OWNERS/OPERATORS MANUAL Model 10054 (S/N 19080 thru 19987 and S/N 0160002340 thru 0160029586) OH2462 Keep this manual with the vehicle at all times. 8990502 C Printed in U.S.A.
WARNING: Improper operation of this vehicle can cause injury or death. Only trained and authorized operators should operate this vehicle. Before starting the engine, do the following: 1. Read this owner/operators manual. 2. Read all the safety decals on the vehicle. 3. Clear the area of other persons. Learn and practice safe use of vehicle controls in a safe, clear area before you operate this vehicle on a worksite.
Table of Contents Introduction The Manual....................................2 Replacement Parts ........................2 Reports ..........................................2 Safety Practices Disclaimer......................................3 Hazard Classification System........3 Accident Prevention Tags..............5 New or Additional Operators .........5 Instructional Symbols ....................6 Hazard Symbols ............................7 Avoidance Symbols .......................
Introduction Introduction The Manual This Owners/Operators Manual provides the information you need to properly operate and maintain this vehicle. IMPORTANT! Before you operate this vehicle, read this manual completely and carefully so you will understand the safety instructions and the operation of the controls and safety equipment. You must comply with all Danger, Warning, and Caution notices. They are for your benefit.
Safety Practices Safety Practices Disclaimer JLG reserves the right to make changes on and to add improvements upon its products at any time without public notice or obligation. JLG also reserves the right to discontinue manufacturing any product at its discretion at any time. NOTICE: Under OSHA rules, it is the responsibility of the employer to provide operator training. Successful completion and certification of Safety Training for Rough Terrain Forklifts is required.
Safety Practices Signal Word A signal word is a distinctive word located on hazard decals and used throughout this manual that alerts the viewer to the existence of and relative degree of the hazard. DANGER: The signal word “DANGER” indicates an imminently hazardous situation which, if not avoided, will result in death or serious personal injury. WARNING: The signal word “WARNING” indicates a potentially hazardous situation which, if not avoided, could result in death or serious personal injury.
Safety Practices Accident Prevention Tags Before beginning any maintenance or service, place an Accident Prevention Tag (1) on both the starter key switch (2) and the steering wheel (3), stating that the vehicle should not be operated. Actual Accident Prevention Tags, which can be punched out and used, are included as the last page of this manual. Retain these Accident Prevention Tags for reuse at a later date.
Safety Practices Instructional Symbols The following symbol definitions will help you understand all hazard related decals and load charts used on this vehicle. OP0330 Safety Alert Symbol OH2100 Read Operator’s Manual OH2090 Fasten Seat Belt OH3100 This Symbol Signifies That Specific Attachments Must Only Be Used On Vehicles Equipped With Auxiliary Hydraulics. Always Connect Couplers. 6 Model 10054 Rev.
Safety Practices Hazard Symbols OH2110 OH2120 Lead Acid Batteries Generate Explosive Gases Rotating Fan Blades Can Cut Vehicle Tipover Can Crush OH2150 OH2140 OH2130 - OH2300 Rotating Belts Can Cut Or Entangle Electrocution Can Cause Death Or Serious Injury Vehicle Roll Away Can Cause Death Or Serious Injury OH3110 OH3160 OU1450 AVOID CRUSHING, Falling Off Vehicle Can Cause Death Or Serious Injury ENGINE EXPLOSION Can Result In Death Or Serious Injury OH2161 FALLING OFF ATTACHMENT Can Resul
Safety Practices Avoidance Symbols OH2320 OH2330 OU1520 Keep Lit Cigarettes Away Stop Operation At This Point Keep Flames and Ignition Sources Away OU1460 OH2310 OU1510 Keep Away From Rotating Fan Blades Prohibition Symbol. DO NOT Operate OH2280 Do Not Raise Boom While On A Slope DO NOT Use Ether Or Other High Energy Starting Aids. Engine Equipped With Grid Heating System.
Safety Practices Avoidance Symbols (cont’d) OH2250 OH2260 Keep Clear Of Power Lines Engage Parking Brake OH2230 Carry No Riders OH2240 Do Not Travel With Personnel In Work Platform OH2170 Use Only Compliant Work Platforms To Raise Or Lower Personnel OH2220 DO NOT JUMP • Brace Yourself and Stay With Vehicle • Keep Seat Belt Fastened • Hold On Firmly • Lean Away From The Point Of Impact Model 10054 Rev.
Safety Practices 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 protective clothing and personal safety gear issued or called for by job conditions. 3.
Safety Practices C. Ether or High Energy Starting Aids The engine utilizes a grid heating system inside the induction manifold for cold starting conditions. WARNING: This diesel engine uses a grid heating system inside the induction manifold. DO NOT use ether or any high energy fuels to assist starting. An explosion may cause death or serious personal injury or engine damage. DO NOT use ether or any other high energy starting aids during cold starting.
Safety Practices E. Batteries The following WARNING is intended to supplement and does not replace the warnings and information provided on the battery by the battery manufacturer. When jump starting the vehicle, carefully follow instructions found under “Jump Starting” on page 60. - OS0621 Keep sparks, flames and lit smoking materials away from the battery at all times. Lead acid batteries generate explosive gases. Severe chemical burns can result from improper handling of battery electrolyte.
Safety Practices 5. Moving Parts Hazard DO NOT place limbs near moving parts. Severing of any body part can result. Turn OFF engine and wait until fan and belts stop moving before servicing. MOVING PARTS can cut. Keep clear of fan and belts while engine is running. MOVING PARTS can entangle. OT0810 6. Lowering Boom or Falling Load Hazard DO NOT get under a raised boom unless it is blocked up safely.
Safety Practices 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) NEUTRAL position with the parking brake switch engaged before starting the engine. Holes, obstructions, debris and other worksite hazards can cause death or serious personal injury. Always walk around and look for these and other hazards before operating the vehicle in a new worksite.
Safety Practices 4. Underground Hazards Know the location of all underground hazards before operating this vehicle in a new area or worksite. Electrical cables, gas and water pipes, sewer, or other underground objects can cause death or serious personal injury. Contact your local underground utility service or diggers hotline to mark all underground hazards. 5.
Safety Practices 6. Elevating Personnel Use only a compliant work platform meeting the ASME B56.6 standards for lifting and lowering personnel. NEVER transport personnel in a work platform for even the shortest distance. Death or serious personal injury can occur if these rules are not obeyed. Riders can fall and be crushed or run over. Avoid accidents. For other specific precautions, see “Elevating Personnel” on page 90. WARNING WARNING FALLING OFF ATTACHMENT, can result in death or serious injury.
Safety Practices DO NOT exceed the rated lift capacity of the vehicle as structural damage and unstable conditions will result. To ensure that the vehicle is positioned in the most stable condition before operating an attachment, use the frame sway control (frame tilt) to level the vehicle. The vehicle is level when the frame level indicator gauge reaches (0°) zero degrees. If the vehicle cannot be leveled using the frame sway control, reposition the vehicle.
Safety Practices 8. Emergency Exit Rear Window The rear window (1) in the enclosed cab can be used as an emergency exit by removing the latch pin (2) located on the window latch (3). The window is then free to swing open. 2 1. 1 2. 3. 3 4109 791 OH1730 9. Tire Pressure VEHICLE TIPOVER can result in death or serious injury. DANGER DO NOT travel with the boom raised. DO NOT raise boom while on a slope unless load is level. MAINTAIN proper tire pressure at all times.
Safety Practices 10. Do Not Jump DANGER AVOID CRUSHING if vehicle tips. Jumping can result in death or serious injury. DO NOT JUMP. Brace yourself. Stay in cab. Keep seat belt on. OH3190 If a vehicle ever becomes unstable and starts to tip over: • BRACE YOURSELF and STAY WITH THE VEHICLE, • KEEP YOUR SEAT BELT FASTENED, • HOLD ON FIRMLY and • LEAN AWAY FROM THE POINT OF IMPACT. Indecision and trying to escape from a tipping vehicle can result in death or serious personal injury. 11.
Safety Practices 12. Falling Load Hazard DO NOT exceed the total rated load capacity of the specific type fork being used. Each fork is stamped with a maximum load capacity. If the capacity is exceeded, forks may break. See “Fork Ratings” on page 89. 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.
Safety Practices Equipment Considerations WARNING: DO NOT modify or alter (weld, drill, etc.) any part of this vehicle without first consulting JLG. Modifications can weaken the structure creating a hazard that can cause death or serious personal injury. DO NOT by-pass or disconnect any electrical or hydraulic circuits. Consult the JLG Service Department or your local Sky Trak Distributor if any circuit is malfunctioning.
Safety Practices 3 5 7 6 2 1. Read operator's manual before operating. 3. Allow no riders. 2. Fasten seat belt. 4. Use a compliant work platform to lift or lower personnel. DANGER AVOID CRUSHING if vehicle tips. Jumping can result in death or serious injury. DO NOT JUMP. Brace yourself. Stay in cab. Keep seat belt on.
Safety Practices ENGINE EXPLOSION can DO NOT use Ether or other result in death or serious high energy starting aids. personal injury. Engine equipped with grid heating system. 15 4110460 10 WARNING FALLING OFF ATTACHMENT, can result in death or serious injury. 14 Lift or lower personnel only in a compliant work platform. 13 DO NOT TRAVEL with personnel in a work platform.
Operation Operation Operator Controls Accelerator Pedal Pressing down the accelerator pedal (1) increases engine and hydraulic speed of the vehicle. The pedal is spring-loaded to return to idle speed. NOTE: The accelerator pedal is also used to activate the Cummins ECM Diagnostic system. With the ignition switch in the RUN position, depress and release the pedal three times to activate the system.
Operation Ignition Switch Using the ignition switch key (5), the switch may be turned clockwise from the OFF (6) position to the RUN (7) and START (8) positions. The START position is spring-loaded to return to the RUN position and must be manually held in place for starting. OFF position (6) — The entire electrical system is shut down. RUN position (7) — All controls and indicators are operable.
