Dispose of properly.
            • 19. Recheck the hydraulic oil level. Add if necessary.
      • 2
        • Figure 64
  • General Maintenance
    • General Maintenance
      • NOTE: The Lubrication (Figure 65, 1) and Maintenance Chart (2) decals are located inside the righ...
      • 1
        • Figure 65
        • NOTE: The engine side cover props can be manually pinned in the open position. To manually pin th...
    • Maintenance Schedule And Checklist
      • 1. Lubrication Points
        • A. Carriage pivot pins (2 points)
        • B. Attachment tilt cylinder pins (2 points)
        • C. Boom attachments (all points)
        • D. Extend Chain Sheave (1 point)
        • E. Retract Chain Sheave (1 point)
        • F. Hydraulic cylinder pins (12 points)
        • G. Drive shaft slip joints (3 points)
        • H. Boom pivot pin (2 points)
        • I. Axle U-Joints (8 points)
        • J. Axle pivot pins (4 points)
        • K. Extend cylinder pins (2 points)
      • NOTE: Shorten the lubrication interval on all lube points when operating in severe conditions.
      • Lubrication Points
        • Figure 66
        • 2. Air Cleaner & Restriction Indicator
        • A. Filter Check
          • (10 Hour Intervals)
            • 1. Ground the carriage, place the travel select lever in (N) NEUTRAL, move the neutral lock lever...
            • 2. Unlock and open the left rear engine access door to access air cleaner restriction indicator (...
          • NOTE: Depress button (Figure 67, 3) on top of indicator to reset indicator after servicing element.
            • Figure 67
              • 3. Remove dust from vacuator valve (Figure 68, 1) by squeezing bottom of vacuator to allow loose ...
            • Figure 68
        • B. Element: Change
          • 1. Pull the air cleaner cover lock (Figure 69, 1) OUT, turn the air cleaner cover (2) counter-clo...
          • Figure 69
            • 2. Remove the primary element (Figure 70, 1). Inspect element for damage. Damaged elements should...
            • 3. Thoroughly clean the interior of the air filter canister (Figure 70, 2) and vacuator valve (3).
            • 4. If replacing the inner safety element (Figure 70, 4) at this time, carefully slide the inner s...
            • 5. Slide the new primary element over the inner safety element making sure the sealing edge is fl...
            • 6. Position canister cover (Figure 70, 5) in place, turn clockwise to lock into position and secu...
          • Figure 70
        • C. Air Intake System-Inspection
          • (1000 Hour Intervals)
            • 3. Engine Cooling System
        • A. Engine Coolant Level Check
          • (10 Hour Intervals)
            • 1. Level the vehicle, ground the carriage, place the travel select lever in (N) NEUTRAL, move neu...
            • 2. Unlock and open the right rear engine access door. Check level of coolant in overflow bottle (...
            • Figure 71
        • B. Drain And Flush Radiator
          • (2000 Hour Intervals)
            • 1. Level the vehicle, ground the carriage, place the travel select lever in (N) NEUTRAL, move neu...
            • 2. Unlock and open the right rear engine access door. Allow time for the engine to cool down befo...
            • 3. Unlock and open rear radiator door. Remove radiator cap. Through the right engine access door ...
            • Figure 72
          • NOTE: Attach a hose to the petcock to allow draining directly into a container.
            • 4. Allow coolant to drain from the radiator. Detach line from bottom of coolant overflow bottle a...
            • 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 ...
            • 6. Remove the coolant drain plug (Figure 73, 1) and drain any coolant from the engine block. Repl...
            • Figure 73
              • 7. Transfer the coolant into a properly labelled container. Dispose of properly.
              • 8. Reconnect line to bottom of overflow bottle and close petcock on the radiator. Reconnect heate...
              • 9. Fill radiator completely with 50/50 mixture of ethylene glycol and water. Total System Capacit...
              • 10. Clean dirt and debris from radiator fins and core, if required.
              • 11. Start engine and run vehicle to normal operating temperature and then shut OFF the engine. Wh...
              • 12. Allow engine to cool to ambient temperature. Check radiator coolant level and top off complet...
