model 10054 - jlg industries...2004/04/29 · 10054 rev 3/04 page 3 ety practices the information...

Operators and Safety Manual

Model

10054S/N 9909 thru 13197

8990362CMARCH 2004

ANSI

Operators and Safety Manual

Model

10054S/N 9909 thru 13197

8990362CMARCH 2004

ANSI

WARNINGIMPROPER OPERATION OF THIS VEHICLE CAN CAUSE INJURY OR DEATH.

BEFORE STARTING THE ENGINE, DO THE FOLLOWING:

1. READ THIS OPERATOR'S 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 YOUOPERATE THIS VEHICLE ON A WORKSITE.

It is your responsibility to observe applicable laws and regulations and to follow manufacturer's instruc-tions on vehicle operation and maintenance.

CALIFORNIA

Proposition 65 Warning

Diesel engine exhaust and some of its constituents are knownto the State of California to cause cancer, birth defects, andother reproductive harm.

WARNINGIMPROPER OPERATION OF THIS VEHICLE CAN CAUSE INJURY OR DEATH.

BEFORE STARTING THE ENGINE, DO THE FOLLOWING:

1. READ THIS OPERATOR'S 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 YOUOPERATE THIS VEHICLE ON A WORKSITE.

It is your responsibility to observe applicable laws and regulations and to follow manufacturer's instruc-tions on vehicle operation and maintenance.

CALIFORNIA

Proposition 65 Warning

Diesel engine exhaust and some of its constituents are knownto the State of California to cause cancer, birth defects, andother reproductive harm.

10054 Rev 3/04

Introduction The Manual .................................. 2Replacement Parts ....................... 2Reports ......................................... 2Disclaimer .................................... 2

Safety Practices Hazard Classification System ....... 3New or Additional Operators ........ 4Personal Considerations .............. 4Operational Considerations .......... 7Equipment Considerations ......... 11

Operation Controls ...................................... 12Instruments/Indicators ................ 20Optional Controls ........................ 23Walk - Around Inspection ........... 25Normal Starting .......................... 25Cold Starting ............................... 26Jump Starting ............................. 28

Operating .................................... 29Stabil-TRAK™ System Test ....... 36Boom/Outrigger InterlockSystem Test .............................. 39

Using The Capacity Chart .......... 41Fork Ratings ............................... 47How To Pick, Carry& Place a Load ......................... 48

Elevating Personnel ................... 48Using Other Attachments ........... 50Shut - Off .................................... 51Towing and Tie Down ................. 51

General Maintenance Routine Equipment Checklist ..... 52Warning Decal Locations ............ 53Maint. Schedule and Checklist ... 541. Lubrication Points ................. 582. Air Cleaner and Restriction Indicator.. .......... 593. Engine Cooling System......... 624. Engine Oil and Filter ............. 64

© 2004 JLG Industries, Inc.

5. Engine Fuel System .............. 666. Engine Fan Belt Check ......... 707. Hydraulic Oil & Filter ............. 718. Transmission Oil & Filter ....... 749. Axle Oil ................................. 76

10. Wheel End Oil ...................... 7711. Wheels and Tires.................. 7912. Battery .................................. 8013. Fuse and Relay Replacement ......................... 82

14. Boom Chains & Wear Pads .. 8415. Emergency Boom Lowering.. 9016. Emergency Brake Test ......... 97

Table Of Contents

SpecificationsFluid & Lubricant Capacities ....... 98Tires ........................................... 99Engine ........................................ 99Weights ...................................... 99Vehicle Dimensions .................. 100Electrical System ...................... 100Stability Tipping Limits .............. 101

Page 1 10054 Rev 3/04

Introduction The Manual .................................. 2Replacement Parts ....................... 2Reports ......................................... 2Disclaimer .................................... 2

Safety Practices Hazard Classification System ....... 3New or Additional Operators ........ 4Personal Considerations .............. 4Operational Considerations .......... 7Equipment Considerations ......... 11

Operation Controls ...................................... 12Instruments/Indicators ................ 20Optional Controls ........................ 23Walk - Around Inspection ........... 25Normal Starting .......................... 25Cold Starting ............................... 26Jump Starting ............................. 28

Operating .................................... 29Stabil-TRAK™ System Test ....... 36Boom/Outrigger InterlockSystem Test .............................. 39

Using The Capacity Chart .......... 41Fork Ratings ............................... 47How To Pick, Carry& Place a Load ......................... 48

Elevating Personnel ................... 48Using Other Attachments ........... 50Shut - Off .................................... 51Towing and Tie Down ................. 51

General Maintenance Routine Equipment Checklist ..... 52Warning Decal Locations ............ 53Maint. Schedule and Checklist ... 541. Lubrication Points ................. 582. Air Cleaner and Restriction Indicator.. .......... 593. Engine Cooling System......... 624. Engine Oil and Filter ............. 64

© 2004 JLG Industries, Inc.

5. Engine Fuel System .............. 666. Engine Fan Belt Check ......... 707. Hydraulic Oil & Filter ............. 718. Transmission Oil & Filter ....... 749. Axle Oil ................................. 76

10. Wheel End Oil ...................... 7711. Wheels and Tires.................. 7912. Battery .................................. 8013. Fuse and Relay Replacement ......................... 82

14. Boom Chains & Wear Pads .. 8415. Emergency Boom Lowering.. 9016. Emergency Brake Test ......... 97

Table Of Contents

SpecificationsFluid & Lubricant Capacities ....... 98Tires ........................................... 99Engine ........................................ 99Weights ...................................... 99Vehicle Dimensions .................. 100Electrical System ...................... 100Stability Tipping Limits .............. 101

10054 Rev 3/04

OH0280

MODEL & SERIAL NUMBERS

For your easy referencewhen ordering replacementparts or making serviceinquiries on this machine,record its model and serialnumbers on the back cover ofthe manual. The numbersare stamped on the serialnumber plate which is locatedon the front of the machine'sframe tilt cylinder tower.

IntroductionThe Manual

This Owners/Operator’s manual provides the informationyou need to correctly operate and maintain this vehicle.

IMPORTANT! Before you operate this vehicle, read thismanual completely and carefully so you will understandthe safety instructions and the operation of the controlsand safety equipment. You must comply with all Danger,Warning, and Caution notices. They are for your benefit.All reference to the right side, left side, front, or rear aregiven from the operator's seat looking in a forward direction.

JLG Industries, Inc. is hereinafter referred to as JLG.

Replacement Parts

IMPORTANT!The replacement of any part on this product by anythingother than a JLG authorized replacement part may ad-versely affect the performance, durability, or safety of thisproduct and will void the warranty. JLG assumes noliability for unauthorized replacement parts which adverselyaffect the performance, durability or safety of this product.

ReportsIMPORTANT!A Warranty Registration form must be filled out by the SkyTrak distributor, signed by the purchaser, and returned toJLG once the product is sold and/or put into service. Thisreport activates the warranty period, assuring that yourclaims during the warranty period will be honored andprocessed expediently. To guarantee you full warrantyservice, make sure your distributor has returned thebusiness reply card of this form to JLG.

DisclaimerJLG reserves the right to make changes on and to addimprovements upon its products at any time without publicnotice or obligation. JLG also reserves the right to discon-tinue manufacturing any product at its discretion at anytime.

Page 2 10054 Rev 3/04

OH0280

MODEL & SERIAL NUMBERS

For your easy referencewhen ordering replacementparts or making serviceinquiries on this machine,record its model and serialnumbers on the back cover ofthe manual. The numbersare stamped on the serialnumber plate which is locatedon the front of the machine'sframe tilt cylinder tower.

IntroductionThe Manual

This Owners/Operator’s manual provides the informationyou need to correctly operate and maintain this vehicle.

IMPORTANT! Before you operate this vehicle, read thismanual completely and carefully so you will understandthe safety instructions and the operation of the controlsand safety equipment. You must comply with all Danger,Warning, and Caution notices. They are for your benefit.All reference to the right side, left side, front, or rear aregiven from the operator's seat looking in a forward direction.

JLG Industries, Inc. is hereinafter referred to as JLG.

Replacement Parts

IMPORTANT!The replacement of any part on this product by anythingother than a JLG authorized replacement part may ad-versely affect the performance, durability, or safety of thisproduct and will void the warranty. JLG assumes noliability for unauthorized replacement parts which adverselyaffect the performance, durability or safety of this product.

ReportsIMPORTANT!A Warranty Registration form must be filled out by the SkyTrak distributor, signed by the purchaser, and returned toJLG once the product is sold and/or put into service. Thisreport activates the warranty period, assuring that yourclaims during the warranty period will be honored andprocessed expediently. To guarantee you full warrantyservice, make sure your distributor has returned thebusiness reply card of this form to JLG.

DisclaimerJLG reserves the right to make changes on and to addimprovements upon its products at any time without publicnotice or obligation. JLG also reserves the right to discon-tinue manufacturing any product at its discretion at anytime.

10054 Rev 3/04

Safety PracticesThe information in this manual does not replace any safetyrules and laws used in your area. Before operating thistelescopic handler, learn the rules and laws for your area.Make sure the vehicle has the correct equipment accordingto these rules and laws.Your safety and the safety of others in the work areadepend significantly upon your knowledge and understand-ing of all correct operating practices and procedures for thisvehicle.

Hazard Classification System

This safety alert symbol is used with the following signalwords to attract your attention to messages found within themanual and on safety decals located on the vehicle. Theyare reproduced herein and pertain to proper operation andprocedure messages contained throughout the manual.The message that follows the symbol contains importantinformation about Safety. To avoid possible injury or death,carefully read and follow the messages! Be sure to fullyunderstand the potential causes of injury or death.Signal Word: A distinctive word used throughout thismanual that alerts the reader to the existence and relativedegree of the hazard on or near the vehicle.

The signal word “DANGER” indicates an imminentlyhazardous situation which, if not avoided, will result indeath or serious injury.

OP0330

The signal word “WARNING” indicates a potentiallyhazardous situation which, if not avoided, could result indeath or serious injury.

The signal word “CAUTION” indicates a potentiallyhazardous situation which, if not avoided, may result inminor or moderate injury.

The signal word “CAUTION” used without the safety alertsymbol indicates a potentially hazardous situation which, ifnot avoided, may result in property damage.

OL3231

ON0030

ON0010

OS2020

Page 3 10054 Rev 3/04

Safety PracticesThe information in this manual does not replace any safetyrules and laws used in your area. Before operating thistelescopic handler, learn the rules and laws for your area.Make sure the vehicle has the correct equipment accordingto these rules and laws.Your safety and the safety of others in the work areadepend significantly upon your knowledge and understand-ing of all correct operating practices and procedures for thisvehicle.

Hazard Classification System

This safety alert symbol is used with the following signalwords to attract your attention to messages found within themanual and on safety decals located on the vehicle. Theyare reproduced herein and pertain to proper operation andprocedure messages contained throughout the manual.The message that follows the symbol contains importantinformation about Safety. To avoid possible injury or death,carefully read and follow the messages! Be sure to fullyunderstand the potential causes of injury or death.Signal Word: A distinctive word used throughout thismanual that alerts the reader to the existence and relativedegree of the hazard on or near the vehicle.

The signal word “DANGER” indicates an imminentlyhazardous situation which, if not avoided, will result indeath or serious injury.

OP0330

The signal word “WARNING” indicates a potentiallyhazardous situation which, if not avoided, could result indeath or serious injury.

The signal word “CAUTION” indicates a potentiallyhazardous situation which, if not avoided, may result inminor or moderate injury.

The signal word “CAUTION” used without the safety alertsymbol indicates a potentially hazardous situation which, ifnot avoided, may result in property damage.

OL3231

ON0030

ON0010

OS2020

10054 Rev 3/04

3. Dismounting

DO NOT get off the vehicle until you:• place the travel select lever in (N) NEUTRAL,• move neutral lock lever to NEUTRAL LOCK position,• engage the emergency brake switch,• lower the boom,• ground the carriage,• turn engine off,• unbuckle the seat belt, and• exit the vehicle using the hand holds.

OG0400

New or Additional OperatorsAt the time of original purchase, the purchaser of thisvehicle was instructed by the seller on its safe and correctuse. If this vehicle is to be used by an employee or isloaned, rented or sold to someone other than the pur-chaser, make certain that the new operator reads andunderstands the Operator’s Manual and the Rough TerrainForklift Safety Manual that are provided with the vehiclebefore operating the vehicle.

In addition, make sure that the new operator has completeda walk-around inspection of the vehicle, is familiar with alldecals and safety equipment on the vehicle, and hasdemonstrated the correct use of all controls.

Personal Considerations1. Seat Belt

Always adjust the seat and fasten the seat beltsecurely before you start the engine.

2. Clothing and Safety GearDO NOT wear loose clothing or jewelry that can getcaught on controls or moving parts. Wear theprotective clothing and personal safety gear issuedor called for by job conditions.

Page 4 10054 Rev 3/04

3. Dismounting

DO NOT get off the vehicle until you:• place the travel select lever in (N) NEUTRAL,• move neutral lock lever to NEUTRAL LOCK position,• engage the emergency brake switch,• lower the boom,• ground the carriage,• turn engine off,• unbuckle the seat belt, and• exit the vehicle using the hand holds.

OG0400

New or Additional OperatorsAt the time of original purchase, the purchaser of thisvehicle was instructed by the seller on its safe and correctuse. If this vehicle is to be used by an employee or isloaned, rented or sold to someone other than the pur-chaser, make certain that the new operator reads andunderstands the Operator’s Manual and the Rough TerrainForklift Safety Manual that are provided with the vehiclebefore operating the vehicle.

In addition, make sure that the new operator has completeda walk-around inspection of the vehicle, is familiar with alldecals and safety equipment on the vehicle, and hasdemonstrated the correct use of all controls.

Personal Considerations1. Seat Belt

Always adjust the seat and fasten the seat beltsecurely before you start the engine.

2. Clothing and Safety GearDO NOT wear loose clothing or jewelry that can getcaught on controls or moving parts. Wear theprotective clothing and personal safety gear issuedor called for by job conditions.

10054 Rev 3/04

DO NOT use your hand to check for leaks. Use apiece of cardboard or paper to search for leaks.Wear gloves to protect hands from spraying fluid.

Hydraulic fluid can cause permanent eye injury.Wear appropriate eye protection and stop engineand relieve pressure before disconnecting lines.

If anyone is injured by or if any hydraulic fluid isinjected into the skin, obtain medical attentionimmediately or gangrene may result.

D. Battery

The following WARNING is intended to supple-ment and does not replace the warnings andinformation provided on the battery by the batterymanufacturer.

4. Chemical HazardsA. Exhaust Fumes

Fumes from the engine exhaust can causeinjury or death. If operating in an enclosed area,provide good ventilation to replace hazardousexhaust fumes with fresh air.

B. Explosive Fuel

Engine fuel is flammable and can cause a fireand/or an explosion. Avoid danger by keepingsparks, open flames and smoking materialsaway from vehicle and fuel during refueling orfuel system servicing. Know where fire extin-guishers are kept on the worksite and how touse them.

C. Hydraulic Fluid

DO NOT attempt to repair or tighten any hydrau-lic hoses or fittings while the engine is runningor when the hydraulic system is under pressure.Fluid in the hydraulic system is under enoughpressure that it can penetrate the skin causingserious injury or death.

HOT HYDRAULIC FLUID WILL CAUSESEVERE BURNS. Wait for fluid to cool downbefore disconnecting lines.

OG0360

Page 5 10054 Rev 3/04

DO NOT use your hand to check for leaks. Use apiece of cardboard or paper to search for leaks.Wear gloves to protect hands from spraying fluid.

Hydraulic fluid can cause permanent eye injury.Wear appropriate eye protection and stop engineand relieve pressure before disconnecting lines.

If anyone is injured by or if any hydraulic fluid isinjected into the skin, obtain medical attentionimmediately or gangrene may result.

D. Battery

The following WARNING is intended to supple-ment and does not replace the warnings andinformation provided on the battery by the batterymanufacturer.

4. Chemical HazardsA. Exhaust Fumes

Fumes from the engine exhaust can causeinjury or death. If operating in an enclosed area,provide good ventilation to replace hazardousexhaust fumes with fresh air.

B. Explosive Fuel

Engine fuel is flammable and can cause a fireand/or an explosion. Avoid danger by keepingsparks, open flames and smoking materialsaway from vehicle and fuel during refueling orfuel system servicing. Know where fire extin-guishers are kept on the worksite and how touse them.

C. Hydraulic Fluid

DO NOT attempt to repair or tighten any hydrau-lic hoses or fittings while the engine is runningor when the hydraulic system is under pressure.Fluid in the hydraulic system is under enoughpressure that it can penetrate the skin causingserious injury or death.

HOT HYDRAULIC FLUID WILL CAUSESEVERE BURNS. Wait for fluid to cool downbefore disconnecting lines.

OG0360

10054 Rev 3/04

When jump starting the vehicle, carefully followinstructions found under “Jump Starting” later inthis manual.

Keep sparks, flames, and lit cigarettes awayfrom battery at all times. Lead acid batteriesgenerate explosive gases. Severe chemicalburns can result from improper handling ofbattery electrolyte. Wear safety glasses andproper protective gear when handling batteriesto prevent electrolyte from coming in contactwith eyes, skin or clothing.

Battery Electrolyte First Aid• External Contact — Flush with water.

• Eyes — Flush with water for at least 15minutes and get medical attentionimmediately!

• Internal Contact — Drink large quantities ofwater. Follow with Milk of Magnesia, beatenegg or vegetable oil. Get medical attentionimmediately!

IMPORTANT: In case of internal contact, DONOT give fluids that would induce vomiting!

6. Lowering Boom or Falling Load HazardDO NOT get under a raised boom unless the boomis blocked up safely. Always empty the boom of anyload and block up the boom before doing anyservicing which requires the boom to be raised.

NEVER allow anyone to walk or stand under araised boom. A lowering boom or falling load canresult in serious injury or death.

OG0330

5. Moving Parts HazardDO NOT place limbs nearmoving parts. Amputationof any body part can result.Turn off engine and waituntil fan and belts stopmoving before servicing thevehicle.

Page 6 10054 Rev 3/04

When jump starting the vehicle, carefully followinstructions found under “Jump Starting” later inthis manual.

Keep sparks, flames, and lit cigarettes awayfrom battery at all times. Lead acid batteriesgenerate explosive gases. Severe chemicalburns can result from improper handling ofbattery electrolyte. Wear safety glasses andproper protective gear when handling batteriesto prevent electrolyte from coming in contactwith eyes, skin or clothing.

Battery Electrolyte First Aid• External Contact — Flush with water.

• Eyes — Flush with water for at least 15minutes and get medical attentionimmediately!

• Internal Contact — Drink large quantities ofwater. Follow with Milk of Magnesia, beatenegg or vegetable oil. Get medical attentionimmediately!

IMPORTANT: In case of internal contact, DONOT give fluids that would induce vomiting!

6. Lowering Boom or Falling Load HazardDO NOT get under a raised boom unless the boomis blocked up safely. Always empty the boom of anyload and block up the boom before doing anyservicing which requires the boom to be raised.

NEVER allow anyone to walk or stand under araised boom. A lowering boom or falling load canresult in serious injury or death.

OG0330

5. Moving Parts HazardDO NOT place limbs nearmoving parts. Amputationof any body part can result.Turn off engine and waituntil fan and belts stopmoving before servicing thevehicle.

10054 Rev 3/04

OG0380

Operational Considerations

1. Preparation and Prevention

Know the location and function of all vehicle con-trols.

Make sure all persons are away from the vehicleand that the Travel and Gear Select Lever is lockedin the (N) NEUTRAL position with the emergencybrake switch engaged before starting the engine.

Holes, obstructions, debris and other work areahazards can cause injury or death. Always walk

around and look for these and other hazards beforeoperating the vehicle in a new work area.

Prevent accidents when you move the vehiclearound the work site. Know the rules for movementof people and vehicles on the worksite. Follow theinstructions of signals and signs.

DO NOT operate the vehicle unless:

• all four tires are correctly filled with hydrofill,

• all safety equipment is in proper working condition,

• all covers and shields are in place, and

• all safety and instructional decals are in place and readable.

(Replace all missing, illegible, or damaged decals.)

2. Clearances

Always check clearances carefully before drivingunder electrical lines, bridges, etc.

3. Underground Hazards

Know the location of all underground hazards beforeoperating this vehicle in a new work area. Electricalcables, gas pipes, water pipes, sewers, or otherunderground objects can cause injury or death.Contact your local underground utility service ordiggers hotline to mark all underground hazards.

Page 7 10054 Rev 3/04

OG0380

Operational Considerations

1. Preparation and Prevention

Know the location and function of all vehicle con-trols.

Make sure all persons are away from the vehicleand that the Travel and Gear Select Lever is lockedin the (N) NEUTRAL position with the emergencybrake switch engaged before starting the engine.

Holes, obstructions, debris and other work areahazards can cause injury or death. Always walk

around and look for these and other hazards beforeoperating the vehicle in a new work area.

Prevent accidents when you move the vehiclearound the work site. Know the rules for movementof people and vehicles on the worksite. Follow theinstructions of signals and signs.

DO NOT operate the vehicle unless:

• all four tires are correctly filled with hydrofill,

• all safety equipment is in proper working condition,

• all covers and shields are in place, and

• all safety and instructional decals are in place and readable.

(Replace all missing, illegible, or damaged decals.)

2. Clearances

Always check clearances carefully before drivingunder electrical lines, bridges, etc.

3. Underground Hazards

Know the location of all underground hazards beforeoperating this vehicle in a new work area. Electricalcables, gas pipes, water pipes, sewers, or otherunderground objects can cause injury or death.Contact your local underground utility service ordiggers hotline to mark all underground hazards.

10054 Rev 3/04

5. Lifting Personnel

Use only an approved work platform for lifting andlowering personnel. NEVER transport personnel ona work platform for even the shortest distance.

Serious injury or death can occur if these rules arenot obeyed. Riders can fall and be crushed or runover. Avoid accidents. For other specific precau-tions, see “Elevating Personnel” later in this manual.

OG0341

OG0351

NEVER operate this vehicle in an area in whichoverhead power lines, overhead or undergroundcables, or power sources exist without first request-ing that the appropriate power company or utilitycompany de-energize the lines or take other suitableprecautions.

4. Electrocution Hazard

Page 8 10054 Rev 3/04

5. Lifting Personnel

Use only an approved work platform for lifting andlowering personnel. NEVER transport personnel ona work platform for even the shortest distance.

Serious injury or death can occur if these rules arenot obeyed. Riders can fall and be crushed or runover. Avoid accidents. For other specific precau-tions, see “Elevating Personnel” later in this manual.

OG0341

OG0351

NEVER operate this vehicle in an area in whichoverhead power lines, overhead or undergroundcables, or power sources exist without first request-ing that the appropriate power company or utilitycompany de-energize the lines or take other suitableprecautions.

4. Electrocution Hazard

10054 Rev 3/04

6. Tip Over Hazard

OG0371

DO NOT exceed the ratedlift capacity of the vehicle,as structural damage andunstable vehicle conditionswill result.

If proper operating procedures are not followed,this vehicle will tip over. If a vehicle ever becomesunstable and starts to tip over,

• BRACE YOURSELF and STAY WITH THEVEHICLE.

• KEEP SEAT BELT FASTENED,

• HOLD ON FIRMLY and

• LEAN AWAY FROM THE POINT OF IMPACT.

Indecision and trying to escape from a tipping vehiclecan result in death or injury.

ALWAYS make sure that all four tires have been properlyfilled with hydrofill by a qualified tire service center.

Lowering outriggers over holes or on soft terrain cancompromise the stability of the vehicle which could resultin vehicle tipover. For optimum stability, lower theoutriggers just far enough until the front of the vehiclestarts to raise and maintains a firm footing.

NEVER attempt to move the vehicle after the outriggershave been lowered.

Traveling with the boom raised is dangerous and cancause tipover. Keep the load as low as possible. Travelwith extreme caution and at the slowest possible speed.

Driving across a slope is dangerous, as unexpectedchanges in the slope can cause tipover. Ascend ordescend slopes slowly and with caution.

Keep the vehicle under control at all times.Avoid jerky turns, starts, or stops. Reduce operating speedon rough ground and slopes.

OH0800

Page 9 10054 Rev 3/04

6. Tip Over Hazard

OG0371

DO NOT exceed the ratedlift capacity of the vehicle,as structural damage andunstable vehicle conditionswill result.

If proper operating procedures are not followed,this vehicle will tip over. If a vehicle ever becomesunstable and starts to tip over,

• BRACE YOURSELF and STAY WITH THEVEHICLE.

• KEEP SEAT BELT FASTENED,

• HOLD ON FIRMLY and

• LEAN AWAY FROM THE POINT OF IMPACT.

Indecision and trying to escape from a tipping vehiclecan result in death or injury.

ALWAYS make sure that all four tires have been properlyfilled with hydrofill by a qualified tire service center.

Lowering outriggers over holes or on soft terrain cancompromise the stability of the vehicle which could resultin vehicle tipover. For optimum stability, lower theoutriggers just far enough until the front of the vehiclestarts to raise and maintains a firm footing.

NEVER attempt to move the vehicle after the outriggershave been lowered.

Traveling with the boom raised is dangerous and cancause tipover. Keep the load as low as possible. Travelwith extreme caution and at the slowest possible speed.

Driving across a slope is dangerous, as unexpectedchanges in the slope can cause tipover. Ascend ordescend slopes slowly and with caution.

Keep the vehicle under control at all times.Avoid jerky turns, starts, or stops. Reduce operating speedon rough ground and slopes.

OH0800

10054 Rev 3/04

7. SlopesDO NOT park the vehicle on an incline and leave itunattended.

• Driving across a slope is dangerous, asunexpected changes in the slope can causetipover. Ascend or descend slopes slowly andwith caution.

• Ascend or descend slopes with the heavy endof the vehicle pointing up the slope.

NOTE: The rear of the vehicle is normally consid-ered the heavy end unless the carriage is fullyloaded. In this case the front of the vehicle is nowthe heavy end.