Operation Steering Select Switch This vehicle has one steering select switch (1) with three positions. The switch is located in the lower switch bank (2) on right side dash panel. Refer to “Steering Modes” on page 70 for detailed information. 2 1 26 OH3240 Model 10054 Rev.
Operation Park Brake Switch The Parking Brake Switch (3) has two positions: OS0121 P ENGAGED ............toggle switch downward P DISENGAGED............toggle switch upward OS1323 The Parking Brake Switch (3) must be ENGAGED to permit engine starting. A red LED, on the parking brake switch, and a light in the instrument cluster will indicate the brake is ENGAGED. The parking brake may be used to stop in an EMERGENCY situation.
Operation Neutral Lock Lever The Travel Select Lever (1) is equipped with a neutral lock. The Neutral Lock Lever (2) locks the Travel Select Lever in NEUTRAL or unlocks the Travel Select Lever so that it can be moved into the FORWARD or REVERSE drive position. 2 1 ND OH3250 To lock the Travel Select Lever (1) in the NEUTRAL position, place the lever in the NEUTRAL position and move the Neutral Lock Lever (2) to the (N) NEUTRAL LOCK position.
Operation Travel Select Lever The Travel Select Lever (3) has three positions to select direction of travel: F = FORWARD (4) ......... all the way FORWARD N = NEUTRAL (5) .......... CENTER position R = REVERSE (6) ...........all the way REARWARD OS0340 4 5 6 3 OH3260 To change travel selections, move the lever FORWARD or REARWARD to the desired selection. When the Travel Select Lever is shifted to REVERSE, the back-up alarm will automatically sound.
Operation Gear Select Lever The Gear Select Lever (1) has a twist grip handle with four positions. Vehicles have four forward gears and three reverse gears. 1 OH3270 Use first gear for highest torque and pulling power. Use higher gears for higher ground speed. The recommendations listed in the table that follows are guidelines only. Always use good judgement when traveling with a load.
Operation Boom Control Lever The boom control lever (2) is a joystick with variable motion from the center to control the boom functions: Boom Lift............................. move lever backward Boom Lower........................ move lever forward Boom Extend .......................move lever to the right Boom Retract .......................move lever to the left OH0170 Two boom functions can be accomplished at the same time by moving the lever into the proper quadrant.
Operation Attachment Tilt and Frame Sway Control Lever The attachment tilt and frame sway control is a joystick (1) with four perpendicular motions from the center to control two attachment tilt functions and two frame sway functions: Frame Sway Left .................move lever to the left Frame Sway Right ...............move lever to the right Attachment Tilt Down .......... move lever forward OH0410 Attachment Tilt Up...............
Operation Outrigger Control Switches The left (2) and right (3) outrigger control switches raise or lower the corresponding outriggers. The rocker switches are spring loaded to return to the center (stop) position when released. Raise Left Outrigger............ press top of left side switch Lower Left Outrigger ........... press bottom of left side switch Raise Right Outrigger ..........press top of right side switch Lower Right Outrigger..........
Operation IMPORTANT! Outrigger equipped vehicles can be used with the outriggers in either the raised or lowered position. The operator must operate the vehicle within the limits specified on the appropriate capacity chart for the outrigger position (up or down). Procedure for Lowering of Outriggers Secure and proper outrigger placement is critical for stability of the vehicle. Avoid holes or drop-offs and soft or excessively uneven terrain.
Operation Seat Belt WARNING: Death or serious personal injury may result from failure to wear the seat belt installed on this vehicle. The seat belt is a critical component of the Operator’s protective Structure, and is provided for the operator’s protection in case of vehicle upset. The seat belt MUST be worn whenever this vehicle is operated. IMPORTANT! Inspect the seat belt every time it is used, looking for cut or worn webbing, or any defect in the latch assembly.
Operation Operator’s Seat Adjustment The operator’s seat can be adjusted three ways: A. Fore and Aft Adjustment Pull the handle (1) outward to adjust the seats forward and backward. Release the handle to lock the seat in the desired position. B. Suspension Adjustment Turn the knob (2) on the front of the seat (3) to adjust the suspension to correspond with the operator’s weight. Turn clockwise to increase stiffness. Turn counter-clockwise to reduce the stiffness. C.
Operation Instruments and Indicators Hourmeter OS0260 The hourmeter (6) records engine operating hours and has a total readout of 9,999.99 hours. It is located at the lower portion of the instrument cluster (7) on the right side console. Fuel Gauge OH2470 The fuel gauge (8) indicates the quantity of fuel in the fuel tank. The gauge is located in the center of the instrument cluster on the right side console. Capacity of the fuel tank is 37 gallons (140 liters) total capacity with a usable capacity of 35.
Operation Instrument Cluster Light Test Test the bulbs in the instrument cluster before starting the engine. Turn the ignition switch to the RUN position, ALL nine lights in the instrument cluster will come ON for a few seconds and then go out. Replace any bulbs that DO NOT come ON during this test.
Operation Function Indicator Lights A. Stabil-TRAK Indicator Light OH2500 The Stabil-TRAK light (8) will come ON when the system has been activated. The rear axle will lock when one or more of the following conditions exist with the boom above a 40° angle. • Parking Brake Switch engaged • Travel select lever in (N) NEUTRAL • Service brake pedal depressed and held The Stabil-TRAK Light will also come ON when the Boom/Outrigger Interlock system is active.
Operation B. Park Brake Light P The park brake light (1) illuminates any time the park brake is applied and the ignition switch is in the RUN position. OH2480 C. High Beam Light (used with optional road light package only) OH2490 The high beam light (2) illuminates when the road option headlights are on full (high) beam and will turn OFF when the headlights are switched to low beam. D.
Operation Warning Indicator Lights There are five additional indicator lights in the instrument cluster that will illuminate during critical circumstances. All five warning indicator lights demand immediate attention and vehicle servicing. In many cases, the vehicle should be shut down AS SOON AS PRACTICAL to prevent serious mechanical failure. The five warning indicator lights are: A.
Operation D. Engine Oil Pressure Warning Indicator Light OH2550 The engine oil pressure warning indicator light (1) will come ON during engine start-up and go OUT once the engine has started. This is normal. If the light comes ON while the engine is running, this indicates that the engine oil pressure is too low. SHUT THE VEHICLE DOWN AS SOON AS PRACTICAL. 2 1 P 0000 00 OH1810 E.
Operation Function Indicator Lights There are two additional indicator lights located on the right side of the front dash. A. Engine Air-Intake Heater Indicator The engine air-intake heater indicator OU0040 light (3) located in the upper switch bank on the right side of the front dash. This light illuminates, with the ignition switch in the RUN position, any time the ambient temperature drops below 40° F (4° C).
Operation B. Engine Function Indicator Lights 2 3 The engine function indicator lights (1) are located in the upper switch bank on OH3290 the right side of the front dash. The light indicates any faults that arise in the engine during operation. The light contains a RED light (2) and a AMBER light (3). If the RED light (2) comes ON during operation, STOP the engine IMMEDIATELY and diagnose the fault by activating the ECM diagnostic system. Activate the system with the accelerator pedal.
Operation 2 1 3 OH3500 Frame Level Indicator The indicator (4) is mounted on the top inside of the Operator's Protective Structure (cab). This is a bubble type indicator which allows the operator to tell if the vehicle has been positioned in a level condition. Always frame sway the vehicle either right or left until the indicator reads zero degrees (0°). If zero cannot be achieved, then reposition the vehicle until it is level before placing the load. NOTE: Maximum frame sway is 10° in either direction.
Operation Boom Angle Indicator The boom angle indicator is a plumb arrow (1) with angular graduations (2) from minus 10° to plus 80°. It is located on the left side of the boom and is visible from the operator’s position. Use this indicator to determine the boom angle when reading the capacity chart (see “Using The Capacity Chart”). 4105262 1 2 OH0302 Rear View Mirrors Two rear view mirrors are provided to aid the operator's rear vision.
Operation Optional Controls Auxiliary Attachment Control Lever The auxiliary attachment control lever (5) controls the functions of an optional attachment that is mounted to the vehicle and requires a hydraulic supply for operation. Some of the optional attachments that require auxiliary hydraulics are: Side Tilt Carriage, Swing Carriage, Auger, and 3 Foot Truss Boom w/Winch.
Operation Worklight Switch (Front, Rear & Boom Worklights) OH2570 This three position rocker switch (1) controls the front, rear and boom worklights. The switch is located in the upper switch bank on the right side dash panel. These lights will only operate when the ignition switch is in the RUN position. • Push the top of the switch in to turn all the worklights OFF. OH2591 • To turn the front and boom worklight ON, position the rocker switch to the center position.
Operation Beacon Light Switch OH2580 This rocker switch (2) turns the beacon light ON and OFF. The switch is located in the lower switch bank on the right side dash panel. This light will only operate when the ignition switch is in the RUN position. • Push the bottom of the switch in to turn the beacon light ON. OH2611 • Push the top of the switch in to turn the beacon light OFF. OH2591 2 OH3310 Model 10054 Rev.
Operation Worklight Switch (with Optional Road Lights) OH2620 This rocker switch (1) activates the worklight system. The switch is located in the upper switch bank on the right side dash panel. This system will only operate when the ignition switch is in the RUN position. See “Parking Lights, Headlights & High/Low Beam Switch” on page 52 for operation of the road lights. • Push the top of the switch IN to DEACTIVATE the entire the worklight system.
Operation Emergency Flashers OS1920 This switch (2) is located in the upper switch bank on the right side dash panel. • To ACTIVATE the emergency flashers, push the bottom of the switch IN. OH2611 • To DEACTIVATE the emergency flashers push the top of the switch IN. OH2591 2 OH3320 Model 10054 Rev.
Operation Turn Signals OH2510 The directional signals are ACTIVATED from the lever (1) on the right side of the steering wheel and will only operate when the ignition switch is in the RUN position. To activate the left turn signal (2), raise the lever. To activate the right turn signal (3), lower the lever. To deactivate either directional signal, the lever must be manually returned to the center position. The lever will not cancel automatically after a turn.
