Document Outline

• 8990502_C_10054_SkyTrak_Operator
  • TOC
  • Introduction
    • The Manual
    • Replacement Parts
    • Reports
  • Safety Practices
    • Disclaimer
    • Hazard Classification System
      • Signal Word
    • Accident Prevention Tags
    • New or Additional Operators
    • Instructional Symbols
    • Hazard Symbols
    • Avoidance Symbols
    • Avoidance Symbols (cont’d)
    • Personal Considerations
      • 1. Seat Belt
    • Always fasten the seat belt before starting the engine.
      • 2. Clothing and Safety Gear
    • DO NOT wear loose clothing or jewelry that can get caught on controls or moving parts. Wear prote...
      • 3. Dismounting
    • DO NOT get off the vehicle until you:
      • 4. Chemical Hazards
        • A. Exhaust Fumes
        • B. Explosive Fuel
        • C. Ether or High Energy Starting Aids
        • D. Hydraulic Fluid
        • E. Batteries
      • Battery Electrolyte First Aid:
        • 5. Moving Parts Hazard
    • DO NOT place limbs near moving parts. Severing of any body part can result.
    • Turn OFF engine and wait until fan and belts stop moving before servicing.
      • 6. Lowering Boom or Falling Load Hazard
    • DO NOT get under a raised boom unless it is blocked up safely. Always empty the attachment of any...
    • NEVER allow anyone to walk or stand under the boom. A lowering boom or falling load can result in...
      • Operational Considerations
        • 1. Preparation and Prevention
    • 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) NE...
    • Holes, obstructions, debris and other worksite hazards can cause death or serious personal injury...
    • Prevent accidents when you move the vehicle around the worksite. Know the rules for movement of p...
    • DO NOT operate the vehicle unless all hazard and instructional decals are in place and readable. ...
      • 2. Clearances
    • Look out for and avoid other personnel, machinery and vehicles in the area. Use a spotter if you ...
    • Always check boom clearances carefully before driving underneath door openings, bridges, etc.
    • Always check for power lines when raising the boom. Beware of overhead wires. Contact with electr...
      • 3. Visual Obstruction
    • Dust, smoke, fog, etc. can decrease vision and cause an accident. Always stop or slow the vehicle...
    • Where the load will obstruct the operator’s vision, it is recommended that the vehicle be operate...
      • 4. Underground Hazards
    • Know the location of all underground hazards before operating this vehicle in a new area or works...
      • 5. Electrocution Hazards
    • NEVER operate this vehicle in an area where overhead power lines, overhead or underground cables,...
      • 6. Elevating Personnel
    • Use only a compliant work platform meeting the ASME B56.6 standards for lifting and lowering pers...
    • Death or serious personal injury can occur if these rules are not obeyed. Riders can fall and be ...
    • For other specific precautions, see “Elevating Personnel” on page90.
      • 7. Tip Over Hazard
    • Traveling with the boom raised is dangerous and can cause tipover. Keep the boom as low as possib...
    • Keep the vehicle under control at all times. When negotiating turns, slow down and turn the steer...
    • DO NOT exceed the rated lift capacity of the vehicle as structural damage and unstable conditions...
    • To ensure that the vehicle is positioned in the most stable condition before operating an attachm...
    • If the vehicle cannot be leveled using the frame sway control, reposition the vehicle.
    • Frame swaying left or right with the boom raised above horizontal is dangerous. Always use the fr...
    • Lowering outriggers over holes or on soft terrain can compromise the stability of the vehicle whi...
    • NEVER attempt to move the vehicle after the outriggers have been lowered.
      • 8. Emergency Exit Rear Window
    • The rear window (1) in the enclosed cab can be used as an emergency exit by removing the latch pi...
      • 9. Tire Pressure
    • MAINTAIN proper tire pressures at all times. An underpressurized tire(s) adversely affects vehicl...
    • To ensure proper vehicle stability, check all four tire pressures before operating the vehicle.
      • 10. Do Not Jump
    • If a vehicle ever becomes unstable and starts to tip over:
    • Indecision and trying to escape from a tipping vehicle can result in death or serious personal in...
      • 11. Slopes
    • DO NOT park the vehicle on an incline and leave it unattended.
      • NOTE: The rear of the vehicle is normally considered the heavy end unless the carriage is fully l...
        • 12. Falling Load Hazard
    • DO NOT exceed the total rated load capacity of the specific type fork being used. Each fork is st...
    • DO NOT downshift at a high ground speed. Sudden slowing can cause the load to drop off the forks.
      • 13. Ventilation
    • Sparks from the electrical system and the engine exhaust can cause an explosion. DO NOT operate t...
    • Carbon monoxide fumes from the engine exhaust can cause suffocation in an enclosed area. Good ven...