• Unloaded vehicles should be operated on allslopes with the carriage pointing down theslope.

• On all slopes, the load must be tilted back andraised only as far as necessary to clear theground.

• When operating on a downhill slope, reducetravel speed and downshift to a low gear topermit compression braking by the engine andaid in the application of the service brakes.

OH0331

DO NOT remove or unpinthe rear stabilizer cylinderfrom the vehicle, asunstable vehicle conditionswill result.

ALWAYS be sure theStabil-TRAK System andthe Boom/OutriggerInterlock System arefunctioning properly whenoperating this vehicle.Refer to both system testprocedures later in thismanual to assure bothsystems function properly.

Frame tilting with the boom raised above horizontal isdangerous. Always use the frame tilt to level the vehiclebefore raising the boom above horizontal, with or without aload. If the vehicle cannot be leveled using the frame tilt,reposition the vehicle.

Page 10 10054 Rev 3/04

7. SlopesDO NOT park the vehicle on an incline and leave itunattended.

• Driving across a slope is dangerous, asunexpected changes in the slope can causetipover. Ascend or descend slopes slowly andwith caution.

• Ascend or descend slopes with the heavy endof the vehicle pointing up the slope.

NOTE: The rear of the vehicle is normally consid-ered the heavy end unless the carriage is fullyloaded. In this case the front of the vehicle is nowthe heavy end.

• Unloaded vehicles should be operated on allslopes with the carriage pointing down theslope.

• On all slopes, the load must be tilted back andraised only as far as necessary to clear theground.

• When operating on a downhill slope, reducetravel speed and downshift to a low gear topermit compression braking by the engine andaid in the application of the service brakes.

OH0331

DO NOT remove or unpinthe rear stabilizer cylinderfrom the vehicle, asunstable vehicle conditionswill result.

ALWAYS be sure theStabil-TRAK System andthe Boom/OutriggerInterlock System arefunctioning properly whenoperating this vehicle.Refer to both system testprocedures later in thismanual to assure bothsystems function properly.

Frame tilting with the boom raised above horizontal isdangerous. Always use the frame tilt to level the vehiclebefore raising the boom above horizontal, with or without aload. If the vehicle cannot be leveled using the frame tilt,reposition the vehicle.

10054 Rev 3/04

8. Falling Load HazardDO NOT exceed the total rated load capacity of thespecific type fork being used. Each fork is stampedwith a maximum load capacity. If the capacity isexceeded, forks may break. See “Fork Ratings” laterin this manual.

DO NOT downshift at a high ground speed. You maydrop the load off of the forks due to a suddenslowing.

9. Visual Obstruction

Dust, smoke, fog, etc. can decrease vision and causean accident. Always stop or slow the vehicle until theobstruction clears and the work area is visible again.

10. Ventilation

Sparks from the electrical system and engine ex-haust can cause an explosion. DO NOT operate thisvehicle in an area with flammable dust or vapors,unless good ventilation has removed the hazard.

Carbon monoxide fumes from the engine exhaustcan also cause suffocation in an enclosed area.Good ventilation is very important when operatingthis vehicle.

Equipment Considerations

ALWAYS make sure that all four tires have beenproperly filled with hydrofill by a qualified tire servicecenter. Improper hydrofill can cause instabilitywhich can result in tipover.

DO NOT modify or alter (weld, drill, etc.) any part ofthis vehicle without consulting JLG. Modificationscan weaken the structure creating a hazard that cancause injury or death.

WARNING

Page 11 10054 Rev 3/04

8. Falling Load HazardDO NOT exceed the total rated load capacity of thespecific type fork being used. Each fork is stampedwith a maximum load capacity. If the capacity isexceeded, forks may break. See “Fork Ratings” laterin this manual.

DO NOT downshift at a high ground speed. You maydrop the load off of the forks due to a suddenslowing.

9. Visual Obstruction

Dust, smoke, fog, etc. can decrease vision and causean accident. Always stop or slow the vehicle until theobstruction clears and the work area is visible again.

10. Ventilation

Sparks from the electrical system and engine ex-haust can cause an explosion. DO NOT operate thisvehicle in an area with flammable dust or vapors,unless good ventilation has removed the hazard.

Carbon monoxide fumes from the engine exhaustcan also cause suffocation in an enclosed area.Good ventilation is very important when operatingthis vehicle.

Equipment Considerations

ALWAYS make sure that all four tires have beenproperly filled with hydrofill by a qualified tire servicecenter. Improper hydrofill can cause instabilitywhich can result in tipover.

DO NOT modify or alter (weld, drill, etc.) any part ofthis vehicle without consulting JLG. Modificationscan weaken the structure creating a hazard that cancause injury or death.

WARNING

10054 Rev 3/04

Operation

ControlsIgnition Switch (See Figure 1)

Using the ignition switch key, the switch may be turnedclockwise from the OFF position to the RUN and STARTpositions. The START position is spring-loaded toreturn to the RUN position and must be manually held inplace for normal starting.

OFF position — The entire electrical system is shut down.

RUN position — All controls and indicators are operable.

START position — Engages starter to crank the enginewhen the emergency brake switch is engaged and thetransmission is in neutral.

Accelerator Pedal (See Figure 1)

Pressing down the accelerator pedal increases travelspeed of the vehicle. The pedal is spring-loaded toreturn to idle speed.

Service Brake Pedal (See Figure 1)

Pressing down the brake pedal applies the wet discservice brakes located in the axle wheel ends. It alsoactivates and locks the Stabil-TRAK system when boom

STEERING WHEEL

IGNITION SWITCH

SERVICE BRAKE PEDAL

ACCELERATOR PEDAL

OH1150Figure 1

angles are greater than 40°, as long as the pedal isdepressed.

Steering Wheel (See Figure 1)

Turning the steering wheel to the left or right steers thevehicle in the corresponding direction. Any one of threesteering modes are selectable. Refer to “SteeringSelect Switch.”

Page 12 10054 Rev 3/04

Operation

ControlsIgnition Switch (See Figure 1)

Using the ignition switch key, the switch may be turnedclockwise from the OFF position to the RUN and STARTpositions. The START position is spring-loaded toreturn to the RUN position and must be manually held inplace for normal starting.

OFF position — The entire electrical system is shut down.

RUN position — All controls and indicators are operable.

START position — Engages starter to crank the enginewhen the emergency brake switch is engaged and thetransmission is in neutral.

Accelerator Pedal (See Figure 1)

Pressing down the accelerator pedal increases travelspeed of the vehicle. The pedal is spring-loaded toreturn to idle speed.

Service Brake Pedal (See Figure 1)

Pressing down the brake pedal applies the wet discservice brakes located in the axle wheel ends. It alsoactivates and locks the Stabil-TRAK system when boom

STEERING WHEEL

IGNITION SWITCH

SERVICE BRAKE PEDAL

ACCELERATOR PEDAL

OH1150Figure 1

angles are greater than 40°, as long as the pedal isdepressed.

Steering Wheel (See Figure 1)

Turning the steering wheel to the left or right steers thevehicle in the corresponding direction. Any one of threesteering modes are selectable. Refer to “SteeringSelect Switch.”

10054 Rev 3/04

WARNING

MACHINE ROLLMACHINE ROLL AWAY

can cause death orserious injuryous injury.

ALWAYS engageparking brake beforedismounting.

DANGERDANGER

MACHINE TIPOVER can resultin death or serious injury.• Level machine before raising boom.

• Lower raised boom before traveling.

• Operate only with hydrofill in all 4 tires.

• Consult capacity chart for load limits.

SAFETY INSTRUCTIONSRead operator's manual beforeRead operator's manual beforeoperating.operating.

Fasten seat belt.Fasten seat belt.

Allow no riders.Allow no riders.

Use an approved work platformse an approved work platformto lift or lower personnel.to lift or lower personnel.

1.

2.

3.

4.

Lower Boom Before Exiting Loader

Read Operators Manual

Fasten Seat Belt No Riderss

CONTACT WITH ELECTRICPOWER LINES can result inelectrocution.Never operate this machine within10 feet of electric power lines.

Notify the power company tode-energize the lines beforeoperating forklift.

DANGER

EMERGENCYEMERGENCYBRAKE

P

P

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EMERGENCYBRAKESWITCH

OH1160

GEARSELECTLEVER

STEERINGSELECT SWITCH

Figure 2

HORNBUTTON

NEUTRALLOCKLEVER

Steering Select Switch (See Figure 2)

This switch has three positions:

Four Wheel Steer ..........up position

Two Wheel Steer ........... center position

Crab Steer .....................down position

Refer to Steering under “Operating” for detailed information.

Emergency Brake Switch (See Figure 2)

The emergency brake switch has two positions:

Engaged................ lift red switch cover thenpush switch up

Disengaged ........... lower red switch coverthen push switch down

The emergency brake must be ENGAGED to permitengine starting. Operator should use caution whenengaging the emergency brake while vehicle is moving,because the stop will be abrupt and operator may bejolted forward unexpectedly. The emergency brake maybe used to stop in an emergency situation. The emer-gency brake switch will also activate the Stabil-TRAKsystem when boom angles are greater than 40°. Thevehicle will then enter “LOCKED MODE.”

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OH0780

Page 13 10054 Rev 3/04

WARNING


can cause death orserious injuryous injury.

ALWAYS engageparking brake beforedismounting.

DANGERDANGER









1.

2.

3.

4.






DANGER

EMERGENCYEMERGENCYBRAKE

P

P

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EMERGENCYBRAKESWITCH

OH1160

GEARSELECTLEVER

STEERINGSELECT SWITCH

Figure 2

HORNBUTTON

NEUTRALLOCKLEVER

Steering Select Switch (See Figure 2)

This switch has three positions:

Four Wheel Steer ..........up position

Two Wheel Steer ........... center position

Crab Steer .....................down position

Refer to Steering under “Operating” for detailed information.

Emergency Brake Switch (See Figure 2)

The emergency brake switch has two positions:

Engaged................ lift red switch cover thenpush switch up

Disengaged ........... lower red switch coverthen push switch down

The emergency brake must be ENGAGED to permitengine starting. Operator should use caution whenengaging the emergency brake while vehicle is moving,because the stop will be abrupt and operator may bejolted forward unexpectedly. The emergency brake maybe used to stop in an emergency situation. The emer-gency brake switch will also activate the Stabil-TRAKsystem when boom angles are greater than 40°. Thevehicle will then enter “LOCKED MODE.”

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OH0780

10054 Rev 3/04

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Travel Select Lever (See Figure 2)

The travel select lever has three positions to selectdirection of travel:

F = FORWARD ... all the way forward

N = NEUTRAL .... center position

R = REVERSE ... all the way rearward

When the travel select lever is shifted into(R) REVERSE, the back-up alarm will automaticallysound.

NOTE: The travel select lever must be in NEUTRAL to per-mit engine starting and when boom angles are greater than40°, shifting into NEUTRAL locks the Stabil-TRAK system.

Neutral Lock Lever (See Figure 2)

The travel select lever is equipped with a neutral lock.

To lock the travel select lever in the NEUTRAL position:

Place the lever in the NEUTRAL position and movethe neutral lock lever to the (N) NEUTRAL LOCKposition.

To unlock, move the neutral lock lever to the (D) DRIVEposition.

Horn Button (See Figure 2)

Pressing the momentary-contact horn button sounds thevehicle horn.

OH1270Figure 3

GEAR SELECTLEVER

Gear Select Lever (See Figure 3)

The gear select lever has a four position twist griphandle. The vehicle’s transmission has three (3) forwardgears and three (3) reverse gears. To change gears,rotate the twist grip to the next desired gear. Use firstgear for highest torque and pulling power. Use highergears for higher ground speed. Selecting the fourthposition on the gear select lever will have no effect onthe three speed transmission.

Page 14 10054 Rev 3/04

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Travel Select Lever (See Figure 2)

The travel select lever has three positions to selectdirection of travel:

F = FORWARD ... all the way forward

N = NEUTRAL .... center position

R = REVERSE ... all the way rearward

When the travel select lever is shifted into(R) REVERSE, the back-up alarm will automaticallysound.

NOTE: The travel select lever must be in NEUTRAL to per-mit engine starting and when boom angles are greater than40°, shifting into NEUTRAL locks the Stabil-TRAK system.

Neutral Lock Lever (See Figure 2)

The travel select lever is equipped with a neutral lock.

To lock the travel select lever in the NEUTRAL position:

Place the lever in the NEUTRAL position and movethe neutral lock lever to the (N) NEUTRAL LOCKposition.

To unlock, move the neutral lock lever to the (D) DRIVEposition.

Horn Button (See Figure 2)

Pressing the momentary-contact horn button sounds thevehicle horn.

OH1270Figure 3

GEAR SELECTLEVER

Gear Select Lever (See Figure 3)

The gear select lever has a four position twist griphandle. The vehicle’s transmission has three (3) forwardgears and three (3) reverse gears. To change gears,rotate the twist grip to the next desired gear. Use firstgear for highest torque and pulling power. Use highergears for higher ground speed. Selecting the fourthposition on the gear select lever will have no effect onthe three speed transmission.

10054 Rev 3/04

Boom Control Lever (See Figure 4)

The boom control lever is a joystick with variable motionfrom the center to control the boom functions:

Attachment and Frame Tilt Control Lever(See Figure 4)

The attachment and frame tilt control is a joystick withfour perpendicular motions from the center to control twoattachment functions and two frame tilt functions:

Two boom functions can be accomplished at the sametime by moving the lever into the proper quadrant. Forexample: moving the lever forward and to the left willlower and retract the boom simultaneously.

The speed of boom movement depends on the amount oflever movement in the corresponding direction. Theoverall speed of movement depends directly upon thespeed of the engine.

0H0360

BOOM CONTROLLEVER

ATTACHMENT ANDFRAME TILTCONTROL

LEVER

Figure 4

OH01701

Boom Raise ........ move lever backward

Boom Lower ........ move lever forward

Boom Extend ...... move lever to the right

Boom Retract ..... move lever to the left

Frame Tilt Left ................move lever to the left

Frame Tilt Right ..............move lever to the right

Attachment Tilt Down .....move lever forward

Attachment Tilt Up ..........move lever backward

OH0410

The attachment is self leveling and will retain any setangle throughout boom raising, lowering, retracting orextending operations.

Page 15 10054 Rev 3/04

Boom Control Lever (See Figure 4)

The boom control lever is a joystick with variable motionfrom the center to control the boom functions:

Attachment and Frame Tilt Control Lever(See Figure 4)

The attachment and frame tilt control is a joystick withfour perpendicular motions from the center to control twoattachment functions and two frame tilt functions:

Two boom functions can be accomplished at the sametime by moving the lever into the proper quadrant. Forexample: moving the lever forward and to the left willlower and retract the boom simultaneously.

The speed of boom movement depends on the amount oflever movement in the corresponding direction. Theoverall speed of movement depends directly upon thespeed of the engine.

0H0360

BOOM CONTROLLEVER

ATTACHMENT ANDFRAME TILTCONTROL

LEVER

Figure 4

OH01701

Boom Raise ........ move lever backward

Boom Lower ........ move lever forward

Boom Extend ...... move lever to the right

Boom Retract ..... move lever to the left

Frame Tilt Left ................move lever to the left

Frame Tilt Right ..............move lever to the right

Attachment Tilt Down .....move lever forward

Attachment Tilt Up ..........move lever backward

OH0410

The attachment is self leveling and will retain any setangle throughout boom raising, lowering, retracting orextending operations.

10054 Rev 3/04

Figure 5

OUTRIGGERCONTROLSWITCHES

OH0360

Outrigger Control Switches (See Figure 5)

The left and right outrigger control switches raise or lowerthe corresponding outriggers.

Raise Left Outrigger ............ lift switch up

Lower Left Outrigger ............ push switch down

Raise Right Outrigger .......... lift switch up

Lower Right Outrigger .......... push switch down

OH04201

NOTE: Outrigger position is critical to allow full extensionof the boom. Refer to “Understanding the Boom/OutriggerInterlock System” later in this manual for a detailed expla-nation of this interlock.

IMPORTANT! Outrigger equipped vehicles can be usedwith the outriggers in either the raised or lowered position.The operator must operate the vehicle within the limitsspecified on the appropriate capacity chart for the outriggerposition.

(continued on next page)

Page 16 10054 Rev 3/04

Figure 5

OUTRIGGERCONTROLSWITCHES

OH0360

Outrigger Control Switches (See Figure 5)

The left and right outrigger control switches raise or lowerthe corresponding outriggers.

Raise Left Outrigger ............ lift switch up

Lower Left Outrigger ............ push switch down

Raise Right Outrigger .......... lift switch up

Lower Right Outrigger .......... push switch down

OH04201

NOTE: Outrigger position is critical to allow full extensionof the boom. Refer to “Understanding the Boom/OutriggerInterlock System” later in this manual for a detailed expla-nation of this interlock.

IMPORTANT! Outrigger equipped vehicles can be usedwith the outriggers in either the raised or lowered position.The operator must operate the vehicle within the limitsspecified on the appropriate capacity chart for the outriggerposition.

(continued on next page)

10054 Rev 3/04

3. Lower the right outrigger until the right front tire juststarts to raise and maintains this position.

4. Lower the left outrigger until the left front tire just startsto raise and again maintains this position.

5. Frame tilt the vehicle back to level (0°) if necessary.

Circulation Fan (Enclosed Cab Only)

(Not Pictured)

The circulation fan is only operable when the ignitionswitch in is the RUN position. The fan switch is locatedat the base of the fan mount.

Sliding Windows (Enclosed Cab Only)(Not Pictured)

The sliding windows are latched with a combination slidebar and squeeze actuated latch.

Door Latches (Enclosed Cab Only)(Not Pictured)

There are two door latches. The outside latch is a keylockable pull to release type. The inside latch is a pushto release type.

Procedure for Lowering of Outriggers

Secure and proper outrigger placement is critical forstability of the vehicle. Avoid holes or drop-offs and soft orexcessively uneven terrain. Lower outriggers just farenough until the front of the vehicle starts to raise andmaintain a level position. Use the following procedure toassure that both outriggers have been lowered securely.

IMPORTANT: For optimum vehicle stability, never lowerthe outriggers to the point at which the tires come com-pletely off the ground.

1. Before locating the vehicle at the lift point, observe thatthe landing area for the outriggers is free of loosematerial or debris and that the terrain appears to besolid and free of holes.

2. Position the vehicle at the lift point and level the vehicleto zero degrees (0°). If the vehicle cannot be leveled,reposition the vehicle.

Page 17 10054 Rev 3/04

3. Lower the right outrigger until the right front tire juststarts to raise and maintains this position.

4. Lower the left outrigger until the left front tire just startsto raise and again maintains this position.

5. Frame tilt the vehicle back to level (0°) if necessary.

Circulation Fan (Enclosed Cab Only)

(Not Pictured)

The circulation fan is only operable when the ignitionswitch in is the RUN position. The fan switch is locatedat the base of the fan mount.

Sliding Windows (Enclosed Cab Only)(Not Pictured)

The sliding windows are latched with a combination slidebar and squeeze actuated latch.

Door Latches (Enclosed Cab Only)(Not Pictured)

There are two door latches. The outside latch is a keylockable pull to release type. The inside latch is a pushto release type.

Procedure for Lowering of Outriggers

Secure and proper outrigger placement is critical forstability of the vehicle. Avoid holes or drop-offs and soft orexcessively uneven terrain. Lower outriggers just farenough until the front of the vehicle starts to raise andmaintain a level position. Use the following procedure toassure that both outriggers have been lowered securely.

IMPORTANT: For optimum vehicle stability, never lowerthe outriggers to the point at which the tires come com-pletely off the ground.

1. Before locating the vehicle at the lift point, observe thatthe landing area for the outriggers is free of loosematerial or debris and that the terrain appears to besolid and free of holes.

2. Position the vehicle at the lift point and level the vehicleto zero degrees (0°). If the vehicle cannot be leveled,reposition the vehicle.

10054 Rev 3/04

Windshield Washer/Wiper Control(Enclosed Cab Only) (Not Pictured)

Turn the knob counterclockwise to operate the wipers atlow speed; turn the knob clockwise to operate thewipers at high speed. Pressing the knob activates thewindshield washer for as long as it is held in. Thewindshield washer fluid tank is located to the rear of theright console (early models) or it is the front tank next tothe seat support (later models).

PIVOT ARM KNOB

Figure 6OA0052

Rear Window Control (Enclosed Cab Only)(See Figure 6)

Loosen the knob and slide the pivot arm in the slot toopen the rear window. Tighten the knob to secure.

Reverse the procedure to close the window.

NOTE: The rear window can be used as an emergencyexit if necessary. Unscrew the knob from the stud, raisethe pivot arm over the stud, and push the window out.

Roof Washer/Wiper Control(Enclosed Cab Only) (Not Pictured)

Turn the knob clockwise to operate the wiper. Pressingthe knob activates the roof washer for as long as it isheld in. The washer fluid tank is the rear tank locatednext to the seat support.

Page 18 10054 Rev 3/04

Windshield Washer/Wiper Control(Enclosed Cab Only) (Not Pictured)

Turn the knob counterclockwise to operate the wipers atlow speed; turn the knob clockwise to operate thewipers at high speed. Pressing the knob activates thewindshield washer for as long as it is held in. Thewindshield washer fluid tank is located to the rear of theright console (early models) or it is the front tank next tothe seat support (later models).

PIVOT ARM KNOB

Figure 6OA0052

Rear Window Control (Enclosed Cab Only)(See Figure 6)

Loosen the knob and slide the pivot arm in the slot toopen the rear window. Tighten the knob to secure.

Reverse the procedure to close the window.

NOTE: The rear window can be used as an emergencyexit if necessary. Unscrew the knob from the stud, raisethe pivot arm over the stud, and push the window out.

Roof Washer/Wiper Control(Enclosed Cab Only) (Not Pictured)

Turn the knob clockwise to operate the wiper. Pressingthe knob activates the roof washer for as long as it isheld in. The washer fluid tank is the rear tank locatednext to the seat support.

10054 Rev 3/04

Cab Heater (Enclosed Cab Only)(See Figure 7)

The cab heater fan is only operable when the ignitionswitch is in the RUN position. The heater fan switch islocated on the left side of the seat base (Figure 7). Theswitch has three positions: OFF, LO, and HI.

NOTE: During warm weather operation, close the heaterline shut-off valve, located in the heater hose connection atthe engine. (Valve is located below engine alternator.)

Seat Belt (See Figure 7)The seat belt has a slide on each strap that is used totighten and loosen the strap on each side of the buckle.To shorten, pull bottom of loop toward buckle. Tolengthen, hold slide strap, pull slide toward buckle andreadjust buckle on loop. Buckle the two straps togetherto fasten. Lift the buckle latch or press the center buttonto unfasten the seat belt.

Always wear the seat belt when operating the vehicle. Anoptional 3 inch wide seat belt is available for thoselocations that require a 3 inch seat belt.

Operator's Seat Adjustment (See Figure 7)

The position and suspension of the operator's seat can beadjusted.

Suspension — Turn the knob on the front of the seat toadjust suspension stiffness for operator weight.

SEATBELT

FORWARD/BACKWARD

LEVER

HEATERCONTROLCAB HEATER

SUSPENSIONADJUST KNOB

Figure 7 OA0071

Height — Height adjustment is achieved by grasping thebottom of the seat and raising upward into one of thethree detent positions. Once the seat has reached thehighest detent position, it can be lowered by raising theseat all the way and lowering it fully. The seat can thenbe raised, one detent at a time to the desired height.

Forward/Backward — Release the lever on the left sideof the seat and slide seat forward or backward to suit.

Page 19 10054 Rev 3/04

Cab Heater (Enclosed Cab Only)(See Figure 7)

The cab heater fan is only operable when the ignitionswitch is in the RUN position. The heater fan switch islocated on the left side of the seat base (Figure 7). Theswitch has three positions: OFF, LO, and HI.

NOTE: During warm weather operation, close the heaterline shut-off valve, located in the heater hose connection atthe engine. (Valve is located below engine alternator.)

Seat Belt (See Figure 7)The seat belt has a slide on each strap that is used totighten and loosen the strap on each side of the buckle.To shorten, pull bottom of loop toward buckle. Tolengthen, hold slide strap, pull slide toward buckle andreadjust buckle on loop. Buckle the two straps togetherto fasten. Lift the buckle latch or press the center buttonto unfasten the seat belt.

Always wear the seat belt when operating the vehicle. Anoptional 3 inch wide seat belt is available for thoselocations that require a 3 inch seat belt.

Operator's Seat Adjustment (See Figure 7)

The position and suspension of the operator's seat can beadjusted.

Suspension — Turn the knob on the front of the seat toadjust suspension stiffness for operator weight.

SEATBELT

FORWARD/BACKWARD

LEVER

HEATERCONTROLCAB HEATER

SUSPENSIONADJUST KNOB

Figure 7 OA0071

Height — Height adjustment is achieved by grasping thebottom of the seat and raising upward into one of thethree detent positions. Once the seat has reached thehighest detent position, it can be lowered by raising theseat all the way and lowering it fully. The seat can thenbe raised, one detent at a time to the desired height.

Forward/Backward — Release the lever on the left sideof the seat and slide seat forward or backward to suit.

10054 Rev 3/04

WARNING


can cause death orserious injury.

ALWAYS engageparking brake beforeparking brake beforedismounting.dismounting.

DANGER









1.

2.

3.

4.






DANGER

EMERGENCYBRAKE

P

P

Instruments and Indicators

STABIL-TRAKLIGHT

The Stabil-TRAK light will come ON when the systemhas been activated. The rear axle will lock when one ormore of the following conditions exist with the boomabove a 40° angle.

• Emergency brake switch engaged

• Travel select lever in (N) NEUTRAL

• Service brake pedal depressed

Stabil-TRAK™ Light(See Figure 8)

With the boom above a 40° angle and traveling in aforward or reverse drive gear, the Stabil-TRAK Light willgo OFF. In this condition the rear axle is unlocked andis allowed to pivot, but will respond slowly to changes interrain.

ALWAYS be sure the Stabil-TRAK system is functioningproperly when operating the vehicle. Refer to “Under-standing the Stabil-TRAK System” later in this manualfor a detailed explanation of this system.