Operation Windshield Wiper Control OS1930 This three position rocker switch (7) controls the speed of the windshield wiper. This switch is located in the lower switch bank on the right side dash panel. • To STOP the windshield wiper, push the top of the switch IN. • To OPERATE the windshield wiper at LOW speed, position the switch in the CENTER POSITION. • To OPERATE the windshield wiper at HIGH speed, push the bottom of the switch IN. 7 Model 10054 Rev.
Operation Skylight Wiper Control OH1900 This rocker switch (1) turns the skylight wiper ON and OFF. This switch is located in the lower switch bank on the right side dash panel. • Push the bottom of the switch IN to turn the skylight wiper ON. • Push the top of the switch IN to turn the skylight wiper OFF. OH2611 OH2591 Windshield & Skylight Washer Control OS1940 OH1910 This rocker switch (2) is spring loaded to return to the OFF position when released.
Operation Cab Heater & Fan Control OS1950 The cab heater controls (3) are located directly below the switch banks on the right side dash panel. The control panel consists of: a variable speed fan control knob (4) and a temperature control knob (5). Control of air flow to the windshield is made by opening, closing or redirecting the air vent louver on the front dash. The cab is heated by the heater unit positioned under the operators seat.
Operation Rear Window Latch The rear window (1) can be partially opened and secured in place with the rear window latch (2). To open the window, grab the latch handle and pull up and then push the window outward. To close and secure the window, pull the latch handle forward and down. NOTE: In an emergency situation, the operator can exit through the rear window opening by removing the latch pin (3) on the window latch. The window is then free to swing open. 1 1. 3 2. 3.
Operation Pre-Operation Inspection 1. Check safety belt for damage. Check for frayed or cut seat belt webbing, damaged buckles or loose mounting brackets. Make any necessary repairs before operating the vehicle. 2. Check all four tires and rims for damage. Check for proper tire pressure, add air if required. Observe the condition of each tire looking specifically for punctures, cracks, cuts, gouges, bulges or any other damage. Check the condition of each rim for bent flanges or any other damage.
Operation Normal Starting 1. Enter the cab using the hand holds and adjust the seat for comfortable operation. 2. Adjust the mirrors to obtain the best rear view from the operator’s position. WARNING: DO NOT start the engine unless you are in the seat with the seat belt fastened around you. Death or serious personal injury could result if the belt is not securely fastened. 3. Fasten the seat belt. 4. Make sure the parking brake switch is ENGAGED. 5.
Operation Cold Starting The engine is equipped with a 120 volt 750 watt block heater. Block heaters are recommended when temperatures drop below 10° F (-12° C). (Temperature ranges will vary when using different oil weights. Consult the engine manufacturer’s manual for other variables.) WARNING: This diesel engine uses a grid heating system inside the induction manifold. DO NOT use ether or any high energy fuels to assist starting. An explosion may cause death or serious personal injury or engine damage.
Operation 8. The engine oil pressure warning indicator light should go OFF within five seconds after starting. If the light remains ON, turn the ignition switch OFF immediately and check the oil level or change to a lighter weight oil. Consult the engine manufacturer’s manual for alternative oils for cold weather operation. Jump Starting Jump starting at the batteries or battery replacement is required when the batteries are discharged to the point where the batteries will not crank the starter.
Operation Refueling Make sure the vehicle is level to assure an accurate fuel level reading. The fuel tank is capable of holding 37 gallons (140 liters) of diesel fuel. The usable capacity of the fuel tank is 35.6 gallons (135 liters). Fuel Types OH0480 Use ASTM #2 diesel fuel with a minimum Cetane rating of 40. #2 diesel fuel gives the best fuel economy and performance under most operating conditions.
Operation Fuel Cap Unlock the fuel cap (1) through the fuel cap access hole (2). Slowly remove the fuel cap from the fuel fill neck. 2 1 OH1920 Fill fuel tank. Reassemble the fuel cap onto the fill neck and turn to lock in place. Line up the locking tabs to reassemble a lock if desired. 62 Model 10054 Rev.
Operation Stabil-TRAK System Understanding the Stabil-TRAK System OS1970 The following describes the three basic modes of the patented Stabil-TRAK system. The vehicle may operate in any one of these three modes. With the OUTRIGGERS RAISED, the unit may operate in any one of these three modes at any given time while the boom is within the OUTRIGGER UP extension limit.
Operation Locked Mode With the boom above 40° (1) and by activating one or more of the functions (as follows), the Stabil-TRAK system is in the LOCKED MODE (2). The rear axle is locked so it is rigid with the frame. The Stabil-TRAK light will be ON (3). • Engaging the parking brake switch • Placing the travel select lever in (N) NEUTRAL • Depressing and holding the service brake pedal The frame sway will function slower than normal in this mode with or without the outriggers down.
Operation Slow Pivot Mode With the boom above 40° (4), the Stabil-TRAK System is now in the SLOW PIVOT MODE (5). In this mode the rear axle is UNLOCKED and is allowed to pivot but will respond SLOWLY to changes in terrain. The Stabil-TRAK light will be OFF (6). The frame sway will function normally in this mode. To check that the Stabil-TRAK System is functioning properly, refer to the test procedure on page 185 for the proper system function. H G F E D C 4 5 B A 6 OH0624 Model 10054 Rev.
Operation Understanding the Boom/Outrigger Interlock System The ultimate purpose of this interlock system is to add an extra measure of stability allowing the boom to be extended to its maximum limits. There are two modes to this interlock, the Extend Interlock and the Outrigger Interlock. Extend Interlock Mode The Extend Interlock Mode, limits boom extension (1) to a point after letter "E" has appeared on the side of the boom and before letter "F" appears.
Operation IMPORTANT! As an added measure of safety, ALWAYS remember to shift the Travel Select Lever into (N) NEUTRAL, move the neutral lock lever to NEUTRAL LOCK position and engage the parking brake when outriggers are lowered. With the outrigger interlock engaged additional systems are automatically activated which enhance the stability of the vehicle: • Stabil-TRAK is in the LOCKED Mode. • Transmission has been DECLUTCHED. • Parking brake is ENGAGED. • Outrigger RAISE function is inoperable.
Operation Operating Starting Travel 1. Enter the operator cab, fasten the seat belt, start the engine, apply the service brake pedal and disengage the parking brake switch. 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) REVERSE to travel backward. 4. Slowly remove your foot from the service brake pedal and press the accelerator pedal to start travel.
Operation Shifting Gears 1. Rotate the twist grip of the gear select lever to the next desired gear. The transmission has four forward gears and three reverse gears. 2. Use first gear for highest torque and pulling power. Use higher gears for higher ground speed. The recommendations listed in the table that follows are guidelines only. Always use good judgement when traveling with a load.
Operation Steering Modes IMPORTANT! DO NOT change steering modes unless you are at a complete stop and all four tires are in the “straight-ahead” position. The three steering modes are: • Four Wheel Steering (1) • Front Wheel Steering (2) • Crab Steering (3) The steering modes can be changed using a single rocker switch (4) located in the lower switch bank on the right side dash panel. 4 3 2 1 OH3360 70 Model 10054 Rev.
Operation Four Wheel Steer Indexing If the vehicle does not drive “straight,” the steering could be ”out of phase.” Perform the “Four Wheel Steer Indexing Procedure” on page 193 to synchronize the front and rear steering. 1. Four Wheel Steering WARNING: NEVER use the Four Wheel Steering Mode when traveling at high speed. Rapid turning in this mode can cause tipover. Use only the Front Wheel Steering Mode at higher speeds and slow the vehicle when turning.
Operation 2. Front Wheel Steering The front wheels will steer in the direction that the steering wheel is turned. The rear wheels will remain in a fixed forward position. This steering mode should be used when loading or unloading the vehicle from a trailer and for on-highway travel at higher speeds. OH1670 3. Crab Steering WARNING: NEVER use the Crab Steering Mode when traveling at high speed. Rapid turning in this mode can cause tipover.
Operation 4. Maximum Fork Sweep CAUTION: Allow for adequate clearance between the attachment and other objects when turning. The attachment extends beyond the end of the vehicle (1). The operator must be aware of the maximum sweep (2) of the attachment when turning in order to avoid hitting personnel and other objects in the area. 1 2 OH1690 Leveling Frame When placing a load while on a slope, use the frame sway control to keep the vehicle level.
Operation Quick Attach This vehicle is equipped with a quick attach system for easy attachment changing. Attachment Removal Be sure you are performing this procedure on level ground. 1. Place the travel select lever in (N) NEUTRAL, come to a complete stop, move the neutral lock lever to NEUTRAL LOCK position and engage the parking brake switch. 2. Extend the boom approximately 10 feet (3 meters) and tilt the carriage backward. 3. Exit the vehicle using the hand holds.
Operation Attachment Reconnect Be sure you are performing this procedure on level ground. 1. Position the vehicle directly behind the attachment to be mounted. 2. Tilt the quick attach backward. 3. Extend the boom approximately 10 feet (3 meters) and drive the vehicle forward until the attachment pivot pins are below and between the two hooks on the attachment. 4. Raise the boom until the attachment pivot pins have seated fully in the hooks of the attachment. 5. Tilt the attachment up slightly.
Operation Using The Capacity Chart The individual capacity charts are located inside a booklet (1) on the right side of the front dash. Capacity charts are provided to assist the operator in determining how far in front, how high and at what angle a specific load can be safely handled with this vehicle. 1 10054 OH2740 The vehicle is equipped with two indicators that will assist the operator in determining how to accurately use the capacity chart.
Operation As the boom is extended, boom extend letters (2) will appear on the left side of the primary intermediate boom (4) visible to the operator. The letters are graduated in four foot increments. These letters indicate the point of boom extension and correspond to the capacity chart. For example, when the letter “A” first appears, the boom is at the point of boom extension corresponding to the arc of line “A” throughout all the capacity charts that follow.
Operation Reading The Capacity Chart Example (1): 1. The operator has placed the load onto the forks, fully retracted the boom, positioned the vehicle perpendicular to the structure and leveled the vehicle with the outriggers up. 2. The operator then determines that: • The load weight is 4,000 pounds (1.814 kg). • The height of the structure the load is to be placed upon is 27 feet (8,2 meters) from ground level.