      • Equipment Considerations
    • DO NOT by-pass or disconnect any electrical or hydraulic circuits. Consult the JLG Service Depart...
    • DO check for frayed or cut seat belt webbing, damaged buckles or loose mounting brackets. Replace...
    • ALWAYS wear a seat belt when operating the vehicle.
    • DO check tire pressure on all four tires. Add air if required.
    • DO check the condition of all four rims. Check for bent flanges and/or bead mounting areas.
    • DO check the parking brake/transmission de-clutch operation. Refer to the test procedures on page...
    • DO keep all non-skid surfaces clean and free of debris. Replace if worn, damaged or missing.
    • DO check the condition of decals. Replace decals if missing, damaged or illegible. The following ...
      • 2
      • 3
      • 4
      • 5
      • 6
      • 7
      • 8
      • 9
      • 10
      • 11
      • 12
      • 13
      • 14
      • 15
  • Operation
    • Operator Controls
      • Accelerator Pedal
        • NOTE: The accelerator pedal is also used to activate the Cummins ECM Diagnostic system. With the ...
      • Service Brake Pedal
      • Steering Wheel
      • Horn Button
      • Ignition Switch
      • Steering Select Switch
      • Park Brake Switch
      • Neutral Lock Lever
      • Travel Select Lever
        • NOTE: The Travel Select Lever must be in the (N) NEUTRAL position to permit engine starting and w...
      • Gear Select Lever
      • 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 4,500 lbs
        • Improved
        • 2nd
        • 0 to 6 mph (0 to 9,7 km/h)
        • (up to 2.041 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)
        • 4,500 to 8,000 lbs
        • Improved
        • 2nd
        • 0 to 6 mph (0 to 9,7 km/h)
        • (2.041 to 3.629 kg)
        • Rough
        • 1st
        • 0 to 3.5 mph (0 to 5,6 km/h)
        • Load
        • Smooth
        • 2nd
        • 0 to 6 mph (0 to 9,7 km/h)
        • 8,000 to 10,000 lbs
        • Improved
        • 1st
        • 0 to 3.5 mph (0 to 5,6 km/h)
        • (3.629 to 4.536 kg)
        • Rough
        • 1st
        • 0 to 3.5 mph (0 to 5,6 km/h)
          • Boom Control Lever
          • Attachment Tilt and Frame Sway Control Lever
          • Outrigger Control Switches
            • NOTE: Outrigger position is critical to allow full extension of the boom. Refer to “Understanding...
              • 1. Before locating the vehicle at the lift point, observe that the landing area for the outrigger...
              • 2. Position the vehicle at the lift point and level the vehicle to zero degrees (0˚). If the vehi...
              • 3. Lower the right outrigger until the right front tire just starts to raise and maintains this p...
              • 4. Lower the left outrigger until the left front tire just starts to raise and again maintains th...
              • 5. Frame sway the vehicle back to level (0˚) if necessary.
          • Seat Belt
            • 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 the retractable end or the male end of the belt in...
            • 3. With the belt buckle as low on your body as possible, pull the retractable end of the belt or ...
            • 4. To release the belt latch, depress the red button (1) or lift the black cover (2) of the buckl...
          • Operator’s Seat Adjustment
            • A. Fore and Aft Adjustment
            • B. Suspension Adjustment
            • C. Backrest Angle Adjustment
    • Instruments and Indicators
      • Hourmeter
      • Fuel Gauge
      • Instrument Cluster Light Test
      • Function Indicator Lights
        • A. Stabil-TRAK Indicator Light
    • The Stabil-TRAK light (8) will come ON when the system has been activated. The rear axle will loc...
    • The Stabil-TRAK Light will also come ON when the Boom/Outrigger Interlock system is active.
    • With the boom above a 40˚ angle and traveling in a forward or reverse drive gear, the Stabil-TRAK...
    • ALWAYS be sure the Stabil-TRAK system is functioning properly when operating vehicle. Refer to “U...
      • B. Park Brake Light
    • The park brake light (1) illuminates any time the park brake is applied and the ignition switch i...
      • C. High Beam Light
    • (used with optional road light package only)
    • The high beam light (2) illuminates when the road option headlights are on full (high) beam and w...
      • D. Turn Signal Light
    • (used with optional road light package only)
    • The turn signal light (3) will illuminate and flash when the road option turn signals are activat...
      • Warning Indicator Lights
        • A. Engine Coolant Temperature Warning Indicator Light
        • B. Transmission Temperature Warning Indicator Light
        • C. Hydraulic Oil Temperature Warning Indicator Light
        • D. Engine Oil Pressure Warning Indicator Light
        • E. Alternator Charging Warning Indicator Light
      • Function Indicator Lights
        • A. Engine Air-Intake Heater Indicator
        • NOTE: This indicator light may come ON when the engine is running to indicate that the post heat ...