The Stabil-TRAK light will also come ON when theBoom/Outrigger Interlock system is active.

Vehicle tipover can result in death or seriousinjury.Traveling with the boom raised is dangerous andcan cause vehicle tipover. Keep the load as lowas possible. Travel with extreme caution and atthe slowest possible speed.

OH0790

Figure 8 OH1220

WARNINGLIGHTSHOURMETER

FUELGAUGE

WARNING LIGHTBULB TEST

BUTTON

DANGER

Page 20 10054 Rev 3/04

WARNING


can cause death orserious injury.

ALWAYS engageparking brake beforeparking brake beforedismounting.dismounting.

DANGER









1.

2.

3.

4.






DANGER

EMERGENCYBRAKE

P

P

Instruments and Indicators

STABIL-TRAKLIGHT

The Stabil-TRAK light will come ON when the systemhas been activated. The rear axle will lock when one ormore of the following conditions exist with the boomabove a 40° angle.

• Emergency brake switch engaged

• Travel select lever in (N) NEUTRAL

• Service brake pedal depressed

Stabil-TRAK™ Light(See Figure 8)

With the boom above a 40° angle and traveling in aforward or reverse drive gear, the Stabil-TRAK Light willgo OFF. In this condition the rear axle is unlocked andis allowed to pivot, but will respond slowly to changes interrain.

ALWAYS be sure the Stabil-TRAK system is functioningproperly when operating the vehicle. Refer to “Under-standing the Stabil-TRAK System” later in this manualfor a detailed explanation of this system.

The Stabil-TRAK light will also come ON when theBoom/Outrigger Interlock system is active.

Vehicle tipover can result in death or seriousinjury.Traveling with the boom raised is dangerous andcan cause vehicle tipover. Keep the load as lowas possible. Travel with extreme caution and atthe slowest possible speed.

OH0790

Figure 8 OH1220

WARNINGLIGHTSHOURMETER

FUELGAUGE

WARNING LIGHTBULB TEST

BUTTON

DANGER

10054 Rev 3/04

Warning Light Bulb Test Button (See Figure 8)

Directly to the right of the instrument cluster is a warninglight bulb test button. With ignition switch in the RUNposition and engine OFF, depress this button to test allwarning lights. If any of the lights are burnt out, replacethe bulb(s) immediately.

Fuel Gauge (See Figure 8)Indicates the quantity of fuel in the fuel tank. Capacity ofthe fuel tank is 35.5 gallons (134,4 ltr), total of 33.5(126,8 ltr) usable gallons.

Hourmeter (See Figure 8)Indicates the total elapsed hours of vehicle operation.

OH0371

ALTERNATORCHARGING

LIGHT

ENGINE WATERTEMPERATURE

LIGHT

ENGINE OILPRESSURE

LIGHT

TRANSMISSION/HYDRAULIC OILTEMPERATURE

LIGHT

Rear View Mirrors (Not Pictured)

Two rear view mirrors are provided to aid the operator'srear vision. A rectangular flat lens mirror is mounted onthe upper left of the cab. A convex lens mirror ismounted on the right side of the frame. Both mirrors areadjustable to obtain the best rear view by the operator.

There are four warning lights in a cluster between thehourmeter and fuel gauge. When the ignition switch isturned to the RUN position the Engine Oil Pressure andAlternator Charge indicators will light up. This is a normalcondition. While the engine is running, all lights should beOFF. However, if any of the lights turn ON an abnormalcondition exists. These conditions are:

• Engine Water Temperature LightIndicates high engine coolant temperature.

• Engine Oil Pressure LightIndicates low engine oil pressure.

• Alternator Charging LightIndicates alternator is not charging.

• Transmission/Hydraulic Oil Temperature LightIndicates high transmission or hydraulic oiltemperature.

Warning Lights (See Figure 8)

Page 21 10054 Rev 3/04

Warning Light Bulb Test Button (See Figure 8)

Directly to the right of the instrument cluster is a warninglight bulb test button. With ignition switch in the RUNposition and engine OFF, depress this button to test allwarning lights. If any of the lights are burnt out, replacethe bulb(s) immediately.

Fuel Gauge (See Figure 8)Indicates the quantity of fuel in the fuel tank. Capacity ofthe fuel tank is 35.5 gallons (134,4 ltr), total of 33.5(126,8 ltr) usable gallons.

Hourmeter (See Figure 8)Indicates the total elapsed hours of vehicle operation.

OH0371

ALTERNATORCHARGING

LIGHT

ENGINE WATERTEMPERATURE

LIGHT

ENGINE OILPRESSURE

LIGHT

TRANSMISSION/HYDRAULIC OILTEMPERATURE

LIGHT

Rear View Mirrors (Not Pictured)

Two rear view mirrors are provided to aid the operator'srear vision. A rectangular flat lens mirror is mounted onthe upper left of the cab. A convex lens mirror ismounted on the right side of the frame. Both mirrors areadjustable to obtain the best rear view by the operator.

There are four warning lights in a cluster between thehourmeter and fuel gauge. When the ignition switch isturned to the RUN position the Engine Oil Pressure andAlternator Charge indicators will light up. This is a normalcondition. While the engine is running, all lights should beOFF. However, if any of the lights turn ON an abnormalcondition exists. These conditions are:

• Engine Water Temperature LightIndicates high engine coolant temperature.

• Engine Oil Pressure LightIndicates low engine oil pressure.

• Alternator Charging LightIndicates alternator is not charging.

• Transmission/Hydraulic Oil Temperature LightIndicates high transmission or hydraulic oiltemperature.

Warning Lights (See Figure 8)

10054 Rev 3/04

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Frame Level Indicator (See Figure 9)

The indicator is mounted on the top inside of the Opera-tor's Protective Structure (cab). This is a bubble typeindicator which allows the operator to tell if the vehiclehas been positioned in a level condition. Always frametilt the vehicle either right or left until the indicator readszero degrees (0°). If zero cannot be achieved, thenreposition the vehicle until it is level before placing theload.

NOTE: Maximum frame tilt is 10° in either direction. SCALE

PLUMBARROW

FRAME LEVELINDICATOR

Figure 9OA0092

Figure 10 OH0302

Boom Angle Indicator (See Figure 10)

The boom angle indicator is a plumb arrow with angulargraduations from minus 10° to plus 80°. It is located onthe left side of the boom and is visible from theoperator’s position. Use this indicator to determine theboom angle when reading the capacity chart (see “UsingThe Capacity Chart”).

Page 22 10054 Rev 3/04

��

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Frame Level Indicator (See Figure 9)

The indicator is mounted on the top inside of the Opera-tor's Protective Structure (cab). This is a bubble typeindicator which allows the operator to tell if the vehiclehas been positioned in a level condition. Always frametilt the vehicle either right or left until the indicator readszero degrees (0°). If zero cannot be achieved, thenreposition the vehicle until it is level before placing theload.

NOTE: Maximum frame tilt is 10° in either direction. SCALE

PLUMBARROW

FRAME LEVELINDICATOR

Figure 9OA0092

Figure 10 OH0302

Boom Angle Indicator (See Figure 10)

The boom angle indicator is a plumb arrow with angulargraduations from minus 10° to plus 80°. It is located onthe left side of the boom and is visible from theoperator’s position. Use this indicator to determine theboom angle when reading the capacity chart (see “UsingThe Capacity Chart”).

10054 Rev 3/04

OA0623Figure 12

DIRECTIONAL SIGNALLEVER

Optional ControlsLight Switch (See Figure 11)

A three-position push-pull switch controls the lights of theoptional light package.

• Switch In = Lights OFF.

• Switch Halfway Out = Headlights and Taillights.

• Switch Fully Out = Headlights, Taillights, Rear WorkLights and Boom Work Light.

EMERGENCY FLASHERSLIDE CONTROL

Directional Signals (See Figure 12)

Push the lever to the left and down to signal a left turn; tothe right and up for a right turn. The signals are NOTself-canceling; the lever must be moved to the centerOFF position after the indicated turn is negotiated.

To operate the emergency flashers, push or lift up theslide control. To cancel the flashers, engage the direc-tional lever momentarily.Figure 11 OA0612

LIGHTSWITCH

HORNBUTTON

Page 23 10054 Rev 3/04

OA0623Figure 12

DIRECTIONAL SIGNALLEVER

Optional ControlsLight Switch (See Figure 11)

A three-position push-pull switch controls the lights of theoptional light package.

• Switch In = Lights OFF.

• Switch Halfway Out = Headlights and Taillights.

• Switch Fully Out = Headlights, Taillights, Rear WorkLights and Boom Work Light.

EMERGENCY FLASHERSLIDE CONTROL

Directional Signals (See Figure 12)

Push the lever to the left and down to signal a left turn; tothe right and up for a right turn. The signals are NOTself-canceling; the lever must be moved to the centerOFF position after the indicated turn is negotiated.

To operate the emergency flashers, push or lift up theslide control. To cancel the flashers, engage the direc-tional lever momentarily.Figure 11 OA0612

LIGHTSWITCH

HORNBUTTON

10054 Rev 3/04

Figure 13

AUXILIARY ATTACHMENTCONTROL LEVER

Auxiliary Attachment Control Lever(See Figure 13)

The auxiliary attachment control lever controls thefunctions of an optional attachment that is mountedto the vehicle and requires a hydraulic supply foroperation. Some of the optional attachments thatrequire auxiliary hydraulics are: Side Tilt Carriage,Auger and Swing Carriage.

When the control lever is moved to the right itwill provide hydraulic system pressure throughthe female disconnect coupling for the auxiliaryattachment. Hydraulic fluid will return to thetank through the male disconnect coupling.

OH0381

OH0431

OH0451

When the control lever is moved to the left it willprovide hydraulic system pressure to the maledisconnect coupling for the auxiliary attachment.Hydraulic fluid will return to the tank through thefemale disconnect coupling.

The control lever will provide the following typical func-tions for each specific attachment if they are connectedproperly. Operation will be reversed if incorrectly con-nected. We recommend reversing the disconnectcouplings on the hoses that are supplied with the attach-ment if operation is reversed.

Side Tilt Carriage Operation:• Lever right ....... tilt right• Lever left ......... tilt left

Auger Operation:• Lever right ....... auger dig• Lever left ......... auger retract

Swing Carriage:• Lever right ....... swing right• Lever left ......... swing left

Page 24 10054 Rev 3/04

Figure 13

AUXILIARY ATTACHMENTCONTROL LEVER

Auxiliary Attachment Control Lever(See Figure 13)

The auxiliary attachment control lever controls thefunctions of an optional attachment that is mountedto the vehicle and requires a hydraulic supply foroperation. Some of the optional attachments thatrequire auxiliary hydraulics are: Side Tilt Carriage,Auger and Swing Carriage.

When the control lever is moved to the right itwill provide hydraulic system pressure throughthe female disconnect coupling for the auxiliaryattachment. Hydraulic fluid will return to thetank through the male disconnect coupling.

OH0381

OH0431

OH0451

When the control lever is moved to the left it willprovide hydraulic system pressure to the maledisconnect coupling for the auxiliary attachment.Hydraulic fluid will return to the tank through thefemale disconnect coupling.

The control lever will provide the following typical func-tions for each specific attachment if they are connectedproperly. Operation will be reversed if incorrectly con-nected. We recommend reversing the disconnectcouplings on the hoses that are supplied with the attach-ment if operation is reversed.

Side Tilt Carriage Operation:• Lever right ....... tilt right• Lever left ......... tilt left

Auger Operation:• Lever right ....... auger dig• Lever left ......... auger retract

Swing Carriage:• Lever right ....... swing right• Lever left ......... swing left

10054 Rev 3/04

Normal Starting

1. Using hand holds, enter the cab and adjust theoperator’s seat for comfortable operation.

2. Adjust mirrors to obtain best rear view from theoperators position.

3. Fasten seat belt.

4. Check that the emergency brake switch is engaged.

Walk-Around Inspection1. Check the air cleaner restriction indicator for required

service.

2. Check and add engine oil if required.

3. Check cooling system overflow bottle for coolant.Add coolant if required and remove debris or otherforeign material from the radiator as necessary.

4. Check hydraulic oil level sight gauge and add oil ifrequired.

5. Walk around the vehicle and check for leakage,damaged or missing parts, proper tire inflation andhydrofill. Make necessary repairs before operating.

6. Check the condition of the rims, check for bentflanges and/or bead mounting areas. On three piecerims, check the retaining ring on the backside of therim for wear or improper fit. Replace any damagedparts before using the vehicle.

DO NOT start the engine unless you are in the seatwith the seat belt fastened around you. Serious injuryor death could result if the belt is not securelyfastened.

The transmission requires 3 seconds immediatelyafter engine start for self-diagnostics. Always wait atleast 3 seconds after engine start before engagingtransmission. Failure to do so could damage thetransmission.

WARNING

CAUTION

Page 25 10054 Rev 3/04

Normal Starting


2. Adjust mirrors to obtain best rear view from theoperators position.



Walk-Around Inspection1. Check the air cleaner restriction indicator for required

service.

2. Check and add engine oil if required.

3. Check cooling system overflow bottle for coolant.Add coolant if required and remove debris or otherforeign material from the radiator as necessary.

4. Check hydraulic oil level sight gauge and add oil ifrequired.

5. Walk around the vehicle and check for leakage,damaged or missing parts, proper tire inflation andhydrofill. Make necessary repairs before operating.

6. Check the condition of the rims, check for bentflanges and/or bead mounting areas. On three piecerims, check the retaining ring on the backside of therim for wear or improper fit. Replace any damagedparts before using the vehicle.


The transmission requires 3 seconds immediatelyafter engine start for self-diagnostics. Always wait atleast 3 seconds after engine start before engagingtransmission. Failure to do so could damage thetransmission.

WARNING

CAUTION

10054 Rev 3/04




4. Place the travel select lever in (N) NEUTRAL andmove neutral lock lever to NEUTRAL LOCK position.

5. Depress the accelerator pedal to half speed.Cold StartingThe engine on this vehicle is not normally equipped witha cold starting aid. Cold starting aids such as mechani-cal or electrical ether metering equipment or blockheaters are recommended when temperatures are below


6. Turn ignition switch to START position (fully clock-wise) to crank engine. Release key when enginestarts. If engine fails to start on first try, wait untilengine and starter come to a complete stop beforecranking engine again.

10° F (-12° C). (Temperature ranges will vary when usingdifferent oil weights. Consult the engine manufacturer'smanual for other variables.)

At temperatures below 10° F (-12° C), operate the engineat moderate speeds for 5 minutes before loads areapplied.


7. After engine starts, run engine at partial throttle for30 to 60 seconds before operating the vehicle.Return to idle before using travel or range selectlevers.

8. Disengage emergency brake switch before you startoperating.

DO NOT crank starting motor continuously for morethan 15 seconds. This will avoid starter motoroverheating.

WARNINGCAUTION

Page 26 10054 Rev 3/04





5. Depress the accelerator pedal to half speed.Cold StartingThe engine on this vehicle is not normally equipped witha cold starting aid. Cold starting aids such as mechani-cal or electrical ether metering equipment or blockheaters are recommended when temperatures are below


6. Turn ignition switch to START position (fully clock-wise) to crank engine. Release key when enginestarts. If engine fails to start on first try, wait untilengine and starter come to a complete stop beforecranking engine again.

10° F (-12° C). (Temperature ranges will vary when usingdifferent oil weights. Consult the engine manufacturer'smanual for other variables.)

At temperatures below 10° F (-12° C), operate the engineat moderate speeds for 5 minutes before loads areapplied.


7. After engine starts, run engine at partial throttle for30 to 60 seconds before operating the vehicle.Return to idle before using travel or range selectlevers.

8. Disengage emergency brake switch before you startoperating.

DO NOT crank starting motor continuously for morethan 15 seconds. This will avoid starter motoroverheating.

WARNINGCAUTION

10054 Rev 3/04

NEVER use starting fluid near an open flame, or withelectric preheater or flame air heater equipment.Serious injury or death could result from explosion.

DO NOT breathe starting fluid fumes. Serious injuryor death could result from toxic fumes.

DO NOT use excessive amounts of starting fluidwhen starting an engine. Serious injury or deathcould result from a backfire of flame which couldignite the starting fluid canister and cause anexplosion.

IMPORTANT: It is recommended that two people arepresent when attempting to start the engine without meteredstarting fluid equipment. One to operate the ignition switchand the other to spray the fluid. Avoid soaking the aircleaner element with ether. This is extremely importantbecause a backfire of flame can completely destroy both theprimary and secondary air cleaner elements and otherpossible engine damage may occur.

Turn the ignition switch to the START position toengage the starter motor. After the engine hasstarted to crank, not before, the other person canspray starting fluid into the air cleaner intake.

As the engine starts, stop spraying starting fluid andrelease the ignition key to the RUN position. Re-lease the accelerator pedal to give a smooth idlespeed.

IMPORTANT: Never spray excessive amounts of ether! Toomuch ether will wash oil off cylinder bores and cause severeengine damage.

7. The engine oil pressure warning light should turnOFF within 5 seconds after the engine has started.If the light remains ON, turn engine OFF immediatelyand check oil level or change type of oil being usedto a lighter weight oil. Consult engine manufacturer'smanual for other oils that can be used.

6. If using starting fluid with mechanical or electricalmetering equipment:

Turn the ignition switch to the START position toengage the starter motor and inject metered amountsof starting fluid.

As the engine starts, stop injection of starting fluidand release the ignition key to the RUN position.Release the accelerator pedal to give a smooth idlespeed.

If using starting fluid without metering equipment:

WARNING

Page 27 10054 Rev 3/04

NEVER use starting fluid near an open flame, or withelectric preheater or flame air heater equipment.Serious injury or death could result from explosion.

DO NOT breathe starting fluid fumes. Serious injuryor death could result from toxic fumes.

DO NOT use excessive amounts of starting fluidwhen starting an engine. Serious injury or deathcould result from a backfire of flame which couldignite the starting fluid canister and cause anexplosion.

IMPORTANT: It is recommended that two people arepresent when attempting to start the engine without meteredstarting fluid equipment. One to operate the ignition switchand the other to spray the fluid. Avoid soaking the aircleaner element with ether. This is extremely importantbecause a backfire of flame can completely destroy both theprimary and secondary air cleaner elements and otherpossible engine damage may occur.

Turn the ignition switch to the START position toengage the starter motor. After the engine hasstarted to crank, not before, the other person canspray starting fluid into the air cleaner intake.

As the engine starts, stop spraying starting fluid andrelease the ignition key to the RUN position. Re-lease the accelerator pedal to give a smooth idlespeed.

IMPORTANT: Never spray excessive amounts of ether! Toomuch ether will wash oil off cylinder bores and cause severeengine damage.

7. The engine oil pressure warning light should turnOFF within 5 seconds after the engine has started.If the light remains ON, turn engine OFF immediatelyand check oil level or change type of oil being usedto a lighter weight oil. Consult engine manufacturer'smanual for other oils that can be used.

6. If using starting fluid with mechanical or electricalmetering equipment:

Turn the ignition switch to the START position toengage the starter motor and inject metered amountsof starting fluid.

As the engine starts, stop injection of starting fluidand release the ignition key to the RUN position.Release the accelerator pedal to give a smooth idlespeed.

If using starting fluid without metering equipment:

WARNING

10054 Rev 3/04

Jump Starting

Jump starting at the battery or battery replacement isrequired when the battery is discharged to the pointwhere the battery will not crank the starter.

To avoid personal injury when jump starting withanother vehicle, be certain that the vehicles arenot touching. Never jump start a frozen battery asit will explode. Keep sparks, flames and lightedsmoking materials away from the battery. Leadacid batteries generate explosive gases whencharging. Wear safety glasses when working nearbatteries.

NEVER jump start the vehicle directly to thestarter or starter solenoid. Serious injury or deathcould result from the vehicle moving forward orbackward and running over the person jumpstarting the vehicle.

1. The booster battery must be a 12 volt type. Thevehicle used for jump starting must have a negativeground electrical system. To jump start the vehicle,proceed as follows.

2. Connect the positive (+) jumper cable to the positive(+) post of the discharged battery.

3. Connect the other end of the same jumper cable tothe positive (+) post of the booster battery.

4. Connect one end of the second jumper cable to thenegative (-) post of the booster battery.

5. Make the final jumper cable connection to thefurthest ground point away from the dischargedbattery.

6. Follow the steps in “Normal Starting.”

7. Remove the jumper cables in the reverse order oftheir connection (i.e. negative cable ground connec-tion first, etc.)

WARNING

WARNING

Page 28 10054 Rev 3/04

Jump Starting

Jump starting at the battery or battery replacement isrequired when the battery is discharged to the pointwhere the battery will not crank the starter.

To avoid personal injury when jump starting withanother vehicle, be certain that the vehicles arenot touching. Never jump start a frozen battery asit will explode. Keep sparks, flames and lightedsmoking materials away from the battery. Leadacid batteries generate explosive gases whencharging. Wear safety glasses when working nearbatteries.

NEVER jump start the vehicle directly to thestarter or starter solenoid. Serious injury or deathcould result from the vehicle moving forward orbackward and running over the person jumpstarting the vehicle.

1. The booster battery must be a 12 volt type. Thevehicle used for jump starting must have a negativeground electrical system. To jump start the vehicle,proceed as follows.

2. Connect the positive (+) jumper cable to the positive(+) post of the discharged battery.

3. Connect the other end of the same jumper cable tothe positive (+) post of the booster battery.

4. Connect one end of the second jumper cable to thenegative (-) post of the booster battery.

5. Make the final jumper cable connection to thefurthest ground point away from the dischargedbattery.

6. Follow the steps in “Normal Starting.”

7. Remove the jumper cables in the reverse order oftheir connection (i.e. negative cable ground connec-tion first, etc.)

WARNING

WARNING

10054 Rev 3/04

Operating

Understanding the Stabil-TRAK™ SystemThe following describes the three basic modes of theStabil-TRAK system. With the outriggers raised, the unitmay operate in any one of these three modes at anygiven time while the boom is within the 42 series exten-sion limit.

• Placing Travel SelectLever in(N) NEUTRAL

• Depressing andholding the ServiceBrake Pedal

The frame tilt functionsslower than normal inthis mode, with orwithout the outriggersdown.

Free Pivot Mode

With the boom below40°, the Stabil-TRAKsystem is in the freepivot mode and therear axle is allowed topivot freely.

The frame tilt functionsnormally, with orwithout the outriggersdown.

Locked Mode

With the boom above 40°, the Stabil-TRAK system is inthe locked mode and the rear axle is locked so it is rigidwith the frame. This mode is activated by one or moreof the following functions:

• Engaging the Emergency Brake Switch

FREE PIVOT MODE

OH0600

LOCKED MODE

OH0610

FINAL POSITIONING MODE

OH0621

Final Positioning Mode

With the boom above40° and vehicletraveling the Stabil-TRAK system is inthe final positioningmode. In this modethe rear axle isunlocked and isallowed to pivot, butwill respond SLOWLYto changes in terrain.

The frame tilt functionsnormally in this mode.

It is important that you regularly check that this systemis functioning properly. Refer to the test procedure laterin this manual for proper system function.

Page 29 10054 Rev 3/04

Operating

Understanding the Stabil-TRAK™ SystemThe following describes the three basic modes of theStabil-TRAK system. With the outriggers raised, the unitmay operate in any one of these three modes at anygiven time while the boom is within the 42 series exten-sion limit.

• Placing Travel SelectLever in(N) NEUTRAL

• Depressing andholding the ServiceBrake Pedal

The frame tilt functionsslower than normal inthis mode, with orwithout the outriggersdown.

Free Pivot Mode

With the boom below40°, the Stabil-TRAKsystem is in the freepivot mode and therear axle is allowed topivot freely.

The frame tilt functionsnormally, with orwithout the outriggersdown.

Locked Mode

With the boom above 40°, the Stabil-TRAK system is inthe locked mode and the rear axle is locked so it is rigidwith the frame. This mode is activated by one or moreof the following functions:

• Engaging the Emergency Brake Switch

FREE PIVOT MODE

OH0600

LOCKED MODE

OH0610

FINAL POSITIONING MODE

OH0621

Final Positioning Mode

With the boom above40° and vehicletraveling the Stabil-TRAK system is inthe final positioningmode. In this modethe rear axle isunlocked and isallowed to pivot, butwill respond SLOWLYto changes in terrain.

The frame tilt functionsnormally in this mode.


10054 Rev 3/04

Outrigger Interlock Mode

The outrigger interlock allows for full boom extensiononly as long as both outriggers have been lowered ontofirm terrain. Once this condition is met, the boom isallowed to extend to its full limits.

IMPORTANT: As an added measure of safety, ALWAYSremember to shift the Travel Select Lever into neutral(N) NEUTRAL, move neutral lock lever to NEUTRALLOCK position and engage the Emergency Brake whenoutriggers are lowered.

With the outrigger interlock engaged additional systemsare automatically activated which enhance the stabilityof the vehicle. These are:

• Stabil-TRAK is in the locked mode.• The transmission has been declutched.• The emergency brake is engaged.• The outrigger RAISE function

is inoperable.Other effects that you willexperience while the outriggerinterlock is engaged are:

• With Stabil-TRAK active,frame tilting will be slowerthan normal.

• The outriggers are still allowed to lower to adjustfor any changes in outrigger footing.

Understanding the Boom/Outrigger InterlockSystem

The ultimate purpose of this interlock system is to addan extra measure of stability allowing the boom to beextended to its maximum limits. There are two modesto this interlock, the Extend Interlock and the OutriggerInterlock.

Extend Interlock Mode

The extend interlock limits boom extension of the 10054to the same maximum extension limits as an 8042 or10042. A sensor in the boom will automatically stop theboom from extending past this point until the outriggershave been lowered onto firm terrain.

With the outriggers raised and the boom inside of theextension limit the vehicle will function normally. TheStabil-TRAK systemshould also performas designed.

OH06301

OH0640

Page 30 10054 Rev 3/04

Outrigger Interlock Mode

The outrigger interlock allows for full boom extensiononly as long as both outriggers have been lowered ontofirm terrain. Once this condition is met, the boom isallowed to extend to its full limits.