Operation Standard Carriage Capacity Chart - Outriggers Up 10054 WITH SKY TRAK MANUFACTURED STANDARD CARRIAGES ONLY 40 36 32 28 24 16 20 12 56 8 4 0 ft 68° 52 60° 48 50° 44 E 40 D 40° 36 32 30° 28 24 20° 20 16 1 4 0 0 10° 12 8 4 l b s 0° 0 ft -4 1 C 3 0 2 0 0 0 0 0 l b l s b s B 6 0 0 0 4 0 0 0 A 8000 lbs l b s l b s 10,000 lbs 24" -8° 26 23 20 17 12 9 7 ASME B56.6 - 2002 PART lll 4110452 OH2762 Model 10054 Rev.
Operation Standard Carriage Capacity Chart - Outriggers Down 10054 WITH SKY TRAK MANUFACTURED STANDARD CARRIAGES ONLY 40 36 32 28 24 20 16 56 12 8 68° 52 60° H G 48 50° 44 F E 40 40° D 36 C 32 30° 24 20° 16 12 10° 8 4 A 8000 lbs l b s l b s l b s 0° 0 ft -4 4 0 0 0 3 0 0 0 B 6 0 0 0 28 20 0 ft 4 10,000 lbs 24" -8° 39 31 22 9 7 ASME B56.6 - 2002 PART lll 4110453 OH2772 80 Model 10054 Rev.
Operation Side Tilt Carriage - Outriggers Up 10054 WITH SKY TRAK MANUFACTURED SIDE TILT CARRIAGES ONLY 40 36 32 28 24 16 20 12 56 4 0 ft 68° 60° 52 8 SAFETY INSTRUCTIONS 48 50° 44 40 E 40° D C 36 32 30° 28 24 20 3 2 0 1 0 0 4 0 0 0 0 l 0 l b l b s b s s 20° 16 12 10° 8 4 0° 0 ft -4 4 0 0 0 l b s B A 6 0 0 0 Use only with vehicles equipped with auxiliary hydraulics. Always connect couplers. 8000 lbs l b s 10,000 lbs 24" -8° 27.4 23 20 17 12 9 ASME B56.
Operation Side Tilt Carriage - Outriggers Down 10054 WITH SKY TRAK MANUFACTURED SIDE TILT CARRIAGES ONLY 40 36 32 28 24 20 16 12 56 48 SAFETY INSTRUCTIONS H G 50° F E D C B 44 40 40° 36 32 30° 28 24 20 20° 16 12 10° 8 4 0° 0 ft -4 3 0 0 0 8000 lbs 10,000 lbs l b s l b s l b s Use only with vehicles equipped with auxiliary hydraulics. Always connect couplers. A 6 0 0 0 4 0 0 0 0 ft 4 68° 60° 52 8 24" -8° 39 31 22 9 ASME B56.
Operation Swing Carriage - Outriggers Up 10054 WITH SKY TRAK MANUFACTURED SWING CARRIAGES ONLY 56 40 36 32 28 24 20 16 12 8 4 60° 52 48 SAFETY INSTRUCTIONS 50° 44 40 E 40° D C B A 36 32 30° 28 24 20 1 10° 2 3 4 4 -4 5 24" 8 0 ft Use only with vehicles equipped with auxiliary hydraulics. Always connect couplers. 20° 16 12 0 ft 0° -8° 28 20 16.5 11 9 1000 lbs 2000 lbs 3000 lbs ASME B56.
Operation Swing Carriage - Outriggers Down 10054 WITH SKY TRAK MANUFACTURED SWING CARRIAGES ONLY 56 40 36 28 32 24 20 16 12 8 68° 52 48 50° 44 40 4 H G F 36 C B A 30° 28 24 20 20° 16 12 10° 8 4 0 ft -4 1 SAFETY INSTRUCTIONS E D 40° 32 0 ft 2 3 Use only with vehicles equipped with auxiliary hydraulics. Always connect couplers. 5 4 24" 0° -8° 39 32 29 11 9 2000 lbs 3000 lbs 4000 lbs ASME B56.
Operation 15 Foot Truss Boom - Outriggers Up 10054 15' WITH SKY TRAK MANUFACTURED 15' TRUSS BOOMS ONLY 40 44 36 32 28 24 20 16 12 8 4 0 ft 72 68 64 60 56 68° 52 60° 48 SWINGING LOADS can MACHINE TIPOVER B cause which can result in death or serious injury. A 44 50° 40 F E D C 36 40° 32 28 24 20 16 12 8 4 0 ft -4 30° 1 5 20° 1 0 0 0 0 10° 0 l b l s 0° b s 2 0 0 0 l b s ALWAYS travel slowly rig properly use two tethers -8° 39 35 31 ASME B56.
Operation 15 Foot Truss Boom - Outriggers Down 10054 15' WITH SKY TRAK MANUFACTURED 15' TRUSS BOOMS ONLY 72 52 48 44 40 36 32 28 24 68 68° 64 60 60° 56 52 50° 48 44 40° 40 36 32 28 24 20 30° 20° 16 12 10° 2 0 0 0 l b s 20 16 12 8 4 0 ft H G F E D C B A SWINGING LOADS can cause MACHINE TIPOVER which can result in death or serious injury. ALWAYS travel slowly rig properly use two tethers 8 4 0° 0 ft -4 -8° 51 ASME B56.
Operation 3 Foot Truss Boom w/Winch - Outriggers Up 10054 WITH SKY TRAK APPROVED TRUSS BOOM WINCH ONLY 40 36 32 28 24 20 16 56 SAFETY INSTRUCTIONS 12 8 4 Use only with vehicles equipped with auxiliary hydraulics. Always connect couplers. 0 ft 68° 60° 52 48 50° 44 40 E 40° D C 36 32 B A 30° 28 SWINGING LOADS can cause MACHINE TIPOVER which can result in death or serious injury.
Operation 3 Foot Truss Boom w/Winch - Outriggers Down 10054 WITH SKY TRAK APPROVED TRUSS BOOM WINCH ONLY 40 36 32 28 24 20 SAFETY INSTRUCTIONS 16 56 12 8 Use only with vehicles equipped with auxiliary hydraulics. Always connect couplers. 0 ft 4 68° 60° 52 48 50° 44 40 40° 36 32 30° 28 H G F E D C B SWINGING LOADS can cause MACHINE TIPOVER which can result in death or serious injury.
Operation Fork Ratings All approved forks for this vehicle are marked with a maximum load capacity rating. This rating is stamped on the left edge of the fork (1) just below the fork pivot shaft (2). The rating is listed in U.S. pounds and based upon a 24" (610 mm) load center (3). This rating specifies the maximum load capacity that the individual fork can safely carry at a maximum load center (4) of 24" (610 mm).
Operation How To Pick, Carry & Place A Load To pick a load, tilt the carriage forward so the forks hang freely on the fork shaft. Move the forks inward or outward on the fork shaft so that they are aligned with the openings in the pallet. Tilt the carriage back and extend the boom slowly so the forks slide into the openings in the pallet. Raise the boom so that the load is lifted. To carry a load, position the boom so that the load is as low as possible and the travel area is visible to the operator.
Operation b. Width of the platform shall not be wider than the width of the vehicle, measured across the load bearing tires plus 10" (250 mm) on each side. c. Minimum space requirements for each person on the platform shall not be less than 18" (450 mm) in either direction. 3. The platform shall have a 4" (100 mm) minimum high toe plate around the perimeter of the platform. The toe plate may be omitted at the access opening. 4.
Operation 10. A body belt and lanyard is to have an attaching point for freedom of movement, and its length is to limit free fall to 5 feet (1500 mm) measured from the point of attachment to the operator. The complete system shall be capable of withstanding three consecutive drop tests to simulate a 250 lb (113 kg) person falling 6 feet (1800 mm) without allowing the test weight to fall free to the ground. A deceleration device may be included. 11.
Operation 6. Be sure the vehicle is in a level position (side to side) before any operation is begun. Use the frame sway to level the vehicle. If the vehicle cannot be leveled, reposition the vehicle. 7. Place the travel select lever in the (N) NEUTRAL position and move the neutral lock lever to the NEUTRAL LOCK position. 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.
Operation Elevating Personnel WARNING: Never operate the Attachment Tilt function to tilt the platform forward or rearward when elevating with personnel aboard. Death or serious personal injury could result. DANGER: Never operate this or any equipment in an area in which overhead or underground cables or power sources exist without first requesting that the appropriate power company or utility company de-energize the lines or take other suitable precautions. 1.
Operation Using Other Attachments Numerous attachments, marketed by JLG are available for this vehicle. The capacity charts attached to this vehicles dash are to be used with Sky Trak approved attachments only. Hydraulically powered attachments must only be used on vehicles equipped with auxiliary hydraulics. IMPORTANT! This vehicle is intended for the function of lifting only. This vehicle is not designed to PULL, TOW or DRAG other objects.
Operation Shut-Off 1. Bring the vehicle to a complete stop using the service brakes. 2. Park the vehicle on level ground. WARNING: To prevent death or serious personal injury, be certain to lower the boom, engage the parking brake switch, and shut off the engine prior to exiting the vehicle. 3. Place the travel select lever in (N) NEUTRAL, move the neutral lock lever to NEUTRAL LOCK position and engage the parking brake switch. 4. Lower the boom and ground the carriage. 5.
Emergency Operations Emergency Operations Towing A Disabled Vehicle Towing a disabled vehicle should only be attempted after exhausting all other options. Every effort should be made to repair the vehicle and move it under its own power. Towing the vehicle improperly can result in damage to the vehicle drivetrain. IMPORTANT! In the event the vehicle is disabled and cannot be moved under engine power, the situation must be properly evaluated and dealt with on an individual basis.
Emergency Operations 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 the secondary function manifold (2) mounted on the inside wall of the frame (3) on the left side next to the transmission. 3 Front Of Vehicle 2 1 OH1840 6.