              • 13. Overflow bottle should be 1/4 to 1/2 full. If it is not, add coolant to overflow bottle. Clos...
            • 4. Engine Oil And Filter
        • A. Oil Level Check
          • (10 Hour Intervals)
            • 1. Level the vehicle, ground the carriage, place the travel select lever in (N) NEUTRAL, move neu...
            • 2. Unlock and open right rear engine access door.
            • 3. Remove dipstick (Figure 74, 1) and check mark on dipstick. Oil should be within the crosshatch...
            • Figure 74
              • 4. If oil is low, remove oil fill cap (Figure 75, 1) and add 15W40 motor oil that is equal to API...
            • Figure 75
        • B. Oil And Filter Change
          • (First 50 Hours) (250 Hour Intervals)
            • 1. Operate the engine until warm (approximately 5 minutes).
            • 2. Level the vehicle, ground the carriage, place the travel select lever in (N) NEUTRAL, move neu...
            • 3. Place receptacle under engine oil pan drain.
            • 4. Remove drain plug from engine oil pan.
            • 5. Allow oil to drain completely into a receptacle. Transfer the oil to a container with a cover ...
            • 6. Unlock and open the left engine access door. Remove oil filter (Figure 76, 1). A strap or chai...
            • Figure 76
              • 7. Clean filter sealing surface. Make sure the o-ring seal from the filter comes off the sealing ...
          • NOTE: The filter o-ring may stick to the filter head. Make sure the old o-ring is removed before ...
            • 8. Apply a thin coat of clean engine oil to seal on new filter.
            • 9. Install the new oil filter and hand tighten 1/2 turn after initial contact.
            • 10. Clean and re-install oil pan drain plug.
            • 11. Unlock and open the right engine access door.
            • 12. Remove oil fill cap (Figure 77, 1) and add 15W40 motor oil that is equal to API, CD or CE spe...
            • 13. Clear all personnel from area. Start engine and run for several minutes.
            • 14. Stop engine. Let the oil drain back for a few minutes. Check oil level on dipstick (Figure 77...
            • 15. Add oil to bring oil level up to the FULL mark in the crosshatched area. Replace dipstick and...
            • Figure 77
            • 5. Engine Fuel System
        • A. Drain Water From Fuel Water Separator/Filter
          • (10 Hour Intervals)
            • Figure 78
        • B. Change Fuel Filter
          • (500 Hour Intervals)
            • 1. Unlock and open the right rear engine access door.
            • 2. Clean around the fuel filter head (Figure 79, 1).
            • 3. Unscrew the fuel filter (Figure 79, 2) and dispose of properly.
            • 4. Clean the gasket surface of the filter head and replace the o-ring.
            • Figure 79
              • 5. Fill the new fuel filter with clean No. 2 diesel fuel.
              • 6. Lubricate the o-ring seal with clean No. 2 diesel fuel.
              • 7. Install the fuel-filled filter and hand tighten. DO NOT overtighten.
          • NOTE: Mechanical over-tightening may distort the threads or damage the sealing ring.
            • 8. Close and lock the right rear engine access door.
        • C. Replace In-line Fuel Strainer
          • (500 Hour Intervals)
            • 1. Unlock and open the right rear engine access door.
            • 2. The in-line fuel strainer (Figure 80, 1) is located down line from the engines lift pump (2). ...
            • 3. Remove the old in-line fuel strainer and dispose of properly.
            • 4. Install the new in-line fuel strainer (Figure 80, 1) with arrow pointing toward the lift pump ...
            • 5. Assemble the hoses to the in-line fuel strainer and tighten the hose clamps.
            • 6. Remove air from the fuel system (see “Bleeding Fuel System” on page128).
            • 7. Close and lock the right rear engine access door.
            • Figure 80
        • D. Bleeding Fuel System
          • 1. To vent the low pressure lines and fuel filter (Figure 81, 1), open the vent screw (2) located...
          • 2. Operate the hand plunger (Figure 81, 4) on the lift pump (5) until fuel flowing from the fitti...
          • 3. Tighten the vent screw (Figure 81, 2) and torque to 7 lb-ft (9 Nm).