          • B. Engine Function Indicator Lights
      • Frame Level Indicator
        • NOTE: Maximum frame sway is 10˚ in either direction.
      • Boom Angle Indicator
      • Rear View Mirrors
      • Optional Controls
        • Auxiliary Attachment Control Lever
        • Worklight Switch (Front, Rear & Boom Worklights)
        • Beacon Light Switch
        • Worklight Switch (with Optional Road Lights)
        • Emergency Flashers
        • Turn Signals
        • Parking Lights, Headlights & High/Low Beam Switch
        • Windshield Wiper Control
        • Skylight Wiper Control
        • Windshield & Skylight Washer Control
        • Cab Heater & Fan Control
        • To heat the cab:
        • To defrost the cab:
        • Rear Window Latch
          • NOTE: In an emergency situation, the operator can exit through the rear window opening by removin...
        • 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 page127.
        • 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. Walk around the vehicle and check for oil leakage as well as damaged or missing parts. Make an...
      • 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...
      • 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 batteries.
        • 5. Follow the steps in “Normal Starting” on page58.
        • 6. Remove the jumper cables in the reverse order of their connection (i.e. negative cable ground ...
      • Refueling
        • Fuel Types
        • Fuel Cap
      • Stabil-TRAK System
        • Understanding the Stabil-TRAK System
        • Free Pivot Mode
        • Locked Mode
        • Slow Pivot Mode
        • Understanding the Boom/Outrigger Interlock System
        • Extend Interlock Mode
        • Outrigger Interlock Mode
      • Operating
        • Starting Travel
          • 1. Enter the operator cab, fasten the seat belt, start the engine, apply the service brake pedal ...
          • 2. Rotate the twist grip of the range select lever (1) to 1st gear.
          • 3. Move the travel select lever (2) to (F) FORWARD to travel in a forward direction or to (R) REV...
          • 4. Slowly remove your foot from the service brake pedal and press the accelerator pedal to start ...
        • Changing Travel Direction
          • 1. Stop the vehicle by applying the service brakes.
          • 2. Grasp the travel select lever, pull it toward the steering wheel, then move the lever up or do...
        • 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 4,500 lbs
          • Improved
          • 2nd
          • 0 to 6 mph (0 to 9,7 km/h)
          • (up to 2.041 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)
          • 4,500 to 8,000 lbs
          • Improved
          • 2nd
          • 0 to 6 mph (0 to 9,7 km/h)
          • (2.041 to 3.629 kg)
          • Rough
          • 1st
          • 0 to 3.5 mph (0 to 5,6 km/h)
          • Load
          • Smooth
          • 2nd
          • 0 to 6 mph (0 to 9,7 km/h)
          • 8,000 to 10,000 lbs
          • Improved
          • 1st
          • 0 to 3.5 mph (0 to 5,6 km/h)
          • (3.629 to 4.536 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
            • Four Wheel Steer Indexing
            • 1. Four Wheel Steering
            • 2. Front Wheel Steering
            • 3. Crab Steering
            • 4. Maximum Fork Sweep
            • 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 (1) and pull out the pin (2) at the bottom of the quick ...
                • 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 (1). Insert the quick attach pin (2) completely through the attach...
              • 8. Return to the cab, fasten the seat belt and resume operation.
      • Using The Capacity Chart
        • 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 - Outriggers Up
        • Standard Carriage Capacity Chart - Outriggers Down
        • Side Tilt Carriage - Outriggers Up
        • Side Tilt Carriage - Outriggers Down
        • Swing Carriage - Outriggers Up
        • Swing Carriage - Outriggers Down
        • 15 Foot Truss Boom - Outriggers Up
        • 15 Foot Truss Boom - Outriggers Down
        • 3 Foot Truss Boom w/Winch - Outriggers Up
        • 3 Foot Truss Boom w/Winch - Outriggers Down
      • Fork Ratings
      • How To Pick, Carry & Place A Load
      • Elevating Personnel
        • Defining Platforms For Elevating Personnel
          • 1. The platform floor must have a slip resistant surface not more than 8"(200mm) above the norm...
          • 2. The platform floor dimensions shall not exceed:
          • a. Two times the load center distance as listed on the load chart that is attached to the vehicle...
    • b. Width of the platform shall not be wider than the width of the vehicle, measured across the lo...
    • c. Minimum space requirements for each person on the platform shall not be less than 18" (450 mm)...
      • 3. The platform shall have a 4" (100 mm) minimum high toe plate around the perimeter of the platf...
      • 4. Protection must be provided for the personnel on the work platform from any pinch points or mo...