Emergency Operations Emergency Boom Lowering This section discusses emergency boom lowering procedures: Part I In case of loss of engine power or hydraulic pump failure. Part II In case of hydraulic line failure. Part I Loss of Engine Power or Hydraulic Pump Failure IMPORTANT! In the event of total loss of engine power or hydraulic pump failure with an elevated load, the situation must be properly evaluated and dealt with on an individual basis.
Emergency Operations Part ll - Hydraulic Line Failure In case of hydraulic line failure, there are step-by-step procedures available to assist you in safely retracting and then lowering the boom. Read Part II from start to finish before performing any of these procedures so you fully understand the process and the danger involved. If you are unsure about any part of these procedures contact your local Sky Trak Distributor or the JLG Service Department.
Emergency Operations In any case of hydraulic line failure, it is critical to correctly identify which hydraulic line has failed. Identify the hydraulic line that has failed and use the table that follows to determine which Step to follow to retract and lower the boom.
Emergency Operations 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 position and engage the parking brake switch. 3. Block all four wheels. WARNING: DO NOT get under a raised boom unless the boom is blocked up. Always block the boom before doing any servicing that requires the boom to be up. 4.
Emergency Operations 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. 3 3 1 2 2 4 1 OH1931 4 Model 10054 Rev.
Emergency Operations STEP 2 USE IN CASE OF: BOOM LIFT LINE FAILURE (Lift Cylinders to Control Valve) BOOM EXTEND LINE FAILURE 1. Clear the area of any unnecessary personnel. 2. Place the travel select lever in (N) NEUTRAL, move the neutral lock lever to NEUTRAL LOCK position and engage the parking brake switch. 3. Block all four wheels. WARNING: Wear protective clothing and proper eye protection when working with or around hydraulic oil.
Emergency Operations 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. 3 3 1 2 2 4 1 OH1931 4 Model 10054 Rev.
Emergency Operations STEP 3 BOOM LOWER LINE FAILURE (Lift Cylinders to Control Valve) 1. Clear the area of any unnecessary personnel. 2. Place the travel select lever in (N) NEUTRAL, move the neutral lock lever to NEUTRAL LOCK position and engage the parking brake switch. 3. Block all four wheels. WARNING: DO NOT get under a raised boom unless the boom is blocked up. Always block the boom before doing any servicing that requires the boom to be up. 4. Temporarily block up or support the outer boom. 5.
Emergency Operations 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. 1 2 2 1 OH1931 IMPORTANT! Have the vehicle serviced and hoses replaced as soon as the boom has been lowered and the vehicle is in a secure location. Model 10054 Rev.
Emergency Operations 12. Tilt the carriage and/or attachment upward if necessary for clearance before retracting the boom. 13. SLOWLY RETRACT the boom. 14. SLOWLY LOWER the boom and ground the carriage. 15. Completely remove the load from the carriage and/or attachment if you haven’t already done so. 16. Have the vehicle serviced immediately. 17. Replace any faulty hydraulic lines. 18. Return to the cab, fasten your seat belt and start the engine. 19.
Emergency Operations STEP 4 BOOM RETRACT LINE FAILURE 1. Clear the area of any unnecessary personnel. 2. Place the travel select lever in (N) NEUTRAL, move the neutral lock lever to NEUTRAL LOCK position and engage the parking brake switch. 3. Block all four wheels. WARNING: DO NOT get under a raised boom unless the boom is blocked up. Always block the boom before doing any servicing that requires the boom to be up. 4.
Emergency Operations WARNING: Wear protective clothing and proper eye protection when working with or around hydraulic oil. Wait for hydraulic oil to cool before attempting to repair the failure. Hot hydraulic oil can cause severe burns and other serious injury. NOTE: If a replacement hose is not available, the adjacent boom extend line (1) can be used to replace the failed boom retract line (2). 6. Remove the failed boom retract line (2) from the circuit. 7.
Emergency Operations 1 1 2 1 OH1931 2 Model 10054 Rev.
General Maintenance General Maintenance General Maintenance This section of the manual contains a maintenance schedule and checklist with references to pertinent procedures and instructions. To prevent problems before they occur, follow the maintenance schedule. NOTE: The Lubrication (1) and Maintenance Chart (2) decals are located inside the right side engine cover (3). They contain a general maintenance schedule that should be followed to maintain the vehicle in good operating condition.
General Maintenance Maintenance Schedule And Checklist 10 Hour Intervals OH1980 10 Drain Fuel/ Water Separator Paragraph Ref. 5A Check Check Check Engine Check Engine Hydraulic Oil Transmission Coolant Level Oil Level Level Oil Level 3A 4A 7B 8A Check Tire Pressure 12A OF1190 Air Filter Restriction Indicator Paragraph Ref. Model 10054 2A Rev.
General Maintenance At First 50 Hours of Use OM1460 430-470 (583-637) LB/F T (N m) 50 Change Engine Oil and Filter Change Transmission Filter Change Hydraulic Filter Check Wheel Lug Nut Torque 4B 8B 7C 12B Paragraph Ref. OH2000 Change Axle Oil Change Wheel End Oil Check Boom Chain Tension 9B 11B 15A & 15C Paragraph Ref. 50 Hour Intervals OH2010 50 Paragraph Ref. 114 Inspect Wear Pads Lubricate Pivot Points 15G 1 Model 10054 Rev.
General Maintenance 250 Hour Intervals OH2021 250 Paragraph Ref. Change Air Filter Lubricate Pivot Points Change Engine Oil and Filter 2B 1 4B OA1460 Check Wheel End Oil Level Check Axle Oil Level Inspect Extend chains 11A 9A 15E Paragraph Ref. 500 Hour Intervals OH3150 500 Change Fuel Filter Paragraph Ref. Model 10054 5B & 5C Rev.
General Maintenance 1000 Hour Intervals OH2040 1000 Check Boom Chain Tension Inspect Wear Pads Change Transmission Oil And Filter 15A & 15C 15G 8B Paragraph Ref. OH2050 Change Axle Oil Change Wheel End Oil Change Hydraulic Oil And Filter 9B 11B 7C Paragraph Ref. P Check Fan Belt Paragraph Ref. Check Air Lubricate Intake System Pivot Points 6A 2C 1 OH2061 Check Axle Brake Discs 10A OA1470 Lubricate Boom Chains Paragraph Ref. 116 15F Model 10054 Rev.
General Maintenance 2000 Hour Intervals OH2070 2000 Change Engine Coolant Paragraph Ref. Model 10054 3B Rev.
General Maintenance 1. Lubrication Points 50 Lubricate the following grease fittings using Multi-Purpose Grease (MPG): OS1750 OH2680 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.
General Maintenance Lubrication Points G G J J 2/ 2/ F (Qty. 2) L E G I B D C G H K A K B C H H G OH2840 Model 10054 Rev.
General Maintenance 2. Air Cleaner And Restriction Indicator NEVER operate the vehicle without the air cleaner assembly and both filters in place. A. Filter Check 10 OH2660 OF1190 1. Ground the carriage, place the travel select lever in (N) NEUTRAL, move the neutral lock lever to NEUTRAL LOCK position, engage the parking brake switch and shut off the engine. 2. Unlock and open the left rear engine access door to access air cleaner restriction indicator (1). Check indicator.
General Maintenance 3. Remove dust from vacuator valve by squeezing bottom of vacuator (4) to allow loose particles to fall out. Replace elements, if required, as described in paragraph 2B. 4 OH3380 B. Element: Change (As Restriction Indicator Indicates or) 250 OH2710 OS0790 Outer Primary Element All air cleaner manufacturers agree that attempting to clean or wash an element increases the chance for element damage.
General Maintenance To change elements: 1. Pull the air cleaner cover lock (1) OUT, turn the air cleaner cover (2) counterclockwise and remove the cover from the air cleaner canister (3). 1 3 2 OH3390 2. Remove the primary element (4). Inspect the element for damage. Damaged elements should not be reused. 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.
General Maintenance 4 9 7 5 8 6 OH3400 C. Air Intake System-Inspection 1000 OH2690 OT0880 Inspect the intake piping for cracked hoses, loose clamps or punctures which can allow dirt or debris to enter the combustion chamber. If dirt or debris are allowed to enter the combustion chamber, they can severely damage the engine. If necessary, tighten or replace parts to prevent air intake system leakage. Model 10054 Rev.
General Maintenance 3. Engine Cooling System A. Engine Coolant Level Check 10 OH2660 OS0800 1. Level the vehicle, ground the carriage, place the travel select lever in (N) NEUTRAL, move neutral lock lever to NEUTRAL LOCK position, engage the parking brake switch and shut off the engine. 2. Unlock and open the right rear engine access door. Check level of coolant in overflow bottle (1). When coolant is hot, bottle should be 1/2 to 3/4 full. When coolant is cool, bottle should be 1/4 to 1/2 full.
General Maintenance B. Drain And Flush Radiator OS0810 2000 OH2700 1. Level the vehicle, ground the carriage, place the travel select lever in (N) NEUTRAL, move neutral lock lever to NEUTRAL LOCK position, engage the parking brake switch and shut off the engine. WARNING: DO NOT attempt this procedure when the engine is hot. Wait for the engine, muffler and tailpipes to cool down before proceeding. Failure to do so could result in severe burns. 2. Unlock and open the rear radiator access door.
General Maintenance 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 and drain bottle. 5. Flush system with clean water and drain again. NOTE: On vehicles equipped with a cab heater option, a shut off valve is installed at the engine inlet. Disconnect hose from shut off valve to drain the heater. 6. Transfer the coolant into a properly labelled container.
General Maintenance 4. Engine Oil And Filter Engine Oil Recommendations The use of quality engine oil combined with the appropriate oil and filter change intervals are critical factors in maintaining engine performance and durability. Use 15W40 motor oil that at least meets the manufacturers minimum recommended oil specifications as defined in their operator manual. A. Oil Level Check 10 OH2660 OS0820 1.
General Maintenance 4. If oil is low, remove oil fill cap (1) and add 15W40 motor oil that at least meets the manufacturers minimum recommended oil specifications as defined in their operator manual to bring oil up to the FULL mark (2) in the crosshatched area. Add oil through the opening under the boom. Replace oil fill cap and dipstick (3). Close and lock access door. 1 3 2 4 OH3531 128 Model 10054 Rev.