          • Figure 81
            • 1. To vent the high pressure fuel lines (Figure 82, 1), loosen one fitting at the injector (2).
            • 2. Turn the ignition key to the START position and crank the engine for a maximum of 15 seconds o...
            • 3. Tighten the fitting. Torque to 22 lb-ft (30 Nm).
            • 4. Repeat step 1- step 3 for each fitting until the engine runs smoothly.
            • 5. With the engine running, visually check for leaks. Turn ignition switch OFF.
          • Figure 82
          • 6. Engine Fan Belt
        • A. Engine Fan Belt Check
          • 1. Ground the carriage, place the travel select lever in (N) NEUTRAL, move the neutral lock lever...
          • 2. Unlock and open the left rear engine access door.
          • 3. Inspect the fan belt (Figure 83, 1). Replace if cracked or frayed.
          • 4. This engine is equipped with an automatic belt tensioner (Figure 83, 2). Inspect the tensioner...
          • 5. Spin the fan and check for wobble or excessive play. Maximum play should be .006 inch (0,15 mm).
          • 6. To install the fan belt (Figure 83, 1); first position the belt over the fan pulley (3), crank...
          • 7. Close and lock the left rear engine access door.
          • Figure 83
          • 7. Hydraulic Oil and Filter
        • A. Hydraulic System Oil
      • ISO Grade 46 Hydraulic Oil
      • MIL-L-2104C 10W Motor Oil*
        • Gulf Harmony 46 AW
        • Amoco Rykon 46
        • Mobil DTE-25
        • Arco Duro AW S-215
        • Shell Tullus 46
        • Benz Petraulic 46-7C
        • Sun Sunvis 821 WR
        • Chevron AW 46
        • Texaco Rando HD 46
        • Citgo Pacemaker XD-46
        • Castrol Deusol CRD
        • Esso Essolube D-3HP
        • Esso Essolube XD-3
        • Castrol Agricastrol HDD
        • Shell Rimula CT
        • Shell Rimula X
        • Shell Rimula TX
        • * 5W20 Motor Oil may be substituted for -30˚ F to 70˚ F (-34 to 21˚ C) only
          • B. Hydraulic Oil Level Check
            • (10 Hour Intervals)
              • 1. Be sure all cylinders are fully retracted and oil is at room temperature.
              • 2. Level the vehicle, ground the carriage, place travel select lever in (N) NEUTRAL, move the neu...
              • 3. Check level of hydraulic oil in tank at the sight gauge (Figure 84, 1) on the back side of the...
              • 4. The oil level should be visible in the gauge window.
              • 5. If it is not, add ISO-46 or MIL-L-2104C oil (see table on page131).
                • a. Remove the four capscrews (Figure 84, 3) holding the hydraulic oil tank cover (4) to the tank,...
                • b. Turn the hydraulic oil cap (Figure 84, 5) and remove from the filler neck. Add hydraulic oil a...
              • 6. Install hydraulic oil cap (Figure 84, 5). Reposition the cover (4) on the tank (2) and secure ...
              • Figure 84
          • C. Hydraulic Oil & Filter Change
            • (First 50 Hours)
            • (Filter Only)
              • 1. Level the vehicle, ground the carriage, place travel select lever in (N) NEUTRAL, move the neu...
              • 2. Fully retract all cylinders and shut OFF the engine.
              • 3. Remove the four capscrews (Figure 85, 1) holding the hydraulic oil tank cover (2) to the tank ...
              • Figure 85
                • 4. Clean area around filter head (Figure 86, 1). Loosen but do not remove the nuts that secure th...
                • 5. Rotate and remove the filter head (Figure 86, 1).
                • 6. Remove the seal (Figure 86, 3) and the element (4) from the filter head (1). Dispose of properly.
                • 7. Clean the filter head sealing surfaces.
                • 8. Place a receptacle under the hydraulic reservoir magnetic drain plug. The receptacle must be l...
                • 9. Re-install magnetic drain plug into the reservoir.
                • 10. Re-install the top seal (Figure 86, 3) and push a new filter element (4) all the way onto the...
                • 11. Remove reservoir cap (Figure 86 5) and fill the reservoir with ISO- 46 or MILL2104C Oil (se...