      • 5. Information prominently indicated on the work platform shall include:
      • a. Maximum work load including personnel and equipment.
    • b. Weight of the empty platform.
      • 6. Provide a means to securely mount and attach the platform so it can:
      • a. Only be centered laterally on the vehicle and retained against the vertical face of the forks,...
    • b. Prevent the platform from inadvertent pivoting.
      • 7. The platform must have a restraining means such as a guardrail or a means of securing personne...
      • 8. The guardrail or similar structure shall have a nominal height to the platform floor of 42" (1...
      • 9. The guardrail shall be capable of withstanding a concentrated horizontal force of 200 lb (890 ...
      • 10. A body belt and lanyard is to have an attaching point for freedom of movement, and its length...
      • 11. Lanyards, when provided, shall be arranged so as not to cause a tripping hazard.
      • 12. Body belts, when provided, should have a width of at least 1.75 in. (44mm).
      • 13. Structural safety factor - all load supporting structural elements of the work platform shall...
      • Capacity Limitations
      • Preparation and Set-up
        • 1. DO NOT alter or modify the work platform in any manner.
        • 2. Make sure that the work platform is securely attached to the quick attach or forks. Follow the...
        • 3. Make sure the platform, carriage and forks are secured to prevent them from pivoting from side...
        • 4. On side tilt or swing carriages, the carriage must be centered and/ or leveled horizontally an...
        • 5. Ensure the vehicle has a firm footing and is level.
        • 6. Be sure the vehicle is in a level position (side to side) before any operation is begun. Use t...
        • 7. Place the travel select lever in the (N) NEUTRAL position and move the neutral lock lever to t...
        • 8. Engage the parking brake switch. Blocking the wheels is also recommended.
        • 9. Level the platform in both the side-to-side and front-to-back directions before use.
        • 10. Before lifting or lowering personnel, be sure the vehicle lifting mechanism operates smoothly...
        • 11. Be sure any lift limiting devices and latches are functioning properly.
        • 12. Any body belt, lanyard or deceleration devices which have sustained any deformation or damage...
        • 13. Before elevating personnel, the area around and under the work platform should be marked to w...
        • 14. Protection must be provided for the personnel on the work platform from any pinch points or m...
        • 15. Provide any overhead protection device as required by worksite conditions or if requested by ...
      • 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. Personnel aboard the work platform must maintain a firm footing at all times.
        • 4. Be certain the personnel and related equipment on the platform do not exceed the available spa...
        • 5. The platform shall be lowered to the ground level for personnel to enter or exit the platform ...
        • 6. Always position the platform in the travel position (approximately one foot above ground level...
      • 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 hex nuts (1) securing the transmission covers (2) to the frame. Remove the covers.
      • 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 (1) on th...
      • 6. Turn the key switch to the ON position (with the engine not running), release the park brake (...
      • 7. Pressurize the park brake with the pressurizing unit. Close the pump needle valve on the press...
      • 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
      • 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 with a new part. The hydraulic lines are:
        • 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 and extend cylinders several times to bleed air from the system. Check for leaks.
        • 17. Recheck the hydraulic oil level. Add oil if necessary.
      • 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 with new parts. The...
        • 12. Return to the cab, fasten your seat belt and start the engine.
        • 13. Cycle the lift 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.
      • 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 (1) can be used to repl...
          • 7. Remove the individual failed boom lower line (2) from the circuit.
          • 8. Remove and temporarily reposition the adjacent boom lift line (1) in place of the failed boom ...
          • 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.
          • 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 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 (1) can be used to re...
          • 6. Remove the failed boom retract line (2) from the circuit.
          • 7. Remove and temporarily reposition the adjacent boom extend line (1) in place of the failed boo...
          • 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 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.
  • General Maintenance
    • General Maintenance
      • NOTE: The Lubrication (1) and Maintenance Chart (2) decals are located inside the right side engi...
    • Maintenance Schedule And Checklist
      • 1. Lubrication Points
        • A. Carriage pivot pins (2 points)
        • B. Attachment tilt cylinder pins (2 points)
        • C. Outrigger cylinder and pivot pins (10 points)
        • D. Boom attachments (all points)
        • E. Extend Chain Sheave (2 points)
        • F. Retract Chain Sheave (2 points)
        • G. Hydraulic cylinder pins (12 points)
        • H. Drive shaft slip joints (3 points)
        • I. Boom pivot pin (2 points)
        • J. Axle U-Joints (8 points)
        • K. Axle pivot pins (2 points)
        • L. Extend cylinder pins (2 points)
      • NOTE: Shorten the lubrication interval on all lube points when operating in severe conditions.