IMPORTANT: As an added measure of safety, ALWAYSremember to shift the Travel Select Lever into neutral(N) NEUTRAL, move neutral lock lever to NEUTRALLOCK position and engage the Emergency Brake whenoutriggers are lowered.

With the outrigger interlock engaged additional systemsare automatically activated which enhance the stabilityof the vehicle. These are:

• Stabil-TRAK is in the locked mode.• The transmission has been declutched.• The emergency brake is engaged.• The outrigger RAISE function

is inoperable.Other effects that you willexperience while the outriggerinterlock is engaged are:

• With Stabil-TRAK active,frame tilting will be slowerthan normal.

• The outriggers are still allowed to lower to adjustfor any changes in outrigger footing.

Understanding the Boom/Outrigger InterlockSystem

The ultimate purpose of this interlock system is to addan extra measure of stability allowing the boom to beextended to its maximum limits. There are two modesto this interlock, the Extend Interlock and the OutriggerInterlock.

Extend Interlock Mode

The extend interlock limits boom extension of the 10054to the same maximum extension limits as an 8042 or10042. A sensor in the boom will automatically stop theboom from extending past this point until the outriggershave been lowered onto firm terrain.

With the outriggers raised and the boom inside of theextension limit the vehicle will function normally. TheStabil-TRAK systemshould also performas designed.

OH06301

OH0640

10054 Rev 3/04

6. Avoid operating in too high a gear when moving aheavy load as this may cause excessive “lugging.”This occurs when the engine will not respond to athrottle increase. Use a lower gear when moving aheavy load; a higher gear when moving a light load.Selecting the correct gear ratio will save fuel andprolong engine life.

IMPORTANT: Check warning lights frequently duringoperation. Any abnormal indications or vehicle malfunctionshould be corrected as soon as possible.

Changing Travel Direction1. Stop the vehicle.

2. Move travel select lever to opposite direction,(R) REVERSE or (F) FORWARD.

Shifting Gears1. Rotate the twist grip of the gear select lever to the

next desired gear.

NOTE: Shifting to the next higher gear may be done whilethe vehicle is in motion.

IMPORTANT: When downshifting, allow the engine speedto slow down before shifting to the next lower gear.

Starting Travel

Not until the boom has been retracted past the exten-sion limit will any of these conditions change.


The transmission requires 3 seconds immediatelyafter engine start for self diagnostics. Always wait atleast 3 seconds after engine start before engagingtransmission. Failure to do so could damage thetransmission.

1. Enter operator cab, fasten seat belt, start engine anddisengage emergency brake switch.

2. Place the neutral lock lever to (D) DRIVE position.

3. Move gear select lever to the desired gear.

4. Move travel select lever to (F) FORWARD or(R) REVERSE as needed.

5. Use accelerator pedal to control ground speed.

CAUTION

Page 31 10054 Rev 3/04

6. Avoid operating in too high a gear when moving aheavy load as this may cause excessive “lugging.”This occurs when the engine will not respond to athrottle increase. Use a lower gear when moving aheavy load; a higher gear when moving a light load.Selecting the correct gear ratio will save fuel andprolong engine life.

IMPORTANT: Check warning lights frequently duringoperation. Any abnormal indications or vehicle malfunctionshould be corrected as soon as possible.

Changing Travel Direction1. Stop the vehicle.

2. Move travel select lever to opposite direction,(R) REVERSE or (F) FORWARD.

Shifting Gears1. Rotate the twist grip of the gear select lever to the

next desired gear.

NOTE: Shifting to the next higher gear may be done whilethe vehicle is in motion.

IMPORTANT: When downshifting, allow the engine speedto slow down before shifting to the next lower gear.

Starting Travel

Not until the boom has been retracted past the exten-sion limit will any of these conditions change.


The transmission requires 3 seconds immediatelyafter engine start for self diagnostics. Always wait atleast 3 seconds after engine start before engagingtransmission. Failure to do so could damage thetransmission.

1. Enter operator cab, fasten seat belt, start engine anddisengage emergency brake switch.

2. Place the neutral lock lever to (D) DRIVE position.

3. Move gear select lever to the desired gear.

4. Move travel select lever to (F) FORWARD or(R) REVERSE as needed.

5. Use accelerator pedal to control ground speed.

CAUTION

10054 Rev 3/04

OH0070Figure 14

NEVER use the four wheel steer mode when travelingat high speed. Rapid turning in this mode may causetipover. Use only the two wheel steer mode at highspeeds and slow vehicle when turning.

SteeringThe vehicle can be operated in three steering modesas selected at the steering select switch on theinstrument panel: four wheel steer, two wheel steerand crab steer.

NOTE: DO NOT change steer select switch unless alltires are in the straight ahead position. If tires are not“straight ahead,” steering may become out-of-phase,making it necessary to perform the four wheel steerindexing procedure which follows.

Four Wheel Steer Indexing Procedure

1. With the steering select switch in the Four WheelSteer position, turn the steering wheel full left.While holding the steering wheel full left, togglethe steer select switch to the Front Wheel Steerposition and steer the front wheels back tocenter. Toggle the steer select switch back to

1. Four Wheel Steering (See Figure 14)

Stopping Travel

1. Apply service brakes and downshift to lower gear asnecessary to slow the vehicle until it comes to acomplete stop.

2. Move travel select lever to (N) NEUTRAL for longerstops, place neutral lock lever to NEUTRAL LOCKposition and ENGAGE the emergency brake switch.

Four Wheel Steer position and turn the steeringwheel full left. Toggle the steer select switchback to Front Wheel Steer position and steer thefront wheels full left. Toggle the switch to theFour Wheel Steer position and return to center.

2. The vehicle should now be properly indexed inFour Wheel Steering. If the wheels are still out-of-phase, repeat step 1 again.

WARNING

Page 32 10054 Rev 3/04

OH0070Figure 14

NEVER use the four wheel steer mode when travelingat high speed. Rapid turning in this mode may causetipover. Use only the two wheel steer mode at highspeeds and slow vehicle when turning.

SteeringThe vehicle can be operated in three steering modesas selected at the steering select switch on theinstrument panel: four wheel steer, two wheel steerand crab steer.

NOTE: DO NOT change steer select switch unless alltires are in the straight ahead position. If tires are not“straight ahead,” steering may become out-of-phase,making it necessary to perform the four wheel steerindexing procedure which follows.

Four Wheel Steer Indexing Procedure

1. With the steering select switch in the Four WheelSteer position, turn the steering wheel full left.While holding the steering wheel full left, togglethe steer select switch to the Front Wheel Steerposition and steer the front wheels back tocenter. Toggle the steer select switch back to

1. Four Wheel Steering (See Figure 14)

Stopping Travel

1. Apply service brakes and downshift to lower gear asnecessary to slow the vehicle until it comes to acomplete stop.

2. Move travel select lever to (N) NEUTRAL for longerstops, place neutral lock lever to NEUTRAL LOCKposition and ENGAGE the emergency brake switch.

Four Wheel Steer position and turn the steeringwheel full left. Toggle the steer select switchback to Front Wheel Steer position and steer thefront wheels full left. Toggle the switch to theFour Wheel Steer position and return to center.

2. The vehicle should now be properly indexed inFour Wheel Steering. If the wheels are still out-of-phase, repeat step 1 again.

WARNING

10054 Rev 3/04

3. Crab Steering (See Figure 16)

All wheels will steer in same direction. This modepermits the operator to move the vehicle sidewaystoward the landing point of the load. This is espe-cially helpful in tight quarters on a job, in order to lineup at the exact spot in front of the loading location.

OH0060Figure 16

OH0080Figure 15

The front wheels will steer in the direction that thesteering wheel is turned; the rear wheels will steer inthe opposite direction. This mode allows an ex-tremely short turning radius. It also enables the rearwheels to follow the tracking of front wheels which isan advantage in mud or sand conditions.

2. Two Wheel Steering (See Figure 15)

The front wheels will steer in the direction that thesteering wheel is turned. The rear wheels will remainin the fixed forward position. This mode is used foron-highway travel or at higher speeds.

Page 33 10054 Rev 3/04

3. Crab Steering (See Figure 16)

All wheels will steer in same direction. This modepermits the operator to move the vehicle sidewaystoward the landing point of the load. This is espe-cially helpful in tight quarters on a job, in order to lineup at the exact spot in front of the loading location.

OH0060Figure 16

OH0080Figure 15

The front wheels will steer in the direction that thesteering wheel is turned; the rear wheels will steer inthe opposite direction. This mode allows an ex-tremely short turning radius. It also enables the rearwheels to follow the tracking of front wheels which isan advantage in mud or sand conditions.

2. Two Wheel Steering (See Figure 15)

The front wheels will steer in the direction that thesteering wheel is turned. The rear wheels will remainin the fixed forward position. This mode is used foron-highway travel or at higher speeds.

10054 Rev 3/04

Leveling FrameWhen placing a load while on a slope, use the frametilt control lever to keep the load level. The operatorshould observe the frame level indicator to assurethat the load is level at all times.

Frame tilting with the boom raised above horizontalcan cause tipover resulting in death or serious injury.Always use the frame tilt to level the vehicle beforeraising the boom above horizontal. If the vehiclecannot be leveled using the frame tilt, reposition thevehicle.

MAXIMUMFORK SWEEP

Figure 17 OH0090

VEHICLETURNING RADIUS

The forks extend beyond the end of the carriage. Theoperator must be aware of the maximum sweep of theforks when turning and allow for adequate clearancebetween the forks, personnel and other objects (SeeFigure 17).

Quick Attach (See Figure 18)

This telescopic handler is equipped with a quick attachsystem for easy attachment changing.

Quick Attach Removal

1. Park the vehicle on level ground.

2. Place travel select lever in (N) NEUTRAL, moveneutral lock lever to NEUTRAL LOCK position andengage the emergency brake switch.

3. Extend the boom about 10 feet and tilt the carriagebackward.

CENTER OFTURNINGRADIUS

CAUTION

DANGER

Page 34 10054 Rev 3/04

Leveling FrameWhen placing a load while on a slope, use the frametilt control lever to keep the load level. The operatorshould observe the frame level indicator to assurethat the load is level at all times.

Frame tilting with the boom raised above horizontalcan cause tipover resulting in death or serious injury.Always use the frame tilt to level the vehicle beforeraising the boom above horizontal. If the vehiclecannot be leveled using the frame tilt, reposition thevehicle.

MAXIMUMFORK SWEEP

Figure 17 OH0090

VEHICLETURNING RADIUS

The forks extend beyond the end of the carriage. Theoperator must be aware of the maximum sweep of theforks when turning and allow for adequate clearancebetween the forks, personnel and other objects (SeeFigure 17).

Quick Attach (See Figure 18)

This telescopic handler is equipped with a quick attachsystem for easy attachment changing.

Quick Attach Removal

1. Park the vehicle on level ground.

2. Place travel select lever in (N) NEUTRAL, moveneutral lock lever to NEUTRAL LOCK position andengage the emergency brake switch.

3. Extend the boom about 10 feet and tilt the carriagebackward.

CENTER OFTURNINGRADIUS

CAUTION

DANGER

10054 Rev 3/04

6. Return to the operator’s compartment, lower theattachment to the ground in a level position, andpush the attachment tilt lever forward. This willrotate the quick attach link back away from theattachment.

7. Lower, then retract the boom until the boom hookpins have disconnected from the attachment.

Quick Attach Reconnect

1. Be sure that you are performing this procedure onlevel ground. Position the vehicle directly behindthe attachment to be mounted.

2. Push the attachment tilt control lever forward torotate the quick attach link back.

3. Extend the boom approximately 10 feet and drivethe vehicle forward until the boom hook pins arebelow and between the two hooks on the attach-ment.

4. Raise the boom until the boom hook pins haveseated fully in the hooks on the attachment.

5. Pull the attachment tilt control lever backward untilthe front of the attachment starts to raise. Thequick attach link should be tight up against the rearof the attachment and the holes in the link and theattachment should be aligned.

4. Exit the vehicle using the hand holds.

NOTE: Before removing a carriage type attachment,spread the forks out on the carriage shaft. This will givethe carriage adequate support to stand alone when it isremoved from the boom.

5. Raise the quick attach pin lock lever and pull outthe pin at the bottom of the quick attach link.

PIN LOCKLEVER

Figure 18

QUICK ATTACH PIN

OS03311

Page 35 10054 Rev 3/04

6. Return to the operator’s compartment, lower theattachment to the ground in a level position, andpush the attachment tilt lever forward. This willrotate the quick attach link back away from theattachment.

7. Lower, then retract the boom until the boom hookpins have disconnected from the attachment.

Quick Attach Reconnect

1. Be sure that you are performing this procedure onlevel ground. Position the vehicle directly behindthe attachment to be mounted.

2. Push the attachment tilt control lever forward torotate the quick attach link back.

3. Extend the boom approximately 10 feet and drivethe vehicle forward until the boom hook pins arebelow and between the two hooks on the attach-ment.

4. Raise the boom until the boom hook pins haveseated fully in the hooks on the attachment.

5. Pull the attachment tilt control lever backward untilthe front of the attachment starts to raise. Thequick attach link should be tight up against the rearof the attachment and the holes in the link and theattachment should be aligned.

4. Exit the vehicle using the hand holds.

NOTE: Before removing a carriage type attachment,spread the forks out on the carriage shaft. This will givethe carriage adequate support to stand alone when it isremoved from the boom.

5. Raise the quick attach pin lock lever and pull outthe pin at the bottom of the quick attach link.

PIN LOCKLEVER

Figure 18

QUICK ATTACH PIN

OS03311

10054 Rev 3/04

6. Place travel select lever in (N) NEUTRAL, movethe neutral lock lever to NEUTRAL LOCK position,engage emergency brake switch and exit thevehicle using the hand holds.

7. Lift lever. Insert the quick attach pin completelythrough the attachment and quick attach link. Besure that the quick attach lock lever has loweredand seated itself into the groove in the quick attachpin.

DO NOT operate this vehicle unless you are in theseat with the seat belt fastened around you.Serious injury or death could result if the belt is notsecurely fastened.

8. Return to the operator’s compartment, fasten seatbelt and resume operation.

Stabil-TRAK™ System Test

It is important for the operator to know that the Stabil-TRAK system is active and functioning properly.

Vehicle tipover can result in death or serious injury.Always operate vehicle with rear stabilizer cylinder inplace and functioning properly.DO NOT use the vehicle if the Stabil-TRAK systemis not functioning properly.

To test the function of the Stabil-TRAK system, read theStabil-TRAK system test instructions below and followsteps 1 thru 9 of the Stabil-TRAK system test procedure.

Stabil-TRAK™ System Test Instructions

• Test the Stabil-TRAK system with the vehicle on alevel surface.

• Remove any attachment from the quick attachbefore performing the test.

• Perform the test with the boom fully retracted.DO NOT extend the boom at any time during thetest.

WARNING

DANGER

Page 36 10054 Rev 3/04

6. Place travel select lever in (N) NEUTRAL, movethe neutral lock lever to NEUTRAL LOCK position,engage emergency brake switch and exit thevehicle using the hand holds.

7. Lift lever. Insert the quick attach pin completelythrough the attachment and quick attach link. Besure that the quick attach lock lever has loweredand seated itself into the groove in the quick attachpin.


8. Return to the operator’s compartment, fasten seatbelt and resume operation.

Stabil-TRAK™ System Test

It is important for the operator to know that the Stabil-TRAK system is active and functioning properly.

Vehicle tipover can result in death or serious injury.Always operate vehicle with rear stabilizer cylinder inplace and functioning properly.DO NOT use the vehicle if the Stabil-TRAK systemis not functioning properly.

To test the function of the Stabil-TRAK system, read theStabil-TRAK system test instructions below and followsteps 1 thru 9 of the Stabil-TRAK system test procedure.

Stabil-TRAK™ System Test Instructions

• Test the Stabil-TRAK system with the vehicle on alevel surface.

• Remove any attachment from the quick attachbefore performing the test.

• Perform the test with the boom fully retracted.DO NOT extend the boom at any time during thetest.

WARNING

DANGER

10054 Rev 3/04

• DO NOT raise the boom above 60° for steps3 thru 6.


• Test vehicles with outriggers in the RAISEDposition.

• Follow steps 1 thru 9 of the Stabil-TRAK systemtest procedure exactly as written.

IMPORTANT: If the Stabil-TRAK light goes OFF and thefront left tire lowers to the ground at any time during steps4 thru 7, the test was not performed properly or the Stabil-TRAK system is not functioning properly. Carefully repeatthe steps starting with step 1. If the Stabil-TRAK lightgoes OFF and the front left tire lowers to the groundconsistently during steps 4 thru 7, the Stabil-TRAK systemis not functioning properly and the test should be stoppedimmediately. DO NOT use the vehicle if the Stabil-TRAKsystem is not functioning properly. Contact your SkyTRAK Distributor immediately to repair the system.


Stabil-TRAK™ System Test Procedure

1. Fasten seat belt and place the vehicle on a levelsurface with 0° frame tilt angle, no load on theforks, boom fully retracted and horizontal. Checkto be sure the Stabil-TRAK light is OFF.

2. Locate an eight inch wood or concrete block infront of the left front tire and drive the vehicle upon the block. Frame tilt the vehicle back to 0°.

3. With the service brake pedal depressed, theemergency brake switch OFF, move the travelselect lever to the (N) NEUTRAL position and raisethe boom to exactly 60°. The Stabil-TRAK lightshould come ON when the boom angle is at about40° and remain ON.

WARNING

Page 37 10054 Rev 3/04



• Test vehicles with outriggers in the RAISEDposition.

• Follow steps 1 thru 9 of the Stabil-TRAK systemtest procedure exactly as written.

IMPORTANT: If the Stabil-TRAK light goes OFF and thefront left tire lowers to the ground at any time during steps4 thru 7, the test was not performed properly or the Stabil-TRAK system is not functioning properly. Carefully repeatthe steps starting with step 1. If the Stabil-TRAK lightgoes OFF and the front left tire lowers to the groundconsistently during steps 4 thru 7, the Stabil-TRAK systemis not functioning properly and the test should be stoppedimmediately. DO NOT use the vehicle if the Stabil-TRAKsystem is not functioning properly. Contact your SkyTRAK Distributor immediately to repair the system.


Stabil-TRAK™ System Test Procedure

1. Fasten seat belt and place the vehicle on a levelsurface with 0° frame tilt angle, no load on theforks, boom fully retracted and horizontal. Checkto be sure the Stabil-TRAK light is OFF.

2. Locate an eight inch wood or concrete block infront of the left front tire and drive the vehicle upon the block. Frame tilt the vehicle back to 0°.

3. With the service brake pedal depressed, theemergency brake switch OFF, move the travelselect lever to the (N) NEUTRAL position and raisethe boom to exactly 60°. The Stabil-TRAK lightshould come ON when the boom angle is at about40° and remain ON.

WARNING

10054 Rev 3/04

IMPORTANT: Perform procedures 4 thru 9 with theengine rpm at idle.

4. With the service brake pedal depressed, move thetravel select lever to the (R) REVERSE position.Ease your foot off the service brake pedal andincrease engine RPM slightly if necessary justenough to back the vehicle off of the block, whilekeeping the service brake pedal partially de-pressed so that the Stabil-TRAK light remains ON.The rear axle should remain locked while backingoff of the block and the front left tire should remainoff the ground.

5. While keeping the service brake pedal depressed,move the travel select lever to the (N) NEUTRALposition and take your foot off of the service brakepedal. The rear axle should remain locked, theStabil-TRAK light should remain ON, and the frontleft tire should remain off the ground.

6. With the travel select lever in the (N) NEUTRALposition, engage the emergency brake switch andmove the travel select lever to the (F) FORWARDposition. The rear axle should remain locked, theStabil-TRAK light should remain ON, and the frontleft tire should remain off the ground.

7. With the emergency brake switch ON, move thetravel select lever to the (N) NEUTRAL position,and lower the boom to exactly 45°. Frame tilt thevehicle no more than 5° to the left and then nomore than 5° to the right. The vehicle shouldframe tilt slowly to the left and then to the right.The Stabil-TRAK light should remain ON, and theleft front tire should remain off the ground. Thefront left tire should not raise or lower when frametilting. Leave the vehicle frame tilted to the right 1°to 2°.

8. Depress the service brake pedal. Disengage theemergency brake switch and move the travelselect lever to the (R) REVERSE position.Release the service brake pedal to deactivate theStabil-TRAK system and the Stabil-TRAK lightshould go OFF. The left front tire should return tothe ground while the vehicle travels in reverse.Depress the service brake pedal to stop thevehicle.

Page 38 10054 Rev 3/04

IMPORTANT: Perform procedures 4 thru 9 with theengine rpm at idle.

4. With the service brake pedal depressed, move thetravel select lever to the (R) REVERSE position.Ease your foot off the service brake pedal andincrease engine RPM slightly if necessary justenough to back the vehicle off of the block, whilekeeping the service brake pedal partially de-pressed so that the Stabil-TRAK light remains ON.The rear axle should remain locked while backingoff of the block and the front left tire should remainoff the ground.

5. While keeping the service brake pedal depressed,move the travel select lever to the (N) NEUTRALposition and take your foot off of the service brakepedal. The rear axle should remain locked, theStabil-TRAK light should remain ON, and the frontleft tire should remain off the ground.

6. With the travel select lever in the (N) NEUTRALposition, engage the emergency brake switch andmove the travel select lever to the (F) FORWARDposition. The rear axle should remain locked, theStabil-TRAK light should remain ON, and the frontleft tire should remain off the ground.

7. With the emergency brake switch ON, move thetravel select lever to the (N) NEUTRAL position,and lower the boom to exactly 45°. Frame tilt thevehicle no more than 5° to the left and then nomore than 5° to the right. The vehicle shouldframe tilt slowly to the left and then to the right.The Stabil-TRAK light should remain ON, and theleft front tire should remain off the ground. Thefront left tire should not raise or lower when frametilting. Leave the vehicle frame tilted to the right 1°to 2°.

8. Depress the service brake pedal. Disengage theemergency brake switch and move the travelselect lever to the (R) REVERSE position.Release the service brake pedal to deactivate theStabil-TRAK system and the Stabil-TRAK lightshould go OFF. The left front tire should return tothe ground while the vehicle travels in reverse.Depress the service brake pedal to stop thevehicle.

10054 Rev 3/04

It is important for the operator to know that the Boom/Outrigger Interlock System is active and functioningproperly.

Perform the “Stabil-TRAK System Test” before performingthe following test.

1. Place the vehicle with no load on a flat, level hardsurface such as blacktop or concrete.

2. With outriggers in the raised position and the boomin a horizontal position extend the boom. Theboom should extend until extend letter “E” appearsand then should stop. If boom extends beyondletter “F” fully retract the boom and have thesystem repaired before using the vehicle again.Attempt to frame tilt the vehicle to the right andleft, it should frame tilt normally. Continue with thenext step.

Boom/Outrigger InterlockSystem Test

9. With the service brake pedal depressed, boomangle at exactly 45°, move the range select leverto (3) third and the travel select lever to(F) FORWARD. Release the service brake pedalto deactivate the Stabil-TRAK system and theStabil-TRAK light should go OFF. Slowly drive thevehicle forward against the block to stop thevehicle from moving forward. With the front left tireagainst the block, frame tilt the vehicle no morethan 5° in both directions while checking that thefront tires remain on the ground. It is normal forthe left front tire to raise slightly when frame tiltingto the left and for the right front tire to raise slightlywhen frame tilting to the right, but the tires shouldimmediately lower when the frame tilt function isstopped. The tires should not come completely offthe ground during this step. Frame tilt the vehicleback to zero. Depress the service brake pedal,shift the travel select lever to (N) NEUTRAL andlower the boom.

If steps 1 thru 9 prove positive, the Stabil-TRAK systemis functioning properly and the vehicle can be returned toservice. If any of these steps indicate that the Stabil-TRAK system is not functioning properly, contact yourSky TRAK Distributor immediately to repair the system.

Page 39 10054 Rev 3/04

It is important for the operator to know that the Boom/Outrigger Interlock System is active and functioningproperly.

Perform the “Stabil-TRAK System Test” before performingthe following test.

1. Place the vehicle with no load on a flat, level hardsurface such as blacktop or concrete.

2. With outriggers in the raised position and the boomin a horizontal position extend the boom. Theboom should extend until extend letter “E” appearsand then should stop. If boom extends beyondletter “F” fully retract the boom and have thesystem repaired before using the vehicle again.Attempt to frame tilt the vehicle to the right andleft, it should frame tilt normally. Continue with thenext step.

Boom/Outrigger InterlockSystem Test

9. With the service brake pedal depressed, boomangle at exactly 45°, move the range select leverto (3) third and the travel select lever to(F) FORWARD. Release the service brake pedalto deactivate the Stabil-TRAK system and theStabil-TRAK light should go OFF. Slowly drive thevehicle forward against the block to stop thevehicle from moving forward. With the front left tireagainst the block, frame tilt the vehicle no morethan 5° in both directions while checking that thefront tires remain on the ground. It is normal forthe left front tire to raise slightly when frame tiltingto the left and for the right front tire to raise slightlywhen frame tilting to the right, but the tires shouldimmediately lower when the frame tilt function isstopped. The tires should not come completely offthe ground during this step. Frame tilt the vehicleback to zero. Depress the service brake pedal,shift the travel select lever to (N) NEUTRAL andlower the boom.

If steps 1 thru 9 prove positive, the Stabil-TRAK systemis functioning properly and the vehicle can be returned toservice. If any of these steps indicate that the Stabil-TRAK system is not functioning properly, contact yourSky TRAK Distributor immediately to repair the system.

10054 Rev 3/04

3. Lower both outriggers to the ground (do not lift thefront wheels of the vehicle off the ground at thistime). With boom still in a horizontal positionextend the boom. The amber Stabil-TRAK lightshould come ON somewhere after the letter “E”has appeared and remain ON while the boomextends to full extension. Attempt to raise bothoutriggers, they should not raise. If the outriggersraise STOP and retract the boom and have thesystem repaired before using the vehicle again. Ifthe outriggers could not be raised, attempt to lowerthe outriggers fully until the front wheels are off theground, the outriggers should lower. Continue withthe next step.