                • 12. Reassemble the hydraulic oil tank cover and tighten the hardware securely.
                • 13. Run vehicle and operate all hydraulic functions. Cycle all modes of controls to purge air fro...
                • 14. Check for leaks.
              • Figure 86
              • 8. Transmission Oil and Filter
      • APPROVED UNIVERSAL TRACTOR FLUIDS
        • JOHN DEERE
        • FORD / NEW HOLLAND
        • MASSEY FERGUSON
        • CHEVRON
        • JDM J20C (HY-GARD)
        • ESN-M2C134-D (HYDRAULIC OIL134)
        • M-1141 (PERMATRAN III)
        • CHEVRON 1000 THF
          • A. Transmission Oil Level Check
            • (10 Hour Intervals)
              • 1. Level the vehicle, ground the carriage, place travel select lever in (N) NEUTRAL, move neutral...
              • 2. Check oil level with engine running at idle and oil at normal operating temperature.
              • 3. Remove transmission dipstick (Figure 87, 1) through access hole (2) in transmission covers (3)...
              • 4. Add Universal Tractor Fluid to transmission as required to bring up to full mark.
              • Figure 87
          • B. Transmission Oil & Filter Change
            • (First 50 Hours) (Filter Only)
              • 1. Level the vehicle, ground the carriage, place travel select lever in (N) NEUTRAL, move neutral...
              • 2. Remove the six capscrews (Figure 88, 1) securing the transmission covers (2) to the frame. Rem...
              • Figure 88
                • 3. Allow the transmission to cool.
                • 4. Place a receptacle under the transmission drain plug (Figure 89, 1). Remove the drain plug and...
                • 5. Clean and re-install the drain plug (Figure 89, 1) into the transmission housing.
                • 6. Remove the filter (Figure 89, 2) from the filter mount on the front side of the transmission (...
                • 7. Apply a thin film of clean Universal Tractor Fluid to the new filter gasket. Carefully install...
              • Figure 89
                • 8. Remove the dipstick (Figure 89, 4) and fill with Universal Tractor Fluid approximately 2.6 gal...
                • 9. Check the transmission level and add Universal Tractor Fluid as required following the procedu...
                • 10. Reassemble the transmission covers and secure in place with the six capscrews, washers and lo...
              • 9. Axle Oil
          • A. Axle Oil Level Check
            • (250 Hour Intervals)
      • APPROVED UNIVERSAL TRACTOR FLUIDS
        • JOHN DEERE
        • FORD / NEW HOLLAND
        • MASSEY FERGUSON
        • CHEVRON
        • JDM J20C (HY-GARD)
        • ESN-M2C134-D (HYDRAULIC OIL134)
        • M-1141 (PERMATRAN III)
        • CHEVRON 1000 THF
          • 1. Level the vehicle, ground the carriage, place the travel select lever in (N) NEUTRAL, move neu...
          • 2. Clean the area around the axle fill plug (Figure 90, 1) and the axle level plugs (2) on the op...
          • 3. Add Universal Tractor Fluid to bring the oil level up and even with the plug holes. See chart ...
          • 4. Re-install the axle fill plug (Figure 90, 1) and axle level plugs (2).
          • Figure 90
          • B. Axle Oil Change
            • (First 50 Hours) (1000 Hour Intervals)
            • NOTE: At the 1000 Hour Interval Oil Change also inspect the brake disk wear. Refer to “Brake Disk...
              • 1. Level the vehicle, ground the carriage, place the travel select lever in (N) NEUTRAL, move neu...
              • 2. Clean the area around the axle drain plug (Figure 90, 3), the axle fill plug (1) and the axle ...
              • 3. Place a receptacle under the axle drain plug. Remove the plug from the axle housing and allow ...
              • 4. Transfer the oil to a container with a cover and label the container as used oil. Dispose of p...
              • 5. Clean off the axle drain plug and re-install. Remove the axle fill plug and the axle level plu...
              • 6. Fill the axle with Universal Tractor Fluid through the axle fill hole until the oil level is e...
              • 7. Reassemble the level plugs (Figure 90, 2) using new o-rings.