        • 2. Air Cleaner And Restriction Indicator
      • A. Filter 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 to access air cleaner restriction indicator (...
        • NOTE: Depress button (3) on top of indicator to reset indicator after servicing element.
          • 3. Remove dust from vacuator valve by squeezing bottom of vacuator (4) to allow loose particles t...
      • B. Element: Change
        • 1. Pull the air cleaner cover lock (1) OUT, turn the air cleaner cover (2) counterclockwise and r...
        • 2. Remove the primary element (4). Inspect the element for damage. Damaged elements should not be...
        • 3. Thoroughly clean the interior of the air filter canister (5) and vacuator valve (6).
        • 4. If replacing the inner element (7) at this time, carefully slide the element out. Always disca...
        • 5. Slide the new primary element over the inner element making sure the sealing edge is flush wit...
        • 6. Position the canister cover (8) in place, turn clockwise to lock into position and secure in p...
      • C. Air Intake System-Inspection
        • 3. Engine Cooling System
      • A. Engine Coolant Level Check
        • 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 (...
      • B. Drain And Flush Radiator
        • 1. Level the vehicle, ground the carriage, place the travel select lever in (N) NEUTRAL, move neu...
        • 2. Unlock and open the rear radiator access door. Allow time for the engine to cool down before p...
        • 3. Remove radiator cap and open petcock (2) on the lower right side of radiator (3).
        • NOTE: Use the hose attached 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. Transfer the coolant into a properly labelled container. Dispose of properly.
          • 7. Reconnect line to bottom of overflow bottle and close petcock on the radiator. Reconnect heate...
          • 8. Fill radiator completely with 50/50 mixture of ethylene glycol and water. Total System Capacit...
          • 9. Clean dirt and debris from radiator fins and core, if required.
          • 10. Start engine and run vehicle to normal operating temperature and then shut OFF the engine. Wh...
          • 11. Allow engine to cool to ambient temperature. Check radiator coolant level and top off complet...
          • 12. 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
        • 1. Level the vehicle, raise the boom up to approximately 20˚, place the travel select lever in (N...
        • 2. Unlock and open right rear engine access door.
        • 3. Remove dipstick (1). Check the oil mark on dipstick. The oil should be between the full (2) an...
        • 4. If oil is low, remove oil fill cap (1) and add 15W40 motor oil that at least meets the manufac...
      • B. Oil And Filter Change
        • 1. Operate the engine until warm (approximately 5 minutes).
        • 2. Level the vehicle,raise the boom up to approximately 20˚, place the travel select lever in (N)...
        • 3. Place receptacle under engine oil pan drain plug (4).
        • 4. Remove the drain plug (4) and drain the oil from the 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 (5). A strap or chain filter wr...
        • 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. Install the drain plug (1) into the oil pan and tighten securely.
          • 11. Unlock and open right side engine access door.
          • 12. Remove oil fill cap (2) and add 15W40 motor oil that at least meets the manufacturers minimum...
          • 13. Reinstall the oil fill cap (2). Start engine and run for several minutes.
          • 14. Stop engine. Let the oil drain back for a few minutes. Check oil level on dipstick (3) and ch...
          • 15. Add oil to bring oil level up to the FULL mark in the crosshatched area. Replace dipstick and...
          • 5. Engine Fuel System
      • A. Drain Water From Fuel Water Separator/Filter
      • B. Change Fuel Filter
        • 1. Unlock and open the right rear engine access door.
        • 2. Clean around the fuel filter head (2).
        • 3. Unscrew the fuel filter and dispose of properly.
        • 4. Clean the gasket surface of the filter head and replace the o-ring.
        • 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
        • 1. Unlock and open the right rear engine access door.
        • 2. The in-line fuel strainer (3) is located down line from the engines lift pump (4). Loosen the ...
        • 3. Remove the old in-line fuel strainer and dispose of properly.
        • 4. Install the new in-line fuel strainer with arrow (6) 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 page134).
        • 7. Close and lock the right rear engine access door.
      • D. Bleeding Fuel System
        • 1. To vent the low pressure lines and fuel filter, open the vent screw (1) located on the filter ...
        • 2. Operate the hand plunger (2) on the lift pump (3) until fuel flowing from the fitting is free ...
        • 3. Tighten the vent screw and torque to 7 lb-ft (9 Nm).
        • 1. To vent the high pressure fuel lines (4), loosen one fitting (5) at the injector (6).
        • 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 Steps 1-3 for each fitting until the engine runs smoothly.
        • 5. With the engine running, visually check for leaks. Turn ignition switch OFF.
        • 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 engine access door.
        • 3. Inspect the fan belt (1). Replace if cracked or frayed.
        • 4. This engine is equipped with an automatic belt tensioner (2). Inspect the tensioner bearing. S...