4. Put the travel select lever in the (F) FORWARDposition and the range select lever in the 1st gearposition. Attempt to accelerate the vehicle. Thevehicle should not move. If the vehicle attemptsto move STOP and have the system repairedbefore using the vehicle again. Continue with thenext step.

5. Attempt to frame tilt the vehicle to the right andleft, it should frame tilt but at a slower speed thannormal. The amber Stabil-TRAK light shouldremain ON. Return the vehicle to a level position.

6. Place the travel select lever in the (N) NEUTRALposition, move the neutral lock lever to NEUTRALLOCK position, fully retract the boom, raise theoutriggers, engage the emergency brake switch,shut off the engine and remove the key. Exit thevehicle using the hand holds.

If steps 1 thru 5 prove positive, the boom/outriggerinterlock system is functioning properly and the vehiclecan be returned to service. If any of these stepsindicate that the boom/outrigger interlock system is notfunctioning properly, contact your Sky TRAK Distributorimmediately to repair the system.

Page 40 10054 Rev 3/04

3. Lower both outriggers to the ground (do not lift thefront wheels of the vehicle off the ground at thistime). With boom still in a horizontal positionextend the boom. The amber Stabil-TRAK lightshould come ON somewhere after the letter “E”has appeared and remain ON while the boomextends to full extension. Attempt to raise bothoutriggers, they should not raise. If the outriggersraise STOP and retract the boom and have thesystem repaired before using the vehicle again. Ifthe outriggers could not be raised, attempt to lowerthe outriggers fully until the front wheels are off theground, the outriggers should lower. Continue withthe next step.

4. Put the travel select lever in the (F) FORWARDposition and the range select lever in the 1st gearposition. Attempt to accelerate the vehicle. Thevehicle should not move. If the vehicle attemptsto move STOP and have the system repairedbefore using the vehicle again. Continue with thenext step.

5. Attempt to frame tilt the vehicle to the right andleft, it should frame tilt but at a slower speed thannormal. The amber Stabil-TRAK light shouldremain ON. Return the vehicle to a level position.

6. Place the travel select lever in the (N) NEUTRALposition, move the neutral lock lever to NEUTRALLOCK position, fully retract the boom, raise theoutriggers, engage the emergency brake switch,shut off the engine and remove the key. Exit thevehicle using the hand holds.

If steps 1 thru 5 prove positive, the boom/outriggerinterlock system is functioning properly and the vehiclecan be returned to service. If any of these stepsindicate that the boom/outrigger interlock system is notfunctioning properly, contact your Sky TRAK Distributorimmediately to repair the system.

10054 Rev 3/04

The capacity chart is located on the right side wall of theoperator’s compartment. The chart is provided to assistthe operator in determining how far in front, how high andat what angle a specific load weight can be safelyhandled with this vehicle.

This vehicle is equipped with two major indicators thatwill assist the operator in determining how to accuratelyuse the capacity chart. These components are the boomextend letters and the boom angle indicator.

As the boom is extended, boom extend letters will appearon the left side of the boom visible to the operator. Theletters are graduated in four foot increments. Theseletters indicate the point of boom extension and corre-spond to the capacity chart. For example, when theletter “A” first appears, the boom is at the point of boomextension corresponding to the arc of line “A” throughoutthe entire capacity chart (Figure 19).

Using The Capacity Chart The boom angle indicator located on the left side of theboom indicates the angle of the boom as shown in thecapacity chart.

To accurately use the capacity chart, the operator mustfirst determine the following three things:

1. Weight of the load being lifted.

2. Height of the structure where the load is to beplaced.

3. Distance where the load will ultimately be placed infront of the vehicle.

DO NOT exceed rated capacities. Any attempt to liftor carry loads in excess of those shown on thecapacity chart in the operator's compartment maycause vehicle tipover, loss of load or structural dam-age which could result in death or serious injury.

WARNING

Page 41 10054 Rev 3/04

The capacity chart is located on the right side wall of theoperator’s compartment. The chart is provided to assistthe operator in determining how far in front, how high andat what angle a specific load weight can be safelyhandled with this vehicle.

This vehicle is equipped with two major indicators thatwill assist the operator in determining how to accuratelyuse the capacity chart. These components are the boomextend letters and the boom angle indicator.

As the boom is extended, boom extend letters will appearon the left side of the boom visible to the operator. Theletters are graduated in four foot increments. Theseletters indicate the point of boom extension and corre-spond to the capacity chart. For example, when theletter “A” first appears, the boom is at the point of boomextension corresponding to the arc of line “A” throughoutthe entire capacity chart (Figure 19).

Using The Capacity Chart The boom angle indicator located on the left side of theboom indicates the angle of the boom as shown in thecapacity chart.

To accurately use the capacity chart, the operator mustfirst determine the following three things:

1. Weight of the load being lifted.

2. Height of the structure where the load is to beplaced.

3. Distance where the load will ultimately be placed infront of the vehicle.

DO NOT exceed rated capacities. Any attempt to liftor carry loads in excess of those shown on thecapacity chart in the operator's compartment maycause vehicle tipover, loss of load or structural dam-age which could result in death or serious injury.

WARNING

10054 Rev 3/04

3. After applying the height of the structure and thedistance of load placement away from the vehicleto the “outrigger up” portion of the capacity chart(Figure 19), the operator knows that it will be safeto place the load if the boom extend letter “D” hasappeared and the boom angle indicator readingdoes not go below approximately 40°. Thiscondition is however, a maximum limit for thisweight, height and distance away from the vehicle.The operator could simply lower the outriggers ontofirm terrain or move the vehicle closer to thestructure to assure that the vehicle will not exceedthe maximum limits for placing the load.

IMPORTANT: As an added measure of safety, ALWAYSremember to shift the Travel Select Lever into(N) NEUTRAL, move the neutral lock lever to NEUTRALLOCK position and engage the Emergency Brake whenoutriggers are lowered.

4. Apply the same rules for reading a chart with theoutriggers in a DOWN condition by using the otherhalf of the example chart (Figure 19).

Reading the chart —

EXAMPLE:1. The operator has placed the load onto the forks,

fully retracted the boom, positioned the vehicleperpendicular to the structure and leveled thevehicle with the outriggers in a raised position.

2. The operator then determines that:

• The load weight is 4000 pounds (1810 kg).

• The height of the structure the load is to beplaced upon is 27 feet (8,2 meters) from groundlevel.

• The distance where the load will ultimately beplaced in front of the vehicle is 17 feet(5,2 meters) from the front of the front tires.

Page 42 10054 Rev 3/04

3. After applying the height of the structure and thedistance of load placement away from the vehicleto the “outrigger up” portion of the capacity chart(Figure 19), the operator knows that it will be safeto place the load if the boom extend letter “D” hasappeared and the boom angle indicator readingdoes not go below approximately 40°. Thiscondition is however, a maximum limit for thisweight, height and distance away from the vehicle.The operator could simply lower the outriggers ontofirm terrain or move the vehicle closer to thestructure to assure that the vehicle will not exceedthe maximum limits for placing the load.

IMPORTANT: As an added measure of safety, ALWAYSremember to shift the Travel Select Lever into(N) NEUTRAL, move the neutral lock lever to NEUTRALLOCK position and engage the Emergency Brake whenoutriggers are lowered.

4. Apply the same rules for reading a chart with theoutriggers in a DOWN condition by using the otherhalf of the example chart (Figure 19).

Reading the chart —

EXAMPLE:1. The operator has placed the load onto the forks,

fully retracted the boom, positioned the vehicleperpendicular to the structure and leveled thevehicle with the outriggers in a raised position.

2. The operator then determines that:

• The load weight is 4000 pounds (1810 kg).

• The height of the structure the load is to beplaced upon is 27 feet (8,2 meters) from groundlevel.

• The distance where the load will ultimately beplaced in front of the vehicle is 17 feet(5,2 meters) from the front of the front tires.

10054 Rev 3/04

Figure 19 OH0822

Page 43 10054 Rev 3/04

Figure 19 OH0822

10054 Rev 3/04

Figure 19AOH0772

Page 44 10054 Rev 3/04

Figure 19AOH0772

10054 Rev 3/04

Figure 19B OH0812

Page 45 10054 Rev 3/04

Figure 19B OH0812

10054 Rev 3/04

Figure 19C OH1141

Page 46 10054 Rev 3/04

Figure 19C OH1141

10054 Rev 3/04

Figure 20

LOCATIONSTAMPED FORK

RATING

OH0670

MAXIMUM24" LOADCENTER

Fork RatingsAll forks that can be used on this vehicle are marked witha maximum load capacity rating. This rating can befound stamped on the left edge of the fork just below thefork pivot shaft (See Figure 20). This rating is listed inU.S. pounds and based upon a 24" (610 mm) load center.For metric equivalents see table below.

This rating specifies the maximum load capacity that theindividual fork can safely carry at a maximum load centerof 24" (610 mm) (See Figure 20). Since forks are alwaysused in multiples, the total load rating of any combinationof forks will be the sum of their rated capacities.

The maximum load capacity for this vehicle is 10,000lbs. (4540 kg). Forks used on this vehicle should havetotal load ratings which equal or exceed 10,000 lbs (4540kg). When the load rating of the vehicle differs from theload capacity rating of the forks, the lower value be-comes the overall load capacity. See WARNING thispage.

DO NOT exceed the total rated load capacity of thespecific type fork being used. Forks can breakcausing loss of load and possible death or seriousinjury to the operator or other personnel in the area.If the total rated load capacity of the forks exceedsthe rated capacity of the vehicle, the rated vehiclecapacity governs.

INDIVIDUAL FORK RATING EQUIVALENTS24 INCH LOAD CENTER 610 MM LOAD CENTER

1900 lbs. ..................................... 860 kg3000 lbs. ..................................... 1360 kg4000 lbs. ..................................... 1810 kg5000 lbs. ..................................... 2270 kg

WARNING

Page 47 10054 Rev 3/04

Figure 20

LOCATIONSTAMPED FORK

RATING

OH0670

MAXIMUM24" LOADCENTER

Fork RatingsAll forks that can be used on this vehicle are marked witha maximum load capacity rating. This rating can befound stamped on the left edge of the fork just below thefork pivot shaft (See Figure 20). This rating is listed inU.S. pounds and based upon a 24" (610 mm) load center.For metric equivalents see table below.

This rating specifies the maximum load capacity that theindividual fork can safely carry at a maximum load centerof 24" (610 mm) (See Figure 20). Since forks are alwaysused in multiples, the total load rating of any combinationof forks will be the sum of their rated capacities.

The maximum load capacity for this vehicle is 10,000lbs. (4540 kg). Forks used on this vehicle should havetotal load ratings which equal or exceed 10,000 lbs (4540kg). When the load rating of the vehicle differs from theload capacity rating of the forks, the lower value be-comes the overall load capacity. See WARNING thispage.

DO NOT exceed the total rated load capacity of thespecific type fork being used. Forks can breakcausing loss of load and possible death or seriousinjury to the operator or other personnel in the area.If the total rated load capacity of the forks exceedsthe rated capacity of the vehicle, the rated vehiclecapacity governs.

INDIVIDUAL FORK RATING EQUIVALENTS24 INCH LOAD CENTER 610 MM LOAD CENTER

1900 lbs. ..................................... 860 kg3000 lbs. ..................................... 1360 kg4000 lbs. ..................................... 1810 kg5000 lbs. ..................................... 2270 kg

WARNING

10054 Rev 3/04

How To Pick, Carry & Place A LoadTo pick up a load it may be necessary to adjust thespacing of the forks so the load will be positioned equallyon the forks. Tilt the carriage forward so that the forkshang freely on the fork shaft. Move the forks inward oroutward on the fork shaft so that they are aligned with theopenings in the load. Tilt the carriage back until the forksare straight and level. Lower and extend the boom slowlyto engage the load squarely until the load touches thebackrest of the carriage. Raise the boom so that the loadis lifted and tilt the carriage back for transporting the load.

To carry a load, position the carriage so that the load is aslow as possible and so it permits the best visibility of thetravel area.

Before placing a load, determine whether the outriggers areto be in a raised or lowered position. Then use the capac-ity chart to determine the safe boom extension range forthe applicable load. To place a load, align the forks at thelevel the load is to be placed and then extend the boomslowly until the load is just above the area where it is to beplaced. Lower the boom until the load rests in position andthe forks are free to retract. Retract the forks slowly fromunder the load.

If this vehicle must be used to elevate personnel, use onlyan approved work platform. When using a work platform,the following precautions must be taken:

Elevating Personnel

Use an approved work platform to lift or lowerpersonnel. NEVER move the vehicle with the workplatform in a raised position or with personnel onboard.

Preparation and Setup1. Make sure that the work platform is securely attached

to the quick attach or forks. Follow the platformmanufacturer’s instructions.

2. Make sure that the platform, carriage and forks aresecured to prevent them from pivoting from side to side.

3. Ensure that the vehicle has a firm footing and is level.

4. Place the travel select lever in (N) NEUTRAL and movethe neutral lock lever to NEUTRAL LOCK position.

5. Engage the emergency brake switch. Blocking of thevehicle wheels is also recommended.

6. Level the platform in both the side to side and front toback directions before use.

WARNING

Page 48 10054 Rev 3/04

How To Pick, Carry & Place A LoadTo pick up a load it may be necessary to adjust thespacing of the forks so the load will be positioned equallyon the forks. Tilt the carriage forward so that the forkshang freely on the fork shaft. Move the forks inward oroutward on the fork shaft so that they are aligned with theopenings in the load. Tilt the carriage back until the forksare straight and level. Lower and extend the boom slowlyto engage the load squarely until the load touches thebackrest of the carriage. Raise the boom so that the loadis lifted and tilt the carriage back for transporting the load.

To carry a load, position the carriage so that the load is aslow as possible and so it permits the best visibility of thetravel area.

Before placing a load, determine whether the outriggers areto be in a raised or lowered position. Then use the capac-ity chart to determine the safe boom extension range forthe applicable load. To place a load, align the forks at thelevel the load is to be placed and then extend the boomslowly until the load is just above the area where it is to beplaced. Lower the boom until the load rests in position andthe forks are free to retract. Retract the forks slowly fromunder the load.

If this vehicle must be used to elevate personnel, use onlyan approved work platform. When using a work platform,the following precautions must be taken:

Elevating Personnel

Use an approved work platform to lift or lowerpersonnel. NEVER move the vehicle with the workplatform in a raised position or with personnel onboard.

Preparation and Setup1. Make sure that the work platform is securely attached

to the quick attach or forks. Follow the platformmanufacturer’s instructions.

2. Make sure that the platform, carriage and forks aresecured to prevent them from pivoting from side to side.

3. Ensure that the vehicle has a firm footing and is level.

4. Place the travel select lever in (N) NEUTRAL and movethe neutral lock lever to NEUTRAL LOCK position.

5. Engage the emergency brake switch. Blocking of thevehicle wheels is also recommended.

6. Level the platform in both the side to side and front toback directions before use.

WARNING

10054 Rev 3/04

1. Make sure there are no overhead obstructionsor electrical wires above platform before lifting.

2. A trained telescopic handler operator must operatethe controls from the operator's compartment.Using extreme caution, lift and lower personnelsmoothly and only at their request. The operatorshould always alert personnel on the platform andin the work area before moving it up or down.

NEVER operate this or any equipment in an area inwhich overhead power lines, overhead or under-ground cables, or power sources exist without firstrequesting that the appropriate power company orutility company de-energize the lines or take othersuitable precautions.

Lifting Personnel3. Always lower the platform to the travel position

(approximately one foot above ground level)before moving the vehicle.

IMPORTANT: Make sure that required restraining meanssuch as railings, chains, cable, body belts with lanyards,etc. are in place and properly used. Never use railings,planks, ladders, etc. on the platform for the purpose ofachieving additional reach or height.

In case of engine failure and subsequent loss of power forcontrols, refer to emergency boom lowering procedure(under General Maintenance in this manual).

Capacity Limitation

The combined mass (weight in pounds) of the platform,load and personnel shall not exceed one-third of thecapacity of the related load center position indicated on thecapacity chart, located on the right side wall of theoperator’s compartment. Refer also to “Using the CapacityChart.”

NEVER tilt platform forward or rearward whenelevated with personnel aboard. Serious injury ordeath could result.

WARNING

DANGER

Page 49 10054 Rev 3/04

1. Make sure there are no overhead obstructionsor electrical wires above platform before lifting.

2. A trained telescopic handler operator must operatethe controls from the operator's compartment.Using extreme caution, lift and lower personnelsmoothly and only at their request. The operatorshould always alert personnel on the platform andin the work area before moving it up or down.

NEVER operate this or any equipment in an area inwhich overhead power lines, overhead or under-ground cables, or power sources exist without firstrequesting that the appropriate power company orutility company de-energize the lines or take othersuitable precautions.

Lifting Personnel3. Always lower the platform to the travel position

(approximately one foot above ground level)before moving the vehicle.

IMPORTANT: Make sure that required restraining meanssuch as railings, chains, cable, body belts with lanyards,etc. are in place and properly used. Never use railings,planks, ladders, etc. on the platform for the purpose ofachieving additional reach or height.

In case of engine failure and subsequent loss of power forcontrols, refer to emergency boom lowering procedure(under General Maintenance in this manual).

Capacity Limitation

The combined mass (weight in pounds) of the platform,load and personnel shall not exceed one-third of thecapacity of the related load center position indicated on thecapacity chart, located on the right side wall of theoperator’s compartment. Refer also to “Using the CapacityChart.”

NEVER tilt platform forward or rearward whenelevated with personnel aboard. Serious injury ordeath could result.

WARNING

DANGER

10054 Rev 3/04

Using Other AttachmentsNumerous attachments, some marketed by JLG and somesold by third party sources, are available for this vehicle.The general rule is that any attachment used on thisvehicle must be intended for the function of lifting only.This vehicle is not designed to PULL, TOW or DRAG otherobjects. DO NOT use attachments that perform thesefunctions with this vehicle.

Some JLG attachments are supplied with a capacity chartthat is to be affixed to the vehicle near the original capacitychart (Figure 20 - #4) for operator reference. Third partysources may or may not supply capacity charts with theirattachments. Capacity ratings for these type attachmentsshould be obtained from the third party source.

JLG makes no representations or warranties, express orimplied, as to the design, manufacture or fitness for usewith this vehicle of any third party source attachments.This vehicle is not intended to be used and should not beused with any attachment that would alter the center ofgravity stability of this vehicle. JLG assumes no liabilityfor any third party attachment that would alter the center ofgravity stability.

Following is a list of some of the attachments that areavailable through JLG for this model:

48", 60" and 72" Carriage

1-1/4 Cubic Yard Bucket

Auger Unit with Drive and Extensions

Windrow Broom

The standard capacity chart for this vehicle (Figure 18) isapplicable for all of the above listed attachments. Theattachments listed below are supplied with their own capac-ity charts.

52" and 72" Swing Carriage

48", 60" and 72" Side Tilt Carriage

Truss Boom

Hydraulically actuated attachments also have a maximumhydraulic pressure rating. Make sure that the maximumhydraulic pressure of the attachment is equal to or slightlygreater than 3000 psi, which is the maximum hydraulicpressure of this vehicles auxiliary hydraulics.

IMPORTANT: If the maximum pressure of the vehicleexceeds the pressure rating of the attachment, theattachment’s hydraulic components could burst. If themaximum pressure of the vehicle is much lower than thepressure rating of the attachment, the attachment may notwork properly.

Page 50 10054 Rev 3/04

Using Other AttachmentsNumerous attachments, some marketed by JLG and somesold by third party sources, are available for this vehicle.The general rule is that any attachment used on thisvehicle must be intended for the function of lifting only.This vehicle is not designed to PULL, TOW or DRAG otherobjects. DO NOT use attachments that perform thesefunctions with this vehicle.

Some JLG attachments are supplied with a capacity chartthat is to be affixed to the vehicle near the original capacitychart (Figure 20 - #4) for operator reference. Third partysources may or may not supply capacity charts with theirattachments. Capacity ratings for these type attachmentsshould be obtained from the third party source.

JLG makes no representations or warranties, express orimplied, as to the design, manufacture or fitness for usewith this vehicle of any third party source attachments.This vehicle is not intended to be used and should not beused with any attachment that would alter the center ofgravity stability of this vehicle. JLG assumes no liabilityfor any third party attachment that would alter the center ofgravity stability.

Following is a list of some of the attachments that areavailable through JLG for this model:

48", 60" and 72" Carriage

1-1/4 Cubic Yard Bucket

Auger Unit with Drive and Extensions

Windrow Broom

The standard capacity chart for this vehicle (Figure 18) isapplicable for all of the above listed attachments. Theattachments listed below are supplied with their own capac-ity charts.

52" and 72" Swing Carriage

48", 60" and 72" Side Tilt Carriage

Truss Boom

Hydraulically actuated attachments also have a maximumhydraulic pressure rating. Make sure that the maximumhydraulic pressure of the attachment is equal to or slightlygreater than 3000 psi, which is the maximum hydraulicpressure of this vehicles auxiliary hydraulics.

IMPORTANT: If the maximum pressure of the vehicleexceeds the pressure rating of the attachment, theattachment’s hydraulic components could burst. If themaximum pressure of the vehicle is much lower than thepressure rating of the attachment, the attachment may notwork properly.

Rev 3/04

Shut-Off1. Park the vehicle on level ground.

To prevent personal injury or death, be certain to lowerthe boom, shut off the engine, and engage the emer-gency brake switch before exiting the vehicle.

2. Place travel select lever in (N) NEUTRAL, movethe neutral lock lever to NEUTRAL LOCK positionand engage the emergency brake switch.

3. Lower the boom and ground the carriage.

4. Turn ignition key to OFF position and remove key.

Towing and Tie DownIf the vehicle becomes disabled and cannot be movedunder engine power, the vehicle can be towed a shortdistance (50 to 100 feet) by another piece of equipment,which is designed for towing. However, when consideringtowing the vehicle longer distances (such as site to site),the vehicle should be loaded onto a trailer for transport.

Short Distance Towing —

Short distance towing should only be attempted whenthe vehicle becomes disabled and would create apotentially hazardous situation such as on a roadwayor in an unsafe area on the work site. Prepare thevehicle for towing as follows:

• Detach the front and rear drive shafts from theaxles.

• Tie the drive shafts up to the vehicle's frame.

The vehicle can now be towed or pushed out of the way.

IMPORTANT: Without engine power, the vehicle will nothave service brakes for stopping. Steering will also beextremely difficult. Tow or push the vehicle at a veryslow speed!

Tie Down —

This vehicle is equipped with tie down holes in theframe on the front and rear ends for transport tie down.

WARNING

Page 5110054 Rev 3/04

Shut-Off1. Park the vehicle on level ground.

To prevent personal injury or death, be certain to lowerthe boom, shut off the engine, and engage the emer-gency brake switch before exiting the vehicle.

2. Place travel select lever in (N) NEUTRAL, movethe neutral lock lever to NEUTRAL LOCK positionand engage the emergency brake switch.

3. Lower the boom and ground the carriage.

4. Turn ignition key to OFF position and remove key.

Towing and Tie DownIf the vehicle becomes disabled and cannot be movedunder engine power, the vehicle can be towed a shortdistance (50 to 100 feet) by another piece of equipment,which is designed for towing. However, when consideringtowing the vehicle longer distances (such as site to site),the vehicle should be loaded onto a trailer for transport.

Short Distance Towing —

Short distance towing should only be attempted whenthe vehicle becomes disabled and would create apotentially hazardous situation such as on a roadwayor in an unsafe area on the work site. Prepare thevehicle for towing as follows:

• Detach the front and rear drive shafts from theaxles.

• Tie the drive shafts up to the vehicle's frame.

The vehicle can now be towed or pushed out of the way.

IMPORTANT: Without engine power, the vehicle will nothave service brakes for stopping. Steering will also beextremely difficult. Tow or push the vehicle at a veryslow speed!

Tie Down —

This vehicle is equipped with tie down holes in theframe on the front and rear ends for transport tie down.

WARNING

10054 Rev 3/04

Safety BeltCheck for frayed or cut webbing, damaged buckles, orloose mounting brackets.

Safety SurfacesKeep all non-skid surfaces clean. Replace safetytreads if worn, damaged or missing.

Warning DecalsCheck condition of all decals (Figure 21). Replace ifmissing, damaged or illegible.

CoversKeep all protective covers in place.

Emergency BrakeCheck operation. Have unit repaired immediately ifrequired.

Quick AttachMake sure that the quick attach pin secures attach-ment and that release lever is seated in pin groove.

EngineCheck cleanliness. Remove all dirt or debris, and allflammable materials before running engine.

TiresCheck tire pressure and hydrofill. Add air and/orhydrofill if required per “Specifications.”

General MaintenanceThis section of the manual contains a routine equipmentchecklist and a maintenance schedule and checklist withreferences to pertinent procedures and instructions. Toprevent problems before they occur, follow the schedule.

NOTE: The Lubrication and Maintenance Decal foundinside the right rear engine door contains a generalmaintenance schedule that should be followed tomaintain this vehicle in good operating condition. Thesame schedule is presented in this manual, except itcontains a more detailed account of how to performthese specific maintenance operations.

DO NOT perform service or maintenance on thevehicle with the engine running. Contact with movingparts can cause serious injury or death.

Routine Equipment ChecklistInspect the following equipment daily:

Perform the Stabil-TRAK and the Boom/OutriggerInterlock Tests at regular intervals to insure safeoperation of the vehicle.

WARNING

Page 52 10054 Rev 3/04

Safety BeltCheck for frayed or cut webbing, damaged buckles, orloose mounting brackets.

Safety SurfacesKeep all non-skid surfaces clean. Replace safetytreads if worn, damaged or missing.

Warning DecalsCheck condition of all decals (Figure 21). Replace ifmissing, damaged or illegible.

CoversKeep all protective covers in place.

Emergency BrakeCheck operation. Have unit repaired immediately ifrequired.