General Maintenance B. Oil And Filter Change 1. Operate the engine until warm (approximately 5 minutes). 50 OH2670 250 2. Level the vehicle,raise OH2710 OS0830 the boom up to approximately 20°, place the travel select lever in (N) NEUTRAL, move neutral lock lever to NEUTRAL LOCK position, engage the parking brake switch and shut off the engine. 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.
General Maintenance 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 recommended oil specifications as defined in their operator manual. (Reference engine manufacturer's manual for recommended oil types to be used in various temperature limits.) Fill oil through the opening under the boom. DO NOT over fill.
General Maintenance 5. Engine Fuel System A. Drain Water From Fuel Water Separator/Filter 10 OH2660 H 20 OS0851 Unlock and open the right rear engine access door. Loosen drain cock (4) on underside of the fuel filter (5) and allow all water to drain into a glass until clear fuel is visible. Tighten drain cock after draining. Close and lock access door. 5 4 OU1290 Model 10054 Rev.
General Maintenance B. Change Fuel Filter 500 OT1150 OS0870 The fuel filter (1) must be changed at shorter intervals with water evidence or contaminated fuel. 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. 2 1 OU1290 5. Fill the new fuel filter with clean No. 2 diesel fuel. 6. Lubricate the o-ring seal with clean No. 2 diesel fuel.
General Maintenance C. Replace In-line Fuel Strainer 500 OT1150 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 two hose clamps (5) that secure the strainer in place. 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.
General Maintenance D. Bleeding Fuel System Air must be vented from the fuel system whenever any component between the fuel tank and the injection pump has been disconnected, or when the system has been emptied or run out of fuel. WARNING: DO NOT bleed the fuel system of a hot engine. Doing so could create a fire hazard. Allow the engine to cool before bleeding the fuel system. IMPORTANT! DO NOT attempt to start the engine until the injection pump has been filled and primed with fuel.
General Maintenance The process to vent the high pressure fuel lines involves energizing the starter motor to rotate the crankshaft which will, in turn, pump any unwanted air from the fuel lines. CAUTION: When using the starting motor to vent the fuel system, DO NOT energize the starter solenoid or crank the engine for more than 15 seconds at a time; wait two minutes between engagements. WARNING: KEEP CLEAR of spraying fuel. Fuel can spray when venting high pressure lines.
General Maintenance 6. Engine Fan Belt A. Engine Fan Belt Check 1000 1. Ground the carriage, OH2690 OS08802 place the travel select lever in (N) NEUTRAL, move the neutral lock lever to NEUTRAL LOCK position, engage the parking brake switch and shut off the engine. 2. 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.
General Maintenance 7. Hydraulic Oil and Filter A. Hydraulic System Oil OH2630 Hydraulic system oil can be either a hydraulic oil meeting the requirements of ISO Grade 46 or a 10W motor oil meeting the requirements of U.S. Ordinance Specifications MIL-L-2104C. See table below.
General Maintenance B. Hydraulic Oil Level Check 1. Be sure all cylinders are fully retracted and oil is at room temperature. 10 OH2660 OS0660 2. Level the vehicle, ground the carriage, place travel select lever in (N) NEUTRAL, move the neutral lock lever to NEUTRAL LOCK position, engage the parking brake switch and shut OFF the engine. 3. Check level of hydraulic oil in tank at the sight gauge (1) on the back side of the hydraulic tank (2). 4. The oil level should be visible in the gauge window. 5.
General Maintenance C. Hydraulic Oil & Filter Change (Filter Only) 50 (Oil & Filter) 1000 OH2670 OH2690 OT08402 OS08402 Change the hydraulic oil filter after the first 50 hours of operation and change the hydraulic oil and filter every 1000 hours of operation thereafter. Other than the 1000 hour interval, the hydraulic oil must be changed when a hydraulic component has contaminated the system. 1.
General Maintenance 4. Clean area around filter head (1). Loosen but do not remove the nuts that secure the filter head to the hydraulic tank (2). 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 large enough to hold 38 gallons (144 liters) of oil.
General Maintenance 8. Transmission Oil and Filter APPROVED UNIVERSAL TRACTOR FLUIDS JOHN DEERE JDM J20C (HY-GARD) FORD / NEW HOLLAND ESN-M2C134-D (HYDRAULIC OIL134) MASSEY FERGUSON M-1141 (PERMATRAN III) CHEVRON CHEVRON 1000 THF A. Transmission Oil Level Check 10 OS0890 OH2660 1. Level the vehicle, ground the carriage, place travel select lever in (N) NEUTRAL, move neutral lock lever to NEUTRAL LOCK position and engage the parking brake switch. 2.
General Maintenance B. Transmission Oil & Filter Change (Filter Only) (Oil & Filter) 50 1000 OH2670 OH2690 OT08302 OS09502 Change the transmission oil filter after the first 50 hours of operation and change the transmission oil and filter every 1000 hours of operation thereafter. 1. Level the vehicle, ground the carriage, place travel select lever in (N) NEUTRAL, move neutral lock lever to NEUTRAL LOCK position, engage the parking brake switch and shut OFF the engine. 2.
General Maintenance 3. Allow the transmission to cool. 4. Place a receptacle under the transmission drain plug (3). Remove the drain plug and allow the Universal Tractor Fluid to drain into the receptacle. Transfer the used oil into a suitable container with a cover and label the container as used oil. Dispose of properly. 5. Clean and re-install the drain plug (3) into the transmission housing. 6. Remove the filter (4) from the filter mount on the front side of the transmission (5).
General Maintenance 9. Axle Oil A. Axle Oil Level Check 250 OH2710 OT0460 APPROVED UNIVERSAL TRACTOR FLUIDS JOHN DEERE JDM J20C (HY-GARD) FORD / NEW HOLLAND ESN-M2C134-D (HYDRAULIC OIL134) MASSEY FERGUSON M-1141 (PERMATRAN III) CHEVRON CHEVRON 1000 THF 1. Level the vehicle, ground the carriage, place the travel select lever in (N) NEUTRAL, move neutral lock lever to NEUTRAL LOCK position, engage the parking brake switch and shut off the engine. 2.
General Maintenance B. Axle Oil Change 50 OH2670 1000 OH2690 OT0440 NOTE: At the 1000 Hour Interval Oil Change also inspect the brake disk wear. Refer to “Brake Disk Inspection” on page 146 and follow the inspection procedure. After brake disk inspection is complete, reassemble the level plugs using new o-rings. 1.
General Maintenance 10. Brake Disk Inspection A. Brake Disk Wear Check (1000 Hour Intervals) Check the brake disks for wear every 1,000 hours of operation or yearly. P 1000 OH2690 MT2830 If the brake disks require service due to wear, the axle should be checked, serviced and repaired only by experienced service technicians who are aware of all safety instructions and particular component features. A. Front Axle WARNING: BLOCK ALL FOUR WHEELS.
General Maintenance 3. Attach a remote portable hydraulic pressurizing unit to the parking brake gauge port (3) on the secondary function manifold (4) mounted on the inside wall of the frame (5) on the left side next to the transmission. 5 Front Of Vehicle 4 3 OH1840 4. Turn the key switch to the ON position (with the engine not running), release the park brake (park brake switch OFF), and have an operator seated in the seat. CAUTION: DO NOT exceed 575 psi (40 bar) when pressurizing the park brake.
General Maintenance 5. Pressurize the park brake with the pressurizing unit. Close the pump needle valve on the pressurizing unit. 6. Working through the level plug hole (1), carefully use a screwdriver to spread the brake disks apart. IMPORTANT! DO NOT damage the surfaces of the brake disks when spreading the brake disks. 1 MT2850 7. Using a feeler gauge, check the gap (2) between the brake disks (3). If the gap is greater than .26" (6,75 mm), replace the brake disks.
General Maintenance 2 3 MT2840 B. Rear Axle 1. Working through the level plug hole (1), carefully use a screwdriver to spread the brake disks apart. IMPORTANT! DO NOT damage the surfaces of the brake disks when spreading the brake disks. 2. Using a feeler gauge, check the gap (2) between the brake disks (3). If the gap is greater than .167" (4,25 mm), replace the brake disks. NOTE: If the brake disks are worn beyond .
General Maintenance 11. Wheel End Oil WARNING: DO NOT perform service or maintenance on this vehicle with the engine running. Contact with moving parts can cause death or serious personal injury. APPROVED UNIVERSAL TRACTOR FLUIDS JOHN DEERE JDM J20C (HY-GARD) FORD / NEW HOLLAND ESN-M2C134-D (HYDRAULIC OIL134) MASSEY FERGUSON M-1141 (PERMATRAN III) CHEVRON CHEVRON 1000 THF A. Wheel End Oil Level Check 250 OT0430 OH2710 1.
General Maintenance B. Wheel End Oil Change 50 OH2670 1000 OH2690 OT0450 1. Position the vehicle on level ground, move the vehicle forward or backward enough to ensure that the wheel end fill/drain plug (4) is in the 6 o’clock position (5). 6 4 5 OT0290 2. Ground the carriage, place the travel select lever in (N) NEUTRAL, move neutral lock lever to NEUTRAL LOCK position, engage the parking brake switch and shut off the engine. 3. Clean the area around the wheel end fill/drain plug (4).
General Maintenance 12. Wheels and Tires A. Tire Air Pressure Check 10 OS0900 OH2660 DANGER: LOW TIRE PRESSURE can result in tipover. MAINTAIN proper tire pressure at all times. Check all four tires: 1. Remove the valve stem cap. 2. Check tire pressure using a good quality gauge. You cannot tell if a tire is properly inflated simply by looking at it. 3. Add air if required. Fill the tire(s) to: Standard Tires 17.5 - 25 (12 Ply) ..................60 psi (414 kPa) Optional Radial Tire 17.5R25 One Star...
General Maintenance B. Wheel Lug Nut Torque Check 430-470 (583-637) LB/F T (N m) 50 OM14001 OH2670 1. Wire brush the area around the lug nuts if necessary.There are separate lockwashers (1) under the lug nuts (2). Be sure the lockwashers are installed under each lug nut. 2. Using the torque sequence (A thru K) shown below, alternately check the torque of each of the ten lug nuts. The recommended torque should be 430-470 lb-ft (583-637 Nm). 2 A H E D J 1 K C G F B OM1620 C.