        • 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 (1); first position the belt over the fan pulley (3), crankshaft pulle...
        • 7. Close and lock the left engine access door.
        • 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
            • 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 (1) on the back side of the hydraulic ...
            • 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 page137).
            • a. Remove the four capscrews (3) holding the hydraulic oil tank cover (4) to the tank, remove the...
            • b. Turn the hydraulic oil cap (5) and remove from the filler neck. Add hydraulic oil as needed. T...
              • 6. Install hydraulic oil cap (5). Reposition the cover (4) on the tank and secure in place with t...
          • C. Hydraulic Oil & Filter Change
            • (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 (3) holding the hydraulic oil tank cover (4) to the tank (2), remove...
              • 4. Clean area around filter head (1). Loosen but do not remove the nuts that secure the filter he...
              • 5. Rotate and remove the filter head (1).
              • 6. Remove the seal (3) and the element (4) from the filter head. 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 (3) and push a new filter element (4) all the way onto the filter hea...
              • 11. Remove reservoir cap (5) and fill the reservoir with ISO-46 or MILL2104C Oil (see table on ...
              • 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. Replace hydraulic tank cover.
              • 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
            • 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 (6) through access hole (7) in transmission covers (8) and check ...
            • 4. Add Universal Tractor Fluid to transmission as required to bring up to full mark.
          • B. Transmission Oil & Filter Change
            • (Filter Only)
              • 1. Level the vehicle, ground the carriage, place travel select lever in (N) NEUTRAL, move neutral...
              • 2. Remove the six hex nuts (1) securing the transmission covers (2) to the frame. Remove the covers.
              • 3. Allow the transmission to cool.
              • 4. Place a receptacle under the transmission drain plug (3). Remove the drain plug and allow the ...
              • 5. Clean and re-install the drain plug (3) into the transmission housing.
              • 6. Remove the filter (4) from the filter mount on the front side of the transmission (5). Dispose...
              • 7. Apply a thin film of clean Universal Tractor Fluid to the new filter gasket. Carefully install...
              • 8. Remove the dipstick (6) and fill with Universal Tractor Fluid approximately 2.6 gallons (9,8 l...
              • 9. Check the transmission level and add Universal Tractor Fluid as required following the procedu...
              • 10. Reassemble the transmission covers (2) and secure in place with the six hex nuts (1), washers...
              • 9. Axle Oil
          • A. Axle Oil Level Check
      • 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 (1) and the axle level plugs (2) and remove the plugs...
          • 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 (1) and the axle level plugs (2).
          • B. Axle Oil Change
            • 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 (3), the axle fill plug (1) and the axle level plugs...
              • 3. Place a receptacle under the axle drain plug (3). Remove the plug from the axle housing and al...
              • 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 (3) and re-install. Remove the axle fill plug (1) and the axle l...
              • 6. Fill the axle with Universal Tractor Fluid through the axle fill hole (1) until the oil level ...
              • 7. Reassemble the level plugs (2) using new o-rings.
              • 8. Re-install the axle fill (1) and axle level plugs (2) 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 hex nuts (1) securing the transmission covers (2) to the frame. Remove the covers.
                • 3. Attach a remote portable hydraulic pressurizing unit to the parking brake gauge port (3) on th...
                • 4. Turn the key switch to the ON position (with the engine not running), release the park brake (...
                • 5. Pressurize the park brake with the pressurizing unit. Close the pump needle valve on the press...
                • 6. Working through the level plug hole (1), carefully use a screwdriver to spread the brake disks...
                • 7. Using a feeler gauge, check the gap (2) between the brake disks (3). If the gap is greater tha...
            • NOTE: If the brake disks are worn beyond .26" (6,75 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 page145.
              • B. Rear Axle
                • 1. Working through the level plug hole (1), carefully use a screwdriver to spread the brake disks...
                • 2. Using a feeler gauge, check the gap (2) between the brake disks (3). If the gap is greater tha...
            • 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 page145.
              • 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
            • 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 (2). Slowly remove the plug. Check the oil...
            • 4. Add Universal Tractor Fluid to bring the oil level up and even with the plug hole (2). See the...
            • 5. Clean and re-install the wheel end fill/drain plug (2).
          • B. Wheel End Oil Change
            • 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 (4). Slowly loosen the plug. Hold a recept...
            • 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 (2) is positioned horizontally (3).
            • 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.
            • 12. Wheels and Tires
          • A. Tire Air Pressure Check
            • 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
            • 1. Wire brush the area around the lug nuts if necessary.There are separate lockwashers (1) under ...
            • 2. Using the torque sequence (A thru K) shown below, alternately check the torque of each of the ...
          • C. Replacing Tires
            • 13. Batteries
              • 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 batteries (1) are located inside the frame directly below t...