Quick AttachMake sure that the quick attach pin secures attach-ment and that release lever is seated in pin groove.

EngineCheck cleanliness. Remove all dirt or debris, and allflammable materials before running engine.

TiresCheck tire pressure and hydrofill. Add air and/orhydrofill if required per “Specifications.”

General MaintenanceThis section of the manual contains a routine equipmentchecklist and a maintenance schedule and checklist withreferences to pertinent procedures and instructions. Toprevent problems before they occur, follow the schedule.

NOTE: The Lubrication and Maintenance Decal foundinside the right rear engine door contains a generalmaintenance schedule that should be followed tomaintain this vehicle in good operating condition. Thesame schedule is presented in this manual, except itcontains a more detailed account of how to performthese specific maintenance operations.

DO NOT perform service or maintenance on thevehicle with the engine running. Contact with movingparts can cause serious injury or death.

Routine Equipment ChecklistInspect the following equipment daily:

Perform the Stabil-TRAK and the Boom/OutriggerInterlock Tests at regular intervals to insure safeoperation of the vehicle.

WARNING

Rev 3/04

Warning Decal Locations1. CARRYING PERSONNEL

WARNING2. BOOM EXTEND LETTERS3. BOOM ANGLE INDICATOR4. CAPACITY CHART5. EXPLOSIVE GASES WARNING6. STABILIZER TIPOVER DANGER7. MOVING PARTS WARNING

Figure 21

3 41

8 9

6 75

7

2

LEFT CONSOLE OVERLAY8. MACHINE ROLLAWAY

WARNING9. SAFETY INSTRUCTIONS

RIGHT CONSOLE OVERLAY10. TIPOVER DANGER11. ELECTROCUTION DANGER12. OUTRIGGERS OVER

HOLES DANGER

OH0591

1110 12

NOTE: Many of these hazard related decals are available free of charge by calling OmniQuip Parts Worldwide at (888) 872-5123.

Page 5310054 Rev 3/04

Warning Decal Locations1. CARRYING PERSONNEL

WARNING2. BOOM EXTEND LETTERS3. BOOM ANGLE INDICATOR4. CAPACITY CHART5. EXPLOSIVE GASES WARNING6. STABILIZER TIPOVER DANGER7. MOVING PARTS WARNING

Figure 21

3 41

8 9

6 75

7

2

LEFT CONSOLE OVERLAY8. MACHINE ROLLAWAY

WARNING9. SAFETY INSTRUCTIONS

RIGHT CONSOLE OVERLAY10. TIPOVER DANGER11. ELECTROCUTION DANGER12. OUTRIGGERS OVER

HOLES DANGER

OH0591

1110 12

NOTE: Many of these hazard related decals are available free of charge by calling OmniQuip Parts Worldwide at (888) 872-5123.

10054 Rev 3/04

ReferenceCheck Change Clean Paragraph

Hydraulic Oil Filter X 7CWheel Lug Nuts X 11CBoom Chain Tension X 14A & 14CTransmission Oil and Filter X 8B & 8C


Air Cleaner Restriction Indicator (Air Filter Elements) X 2AAir Cleaner Vacuator Valve X 2AEngine Coolant Level X 3AEngine Oil Level X 4AHydraulic Oil Level and Leaks in System X 7BTire Pressure/Hydrofill and Wear X 11A & BDrain Fuel Water Separator X 5CTransmission Oil Level X 8A

Maintenance Schedule and Checklist

At First 50 Hours of Use

Daily or 10 Hour Intervals

Page 54 10054 Rev 3/04


Hydraulic Oil Filter X 7CWheel Lug Nuts X 11CBoom Chain Tension X 14A & 14CTransmission Oil and Filter X 8B & 8C


Air Cleaner Restriction Indicator (Air Filter Elements) X 2AAir Cleaner Vacuator Valve X 2AEngine Coolant Level X 3AEngine Oil Level X 4AHydraulic Oil Level and Leaks in System X 7BTire Pressure/Hydrofill and Wear X 11A & BDrain Fuel Water Separator X 5CTransmission Oil Level X 8A

Maintenance Schedule and Checklist

At First 50 Hours of Use

Daily or 10 Hour Intervals

Rev 3/04

ReferenceCheck Change Lube Paragraph

Boom Wear Pads X 14FCarriage Pivot Pin X 1Attachment Tilt Cylinder Pins X 1Outrigger Pins X 1Boom Attachments X 1Extend Chain Sheave Pins X 1Emergency Brake Test X 16

50 Hour Intervals

250 Hour Intervals


Boom Wear Pads X 14FAxle Oil Level X 9AWheel End Oil X 10Air Intake Hoses X 2CHydraulic Cylinder Pins X 1Drive Shaft Slip Joints X 1Boom Pivot Pin X 1Carriage Pivot Pin X 1Attachment Tilt Cylinder Pins X 1Axle Pivot Pins X 1Extend Chain Sheave Pins X 1

continued on next page

Page 5510054 Rev 3/04


Boom Wear Pads X 14FCarriage Pivot Pin X 1Attachment Tilt Cylinder Pins X 1Outrigger Pins X 1Boom Attachments X 1Extend Chain Sheave Pins X 1Emergency Brake Test X 16

50 Hour Intervals

250 Hour Intervals


Boom Wear Pads X 14FAxle Oil Level X 9AWheel End Oil X 10Air Intake Hoses X 2CHydraulic Cylinder Pins X 1Drive Shaft Slip Joints X 1Boom Pivot Pin X 1Carriage Pivot Pin X 1Attachment Tilt Cylinder Pins X 1Axle Pivot Pins X 1Extend Chain Sheave Pins X 1


10054 Rev 3/04

Axle Steer Knuckles X 1Axle Tie Rod Ball Joints X 1Axle Steer Cylinder Ball Joints X 1Outrigger Pins X 1Boom Attachments X 1Engine Oil and Filter X 4BDrain or Change Fuel Filters X 5C

250 Hour Intervals (continued)

1,000 Hours or Annually




Boom Wear Pads X 14F

Air Intake Hoses X 2C

Fan Belt Wear X 6

Boom Chain Tension X 14A & 14C

Hydraulic Cylinder Pins X 1

Drive Shaft Slip Joints X 1Boom Pivot Pin X 1

Carriage Pivot Pin X 1

Attachment Tilt Cylinder Pins X 1

Page 56 10054 Rev 3/04

Axle Steer Knuckles X 1Axle Tie Rod Ball Joints X 1Axle Steer Cylinder Ball Joints X 1Outrigger Pins X 1Boom Attachments X 1Engine Oil and Filter X 4BDrain or Change Fuel Filters X 5C

250 Hour Intervals (continued)

1,000 Hours or Annually




Boom Wear Pads X 14F

Air Intake Hoses X 2C

Fan Belt Wear X 6

Boom Chain Tension X 14A & 14C

Hydraulic Cylinder Pins X 1

Drive Shaft Slip Joints X 1Boom Pivot Pin X 1

Carriage Pivot Pin X 1

Attachment Tilt Cylinder Pins X 1

Rev 3/04


1,000 Hours or Annually (continued)

Axle Pivot Pins X 1Extend Chain Sheave Pins X 1

Axle Steer Knuckles X 1

Axle Tie Rod Ball Joints X 1

Axle Steer Cylinder Ball Joints X 1

Outrigger Pins X 1

Boom Attachments X 1Extend Chains X 14E

Engine Oil and Filter X 4B

Drain or Change Fuel Filters X 5C

Axle Oil X 9B

Transmission Oil and Filter X 8B & 8C

Primary Air Filter Element X 2BHydraulic Oil and Filter X 7C

Engine Coolant X 3B

Fuel Pre-Filter X 5C

Page 5710054 Rev 3/04


1,000 Hours or Annually (continued)

Axle Pivot Pins X 1Extend Chain Sheave Pins X 1

Axle Steer Knuckles X 1

Axle Tie Rod Ball Joints X 1

Axle Steer Cylinder Ball Joints X 1

Outrigger Pins X 1

Boom Attachments X 1Extend Chains X 14E

Engine Oil and Filter X 4B

Drain or Change Fuel Filters X 5C

Axle Oil X 9B

Transmission Oil and Filter X 8B & 8C

Primary Air Filter Element X 2BHydraulic Oil and Filter X 7C

Engine Coolant X 3B

Fuel Pre-Filter X 5C

10054 Rev 3/04

A

C

F

F

HF

D

1. Lubrication PointsLubricate the following grease fittings using Multi-PurposeGrease (MPG) every 50 hour interval (Figure 22):

A. Carriage pivot pin ...................... (2 points)B. Attachment tilt cylinder pins ...... (2 Points)C. Outrigger pins ............................ (10 Points)D. Boom attachments .................... (All Points)E. Extend Chain Sheave Pins ....... (2 Points)

B

B

G

Figure 22

Lubricate the following grease fittings using Multi-PurposeGrease (MPG) every 250 hour interval (Figures 22 & 23):

F. Hydraulic cylinder pins .............. (12 points)G. Drive shaft slip joints ................. (3 points)H. Boom pivot pin .......................... (2 points)J. Axle pivot pins .......................... (2 points)K. Axle steer knuckles .................. (8 points)L. Axle tie rod ball joints ................ (4 points)M. Axle steer cylinder ball joints ..... (8 points)

NOTE: Shorten the lubrication interval on all axle and driveshaft lube points, all outrigger pins, and lower tilt, hoist, andstabilizer cylinder pins when operating in wet or muddyconditions.

L

KM

J

KOA0192Figure 23

OH0540

E

Page 58 10054 Rev 3/04

A

C

F

F

HF

D

1. Lubrication PointsLubricate the following grease fittings using Multi-PurposeGrease (MPG) every 50 hour interval (Figure 22):

A. Carriage pivot pin ...................... (2 points)B. Attachment tilt cylinder pins ...... (2 Points)C. Outrigger pins ............................ (10 Points)D. Boom attachments .................... (All Points)E. Extend Chain Sheave Pins ....... (2 Points)

B

B

G

Figure 22

Lubricate the following grease fittings using Multi-PurposeGrease (MPG) every 250 hour interval (Figures 22 & 23):

F. Hydraulic cylinder pins .............. (12 points)G. Drive shaft slip joints ................. (3 points)H. Boom pivot pin .......................... (2 points)J. Axle pivot pins .......................... (2 points)K. Axle steer knuckles .................. (8 points)L. Axle tie rod ball joints ................ (4 points)M. Axle steer cylinder ball joints ..... (8 points)

NOTE: Shorten the lubrication interval on all axle and driveshaft lube points, all outrigger pins, and lower tilt, hoist, andstabilizer cylinder pins when operating in wet or muddyconditions.

L

KM

J

KOA0192Figure 23

OH0540

E

Rev 3/04

Figure 24

RESTRICTION INDICATOR

INDICATOR WINDOWAIR CLEANER

VACUATOR VALVE

OA0212

Figure 25

A. Filter Check (Daily or 10 Hour Intervals)

1. Ground the carriage, place the travel select lever in(N) NEUTRAL, move neutral lock lever toNEUTRAL LOCK position, engage the emergencybrake switch and shut off the engine.

2. Unlock and open the left rear engine access doorto access air cleaner restriction indicator (Figure24). Check indicator. If red band has appeared,filter must be cleaned or replaced.

NOTE: Depress button on top of indicator to resetindicator after servicing element.

IMPORTANT: Only remove canister cover to servicethe elements as restriction indicator indicates or duringscheduled maintenance intervals. Excessive access tocheck or clean an element can lead to prematureelement failure and increase the possibility of dirtentering the engine.

3. Remove dust from vacuator valve (Figure 25) bysqueezing bottom of vacuator to allow looseparticles to fall out. Replace elements, if required,as described in paragraph 2B.

OA0203

2. Air Cleaner & Restriction Indicator

Page 5910054 Rev 3/04

Figure 24

RESTRICTION INDICATOR

INDICATOR WINDOWAIR CLEANER

VACUATOR VALVE

OA0212

Figure 25

A. Filter Check (Daily or 10 Hour Intervals)

1. Ground the carriage, place the travel select lever in(N) NEUTRAL, move neutral lock lever toNEUTRAL LOCK position, engage the emergencybrake switch and shut off the engine.

2. Unlock and open the left rear engine access doorto access air cleaner restriction indicator (Figure24). Check indicator. If red band has appeared,filter must be cleaned or replaced.

NOTE: Depress button on top of indicator to resetindicator after servicing element.

IMPORTANT: Only remove canister cover to servicethe elements as restriction indicator indicates or duringscheduled maintenance intervals. Excessive access tocheck or clean an element can lead to prematureelement failure and increase the possibility of dirtentering the engine.

3. Remove dust from vacuator valve (Figure 25) bysqueezing bottom of vacuator to allow looseparticles to fall out. Replace elements, if required,as described in paragraph 2B.

OA0203

2. Air Cleaner & Restriction Indicator

10054 Rev 3/04

Careful cleaning or washing, if done correctly, canextend the life of an element. But you must realizethat each time an element is cleaned the dirt holdingcapacity is reduced and the risk of dirt reaching theclean side of the filter is increased. Filters shouldnever be washed more than six times or retained formore than one year’s service, whichever comes first.

If you wash an element, it is recommended that youuse a non-sudsing detergent that dissolves combus-tion residues without damaging the filter media. Onesuch detergent that is specifically formulated for thispurpose is FM 1400. This cleaner contains biodegrad-able synthetic detergents and is environmentally safe.It is marketed by Filter Service Corp., 2105 W.Apache, Farmington, New Mexico, 87401, Telephone(505) 326-1127.

Inner Safety Element

An inner safety element should never be washed orreused. Always install a new element. Replace safetyelements after every third primary element change.DO NOT remove a safety element until you havethoroughly cleaned the inside of the air cleanercanister. This will prevent dirt, which could damagethe engine, from entering the induction manifold.

OF0110Figure 26

Outer Primary Element

All air cleaner manufacturers agree that attempting toclean or wash an element increases the chance forelement damage. It is highly recommended that youconsider the value of cleaning an element against therisks which could lead to engine damage. Adopt thepolicy that all elements should be replaced with newand not cleaned.

B. Element: Change or Clean(As Restriction Indicator Indicatesor Every 1000 Hour Interval)

CANNISTER

PRIMARY ELEMENT

WING NUT

COVER WITHWING NUT

Page 60 10054 Rev 3/04

Careful cleaning or washing, if done correctly, canextend the life of an element. But you must realizethat each time an element is cleaned the dirt holdingcapacity is reduced and the risk of dirt reaching theclean side of the filter is increased. Filters shouldnever be washed more than six times or retained formore than one year’s service, whichever comes first.

If you wash an element, it is recommended that youuse a non-sudsing detergent that dissolves combus-tion residues without damaging the filter media. Onesuch detergent that is specifically formulated for thispurpose is FM 1400. This cleaner contains biodegrad-able synthetic detergents and is environmentally safe.It is marketed by Filter Service Corp., 2105 W.Apache, Farmington, New Mexico, 87401, Telephone(505) 326-1127.

Inner Safety Element

An inner safety element should never be washed orreused. Always install a new element. Replace safetyelements after every third primary element change.DO NOT remove a safety element until you havethoroughly cleaned the inside of the air cleanercanister. This will prevent dirt, which could damagethe engine, from entering the induction manifold.

OF0110Figure 26

Outer Primary Element

All air cleaner manufacturers agree that attempting toclean or wash an element increases the chance forelement damage. It is highly recommended that youconsider the value of cleaning an element against therisks which could lead to engine damage. Adopt thepolicy that all elements should be replaced with newand not cleaned.

B. Element: Change or Clean(As Restriction Indicator Indicatesor Every 1000 Hour Interval)

CANNISTER

PRIMARY ELEMENT

WING NUT

COVER WITHWING NUT

Rev 3/04

To change elements:

1. Loosen cover wing nut and remove cover from aircleaner canister (Figure 26).

2. Remove wing nut and primary element. Inspectelement for damage. Damaged elements shouldnot be cleaned or reused.

3. Thoroughly clean the interior of the air filter canis-ter and vacuator valve.

4. If replacing safety element at this time (Figure 27),remove wing nut and carefully slide safety elementout. Always discard this element and replace witha new element and secure with wing nut.

5. Install the new primary element and secure withwing nut.

6. Position canister cover in place and secure withcover wing nut.

Carefully follow these procedures to clean an element:

1. Remove loose particles from the filter with com-pressed air [maximum 30 psi (206 kPa)] or waterhose [maximum 40 psi (275 kPa) without nozzle].Rotate and apply pressure from the inside of theelement.

2. Soak filter in a non-sudsing detergent (such as FM1400) for at least 15 minutes. Never soak morethan 24 hours.

3. Swish filter around in the solution to removeloosened dirt particles.

4. Rinse the filter from the inside out with a gentlestream of water to remove all dirt and suds [lessthan 40 psi (275 kPa), no nozzle]. If the inside ofthe element has been contaminated with dirtywater from the soaking, rinse from both sides.

5. Dry the filter before re-using. Circulate warm air atless than 160° F (71° C). DO NOT use a light bulbto dry the filter.

6. Inspect for holes or tears by looking through thefilter toward a bright light. Check for damagedgaskets or metal parts. DO NOT re-use damagedfilters.

Page 6110054 Rev 3/04

To change elements:

1. Loosen cover wing nut and remove cover from aircleaner canister (Figure 26).

2. Remove wing nut and primary element. Inspectelement for damage. Damaged elements shouldnot be cleaned or reused.

3. Thoroughly clean the interior of the air filter canis-ter and vacuator valve.

4. If replacing safety element at this time (Figure 27),remove wing nut and carefully slide safety elementout. Always discard this element and replace witha new element and secure with wing nut.

5. Install the new primary element and secure withwing nut.

6. Position canister cover in place and secure withcover wing nut.

Carefully follow these procedures to clean an element:

1. Remove loose particles from the filter with com-pressed air [maximum 30 psi (206 kPa)] or waterhose [maximum 40 psi (275 kPa) without nozzle].Rotate and apply pressure from the inside of theelement.

2. Soak filter in a non-sudsing detergent (such as FM1400) for at least 15 minutes. Never soak morethan 24 hours.

3. Swish filter around in the solution to removeloosened dirt particles.

4. Rinse the filter from the inside out with a gentlestream of water to remove all dirt and suds [lessthan 40 psi (275 kPa), no nozzle]. If the inside ofthe element has been contaminated with dirtywater from the soaking, rinse from both sides.

5. Dry the filter before re-using. Circulate warm air atless than 160° F (71° C). DO NOT use a light bulbto dry the filter.

6. Inspect for holes or tears by looking through thefilter toward a bright light. Check for damagedgaskets or metal parts. DO NOT re-use damagedfilters.

10054 Rev 3/04

2. Unlock and open the right rear engine access door.Check level of coolant in overflow bottle (Figure28). When coolant is hot, bottle should be 1/2 to3/4 full. When coolant is cool, bottle should be 1/4to 1/2 full. Add coolant as required through theoverflow bottle (50/50 mixture of ethylene glycoland water). Close and lock access door.

A. Level Check (Daily or 10 Hour Intervals)

1. Level the vehicle, ground the carriage, place thetravel select lever in (N) NEUTRAL, move theneutral lock lever to NEUTRAL LOCK position,engage the emergency brake switch and shut offthe engine.

3. Engine Cooling System

Figure 27 OF0120

WING NUT

SAFETY ELEMENT

C. Air Intake System - Inspection (250 Hour Intervals)

Inspect the intake piping for cracked hoses, looseclamps, or punctures which can allow dirt or debris toenter the combustion chamber. If dirt or debris isallowed to enter the combustion chamber, it canseverely damage the engine. If necessary tighten orreplace parts to prevent air intake system leakage.

MA20211

COOLANTOVERFLOW

BOTTLE

OIL FILLCAPOIL

DIPSTICK

Figure 28

Page 62 10054 Rev 3/04

2. Unlock and open the right rear engine access door.Check level of coolant in overflow bottle (Figure28). When coolant is hot, bottle should be 1/2 to3/4 full. When coolant is cool, bottle should be 1/4to 1/2 full. Add coolant as required through theoverflow bottle (50/50 mixture of ethylene glycoland water). Close and lock access door.

A. Level Check (Daily or 10 Hour Intervals)

1. Level the vehicle, ground the carriage, place thetravel select lever in (N) NEUTRAL, move theneutral lock lever to NEUTRAL LOCK position,engage the emergency brake switch and shut offthe engine.

3. Engine Cooling System

Figure 27 OF0120

WING NUT

SAFETY ELEMENT

C. Air Intake System - Inspection (250 Hour Intervals)

Inspect the intake piping for cracked hoses, looseclamps, or punctures which can allow dirt or debris toenter the combustion chamber. If dirt or debris isallowed to enter the combustion chamber, it canseverely damage the engine. If necessary tighten orreplace parts to prevent air intake system leakage.

MA20211

COOLANTOVERFLOW

BOTTLE

OIL FILLCAPOIL

DIPSTICK

Figure 28

Rev 3/04

Figure 29

NEVER remove the radiator cap while the coolingsystem is hot. The system is under pressure and hotcoolant can cause severe burns or eye injury. Wearprotective clothing and safety glasses. Always turnthe cap slowly to the first stop and allow the pressureto escape before removing the cap completely.

B. Drain and Flush Radiator (1000 Hours or Annually) 1. Open rear radiator door. Remove radiator cap andopen petcock at bottom center of radiator (Figure29).

NOTE: Attach a hose to the petcock to allow drainingdirectly into a container.

2. Allow coolant to drain from the radiator and detachline from bottom of coolant overflow bottle anddrain bottle. Transfer the coolant to a containerwith a cover and label the container as usedcoolant. Dispose of the used coolant at anapproved recycling facility.

3. 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. Discon-nect hose from shut off valve to drain the heater.

4. Reconnect line to bottom of overflow bottle andclose petcock on the radiator. Reconnect heaterhose.

5. Fill radiator completely with 50/50 mixture ofethylene glycol and water. Total System Capacityis 4 gallons (15,1 ltr). Add coolant to overflowbottle until bottle is about 1/2 to 3/4 full [approxi-mately 2 qts. (1,9 ltr)]. This “overfilling” willcompensate for any air in the cooling system.

6. Clean dirt and debris from radiator fins and core, ifrequired.

OH0261

PETCOCK

WARNING

Page 6310054 Rev 3/04

Figure 29

NEVER remove the radiator cap while the coolingsystem is hot. The system is under pressure and hotcoolant can cause severe burns or eye injury. Wearprotective clothing and safety glasses. Always turnthe cap slowly to the first stop and allow the pressureto escape before removing the cap completely.

B. Drain and Flush Radiator (1000 Hours or Annually) 1. Open rear radiator door. Remove radiator cap andopen petcock at bottom center of radiator (Figure29).

NOTE: Attach a hose to the petcock to allow drainingdirectly into a container.

2. Allow coolant to drain from the radiator and detachline from bottom of coolant overflow bottle anddrain bottle. Transfer the coolant to a containerwith a cover and label the container as usedcoolant. Dispose of the used coolant at anapproved recycling facility.

3. 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. Discon-nect hose from shut off valve to drain the heater.

4. Reconnect line to bottom of overflow bottle andclose petcock on the radiator. Reconnect heaterhose.

5. Fill radiator completely with 50/50 mixture ofethylene glycol and water. Total System Capacityis 4 gallons (15,1 ltr). Add coolant to overflowbottle until bottle is about 1/2 to 3/4 full [approxi-mately 2 qts. (1,9 ltr)]. This “overfilling” willcompensate for any air in the cooling system.

6. Clean dirt and debris from radiator fins and core, ifrequired.

OH0261

PETCOCK

WARNING

10054 Rev 3/04

��

�

��

3. Remove dipstick and check mark on dipstick(Figure 30). Oil should be within the crosshatchedarea.

4. If oil is low, remove oil fill cap (Figure 28) and add15W40 or 10W30 motor oil that is equal to API, CDor CE (severe duty diesel engine) specifications tobring oil up to the FULL mark in the crosshatchedarea. Replace oil fill cap and dipstick. Close andlock access door.

Engine Oil Type Ambient Temperature

10W30 Below 23° F (-5° C)15W40 Above 23° F (-5° C)

B. Oil and Filter Change (250 Hour Intervals)

IMPORTANT: The use of quality engine oil combinedwith appropriate oil and filter change intervals arecritical factors in maintaining engine performance anddurability. The use of multi-viscosity, 15W40, oil isrecommended for most climates. Low viscosity,10W30, oil may be used at colder temperatures.However, continuous use of low viscosity oil maydecrease engine life due to wear.

1. Operate engine until warm (approximately 5minutes).

4. Engine Oil and FilterA. Level Check (Daily or 10 Hour Intervals)

1. Level the vehicle, ground the carriage, place thetravel select lever in (N) NEUTRAL, move neutrallock lever to NEUTRAL LOCK position, engage theemergency brake switch and shut off the engine.

2. Unlock and open right rear engine access door.

7. Start engine and run vehicle to normal operatingtemperature. Allow engine to cool to ambienttemperature. Check radiator coolant level and topoff completely. Replace radiator cap. Overflowbottle should be 1/4 to 1/2 full. If it is not, addcoolant to overflow bottle. Close and lock allaccess doors.

CROSSHATCHEDAREA

Figure 30 OG0290

Page 64 10054 Rev 3/04

��

�

��

3. Remove dipstick and check mark on dipstick(Figure 30). Oil should be within the crosshatchedarea.

4. If oil is low, remove oil fill cap (Figure 28) and add15W40 or 10W30 motor oil that is equal to API, CDor CE (severe duty diesel engine) specifications tobring oil up to the FULL mark in the crosshatchedarea. Replace oil fill cap and dipstick. Close andlock access door.

Engine Oil Type Ambient Temperature

10W30 Below 23° F (-5° C)15W40 Above 23° F (-5° C)

B. Oil and Filter Change (250 Hour Intervals)

IMPORTANT: The use of quality engine oil combinedwith appropriate oil and filter change intervals arecritical factors in maintaining engine performance anddurability. The use of multi-viscosity, 15W40, oil isrecommended for most climates. Low viscosity,10W30, oil may be used at colder temperatures.However, continuous use of low viscosity oil maydecrease engine life due to wear.