              • 8. Re-install the axle fill plug (Figure 90, 1) into axle housing.
              • 10. Brake Disk Inspection
          • A. Brake Disk Wear Check
            • (1000 Hour Intervals)
              • A. Front Axle
                • 1. Block all four wheels to help prevent the vehicle from moving after the parking brake is disab...
                • 2. Remove the six capscrews (Figure 91, 1) securing the transmission covers (2) to the frame. Rem...
                • Figure 91
                  • 3. Attach a remote portable hydraulic pressurizing unit to the parking brake gauge port (Figure 9...
        • 2
          • Figure 92
            • 4. Turn the key switch to the ON position (with the engine not running), release the parking brak...
            • 5. Pressurize the parking brake with the pressurizing unit. Close the needle valve on the pressur...
            • 6. Working through the level plug hole (Figure 93, 1), carefully use a screwdriver to spread the ...
          • Figure 93
            • 7. Using a feeler gauge, check the gap (Figure 94, 1) between the brake disks (2). If the gap is ...
          • NOTE: If the brake disks are worn beyond .167" (4,25 mm), the brake disk must be replaced on both...
            • 8. Repeat step 6 and step 7 for the other side of the axle.
            • 9. Continue with step 6 of “B. Axle Oil Change” on page139.
            • Figure 94
            • B. Rear Axle
              • 1. Working through the level plug hole (Figure 93, 1), carefully use a screwdriver to spread the ...
              • 2. Using a feeler gauge, check the gap (Figure 94, 1) between the brake disks (2). If the gap is ...
          • NOTE: If the brake disks are worn beyond .167" (4,25 mm), the brake disk must be replaced on both...
            • 3. Repeat step 1 and step 2 for the other side of the axle.
            • 4. Continue with step 6 of “B. Axle Oil Change” on page139.
            • 11. Wheel End Oil
      • APPROVED UNIVERSAL TRACTOR FLUIDS
        • JOHN DEERE
        • FORD / NEW HOLLAND
        • MASSEY FERGUSON
        • CHEVRON
        • JDM J20C (HY-GARD)
        • ESN-M2C134-D (HYDRAULIC OIL134)
        • M-1141 (PERMATRAN III)
        • CHEVRON 1000 THF
          • A. Wheel End Oil Level Check
            • (250 Hour Intervals)
              • 1. Position the vehicle on level ground, move the vehicle forward or backward enough to ensure th...
              • 2. Ground the carriage, place the travel select lever in (N) NEUTRAL, move neutral lock lever to ...
              • 3. Clean the area around the wheel end fill/drain plug (Figure 95, 2). Slowly remove the plug. Ch...
              • 4. Add Universal Tractor Fluid to bring the oil level up and even with the plug hole (Figure 95, ...
              • 5. Clean and re-install the wheel end fill/drain plug (Figure 95, 2).
              • Figure 95
          • B. Wheel End Oil Change
            • (First 50 Hours) (1000 Hour Intervals)
              • 1. Position the vehicle on level ground, move the vehicle forward or backward enough to ensure th...
              • Figure 96
                • 2. Ground the carriage, place the travel select lever in (N) NEUTRAL, move neutral lock lever to ...
                • 3. Clean the area around the wheel end fill/drain plug (Figure 96, 2). Slowly loosen the plug. Ho...
                • 4. Allow the oil to drain completely into the receptacle. Transfer the oil to a container with a ...
                • 5. Reposition the vehicle so the wheel end fill/drain plug is positioned horizontally (refer back...
                • 6. Fill the wheel end with Universal Tractor Fluid to the level of the drain plug. See chart of a...
                • 7. Clean and re-install the wheel end fill/drain plug (Figure 96, 2).
              • 12. Wheels and Tires
          • A. Tire Air Pressure Check
          • (10 Hour Intervals)
            • 1. Remove the valve stem cap.
            • 2. Check tire pressure using a good quality gauge. You cannot tell if a tire is properly inflated...
            • 3. Add air if required. Fill the tire(s) to:
            • 4. DO NOT overinflate.
            • 5. Replace the valve stem cap.
          • B. Wheel Lug Nut Torque Check
            • (First 50 Hours)
              • 1. Wire brush the area around the lug nuts if necessary. There are separate lockwashers (Figure 9...