              • 3. Wearing safety glasses, visually inspect the batteries. Check terminals for corrosion. Replace...
              • 4. Close and lock rear door
          • Battery Electrolyte First Aid:
            • 14. Fuse and Relay Replacement
            • 4
            • 5
            • 6
            • 7
            • 8
            • 9
            • 10
            • 11
            • 12
            • 13
            • 14
            • 15
            • 2
            • 3
            • 4
            • 5
            • 6
            • 7
            • 8
            • 9
            • 10
            • 11
            • 12
            • 13
            • 14
            • 15
          • Cold Start Grid Heater Fuses
            • 1. Unlock and open the left engine access door.
            • 2. To access the fuses, open the protective covers (17). Allow the covers to rotate on the tether...
            • 3. Remove the two hex nuts (19) and lockwashers (20) securing the fuse (16) and wires to the fuse...
            • 4. Place the new fuse and then the wires onto the studs of the holder. Secure the fuse and wires ...
            • 5. Snap the protective cover back in place. Be sure the cover snaps securely in place on the holder.
            • 6. Close and lock the left side engine access door when complete.
          • ECM Fuses and Relays
            • 1. Unlock and open the left engine access door.
            • 2. Locate the three fuse holders. Remove the clear plastic protective cover (2) from the holder (1).
            • 3. Remove the failed fuse from the holder and replace with a new fuse.
            • 4. Reassemble the plastic cover onto the fuse holder and securely snap the cover in place. Replac...
            • 5. Close and lock the left side engine access door when complete.
            • 6. To gain access the relay, unlock and open the right side engine access door. Locate the relay ...
            • 15. Boom Chains and Wear Pads
          • A. Intermediate Boom Chains Tension Check
            • 1. Park the vehicle on level ground. Place the travel select lever in (N) NEUTRAL, move neutral l...
            • 2. Lower both outriggers completely. Fully extend the boom, then retract it 2" (51 mm). Turn the ...
            • 3. Measure the sag (1) in the intermediate boom extend chains (2) between the bottom of the chain...
            • 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 (4) from the top rear edge of the primary intermediate boom (5) to the t...
            • NOTE: If the measurement is less than 8.5" (216 mm) the boom may require extensive adjustment and...
              • 7. If the measurement is more than 11" (279 mm), tighten the retract chain locknut (1) located on...
              • 8. Start the vehicle, with the outriggers lowered completely, cycle the boom in and out several t...
              • 9. Recheck the measurement at the rear of the boom between the top rear edge of the primary inter...
            • NOTE: If, by adjusting the retract locknut, you cannot get the measurement within the range of 8....
              • 10. Start the vehicle, with the outriggers lowered completely, cycle the boom in and out several ...
              • 11. Measure the sag (3) in the intermediate boom extend chains (4) between the bottom of the chai...
          • B. Intermediate Boom Chain Tension Adjustment
            • (As required)
            • NOTE: Always perform the “Intermediate Boom Chain Tension Check” starting on page161 before adju...
              • 1. Park the vehicle on level ground. Place the travel select lever in (N) NEUTRAL, move neutral l...
              • 2. Adjust the intermediate boom extend chains (1) by tightening the locknuts (3) located at the r...
              • 3. Equal chain tension can be checked by the position of the yoke (2) on the outer boom. The fron...
              • 4. Start the vehicle, with the outriggers lowered completely, cycle the boom in and out several t...
              • 5. Measure the intermediate boom chain sag. Acceptable intermediate boom chain sag is between 1.5...
            • NOTE: If the intermediate boom extend chain sag cannot be adjusted within the acceptable range of...
              • 6. Replace the rear outer boom cover.
          • C. Inner Boom Chain Tension Check
            • 1. Park the vehicle on level ground. Place the travel select lever in (N) NEUTRAL, move neutral l...
            • 2. Lower both outriggers completely. Fully extend the boom, then retract it 2" (51 mm). Turn the ...
            • 3. Measure the sag (1) in the inner boom extend chain (2) between the bottom of the chain and the...
            • 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 (4) from the top rear edge of the secondary intermediate boom (5) to the...
            • NOTE: If the measurement is less than 13.75" (349 mm) the boom may require extensive adjustment a...
              • 7. If the measurement is more than 14.25" (362 mm), tighten the inner boom retract chain locknut ...
              • 8. Start the vehicle, with the outriggers lowered completely, cycle the boom in and out several t...
              • 9. Recheck the measurement at the rear of the boom between the top rear edge of the secondary int...
            • NOTE: If, by adjusting the inner boom retract chain locknut, you cannot get the measurement withi...
              • 10. Start the vehicle, with the outriggers lowered completely, cycle the boom in and out several ...