General Maintenance 13. Batteries WARNING: Lead-acid batteries produce flammable and potentially explosive gases. To avoid personal injury when checking, testing or charging batteries: • DO NOT use smoking materials near batteries. • Keep arcs, sparks and open flames away from batteries. • Provide ventilation and wear safety glasses. The batteries in this vehicle are maintenance free type batteries. They are shipped in the vehicle filled with electrolyte and charged.
General Maintenance WARNING: Fluid in electric storage batteries contains sulfuric acid which is POISON and can cause SEVERE CHEMICAL BURNS. Avoid all contact of fluid with eyes, skin or clothing. Use protective gear when handling batteries. DO NOT tip a battery beyond a 45° angle in any direction. If contact does occur, follow the First Aid suggestions that follows. Battery Electrolyte First Aid: • External Contact — Flush with water.
General Maintenance 14. Fuse and Relay Replacement The fuses and relays in this vehicle protect the electrical system. The fuses most often fail if there is a short or grounded wire in the applicable circuit. The fuses will have to be replaced if they fail. If fuses continually fail, check the system for shorts, grounds or defective electrical components. The fuses and relays are mounted inside the right side console in the operators cab.
General Maintenance 12 13 11 14 7.5 7.5 20 10 10 9 10 10 15 6 10 7.5 7.5 40 7.5 5 4 3 8 7 40 OH3131 15 No. 3 4 5 6 7 8 9 10 11 12 13 14 15 Amp Color 7.5 Amp 7.5 Amp 40 Amp 7.5 Amp 10 Amp 15 Amp 10 Amp 10 Amp 10 Amp 7.5 Amp 7.5 Amp 20 Amp 40 Amp Brown Brown Orange Brown Red Blue Red Red Red Brown Brown Yellow Orange Model 10054 Rev.
General Maintenance 7.5 7.5 20 10 12 13 11 10 6 5 7 4 8 3 10 15 14 10 10 15 9 7.5 7.5 40 7.5 2 1 40 OH3142 No.
General Maintenance Cold Start Grid Heater Fuses The two 125 amp fuses (16) that protect the cold start grid heater are located inside the frame on the left side. 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 tethers on the holder (18). 3. Remove the two hex nuts (19) and lockwashers (20) securing the fuse (16) and wires to the fuse holder (18). Remove the fuse and replace with a new fuse. 4.
General Maintenance ECM Fuses and Relays The three fuse holders (1), that protect the ECM diagnostic system, are located inside the frame on the left side of the engine and are tie wrapped to the wire harness. One holder contains one 7.5 amp fuse (brown), one contains three 7.5 amp fuses (brown) and the other holder contains three 10 amp fuses (red). 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.
General Maintenance 15. Boom Chains and Wear Pads A. Intermediate Boom Chains Tension Check 50 OH2670 1000 OH2390 OH2690 Check the intermediate boom chain tension by measuring the intermediate boom extend chain sag. 1. Park the vehicle on level ground. Place the travel select lever in (N) NEUTRAL, move neutral lock lever to NEUTRAL LOCK position, engage the parking brake switch and raise the boom to a horizontal (level) position. 2. Lower both outriggers completely.
General Maintenance 3. Measure the sag (1) in the intermediate boom extend chains (2) between the bottom of the chains and the top of the primary intermediate boom (3) at their closest point. Acceptable intermediate boom chain sag is between 1.5" (38 mm) and 2.5" (64 mm). If the measurement is less than 1.5" (38 mm) or more than 2.5" (64 mm), the boom chains need to be adjusted.
General Maintenance 5. Go to the back of the vehicle and remove the rear cover from the back of the boom. 6. Check the measurement (4) from the top rear edge of the primary intermediate boom (5) to the top rear edge of the secondary intermediate boom (6). Measurement should be between 8.5" (216 mm) - 11" (279 mm). NOTE: If the measurement is less than 8.5" (216 mm) the boom may require extensive adjustment and/or repair. Contact your local Sky Trak Distributor. REAR OF BOOM 6 4 5 OH2860 Model 10054 Rev.
General Maintenance 7. If the measurement is more than 11" (279 mm), tighten the retract chain locknut (1) located on the bottom of the outer boom (2). 1 2 OA0512 8. Start the vehicle, with the outriggers lowered completely, cycle the boom in and out several times. Then with the boom horizontal, retract the boom completely. Turn the vehicle OFF. 9.
General Maintenance 11. Measure the sag (3) in the intermediate boom extend chains (4) between the bottom of the chains and the top of the primary intermediate boom (5) at their closest point. Acceptable boom chain sag is between 1.5" (38 mm) and 2.5" (64 mm). If the measurement is less than 1.5" (38 mm) or more than 2.5" (64 mm), the intermediate boom chains need to be adjusted. See “Intermediate Boom Chain Tension Adjustment” on page 166. 3 4 5 OA0491 Model 10054 Rev.
General Maintenance B. Intermediate Boom Chain Tension Adjustment (As required) NOTE: Always perform the “Intermediate Boom Chain Tension Check” starting on page 161 before adjusting the boom chain tension. 1. Park the vehicle on level ground. Place the travel select lever in (N) NEUTRAL, move neutral lock lever to NEUTRAL LOCK position, engage the parking brake switch and raise the boom to a horizontal position. Retract the boom completely and turn the vehicle OFF. 2.
General Maintenance 3 OH0531 4. Start the vehicle, with the outriggers lowered completely, cycle the boom in and out several times. With the boom horizontal, fully extend the boom and then retract it 2" (51 mm). Turn the vehicle OFF. 5. Measure the intermediate boom chain sag. Acceptable intermediate boom chain sag is between 1.5" (38 mm) and 2.5" (64 mm). If the chain sag is less than 1.5" (38 mm) or more than 2.5" (64 mm), repeat steps 1 through 5 until the sag is within the acceptable range.
General Maintenance C. Inner Boom Chain Tension Check 1000 50 OH2390 OH2670 OH2690 Check the inner boom chain tension by measuring the inner boom extend chain sag. 1. Park the vehicle on level ground. Place the travel select lever in (N) NEUTRAL, move neutral lock lever to NEUTRAL LOCK position, engage the parking brake switch and raise the boom to a horizontal (level) position. 2. Lower both outriggers completely. Fully extend the boom, then retract it 2" (51 mm). Turn the vehicle OFF. 3.
General Maintenance Before making any adjustments to the inner boom extend chain, check the following measurement at the rear of the boom. 4. Start the vehicle, retract the boom completely and turn the vehicle OFF. 5. Go to the back of the vehicle and remove the rear cover from the back of the boom. 6. Check the measurement (4) from the top rear edge of the secondary intermediate boom (5) to the top rear edge of the inner boom (6). This measurement should be between 13.75" (349 mm) 14.25" (362 mm).
General Maintenance 7. If the measurement is more than 14.25" (362 mm), tighten the inner boom retract chain locknut (1) located on the bottom of the primary intermediate boom (2). Extend the boom far enough to expose the inner boom retract chain locknut (1). 2 1 OH0660 8. Start the vehicle, with the outriggers lowered completely, cycle the boom in and out several times. Then with the boom horizontal, retract the boom completely. Turn the vehicle OFF. 9.
General Maintenance If the measurement is within the range of 13.75" (349 mm) - 14.25" (362 mm) measure the inner boom extend chain sag again. 10. Start the vehicle, with the outriggers lowered completely, cycle the boom in and out several times. With the boom horizontal, fully extend the boom and then retract it 2" (51 mm). Turn the vehicle OFF. 11. Measure the sag (3) in the inner boom extend chain (4) between the bottom of the chain and the top of the secondary intermediate boom (5) at the closest point.
General Maintenance D. Inner Boom Chain Tension Adjustment (As required) NOTE: Always perform the “Inner Boom Chain Tension Check” starting on page 168 before adjusting the boom chain tension. 1. Park the vehicle on level ground. Place the travel select lever in (N) NEUTRAL, move neutral lock lever to NEUTRAL LOCK position, engage the parking brake switch and raise the boom to a horizontal position. Retract the boom completely and turn the vehicle OFF. 2.
General Maintenance 2 OH0531 3. Start the vehicle, with the outriggers lowered completely, cycle the boom in and out several times. With the boom horizontal, fully extend the boom and then retract it 2" (51 mm). Turn the vehicle OFF. 4. Measure the inner boom chain sag. Acceptable inner boom chain sag is between 1.5" (38 mm) and 2.5" (64 mm). If the chain sag is less than 1.5" (38 mm) or more than 2.5" (64 mm), repeat steps 1 through 4 until the sag is within the acceptable range.
General Maintenance E. Boom Chain Inspection (250 Hour Intervals) 250 OA1490 OH2710 WARNING: Worn pins, stretched or cracked links or corrosive environments can cause chain failure. A chain failure could result in uncontrolled boom movement, loss of load or vehicle instability and could cause death or serious injury and/or property damage. Under normal operating conditions the boom chains will need to be inspected every 250 hours of operation.
General Maintenance Following are some examples of dynamic shock loading which can impose abnormal loads above the endurance limit of a leaf chain. • High velocity movement of load, followed by sudden, abrupt stops. • Carrying loads in suspension over irregular surfaces such as railroad tracks, potholes, and rough terrain. • Attempting to “inch” loads which are beyond the rated capacity of the vehicle. The above load cycles and environmental conditions make it impossible to predict chain life.
General Maintenance Inspection Guidelines 1. Park the vehicle on level ground. Place the travel select lever in (N) NEUTRAL, place the neutral lock lever in the (N) NEUTRAL LOCK position, engage the parking brake switch and raise the boom to a horizontal (level) position. 2. Fully extend the boom until the extend chain is taut. Shut the engine off. The extend chains will be visible for inspection with the vehicle in this state.