              • 2. Using the torque sequence (Figure 97, A thru H) from the chart below, alternately check the to...
              • Figure 97
          • C. Replacing Tires
            • 13. Battery
              • 1. Level the vehicle, ground the carriage, place the travel select lever in (N) NEUTRAL, move neu...
              • 2. Unlock and open the rear door. The battery (Figure 98, 1) is located inside the frame directly...
              • 3. Wearing safety glasses, visually inspect the battery. Check terminals for corrosion. Replace t...
              • 4. Close and lock rear door.
              • Figure 98
          • Battery Electrolyte First Aid:
            • 14. Fuse and Relay Replacement
              • Figure 99
              • Figure 100
            • 2
            • 3
            • 4
            • 5
            • 6
            • 7
            • 8
            • 9
            • 10
            • 11
            • 12
            • 13
            • 14
            • 15
            • 16
            • 17
              • 15. Boom Chains and Wear Pads
          • A. Boom Chain Tension Check
            • (First 50 Hours) (1000 Hour Intervals)
              • 1. Park the vehicle on level ground. Place the travel select lever in (N) NEUTRAL, move neutral l...
              • 2. Fully extend the boom, then retract it 2" (51 mm) (one inch per section). Turn the vehicle OFF.
              • 3. Measure the sag (Figure 101, 1) in the top boom extend chains (2) between the bottom of the ch...
              • Figure 101
                • 4. Start the vehicle, retract the boom completely and turn the vehicle OFF.
                • 5. Go to the back of the vehicle and remove the rear cover from the back of the boom.
                • 6. Check the measurement (Figure 102, 1) from the top rear edge of the intermediate boom (2) to t...
            • NOTE: If the measurement is less than 9.62" (244 mm) the boom may require extensive adjustment an...
              • Figure 102
                • 7. If the measurement is more than 10.12" (257 mm), tighten the retract chain locknut (Figure 103...
              • Figure 103
                • 8. Start the vehicle and cycle the boom in and out several times. Then with the boom horizontal, ...
                • 9. Recheck the measurement at the rear of the boom between the top rear edge of the intermediate ...
            • NOTE: If, by adjusting the retract locknut, you cannot get the measurement within the range of 9....
              • 10. Start the vehicle and cycle the boom in and out several times. With the boom horizontal, full...
              • 11. Measure the sag (Figure 104, 1) in the top boom extend chains (2) between the bottom of the c...
              • Figure 104
          • B. Top Boom Chain Tension Adjustment
            • (As required)
            • NOTE: Always perform the “Boom Chain Tension Check” starting on page152 before adjusting the boo...
              • 1. Park the vehicle on level ground. Place the travel select lever in (N) NEUTRAL, move neutral l...
              • 2. Adjust the top extend boom chains (Figure 105, 1) by tightening the locknuts (Figure 106, 1) l...
              • Figure 105
                • 3. Equal chain tension can be checked by the position of the yoke (Figure 105, 2) on the outer bo...
              • Figure 106
                • 4. Start the vehicle and cycle the boom in and out several times. With the boom horizontal, fully...
                • 5. Measure the chain sag. Acceptable boom chain sag is between 1.5" (38 mm) and 2.5" (64 mm). If ...
            • NOTE: If the top boom extend chain sag cannot be adjusted within the acceptable range of 1.5" (38...
              • 6. Replace the rear outer boom cover.
          • C. Boom Chain Inspection
            • (250 Hour Intervals)
              • 1. Park the vehicle on level ground. Place the travel select lever in (N) NEUTRAL, place the neut...
              • 2. Fully extend the boom until the extend chain is taut. Shut the engine off.
              • 3. Inspect the retract chains every 1000 hours of operation. Refer to the Service Manual for prop...
              • 4. Inspect the chains for the following conditions:
              • Figure 107
              • Figure 108
              • Figure 109
              • Figure 110
          • D. Chain Lubrication
            • (1000 Hour Intervals)
          • E. Wear Pad Inspection
          • (50 Hour Intervals)
          • F. Wear Pad Replacement
            • (As Wear Pad Indicators Indicate)
              • Figure 111
    • Storage and Transport
    • Storage
      • A. Before Storing
        • 1. Clean the entire vehicle.