              • 11. Measure the sag (3) in the inner boom extend chain (4) between the bottom of the chain and th...
          • D. Inner Boom Chain Tension Adjustment
            • (As required)
            • NOTE: Always perform the “Inner Boom Chain Tension Check” starting on page168 before adjusting t...
              • 1. Park the vehicle on level ground. Place the travel select lever in (N) NEUTRAL, move neutral l...
              • 2. Adjust the inner boom extend chain (1) by tightening the locknut (2).
              • 3. Start the vehicle, with the outriggers lowered completely, cycle the boom in and out several t...
              • 4. Measure the inner boom chain sag. Acceptable inner boom chain sag is between 1.5" (38 mm) and ...
            • NOTE: If the inner boom extend chain sag cannot be adjusted within the acceptable range of 1.5" (...
              • 5. Replace the rear outer boom cover.
          • E. 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:
    • Check the chain for wear on the link plate edges caused by running back and forth over the sheave...
    • Double Extend Chains:
    • For inspection of the retract chains, refer to the Service Manual.
    • The new chain link measures .713" (18 mm) (1). If the measurement of the worn chain is less than ...
    • Single Extend Chains:
    • The new chain link measures .950" (24 mm) (1). If the measurement of the worn chain is less than ...
    • Double Extend Chains:
    • When the original length (3) of 12.00" (305 mm) per foot of new chain has elongated from wear to ...
    • Single Extend Chains:
    • When the original length (3) of 12.00" (305 mm) per foot of new chain has elongated from wear to ...
    • It is important to measure the chain in the section that moves over the sheaves because it receiv...
    • Double Extend Chains: Measure across a span of 17 pins at the center of the extend chain. Measure...
    • Single Extend Chains: Measure across a span of 13 pins at the center of the extend chain. Measure...
    • All Chains: The maximum measurement allowed is 12.36" (313mm). If the measurement is more than 1...
    • Highly loaded chain, operating with inadequate lubrication can generate abnormal frictional force...
    • Examine the pin head rivets to determine if the “VEE” flats are still in correct alignment (1). C...
    • DO NOT attempt to repair the chain by welding or driving the pin(s) back into the chain. Once the...
    • Any wear pattern on the pin heads or the sides of the link plates indicates misalignment in the s...
    • Distorted or battered link plates (4) on a leaf chain can cause tight joints and prevent flexing.
    • Inspect the chains very carefully, front and back as well as side to side, for any evidence of cr...
    • It is important, however to determine the cause of the crack before installing a new chain so the...
    • The types of cracks are:
      • F. Chain Lubrication
        • (1000 Hour Intervals)
      • G. Wear Pad Inspection
        • (50 Hour Intervals)
      • H. Wear Pad Replacement
        • (As Wear Pad Indicators Indicate)
      • Storage and Transport
      • Storage
        • A. Before Storing
          • 1. Clean the entire vehicle.
          • 2. Lubricate all grease fittings as described in “Lubrication Points” on page118.
          • 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 batteries from the vehicle and store in a dry place ...
          • 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 properly charged batteries. 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 page113. Perform all the maintenance checks ...
          • 6. Review and familiarize yourself and any other operator with all the safe and proper operating ...
      • Transport
        • 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
        • NOTE: Observe that frame sway will be slower than normal during this test.
    • Boom/Outrigger Interlock System Test
    • Parking Brake/Transmission De-Clutch Test Procedures
    • Step 1:
      • 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.
      • Step 2:
        • 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 10,000 lbs (4.536 Kg) on the forks, drive the vehicle forward up a 15% ...
    • 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 (1) on the ignition switch (2) and the steering wheel (3).
      • Four Wheel Steer Indexing Procedure
        • 1. With the steering select switch (4) in the Four Wheel Steer position (5), turn the steering wh...
        • 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 (5) and turn the steering whe...
        • 4. Toggle the steer select switch back to Front Wheel Steer position (6) and steer the front whee...
        • 5. Toggle the switch to the Four Wheel Steer position (5) and return to center.
  • 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):
      • Maximum Ground Pressure (w/full load):
      • Footprint (w/full load):
    • Weights
      • Basic Vehicle:
    • Vehicle Dimensions
      • With Standard 17.5 - 25 Tires:
    • Electrical System
      • Fuse Ratings:
      • Relay Ratings:
      • Grid Heater Fuse Ratings:
      • ECM Fuse Ratings:
    • Engine
      • Cummins:
    • A
    • B
    • C
    • D
    • E
    • F
    • G
    • H
    • I
    • J
    • L
    • M
    • N
    • O
    • P
    • Q
    • R
    • S
    • T
    • U
    • V
    • W
  • Index
  • Accident Prevention Tags