General Maintenance Elongation Double Extend Chains: When the original length (3) of 12.00" (305 mm) per foot of new chain has elongated from wear to a length (4) of 12.36" (313 mm), the chain should be discarded and replaced. Single Extend Chains: When the original length (3) of 12.00" (305 mm) per foot of new chain has elongated from wear to a length (4) of 12.36" (313 mm), the chain should be discarded and replaced.
General Maintenance Turning or Protruding Pins Highly loaded chain, operating with inadequate lubrication can generate abnormal frictional forces between pin and link plates. When chain is allowed to operate in this condition, a pin or series of pins, can begin to twist out of a chain, resulting in failure. Examine the pin head rivets to determine if the “VEE” flats are still in correct alignment (1). Chain with rotated/displaced heads (2) or abnormal pin protrusion (3) should be replaced immediately.
General Maintenance Cracked Plates Inspect the chains very carefully, front and back as well as side to side, for any evidence of cracked plates. If any one crack is discovered, the chain should be replaced in its entirety. It is important, however to determine the cause of the crack before installing a new chain so the condition does not repeat itself. The types of cracks are: • Fatigue Cracking - Fatigue cracks (5) are a result of repeated cyclic loading beyond the chain’s endurance limit.
General Maintenance F. Chain Lubrication (1000 Hour Intervals) 1000 OA1510 After inspection and before OH2690 being returned to service, chains must be lubricated with a quality chain lubricant (“LUBRIPLATE” Chain & Cable Fluid, “LPS3” or equivalent). The lubricant must penetrate the chain joint to prevent wear. Applying lubricant to the external surfaces will prevent rust, but the chains should be articulated to make sure the lubricant penetrates to the working surfaces between the pins and links.
General Maintenance G. Wear Pad Inspection (50 Hour Intervals) 50 Visually inspect boom wear OH2680 pads between the boom sections at the rear and front of the boom for excessive wear at every 50 hour interval. OH2400 The average expected life of boom pads will vary depending upon vehicle use, weight of loads, operating conditions, and the location of boom pads inside the boom.
General Maintenance H. Wear Pad Replacement (As Wear Pad Indicators Indicate) Each boom pad (1) is manufactured with a convenient wear pad indicator. This is the angled cut (2) at each end of all wear pads. The total thickness (3) of a new wear pad is .625" (16 mm). The angled cut will provide a total wear thickness (4) of .25" (6 mm). This will leave approximately .375" (10 mm) of total unused base material.
General Maintenance Storage and Transport Storage A. Before Storing Perform the following steps prior to placing the vehicle in storage: 1. Clean the entire vehicle. 2. Lubricate all grease fittings as described in “Lubrication Points” on page 118. 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.
General Maintenance 6. Review and familiarize yourself and any other operator with all the safe and proper operating procedures contained in this manual. Transport When transporting the vehicle, make use of all four tiedown/lift point locations on the vehicles frame.
Test Procedures Test Procedures Stabil-TRAK System Test To test the function of the Stabil-TRAK system, read the Stabil-TRAK system test instructions on this page and follow steps 1 through 9 of the Stabil-TRAK System Test Procedure. Stabil-TRAK System Test Instructions • Test the Stabil-TRAK system with the vehicle on a level surface. • Remove any attachment from the quick attach before performing the test. • DO NOT extend the boom at any time during the test.
Test Procedures Stabil-TRAK System Test Procedures 186 Service Brake Test LOCKED MODE FREE PIVOT MODE Step 1 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. OH2500 Step 2 a. b. c. d. Start the engine. Turn the parking brake switch OFF.
Test Procedures LOCKED MODE Park Brake Test Neutral Test Stabil-TRAK System Test Procedures IMPORTANT! Perform Steps 5 thru 9 with the engine rpm at idle. Step 5 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 front left tire should remain off the ground. Step 6 a. With the travel select lever in the (N) NEUTRAL position, engage the parking brake switch.
Test Procedures SLOW PIVOT MODE LOCKED MODE SLOW PIVOT MODE Stabil-TRAK System Test Procedures Step 8 (Continued) 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. Step 9 a. With the service brake pedal depressed and the boom angle at exactly 45°, move the range select lever to (3) THIRD gear. b. Move the travel select lever to (F) FORWARD. c.
Test Procedures Boom/Outrigger Interlock System Test To test the function of the Boom/Outrigger Interlock System perform the “Stabil-TRAK System Test” begining on page 185 before performing the following test. BOOM EXTEND MODE 3 BOOM EXTEND MODE 2 BOOM EXTEND MODE 1 Boom/Outrigger Interlock System Test Procedures Step 1 a. Place the vehicle with no load on a hard, level surface such as blacktop or concrete. b. Fasten your seat belt. Step 2 a.
Test Procedures BOOM EXTEND MODE 1 BOOM EXTEND MODE 3 Boom/Outrigger Interlock System Test Procedures IMPORTANT! Perform Steps 5 thru 9 with the engine rpm at idle. Step 5 a. Attempt to frame sway the vehicle to the right and left; it should frame sway, but at a slower speed than normal. b. The Stabil-TRAK light should remain ON. c. Return the vehicle to a level position. Step 6 a. Place the travel select lever in the (N) NEUTRAL position, move the neutral lock lever to the NEUTRAL LOCK position. b.
Test Procedures Parking Brake/Transmission De-Clutch Test Procedures To check that the parking brake/transmission de-clutch system is functioning properly, perform the following tests. IMPORTANT! These tests should be performed in (1) FIRST gear only. WARNING: DO NOT operate this vehicle unless you are in the seat with the seat belt fastened around you. Death or serious personal injury could result if the belt is not securely fastened. Test 1 - Transmission De-Clutch Step 1: a.
Test Procedures Test 3 - Park Brake Hold Performance a. With the rated load of 10,000 lbs (4.536 Kg) on the forks, drive the vehicle forward up a 15% grade (15 ft. rise over 100 ft. run). b. Stop the vehicle using the service brakes, apply the park brake, shift the transmission into NEUTRAL (N). c. Take your foot off the service brake pedal. The vehicle should not move. d.
Test Procedures Four Wheel Steer Indexing Procedure If the vehicle does not drive “straight,” the steering could be out-of-phase. Perform the following Four Wheel Steer Indexing Procedure to synchronize the front and rear steering. 1. With the steering select switch (4) in the Four Wheel Steer position (5), turn the steering wheel full left. 2. While holding the steering wheel full left, toggle the steer select switch to the Front Wheel Steer position (6) and steer the front wheels back to center. 3.
Specifications Specifications Fluid & Lubrication Capacities Engine Crankcase Oil: Capacity with Filter Change ..................................... 10.5 quarts (10 liters) Filter Capacity ......................................................... 0.85 quart (0,80 liters) Type Of Oil.......................................................................................15W40 Fuel Tank: Total Capacity ...........................................................37 gallons (140 liters) Usable Capacity .........
Specifications Wheel Ends: Wheel End Capacity (Front Axle)...............................1.7 quarts (1,6 liters) Wheel End Capacity (Rear Axle) ...............................1.3 quarts (1,2 liters) Type of Fluid.....................Universal Tractor Fluid (see chart on page 150) Tires Air Pressure: Standard Tires 17.5 - 25, 12 ply (minimum)......................60 psi (414 kPa) Optional Radial Tires 17.5R25 One Star ..........................
Specifications Vehicle Dimensions With Standard 17.5 - 25 Tires: (A) Length (less forks) ........................................... 239 inches (6.071 mm) (B) Width (outriggers up) ....................................... 102 inches (2.591 mm) (C) Width (outriggers down) ............................. 156.75 inches (3.981 mm) (D) Height .............................................................. 101 inches (2.565 mm) (E) Wheelbase.................................................... 119.5 inches (3.
Specifications Electrical System Rating: ............................................................ 12V DC Negative Ground Number of Batteries: .................................................................. Two Type of Batteries: Maintenance Free .......................850 Cold Cranking Amps (Each Battery) Series of Batteries:............................................................. Series 27 Fuse Ratings: Main ......................................................................................
Specifications Relay Ratings: Park Brake Disengage..........................................................................12V Optional Headlight Switch ....................................................................12V Light Switch ..........................................................................................12V Neutral Start .........................................................................................12V Stabil-TRAK Lock .......................................................
Index Index A Accelerator Pedal ...........................24 Accident Prevention Tags ................5 Air Cleaner ...................................120 Air Intake System .........................123 Air Pressure .................................195 Alternator Charging Warning Indicator Light ............................42 Attachment Reconnect ...................75 Attachment Removal ......................74 Attachment Tilt ...............................32 Auger Operation .............................
Index Exhaust Fumes ............................. 10 Extend Interlock Mode ................... 66 F Falling Load Hazard ................ 13, 20 Fan Control .................................... 55 Filter Change ............................... 129 Filter Check ................................. 120 Footprint (w/full load) ................... 195 Fork Ratings .................................. 89 Fork Sweep ................................... 73 Four Wheel Steer Indexing ............
Index Operating .......................................68 Operator’s Seat Adjustment ...........36 Outer Primary Element .................121 Outrigger Control Switches ............33 Outrigger Interlock Mode ................66 P Park Brake Light .............................40 Park Brake Switch ..........................27 Parking Brake ...............................191 Parking Brake Test Procedures ...191 Parking Lights ................................52 Pick, Carry & Place A Load ............
Index Truss Boom w/Winch Outriggers Up ............................ 87 Truss Boom w/Winch Operation .... 47 Turn Signal Light ........................... 40 Turn Signals .................................. 52 U Underground Hazards ................... 15 Understanding the Boom/Outrigger Interlock System ...................... 66 Using Other Attachments .............. 95 Using The Capacity Chart ............. 76 V Vehicle Dimensions ..................... 196 Ventilation ......................................
Accident Prevention Tags Accident Prevention Tags 8990401 Origin 5/00 OS2180
Accident Prevention Tags 8990401 Origin 5/00 OS2180
Replacement Manuals If the owner/operator or safety manuals that were originally shipped with your vehicle are lost, stolen or need replacement, contact your local distributor for replacement manuals. If for any reason your distributor cannot supply the manuals you need; write, call or send a fax to the following address for ordering information. JLG Industries, Inc.