1. Operate engine until warm (approximately 5minutes).

4. Engine Oil and FilterA. Level Check (Daily or 10 Hour Intervals)


2. Unlock and open right rear engine access door.

7. Start engine and run vehicle to normal operatingtemperature. Allow engine to cool to ambienttemperature. Check radiator coolant level and topoff completely. Replace radiator cap. Overflowbottle should be 1/4 to 1/2 full. If it is not, addcoolant to overflow bottle. Close and lock allaccess doors.

CROSSHATCHEDAREA

Figure 30 OG0290

Rev 3/04

��

��

ENGINE OILFILTER

Figure 30 OG00311

2. Level the vehicle, ground the carriage, place thetravel select lever in (N) NEUTRAL, moveneutral lock lever to NEUTRAL LOCK position,engage the emergency brake switch and shut offthe engine.

3. Place receptacle under engine oil pan drain.

4. Remove drain plug from engine oil pan.

5. Allow oil to drain completely into receptacle.Transfer the oil to a container with a cover andlabel the container as used oil. Dispose of theused oil at an approved recycling facility.

6. Unlock and open the left engine access door.Remove oil filter (Figure 31). A strap orchainfilter wrench may be required.

12. Clear all personnel from area. Start engine andrun for several minutes.

13. Stop engine. Let the oil drain back for a fewminutes. Check oil level on dipstick (Figure 30)and check for leaks at filter and drain plug.Retighten filter or drain plug if necessary.

14. Add oil to bring oil level up to the FULL mark inthe crosshatched area. Replace dipstick and oilfill cap. Close and lock access door.7. Clean filter sealing surface.

NOTE: The filter o-ring may stick to the filter head.Make sure the old o-ring is removed beforeinstalling the new filter.

8. Apply a thin coat of clean engine oil to seal onnew filter.

9. Install the new oil filter and hand tighten 1/2 turnafter initial contact.

10. Clean and re-install oil pan drain plug.

11. Remove oil fill cap (Figure 28) and add 15W40 or10W30 motor oil that is equal to API, CD or CEspecifications. (Reference engine manufacturersmanual for recommended oil types to be used invarious temperature limits.) DO NOT over fill.Engine oil capacity with filter change is 11.6 qts.(11 ltr.)

Page 6510054 Rev 3/04

��

��

ENGINE OILFILTER

Figure 30 OG00311

2. Level the vehicle, ground the carriage, place thetravel select lever in (N) NEUTRAL, moveneutral lock lever to NEUTRAL LOCK position,engage the emergency brake switch and shut offthe engine.

3. Place receptacle under engine oil pan drain.

4. Remove drain plug from engine oil pan.

5. Allow oil to drain completely into receptacle.Transfer the oil to a container with a cover andlabel the container as used oil. Dispose of theused oil at an approved recycling facility.

6. Unlock and open the left engine access door.Remove oil filter (Figure 31). A strap orchainfilter wrench may be required.

12. Clear all personnel from area. Start engine andrun for several minutes.

13. Stop engine. Let the oil drain back for a fewminutes. Check oil level on dipstick (Figure 30)and check for leaks at filter and drain plug.Retighten filter or drain plug if necessary.

14. Add oil to bring oil level up to the FULL mark inthe crosshatched area. Replace dipstick and oilfill cap. Close and lock access door.7. Clean filter sealing surface.

NOTE: The filter o-ring may stick to the filter head.Make sure the old o-ring is removed beforeinstalling the new filter.

8. Apply a thin coat of clean engine oil to seal onnew filter.

9. Install the new oil filter and hand tighten 1/2 turnafter initial contact.

10. Clean and re-install oil pan drain plug.

11. Remove oil fill cap (Figure 28) and add 15W40 or10W30 motor oil that is equal to API, CD or CEspecifications. (Reference engine manufacturersmanual for recommended oil types to be used invarious temperature limits.) DO NOT over fill.Engine oil capacity with filter change is 11.6 qts.(11 ltr.)

10054 Rev 3/04

��

5. Engine Fuel SystemA. Fuel Types

When operating at temperatures above 32° F (0° C) usestandard #2 diesel fuel.

When operating at temperatures below 32° F (0° C)use a blend of No. 1 diesel and No. 2 diesel fuels,most commonly known as “winterized” No. 2 dieselfuel. Use ASTM No. 2 diesel fuel with a minimumCetane number of 40. No. 2 diesel fuel gives the besteconomy and performance under most operatingconditions. Fuels with Cetane numbers higher than40 may be needed in high altitudes or extremely lowambient temperatures to prevent misfires and ex-cessive smoke.

Engine fuel is flammable and can cause a fire oran explosion. Keep sparks and open flames awayfrom the vehicle and do not use smoking materialsduring refueling or servicing of the fuel system.

OH0480FUELFILL

ACCESSDOOR

Figure 32 OH0393

B. Fuel Tank (Daily Before Operation)

Check fuel supply daily before operation. Open fuel fillaccess door with key (Figure 32). Remove fill cap ontank and fill as required. Replace cap and lock accessdoor. Tank capacity is 35 gals. (132,5 ltr), total of 33(124,9 ltr) usable gals.

C. Fuel System Service

1. Drain water from fuel water separator daily or10 hour intervals. Unlock and open the right rearengine access door. Loosen drain valve on underside of the water separator (Figure 33) and allowall water to drain into a glass until clear fuel isvisible. Tighten drain valve after draining. Closeand lock access door.

WARNING

Page 66 10054 Rev 3/04

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5. Engine Fuel SystemA. Fuel Types

When operating at temperatures above 32° F (0° C) usestandard #2 diesel fuel.

When operating at temperatures below 32° F (0° C)use a blend of No. 1 diesel and No. 2 diesel fuels,most commonly known as “winterized” No. 2 dieselfuel. Use ASTM No. 2 diesel fuel with a minimumCetane number of 40. No. 2 diesel fuel gives the besteconomy and performance under most operatingconditions. Fuels with Cetane numbers higher than40 may be needed in high altitudes or extremely lowambient temperatures to prevent misfires and ex-cessive smoke.

Engine fuel is flammable and can cause a fire oran explosion. Keep sparks and open flames awayfrom the vehicle and do not use smoking materialsduring refueling or servicing of the fuel system.

OH0480FUELFILL

ACCESSDOOR

Figure 32 OH0393

B. Fuel Tank (Daily Before Operation)

Check fuel supply daily before operation. Open fuel fillaccess door with key (Figure 32). Remove fill cap ontank and fill as required. Replace cap and lock accessdoor. Tank capacity is 35 gals. (132,5 ltr), total of 33(124,9 ltr) usable gals.

C. Fuel System Service

1. Drain water from fuel water separator daily or10 hour intervals. Unlock and open the right rearengine access door. Loosen drain valve on underside of the water separator (Figure 33) and allowall water to drain into a glass until clear fuel isvisible. Tighten drain valve after draining. Closeand lock access door.

WARNING

Rev 3/04

2. Change fuel filter elements as needed every250 - (500 maximum) hours of operation. Fuelfilter changes must be more often with waterevidence or contaminated fuel. Unlock and openthe right rear engine access door. Clean the areaaround the fuel filter head. Remove the pre-filterand fuel filter cannisters (Figure 33). The engine isequipped with a single fuel filter/water separatorcannister. Discard the filter cannisters and sealingrings. Clean the sealing surfaces of the filter head.Fill the new cannisters with clean No. 2 Diesel Fueland lubricate the sealing rings with clean lubricatingoil. Install the filters by hand tightening only. DONOT over tighten. Close and lock access door.

NOTE: Mechanical over-tightening may distort thethreads or damage the sealing rings.

Controlled venting is provided at the injection pumpthrough the fuel drain manifold. Small amounts of airintroduced by changing the filter elements will be ventedautomatically as long as the elements were filled withfuel prior to installation.

NOTE: Marginal fuel cleanliness conditions will requirefuel system service more often. Loss of engine power isoften caused by dirty fuel filters.

Figure 33OH3730

FUEL FILTER/WATERSEPARATOR

FUELPRE-FILTER

DRAIN VALVE

3. Replace fuel pre-filter every 1000 hours orannually. Unlock and open the right rear accessdoor. Replace the fuel pre-filter that is installed inthe fuel line (Figure 33).

Page 6710054 Rev 3/04

2. Change fuel filter elements as needed every250 - (500 maximum) hours of operation. Fuelfilter changes must be more often with waterevidence or contaminated fuel. Unlock and openthe right rear engine access door. Clean the areaaround the fuel filter head. Remove the pre-filterand fuel filter cannisters (Figure 33). The engine isequipped with a single fuel filter/water separatorcannister. Discard the filter cannisters and sealingrings. Clean the sealing surfaces of the filter head.Fill the new cannisters with clean No. 2 Diesel Fueland lubricate the sealing rings with clean lubricatingoil. Install the filters by hand tightening only. DONOT over tighten. Close and lock access door.

NOTE: Mechanical over-tightening may distort thethreads or damage the sealing rings.

Controlled venting is provided at the injection pumpthrough the fuel drain manifold. Small amounts of airintroduced by changing the filter elements will be ventedautomatically as long as the elements were filled withfuel prior to installation.

NOTE: Marginal fuel cleanliness conditions will requirefuel system service more often. Loss of engine power isoften caused by dirty fuel filters.

Figure 33OH3730

FUEL FILTER/WATERSEPARATOR

FUELPRE-FILTER

DRAIN VALVE

3. Replace fuel pre-filter every 1000 hours orannually. Unlock and open the right rear accessdoor. Replace the fuel pre-filter that is installed inthe fuel line (Figure 33).

10054 Rev 3/04

D. Bleeding Fuel System

Manual venting of the fuel system is required if the fuelfilter is not filled prior to installation, the injection pumpis replaced, the high pressure fuel lines are loosened orreplaced, the fuel tank has run completely empty, or itis the initial engine start up after an extended period ofno engine operation.

DO NOT bleed a hot engine as this can cause fuel tospill, creating a danger of fire.

IMPORTANT: DO NOT start the engine until theinjection pump has been filled and primed as seriousdamage can be caused to the pump due to lack oflubrication.

Figure 34 OH3730

FUEL LIFTPUMP

VENT SCREW

HAND PLUNGER

WARNING

Page 68 10054 Rev 3/04

D. Bleeding Fuel System

Manual venting of the fuel system is required if the fuelfilter is not filled prior to installation, the injection pumpis replaced, the high pressure fuel lines are loosened orreplaced, the fuel tank has run completely empty, or itis the initial engine start up after an extended period ofno engine operation.

DO NOT bleed a hot engine as this can cause fuel tospill, creating a danger of fire.

IMPORTANT: DO NOT start the engine until theinjection pump has been filled and primed as seriousdamage can be caused to the pump due to lack oflubrication.

Figure 34 OH3730

FUEL LIFTPUMP

VENT SCREW

HAND PLUNGER

WARNING

Rev 3/04

2. To vent the high pressure fuel lines, loosen onefitting at a time at the injectors (Figure 35). Turnthe ignition key to the START position and crankthe engine for a maximum of 15 seconds or untilfuel, free from air, comes from the injector fitting.Tighten the fitting. Repeat procedure for eachfitting until engine starts and runs smoothly. Withengine running, visually check for any leaks. Turnignition switch OFF.

MA1870

INJECTOR HIGHPRESSURE

LINE FITTINGS

Figure 35

Fuel will spray when venting high pressure fuel lines.Keep clear of spraying fuel. The pressure of the fuelin the high pressure lines is sufficient to penetratethe skin and cause serious bodily injury. Wearprotective clothing and safety glasses.

Remove air from the fuel system as follows:

NOTE: More than one person will be required toperform this procedure.

1. To vent the low pressure lines and fuel filters, openthe vent screw (Figure 34). Operate the handplunger on the lift pump, until the fuel flowing fromthe fitting is free of air. Tighten the vent screw andtorque it to 6 lb-ft (8 Nm).

When using the starting motor to vent the system,DO NOT energize starter solenoid or crank theengine for more than 15 seconds at a time; wait twominutes between engagements.

WARNING

CAUTION

Page 6910054 Rev 3/04

2. To vent the high pressure fuel lines, loosen onefitting at a time at the injectors (Figure 35). Turnthe ignition key to the START position and crankthe engine for a maximum of 15 seconds or untilfuel, free from air, comes from the injector fitting.Tighten the fitting. Repeat procedure for eachfitting until engine starts and runs smoothly. Withengine running, visually check for any leaks. Turnignition switch OFF.

MA1870

INJECTOR HIGHPRESSURE

LINE FITTINGS

Figure 35

Fuel will spray when venting high pressure fuel lines.Keep clear of spraying fuel. The pressure of the fuelin the high pressure lines is sufficient to penetratethe skin and cause serious bodily injury. Wearprotective clothing and safety glasses.

Remove air from the fuel system as follows:

NOTE: More than one person will be required toperform this procedure.

1. To vent the low pressure lines and fuel filters, openthe vent screw (Figure 34). Operate the handplunger on the lift pump, until the fuel flowing fromthe fitting is free of air. Tighten the vent screw andtorque it to 6 lb-ft (8 Nm).

When using the starting motor to vent the system,DO NOT energize starter solenoid or crank theengine for more than 15 seconds at a time; wait twominutes between engagements.

WARNING

CAUTION

10054 Rev 3/04

FANBELT

TENSIONERBRACKET

Figure 36 MA1881

6. Engine Fan Belt Check(1000 Hour Intervals)

Check fan belt condition as follows:

1. Ground the carriage, place travel select lever in(N) NEUTRAL, move neutral lock lever toNEUTRAL LOCK position, engage emergencybrake switch and shut off the engine.

2. Unlock and open the left rear engine access door.

3. Remove the fan belt (Figure 36) by carefully liftingthe tensioner with a 1/2 inch square drive installedin square hole in tensioner bracket.

4. Inspect fan belt. Replace cracked or frayed belt.Transverse (across belt width) cracks are accept-able. Longitudinal (along belt length) cracks arenot acceptable.

5. Check tensioner bearing. Spin the bearing andcheck that there are no rough spots detected underhand pressure.

6. Check the fan hub bearing. Spin the fan andcheck for wobble or excessive play. Maximumend play should be 0.006 in. (0,15 mm).

7. To install the fan belt, first position the belt overthe grooved pulleys and then, while holding up thetensioner, slide the belt over the water pumppulley.

8. Close and lock access door.

Page 70 10054 Rev 3/04

FANBELT

TENSIONERBRACKET

Figure 36 MA1881

6. Engine Fan Belt Check(1000 Hour Intervals)

Check fan belt condition as follows:

1. Ground the carriage, place travel select lever in(N) NEUTRAL, move neutral lock lever toNEUTRAL LOCK position, engage emergencybrake switch and shut off the engine.

2. Unlock and open the left rear engine access door.

3. Remove the fan belt (Figure 36) by carefully liftingthe tensioner with a 1/2 inch square drive installedin square hole in tensioner bracket.

4. Inspect fan belt. Replace cracked or frayed belt.Transverse (across belt width) cracks are accept-able. Longitudinal (along belt length) cracks arenot acceptable.

5. Check tensioner bearing. Spin the bearing andcheck that there are no rough spots detected underhand pressure.

6. Check the fan hub bearing. Spin the fan andcheck for wobble or excessive play. Maximumend play should be 0.006 in. (0,15 mm).

7. To install the fan belt, first position the belt overthe grooved pulleys and then, while holding up thetensioner, slide the belt over the water pumppulley.

8. Close and lock access door.

Rev 3/04

��

CAPSCREWS

HYDRAULIC/FUEL TANK

COVER

Figure 37 OH0393

OH04701

ISO Grade 46 MIL-L-2104CHydraulic Oil 10W Motor Oil *

Gulf Harmony 46 AW Castrol Deusol CRDAmoco Rykon 46 Esso Essolube D-3HPMobil DTE-25 Esso Essolube XD-3Arco Duro AW S-215 Castrol Agricastrol HDDShell Tullus 46 Shell Rimula CTBenz Petraulic 46-7C Shell Rimula XSun Sunvis 821 WR Shell Rimula TXChevron AW 46 * 5W20 Motor Oil may beTexaco Rando HD 46 substituted for -30° F toCitgo Pacemaker XD-46 70° F (-34 to 21° C) only.

7. Hydraulic Oil and FilterA. Hydraulic System Oil

Hydraulic system oil can be either a hydraulic oilmeeting the requirements of ISO Grade 46 or a 10Wmotor oil meeting the requirements of U.S. OrdinanceSpecification MIL-L-2104C. See table on this page.

OH04601

HYDRAULICOIL TANK

SIGHT GAUGE

B. Level Check(Daily or 10 Hour Intervals)

1. Be sure all cylinders are fully retracted and oil is atroom temperature.

2. Level the vehicle, ground the carriage, place travelselect lever in (N) NEUTRAL, move neutral locklever to NEUTRAL LOCK position, engage theemergency brake switch and shut off the engine.

3. Check level of hydraulic oil in tank at the sightgauge on the back side of the hydraulic tank(Figure 37).

4. The oil level should be visible in the gauge window.If it is not, remove the reservoir cap and add ISO-46 or MIL-L-2104C oil (see table on this page).The hydraulic oil level should be within 1/2 inch ofthe upper mark on the sight gauge.

5. Install reservoir cap.

Page 7110054 Rev 3/04

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CAPSCREWS

HYDRAULIC/FUEL TANK

COVER

Figure 37 OH0393

OH04701

ISO Grade 46 MIL-L-2104CHydraulic Oil 10W Motor Oil *

Gulf Harmony 46 AW Castrol Deusol CRDAmoco Rykon 46 Esso Essolube D-3HPMobil DTE-25 Esso Essolube XD-3Arco Duro AW S-215 Castrol Agricastrol HDDShell Tullus 46 Shell Rimula CTBenz Petraulic 46-7C Shell Rimula XSun Sunvis 821 WR Shell Rimula TXChevron AW 46 * 5W20 Motor Oil may beTexaco Rando HD 46 substituted for -30° F toCitgo Pacemaker XD-46 70° F (-34 to 21° C) only.

7. Hydraulic Oil and FilterA. Hydraulic System Oil

Hydraulic system oil can be either a hydraulic oilmeeting the requirements of ISO Grade 46 or a 10Wmotor oil meeting the requirements of U.S. OrdinanceSpecification MIL-L-2104C. See table on this page.

OH04601

HYDRAULICOIL TANK

SIGHT GAUGE

B. Level Check(Daily or 10 Hour Intervals)

1. Be sure all cylinders are fully retracted and oil is atroom temperature.

2. Level the vehicle, ground the carriage, place travelselect lever in (N) NEUTRAL, move neutral locklever to NEUTRAL LOCK position, engage theemergency brake switch and shut off the engine.

3. Check level of hydraulic oil in tank at the sightgauge on the back side of the hydraulic tank(Figure 37).

4. The oil level should be visible in the gauge window.If it is not, remove the reservoir cap and add ISO-46 or MIL-L-2104C oil (see table on this page).The hydraulic oil level should be within 1/2 inch ofthe upper mark on the sight gauge.

5. Install reservoir cap.

10054 Rev 3/04

��

1. Level the vehicle, ground the carriage, place travelselect lever in (N) NEUTRAL, move neutral locklever to NEUTRAL LOCK position, engage theemergency brake switch and shut off the engine.NOTE: If oil is to be changed retract all cylindersbefore removing filter head.

2. Remove the four capscrews that fasten the tankcover to the hydraulic/fuel tank and remove thetank cover (Figure 37). Clean area around filterhead. Unscrew the nuts (Figure 38) that secure thefilter head to the hydraulic tank.

3. Remove the filter head, element, and gasket fromthe tank.

4. Pull the element off of the filter head and discardthe element.

C. Oil Change

Change hydraulic oil filter after the first 50 hours ofoperation and every 1000 hours thereafter.

Replace hydraulic oil annually or as required.

Oil must be cool before changing.

Other than the annual interval, the hydraulic oil must bechanged when a hydraulic component has contami-nated the system.

5. Clean filter head sealing surfaces.

6. Place a receptacle under the reservoir drain plug.Remove magnetic drain plug and allow oil to draininto receptacle. Clean loose particles from plug.Transfer the oil to a container with a cover andlabel the container as used oil. Dispose of theused oil at an approved recycling facility.

7. Re-install magnetic drain plug into reservoir.

FILTERHEAD

NUTS

HYDRAULICOIL FILL

Figure 38 OH0402

Page 72 10054 Rev 3/04

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1. Level the vehicle, ground the carriage, place travelselect lever in (N) NEUTRAL, move neutral locklever to NEUTRAL LOCK position, engage theemergency brake switch and shut off the engine.NOTE: If oil is to be changed retract all cylindersbefore removing filter head.

2. Remove the four capscrews that fasten the tankcover to the hydraulic/fuel tank and remove thetank cover (Figure 37). Clean area around filterhead. Unscrew the nuts (Figure 38) that secure thefilter head to the hydraulic tank.

3. Remove the filter head, element, and gasket fromthe tank.

4. Pull the element off of the filter head and discardthe element.

C. Oil Change

Change hydraulic oil filter after the first 50 hours ofoperation and every 1000 hours thereafter.

Replace hydraulic oil annually or as required.

Oil must be cool before changing.

Other than the annual interval, the hydraulic oil must bechanged when a hydraulic component has contami-nated the system.

5. Clean filter head sealing surfaces.

6. Place a receptacle under the reservoir drain plug.Remove magnetic drain plug and allow oil to draininto receptacle. Clean loose particles from plug.Transfer the oil to a container with a cover andlabel the container as used oil. Dispose of theused oil at an approved recycling facility.

7. Re-install magnetic drain plug into reservoir.

FILTERHEAD

NUTS

HYDRAULICOIL FILL

Figure 38 OH0402

Rev 3/04

��

9. Remove reservoir cap and fill the reservoir withISO-46 or MIL-L-2104C Oil (see table on page 71)until the oil level is filled to the minimum oil levelas described in section 7B. Reservoir capacity is30.3 gals. (114,7 ltr).

If the main hydraulic pump ever loses it's prime,serious damage to the pump and/or the entire hy-draulic system may occur. The pump must bereprimed.

Use the following procedure whenever the pump requiresthat it be reprimed. This procedure must be accomplishedbefore starting the engine.

10. Disconnect the wire from the fuel shutoff solenoidon the engine.

11. Position catch container under the inlet pressureport (labeled IN) on the secondary control valve(Figure 39).

12. Loosen, but do not remove, the hydraulic lineconnection to the inlet port at the control valve(this fitting may be an elbow or a tee).

13. Prime the pump by cranking the engine until oilfree of air is dripping from the loosened hydraulicline.

14. Tighten the hydraulic connection and reconnect thewire to the fuel shutoff solenoid.

15. Run the vehicle and operate all hydraulic functionsand then check for leaks.

16. Re-install the tank cover.

Figure 39SH0070

SECONDARYCONTROL VALVE

LOOSEN,BUT DO NOT REMOVE, THIS

CONNECTION

8. Push new filter element fully onto the filter headuntil it seats against the washer. Re-install filterhead assembly and gasket into the tank andsecure with the nuts removed earlier.

CAUTION

Page 7310054 Rev 3/04

��

9. Remove reservoir cap and fill the reservoir withISO-46 or MIL-L-2104C Oil (see table on page 71)until the oil level is filled to the minimum oil levelas described in section 7B. Reservoir capacity is30.3 gals. (114,7 ltr).

If the main hydraulic pump ever loses it's prime,serious damage to the pump and/or the entire hy-draulic system may occur. The pump must bereprimed.

Use the following procedure whenever the pump requiresthat it be reprimed. This procedure must be accomplishedbefore starting the engine.

10. Disconnect the wire from the fuel shutoff solenoidon the engine.

11. Position catch container under the inlet pressureport (labeled IN) on the secondary control valve(Figure 39).

12. Loosen, but do not remove, the hydraulic lineconnection to the inlet port at the control valve(this fitting may be an elbow or a tee).

13. Prime the pump by cranking the engine until oilfree of air is dripping from the loosened hydraulicline.

14. Tighten the hydraulic connection and reconnect thewire to the fuel shutoff solenoid.

15. Run the vehicle and operate all hydraulic functionsand then check for leaks.

16. Re-install the tank cover.

Figure 39SH0070

SECONDARYCONTROL VALVE

LOOSEN,BUT DO NOT REMOVE, THIS

CONNECTION

8. Push new filter element fully onto the filter headuntil it seats against the washer. Re-install filterhead assembly and gasket into the tank andsecure with the nuts removed earlier.

CAUTION

10054 Rev 3/04

8. Transmission Oil and FilterA. Level Check (Daily)

1. Level the vehicle, ground the carriage, place thetravel select lever in (N) NEUTRAL, move neutrallock lever to NEUTRAL LOCK position and engagethe emergency brake switch.

2. Check oil level with engine running at idle, and oilat normal operating temperature.

3. Remove transmission dipstick (Figure 40) throughaccess hole in transmission cover and checkreading.

4. Add 10W-30 Motor Oil (see table for approvedlubricants) to transmission as required to bring upto full mark. Transmission capacity is 4.5 gallons(17,0 ltr).

Figure 40OH1180

TRANSMISSIONDIPSTICK

Top View of Transmission Compartment

Approved Lubricants10W-30 Motor Oil *

• API CD / CE / CF / SF / SG• MIL-L-2104C / -D / -E• MIL-L-46152C / -D / -E• SAE 10W / 10W-30 / 10W-40 / 15W-40 / 20W-20

* Automatic Transmission Fluids (ATF) only at ambienttemperatures below +14 °F (-10 °C)

Page 74 10054 Rev 3/04

8. Transmission Oil and FilterA. Level Check (Daily)

1. Level the vehicle, ground the carriage, place thetravel select lever in (N) NEUTRAL, move neutrallock lever to NEUTRAL LOCK position and engagethe emergency brake switch.

2. Check oil level with engine running at idle, and oilat normal operating temperature.

3. Remove transmission dipstick (Figure 40) throughaccess hole in transmission cover and checkreading.

4. Add 10W-30 Motor Oil (see table for approvedlubricants) to transmission as required to bring upto full mark. Transmission capacity is 4.5 gallons(17,0 ltr).