        • 2. Lubricate all grease fittings as described in “Lubrication Points” on page112.
        • 3. Prepare the engine for storage (refer to the engine manual).
        • 4. Apply rust inhibiting lubricant to all exposed hydraulic cylinder rods.
        • 5. Disconnect the battery cables. Remove the battery from the vehicle and store in a dry place wh...
        • 6. If the ambient temperature is expected to drop below freezing at anytime during the storage pe...
        • 7. Preferably, store the vehicle inside where it will remain dry. If it must be stored outside, p...
      • B. Removing From Storage
        • 1. Reinstall a properly charged battery. Secure the hold-down bracket and attach cables.
        • 2. Change the engine oil and filter to remove condensation or other residuals.
        • 3. If the vehicle has been stored for two years or more, drain the coolant from the engine block ...
        • 4. Wipe off any rust inhibiting lubricant that was applied to vehicles hydraulic cylinder rods pr...
        • 5. Refer to “Maintenance Schedule And Checklist” on page107. Perform all the maintenance checks ...
        • 6. Review and familiarize yourself and any other operator with all the safe and proper operating ...
    • Transport
      • Figure 112
      • NOTE: The user assumes all responsibility for choosing the proper method of transportation, and t...
  • Test Procedures
    • Stabil-TRAK System Test
      • Stabil-TRAK System Test Instructions
      • Stabil-TRAK System Test Procedures
        • a. Place the vehicle on a level surface with 0˚ sway.
        • b. Have the boom fully retracted and horizontal.
        • c. Place an 8" (203 mm) wood or cement block in front of the front left tire.
        • d. Enter the vehicle.
        • e. Fasten the seat belt.
        • f. Turn the key to the RUN position.
        • g. Check to be sure the Stabil-TRAK light is OFF. (See page36 for the location of the light in t...
        • a. Start the engine.
        • b. Turn the parking brake switch OFF.
        • c. Move the range select lever to (1) FIRST gear.
        • d. Move the travel select lever to the (F) FORWARD position.
        • e. Drive the vehicle up on the block.
        • f. Use the frame sway control to level the vehicle back to 0˚.
        • a. Depress the service brake pedal.
        • b. Move the travel select lever to the (N) NEUTRAL position.
        • c. Raise the boom to exactly 60˚. The Stabil-TRAK light should come ON when the boom angle is at ...
        • a. Use your left foot to depress the service brake pedal.
        • b. Move the travel select lever to the (R) REVERSE position.
        • c. Ease your left foot partially off the service brake pedal make sure that the Stabil-TRAK light...
        • d. With your right foot, increase the engine RPM slightly, as necessary, just enough to back the ...
        • a. Keep the service brake pedal depressed.
        • b. Move the travel select lever to the (N) NEUTRAL position.
        • c. Take your foot off the service brake pedal. The Stabil-TRAK light should remain ON and the fro...
        • a. With the travel select lever in the (N) NEUTRAL position, engage the parking brake switch.
        • b. Move the travel select lever to the (F) FORWARD position. The Stabil-TRAK light should remain ...
        • a. With the parking brake switch ON, move the travel select lever to the (N) NEUTRAL position.
        • b. Lower the boom to exactly 45˚.
        • c. Frame sway the vehicle no more than 5˚ to the left.
        • d. Frame sway the vehicle back to 0˚.
        • e. Frame sway the vehicle no more than 5˚ to the right.
        • NOTE: Observe that frame sway will be slower than normal during this test.
          • f. The Stabil-TRAK light should remain ON and the front left tire should remain off the ground. T...
          • g. Frame sway back toward 0˚, leaving the vehicle swayed to the right approximately 1˚ to 2˚.
          • a. Depress the service brake pedal.
          • b. Disengage the parking brake switch.
          • c. With the range select lever in (1) FIRST gear, move the travel select lever to the (R) REVERSE...
          • d. Release the service brake pedal to deactivate the Stabil-TRAK system.
          • e. The Stabil-TRAK light should go OFF.
          • f. The front left tire should return to the ground while the vehicle travels in reverse.
          • g. Depress the service brake pedal to stop the vehicle.
          • a. With the service brake pedal depressed and the boom angle at exactly 45˚, move the range selec...
          • b. Move the travel select lever to (F) FORWARD.
          • c. Release the service brake pedal to deactivate the Stabil-TRAK system. The Stabil-TRAK light sh...
          • d. Slowly drive the vehicle forward against the block to stop the vehicle from moving forward.
          • e. With the front left tire against the block, frame sway the vehicle no more than 5˚ to the left.
          • f. Check that the front left tire remains on the ground. It is normal for the front left tire to ...
          • g. Frame sway the vehicle back to 0˚ and pause briefly.
          • h. Frame sway the vehicle no more than 5˚ to the right.
          • i. Check that the front right tire remains on the ground. It is normal for the front right tire t...
          • j. Frame sway the vehicle back to 0˚.
          • k. Depress the service brake pedal.
          • l. Shift the travel select lever to (N) NEUTRAL.
          • m. Lower the boom.
    • Parking Brake/Transmission De-Clutch Test Procedures
      • a. Place the vehicle on a level surface.
      • b. Clear the area in front and behind the vehicle of any obstacles.
      • c. Fasten your seat belt.
      • d. Turn the key and start the engine.
      • e. With the parking brake applied, move the range select lever to (1) FIRST gear.
      • f. Move the travel select lever to (F) FORWARD.
      • g. Depress the throttle pedal fully. The unit should not move.
      • a. Remove your foot from the throttle pedal.
      • b. Move the travel select lever to (R) REVERSE.
      • c. Depress the throttle pedal fully. The unit should not move.
      • d. Remove your foot from the throttle pedal.
      • e. Move the travel select lever to (N) NEUTRAL.
      • a. Disengage the parking brake.
      • b. Move the travel select lever to (F) FORWARD.
      • c. Move the unit slowly in a forward direction (approximately 1 mph [1,6 kmh]).
      • d. Engage the parking brake. The unit should stop abruptly.
      • a. With the rated load of 6,000 lbs (2.721 Kg) on the forks, drive the vehicle forward up a 15% g...
      • b. Stop the vehicle using the service brakes, apply the park brake, shift the transmission into N...
      • c. Take your foot off the service brake pedal. The vehicle should not move.
      • d. Apply the service brakes, shift the transmission into REVERSE (R), move the park brake switch ...
      • e. Repeat “Test 3” by backing up the grade and checking the park brake holding performance.
      • 1. Immediately remove the vehicle from service.
      • 2. Block all four wheels to prevent the vehicle from moving.
      • 3. Place the accident prevention tags on the ignition switch and the steering wheel (Figure 113).
      • 4. Service the parking brake immediately or contact your local OmniQuip Authorized Service Center...
      • Figure 113
    • Four Wheel Steer Indexing Procedure
      • 1. With the steering select switch (Figure 114, 1) in the Four Wheel Steer position (2), turn the...
      • 2. While holding the steering wheel full left, toggle the steer select switch to the Front Wheel ...
      • 3. Toggle the steer select switch back to Four Wheel Steer position (Figure 114, 2) and turn the ...
      • 4. Toggle the steer select switch back to Front Wheel Steer position (Figure 114, 3) and steer th...
      • 5. Toggle the switch to the Four Wheel Steer position (Figure 114, 2) and return to center.
      • Figure 114
  • Specifications
    • Fluid & Lubrication Capacities
      • Engine Crankcase Oil:
      • Fuel Tank:
      • Cooling System:
      • Hydraulic System:
      • Transmission:
      • Axles:
      • Wheel Ends:
    • Tires
      • Air Pressure:
      • Tire Ballast (Minimum per Tire):
      • Tire Footprint Area (w/full load):
      • Maximum Ground Pressure (w/full load):
    • Weights
      • Basic Vehicle:
    • Vehicle Dimensions
      • With Standard 13.00 - 24 Tires:
    • Electrical System
      • Fuse Ratings:
      • Relay Ratings:
    • Engine
      • Cummins:
  • Index
  • Accident Prevention Tags