Figure 40OH1180

TRANSMISSIONDIPSTICK

Top View of Transmission Compartment

Approved Lubricants10W-30 Motor Oil *

• API CD / CE / CF / SF / SG• MIL-L-2104C / -D / -E• MIL-L-46152C / -D / -E• SAE 10W / 10W-30 / 10W-40 / 15W-40 / 20W-20

* Automatic Transmission Fluids (ATF) only at ambienttemperatures below +14 °F (-10 °C)

Rev 3/04

C. Oil Change (At First 50 Hours of Use and 1000 HourIntervals Thereafter)

1. Level the vehicle, ground the carriage, place travelselect lever in (N) NEUTRAL, move the neutrallock lever to NEUTRAL LOCK position, engage theemergency brake switch and shut off engine.

B. Filter Change (At First 50 Hours of Use and 1000Hour Intervals Thereafter)

1. Level the vehicle, ground the carriage, place travelselect lever in (N) NEUTRAL, move the neutral locklever to NEUTRAL LOCK position and engage theemergency brake switch and shut off the engine.

2. Place a small pan or receptacle under the transmis-sion filter (Figure 41) to catch fluid when the filter isremoved.

3. Remove the transmission filter cover from trans-mission drop box.

4. Remove the old filter element. Discard element ando-rings.

5. Apply a thin film of clean 10W-30 Motor Oil (seetable for approved lubricants on page 74) to the newelement o-rings.

6. Install new element into transmission drop box.Install transmission filter cover.

7. Remove and discard drained fluid. Transfer the oilto a container with a cover and label the containeras used oil. Dispose of the used oil at an approvedrecycling facility.

8. Check transmission level and add 10W-30 MotorOil (see table for approved lubricants on page 74)as required following procedures in paragraph 8A. OH1200Figure 41

TRANSMISSIONDRAIN PLUG

TRANSMISSIONFILTER

TRANSMISSIONFILTER COVER

O-RINGS

Page 7510054 Rev 3/04

C. Oil Change (At First 50 Hours of Use and 1000 HourIntervals Thereafter)

1. Level the vehicle, ground the carriage, place travelselect lever in (N) NEUTRAL, move the neutrallock lever to NEUTRAL LOCK position, engage theemergency brake switch and shut off engine.

B. Filter Change (At First 50 Hours of Use and 1000Hour Intervals Thereafter)

1. Level the vehicle, ground the carriage, place travelselect lever in (N) NEUTRAL, move the neutral locklever to NEUTRAL LOCK position and engage theemergency brake switch and shut off the engine.

2. Place a small pan or receptacle under the transmis-sion filter (Figure 41) to catch fluid when the filter isremoved.

3. Remove the transmission filter cover from trans-mission drop box.

4. Remove the old filter element. Discard element ando-rings.

5. Apply a thin film of clean 10W-30 Motor Oil (seetable for approved lubricants on page 74) to the newelement o-rings.

6. Install new element into transmission drop box.Install transmission filter cover.

7. Remove and discard drained fluid. Transfer the oilto a container with a cover and label the containeras used oil. Dispose of the used oil at an approvedrecycling facility.

8. Check transmission level and add 10W-30 MotorOil (see table for approved lubricants on page 74)as required following procedures in paragraph 8A. OH1200Figure 41

TRANSMISSIONDRAIN PLUG

TRANSMISSIONFILTER

TRANSMISSIONFILTER COVER

O-RINGS

10054 Rev 3/04

9. Axle OilA. Level Check (250 Hour Intervals)

1. Level the vehicle, ground the carriage, place travelselect lever in (N) NEUTRAL, move neutral locklever to NEUTRAL LOCK position, engage theemergency brake switch and shut off engine.

2. Clean area around axle fill/level plug, remove plug(Figure 42) from axle housing and check oil level.Add 80W90 gear oil as required to bring the oillevel up even with the plug hole (for temperaturesbelow -15° F (-26° C) 75W gear oil can be used).

3. Reinstall plug.

2. Place a funnel with flexible drain under the trans-mission housing (Figure 41) and a receptacle tocatch fluid.

3. Remove drain plug (Figure 41) and allow the oil todrain completely. Transfer the oil to a containerwith a cover and label the container as used oil.Dispose of the used oil at an approved recyclingfacility.

4. Clean drain plug thoroughly with a standardsolvent.

5. Install new filter element by following procedures inparagraph 8B, but DO NOT start engine at thistime.

6. Install cleaned drain plug with new o-rings into dropcase.

7. Remove and discard old fluid in receptacle.

8. Fill transmission to the LOW mark on the dipstick.Check transmission level and add 10W-30 MotorOil as required following procedures in paragraph8A.

OH0030

AXLEFILL/LEVEL

PLUGAXLE DRAIN PLUG

Figure 42

Page 76 10054 Rev 3/04

9. Axle OilA. Level Check (250 Hour Intervals)

1. Level the vehicle, ground the carriage, place travelselect lever in (N) NEUTRAL, move neutral locklever to NEUTRAL LOCK position, engage theemergency brake switch and shut off engine.

2. Clean area around axle fill/level plug, remove plug(Figure 42) from axle housing and check oil level.Add 80W90 gear oil as required to bring the oillevel up even with the plug hole (for temperaturesbelow -15° F (-26° C) 75W gear oil can be used).

3. Reinstall plug.

2. Place a funnel with flexible drain under the trans-mission housing (Figure 41) and a receptacle tocatch fluid.

3. Remove drain plug (Figure 41) and allow the oil todrain completely. Transfer the oil to a containerwith a cover and label the container as used oil.Dispose of the used oil at an approved recyclingfacility.

4. Clean drain plug thoroughly with a standardsolvent.

5. Install new filter element by following procedures inparagraph 8B, but DO NOT start engine at thistime.

6. Install cleaned drain plug with new o-rings into dropcase.

7. Remove and discard old fluid in receptacle.

8. Fill transmission to the LOW mark on the dipstick.Check transmission level and add 10W-30 MotorOil as required following procedures in paragraph8A.

OH0030

AXLEFILL/LEVEL

PLUGAXLE DRAIN PLUG

Figure 42

Rev 3/04

10. Wheel End Oil

DO NOT perform service or maintenance on the vehiclewith the engine running. Contact with moving parts cancause serious injury or death

B. Oil Change (1000 Hour Intervals)

1. Level the vehicle, ground the carriage, place travelselect lever in (N) NEUTRAL,move neutral locklever to NEUTRAL LOCK position, engage theemergency brake switch and shut off engine.

2. Clean area around axle fill/level plug and drainplug.

3. Place receptacle under the axle housing drain plug.Remove fill/level plug and drain plug from axlehousing.

4. Allow oil to drain completely. Transfer the oil to acontainer with a cover and label the container asused oil. Dispose of the used oil at an approvedrecycling facility.

5. Clean and reinstall drain plug.

6. Fill axle to level plug hole with 80W90 gear oil (fortemperatures below -15° F (-26° C) 75W gear oilcan be used). Axle capacity is 18 qts. (17 ltr).

7. Install fill/level plug.

Oil Change (250 Hour Intervals)

1. Be sure that the drain plug on the wheel endhousing (Figure 43) is down. Level the vehicle,ground the carriage, place the travel select lever in(N) NEUTRAL, move neutral lock lever toNEUTRAL LOCK position, engage the emergencybrake switch and shut off the engine.

2. Clean the areas around the magnetic drain plugand vent plug.

3. Remove vent plug.

4. Remove the drain plug and allow the fluid to drain.Transfer the oil to a container with a cover andlabel the container as used oil. Dispose of theused oil at an approved recycling facility.

WARNING

Page 7710054 Rev 3/04

10. Wheel End Oil

DO NOT perform service or maintenance on the vehiclewith the engine running. Contact with moving parts cancause serious injury or death

B. Oil Change (1000 Hour Intervals)

1. Level the vehicle, ground the carriage, place travelselect lever in (N) NEUTRAL,move neutral locklever to NEUTRAL LOCK position, engage theemergency brake switch and shut off engine.

2. Clean area around axle fill/level plug and drainplug.

3. Place receptacle under the axle housing drain plug.Remove fill/level plug and drain plug from axlehousing.

4. Allow oil to drain completely. Transfer the oil to acontainer with a cover and label the container asused oil. Dispose of the used oil at an approvedrecycling facility.

5. Clean and reinstall drain plug.

6. Fill axle to level plug hole with 80W90 gear oil (fortemperatures below -15° F (-26° C) 75W gear oilcan be used). Axle capacity is 18 qts. (17 ltr).

7. Install fill/level plug.

Oil Change (250 Hour Intervals)

1. Be sure that the drain plug on the wheel endhousing (Figure 43) is down. Level the vehicle,ground the carriage, place the travel select lever in(N) NEUTRAL, move neutral lock lever toNEUTRAL LOCK position, engage the emergencybrake switch and shut off the engine.

2. Clean the areas around the magnetic drain plugand vent plug.

3. Remove vent plug.

4. Remove the drain plug and allow the fluid to drain.Transfer the oil to a container with a cover andlabel the container as used oil. Dispose of theused oil at an approved recycling facility.

WARNING

10054 Rev 3/04

OIL BRAND NAME AND DESCRIPTION

*AMOCO Oil Company AMOCO 1000 FluidP/N 8522045 (2.5 gal.)

J.I. CASE HY-TRAN TCHJOHN DEERE J20FORD-NEW HOLLAND M2C-134

MOBIL FLUID 424

FRICTION MODIFIER BRAND PART NUMBER

*Sky Trak 8522043 (32 oz.)Ford C8AZ19B546A (4 oz.)

* = Recommended Oil

��

��

��

��

VENT PLUG

OA0432Figure 43

MAGNETICWHEEL ENDDRAIN PLUG

IMPORTANT: All wheel ends are factory filled with oil thatcontains friction modifier. DO NOT add additional frictionmodifier to factory filled wheel ends. The addition of frictionmodifier to a factory fill will dilute the properties of the oiland could cause loss of braking ability. If a noisy brakecondition exists after a fresh fill of oil add 6 ozs. (0,18 ltr) offriction modifier per wheel end. NEVER add more than6 ozs. (0,18 ltr) of friction modifier to any wheel end as toomuch modifier could cause loss of braking ability. Brakenoise is not harmful to the operation of the wheel endbrakes and any oil type may result in a certain amount ofnoise, especially during hard braking conditions.

5. Move the vehicle so the arrow on the wheel endhousing is pointing down (Figure 43).

6. Fill the wheel end with recommended oil listed intable on this page to the level of the drain plug.Capacity of wheel end is approximately 54 ozs.(1,6 ltr).

7. Clean and install drain plug and vent plug. Drainand fill three remaining wheel ends using the sameprocedure.

Page 78 10054 Rev 3/04

OIL BRAND NAME AND DESCRIPTION

*AMOCO Oil Company AMOCO 1000 FluidP/N 8522045 (2.5 gal.)

J.I. CASE HY-TRAN TCHJOHN DEERE J20FORD-NEW HOLLAND M2C-134

MOBIL FLUID 424

FRICTION MODIFIER BRAND PART NUMBER

*Sky Trak 8522043 (32 oz.)Ford C8AZ19B546A (4 oz.)

* = Recommended Oil

��

��

��

��

VENT PLUG

OA0432Figure 43

MAGNETICWHEEL ENDDRAIN PLUG

IMPORTANT: All wheel ends are factory filled with oil thatcontains friction modifier. DO NOT add additional frictionmodifier to factory filled wheel ends. The addition of frictionmodifier to a factory fill will dilute the properties of the oiland could cause loss of braking ability. If a noisy brakecondition exists after a fresh fill of oil add 6 ozs. (0,18 ltr) offriction modifier per wheel end. NEVER add more than6 ozs. (0,18 ltr) of friction modifier to any wheel end as toomuch modifier could cause loss of braking ability. Brakenoise is not harmful to the operation of the wheel endbrakes and any oil type may result in a certain amount ofnoise, especially during hard braking conditions.

5. Move the vehicle so the arrow on the wheel endhousing is pointing down (Figure 43).

6. Fill the wheel end with recommended oil listed intable on this page to the level of the drain plug.Capacity of wheel end is approximately 54 ozs.(1,6 ltr).

7. Clean and install drain plug and vent plug. Drainand fill three remaining wheel ends using the sameprocedure.

Rev 3/04

11. Wheels and TiresA. Air Pressure / Hydrofill Check

(Daily or 10 Hour Intervals)

IMPORTANT: Before checking air pressure be sure toposition the valve stem at the top of the wheel to preventloss of hydrofill. To check hydrofill level, position valve sothat it is nearly, but not quite, at the top of the wheel.Depress valve stem. Hydrofill should escape. If hydrofilldoes not escape from the valve, see “Filling with Hydrofill.”

Clean the area around the valve stems and checkair pressure at all four tires:

Size psi Air Pressure

B. Filling with Hydrofill

Hydrofill is a mixture of water and calcium chlorideand provides the vehicle with additional weight forstability. All hydrofill service to tires should beperformed by a qualified tire service center. Hydrofillmust be refilled after any tire repair. Refer to the“Specifications” section for details of the hydrofillcontent required for each tire size. JLG assumes noliability for damage or injury incurred while operatingwithout proper hydrofill in all four tires.

C. Replacing Tires

17.50 R25, RADIAL 73 psi (503 kPa)

17.50 x 25, 12 PLY 51 psi (352 kPa)Mis-Matched tire sizes or mixing of tire types (Radial andBias ply) may compromise vehicle stability and mayresult in vehicle tipover.

Improper hydrofill can cause instability which can resultin tipover. ALWAYS make sure that all four tires havebeen properly filled with hydrofill by a qualified tireservice center.

The chart on this page depicts the minimum sizeand ply ratings (star rating for radial tires) thatshould be used on this vehicle. Make sure thereplacement tire is of the same size and ply rating(star rating for radial tires) as all the other tires.Higher ply (star for radial) rated tires can be used onthis vehicle, but only when all four tires have thesame ply rating.

WARNING

WARNING

Page 7910054 Rev 3/04

11. Wheels and TiresA. Air Pressure / Hydrofill Check

(Daily or 10 Hour Intervals)

IMPORTANT: Before checking air pressure be sure toposition the valve stem at the top of the wheel to preventloss of hydrofill. To check hydrofill level, position valve sothat it is nearly, but not quite, at the top of the wheel.Depress valve stem. Hydrofill should escape. If hydrofilldoes not escape from the valve, see “Filling with Hydrofill.”

Clean the area around the valve stems and checkair pressure at all four tires:

Size psi Air Pressure

B. Filling with Hydrofill

Hydrofill is a mixture of water and calcium chlorideand provides the vehicle with additional weight forstability. All hydrofill service to tires should beperformed by a qualified tire service center. Hydrofillmust be refilled after any tire repair. Refer to the“Specifications” section for details of the hydrofillcontent required for each tire size. JLG assumes noliability for damage or injury incurred while operatingwithout proper hydrofill in all four tires.

C. Replacing Tires

17.50 R25, RADIAL 73 psi (503 kPa)

17.50 x 25, 12 PLY 51 psi (352 kPa)Mis-Matched tire sizes or mixing of tire types (Radial andBias ply) may compromise vehicle stability and mayresult in vehicle tipover.

Improper hydrofill can cause instability which can resultin tipover. ALWAYS make sure that all four tires havebeen properly filled with hydrofill by a qualified tireservice center.

The chart on this page depicts the minimum sizeand ply ratings (star rating for radial tires) thatshould be used on this vehicle. Make sure thereplacement tire is of the same size and ply rating(star rating for radial tires) as all the other tires.Higher ply (star for radial) rated tires can be used onthis vehicle, but only when all four tires have thesame ply rating.

WARNING

WARNING

10054 Rev 3/04

C. Wheel Lug Nuts (Check at 50 Hour Intervals or AsNecessary For Operating Conditions)

Clean the area around all wheel lug nuts. Check andtorque wheel lug nuts to 450 - 500 lb-ft (610 - 678 Nm)using the torque sequence (Figure 44).

OA0453Figure 44

2

8

4

9

51

7

3

10

6TIRE

VALVE

12. Battery (250 Hour Intervals)

Lead-acid batteries produce flammable and explosivegases. To avoid personal injury when checking, testingor charging battery:

• DO NOT use smoking materials near battery.

• Keep arcs, sparks and flames away from battery.

• Provide ventilation and wear safety glasses.


2. Unlock the battery cover and lower or remove thecover (Figure 45) to gain access to the battery.

3. The battery in this vehicle is a maintenance freetype battery. It is shipped in the vehicle filled withelectrolyte and charged.

4. Replace battery if case is cracked, melted ordamaged. Check terminals for corrosion.

WARNING

Page 80 10054 Rev 3/04

C. Wheel Lug Nuts (Check at 50 Hour Intervals or AsNecessary For Operating Conditions)

Clean the area around all wheel lug nuts. Check andtorque wheel lug nuts to 450 - 500 lb-ft (610 - 678 Nm)using the torque sequence (Figure 44).

OA0453Figure 44

2

8

4

9

51

7

3

10

6TIRE

VALVE

12. Battery (250 Hour Intervals)

Lead-acid batteries produce flammable and explosivegases. To avoid personal injury when checking, testingor charging battery:

• DO NOT use smoking materials near battery.

• Keep arcs, sparks and flames away from battery.

• Provide ventilation and wear safety glasses.


2. Unlock the battery cover and lower or remove thecover (Figure 45) to gain access to the battery.

3. The battery in this vehicle is a maintenance freetype battery. It is shipped in the vehicle filled withelectrolyte and charged.

4. Replace battery if case is cracked, melted ordamaged. Check terminals for corrosion.

WARNING

Rev 3/04

OH1210

KEY LOCK

BATTERYCOVER

Figure 45

Battery Electrolyte First Aid:• External Contact — Flush with water.

• Eyes — Flush with water for at least 15 minutesand get medical attention immediately!

• Internal Contact — Drink large quantities ofwater. Follow with Milk of Magnesia, beaten eggor vegetable oil. Get medical attention immedi-ately!

IMPORTANT: In case of internal contact, DO NOTgive fluids that would induce vomiting!

Fluid in electric storage batteries contains sulfuric acidwhich is POISON and can cause SEVERE CHEMI-CAL BURNS. Avoid all contact of fluid with eyes, skin,or clothing. Use proper protective gear when handlingbatteries. DO NOT tip any battery beyond a 45° anglein any direction. If contact does occur, follow the FirstAid suggestions below.

5. Battery Charging —

Under normal conditions the engine alternator will haveno problem keeping the battery charged. The onlycondition in which the battery may cause a problem iswhen it has been completely discharged for an ex-tended period of time. Under these conditions thealternator may be unable to recharge the battery. Abattery charger will be required for recharging.Before using a charger, an attempt can be made torecharge the battery using the engine alternator by firstjump starting the vehicle and letting the engine run.See “Jump Starting” instructions earlier in this manual.

WARNING

Page 8110054 Rev 3/04

OH1210

KEY LOCK

BATTERYCOVER

Figure 45

Battery Electrolyte First Aid:• External Contact — Flush with water.

• Eyes — Flush with water for at least 15 minutesand get medical attention immediately!

• Internal Contact — Drink large quantities ofwater. Follow with Milk of Magnesia, beaten eggor vegetable oil. Get medical attention immedi-ately!

IMPORTANT: In case of internal contact, DO NOTgive fluids that would induce vomiting!

Fluid in electric storage batteries contains sulfuric acidwhich is POISON and can cause SEVERE CHEMI-CAL BURNS. Avoid all contact of fluid with eyes, skin,or clothing. Use proper protective gear when handlingbatteries. DO NOT tip any battery beyond a 45° anglein any direction. If contact does occur, follow the FirstAid suggestions below.

5. Battery Charging —

Under normal conditions the engine alternator will haveno problem keeping the battery charged. The onlycondition in which the battery may cause a problem iswhen it has been completely discharged for an ex-tended period of time. Under these conditions thealternator may be unable to recharge the battery. Abattery charger will be required for recharging.Before using a charger, an attempt can be made torecharge the battery using the engine alternator by firstjump starting the vehicle and letting the engine run.See “Jump Starting” instructions earlier in this manual.

WARNING

10054 Rev 3/04

No. Amp Circuit Protectedor Volt

1 7.5 amp Outrigger Switches

2 10 amp Enclosed Cab Windshield Washer/WiperSwitch and Circulation Fan (Optional thisfuse will not be found on vehicles with anopen cab)

3 7.5 amp Stabil-TRAK Solenoids, Relays andProximity Switch

4 7.5 amp Steering Select Circuit and Stabilizer LockRelay

5 10 amp Horn and Back-up Alarm (Optional - CabHeater Fan)

6 10 amp Warning Lights, Emergency Brake Switch,Fuel Gauge and Hourmeter

7 7.5 amp (Optional - Light Switch Relay)

8 40 amp Ignition Switch Feed For Entire ElectricalSystem (Main)

DO NOT charge a frozen battery, it may explode andcause injury. Let the battery thaw out before putting ona charger.

Charging rates between 3 and 50 amperes are satisfactoryif excessive gassing or spewing of electrolyte does notoccur or the battery does not feel excessively hot [over125° F (52° C)]. If spewing or gassing occurs or thetemperature exceeds 125° F, the charging rate must bereduced or temporarily stopped to permit cooling.

WARNINGThe following fuses and relays are used (See Figure 46).

The fuses (1-9) and relays (12-14) are located inside theright console (Figure 46). The fuses (10 & 11) and relays(15-25) are located under the dash panel. Note that you willrequire a #T-27 TORX driver to remove the side consoleaccess panel.

13. Fuse and Relay Replacement

The fuses and relays in this vehicle protect the entireelectrical system. The fuses most often fail if there is ashorted or grounded wire in the applicable circuit. Thefuses will have to be replaced if they fail. If the fuses orrelays continually fail, check the system for shorts,grounds or defective electrical components.

IMPORTANT: Be sure to shut off the engine and discon-nect the negative battery cable before using an ohmmeterto check the resistance of the electrical system.

Page 82 10054 Rev 3/04


1 7.5 amp Outrigger Switches

2 10 amp Enclosed Cab Windshield Washer/WiperSwitch and Circulation Fan (Optional thisfuse will not be found on vehicles with anopen cab)

3 7.5 amp Stabil-TRAK Solenoids, Relays andProximity Switch

4 7.5 amp Steering Select Circuit and Stabilizer LockRelay

5 10 amp Horn and Back-up Alarm (Optional - CabHeater Fan)

6 10 amp Warning Lights, Emergency Brake Switch,Fuel Gauge and Hourmeter

7 7.5 amp (Optional - Light Switch Relay)

8 40 amp Ignition Switch Feed For Entire ElectricalSystem (Main)

DO NOT charge a frozen battery, it may explode andcause injury. Let the battery thaw out before putting ona charger.

Charging rates between 3 and 50 amperes are satisfactoryif excessive gassing or spewing of electrolyte does notoccur or the battery does not feel excessively hot [over125° F (52° C)]. If spewing or gassing occurs or thetemperature exceeds 125° F, the charging rate must bereduced or temporarily stopped to permit cooling.

WARNINGThe following fuses and relays are used (See Figure 46).

The fuses (1-9) and relays (12-14) are located inside theright console (Figure 46). The fuses (10 & 11) and relays(15-25) are located under the dash panel. Note that you willrequire a #T-27 TORX driver to remove the side consoleaccess panel.

13. Fuse and Relay Replacement

The fuses and relays in this vehicle protect the entireelectrical system. The fuses most often fail if there is ashorted or grounded wire in the applicable circuit. Thefuses will have to be replaced if they fail. If the fuses orrelays continually fail, check the system for shorts,grounds or defective electrical components.

IMPORTANT: Be sure to shut off the engine and discon-nect the negative battery cable before using an ohmmeterto check the resistance of the electrical system.

Rev 3/04

9 20 amp (Optional - Lighting Package)

10 7.5 amp Outrigger and Extend Proximity Switch

11 7.5 amp Outrigger Pressure Switches

12 12 volt Light Switch Relay (30 amp)

13 12 volt Boom Switch Relay (40 amp)

14 12 volt Stabilizer Lock Relay (40 amp)

15 12 volt Back-Up Alarm Relay (40 amp)

16 12 volt Neutral Start Relay (40 amp)

17 12 volt Emergency Brake DisconnectRelay (40 amp)

18 12 volt Emergency Brake Interlock Relay (30 amp)

19 12 volt Boom Extend Interlock Relay (30 amp)

20 12 volt Boom Extend Lockout Relay (30 amp)

21 12 volt Right Outrigger Lockout Relay (30 amp)

22 12 volt Outrigger Lockout Relay (30 amp)

23 12 volt Left Outrigger Lockout Relay (30 amp)

24 12 volt Stabilizer Lock-Up Relay (30 amp)

25 12 volt Stabilizer Interlock Relay (30 amp)


Figure 46

10

11

3

4

5

6

7

8

912

14

13

17

15

16

SPAREFUSES

25

23

24

21

22

19

2018

1

2

OH3740

Page 8310054 Rev 3/04

9 20 amp (Optional - Lighting Package)

10 7.5 amp Outrigger and Extend Proximity Switch

11 7.5 amp Outrigger Pressure Switches

12 12 volt Light Switch Relay (30 amp)

13 12 volt Boom Switch Relay (40 amp)

14 12 volt Stabilizer Lock Relay (40 amp)

15 12 volt Back-Up Alarm Relay (40 amp)

16 12 volt Neutral Start Relay (40 amp)

17 12 volt Emergency Brake DisconnectRelay (40 amp)

18 12 volt Emergency Brake Interlock Relay (30 amp)

19 12 volt Boom Extend Interlock Relay (30 amp)

20 12 volt Boom Extend Lockout Relay (30 amp)

21 12 volt Right Outrigger Lockout Relay (30 amp)

22 12 volt Outrigger Lockout Relay (30 amp)

23 12 volt Left Outrigger Lockout Relay (30 amp)

24 12 volt Stabilizer Lock-Up Relay (30 amp)

25 12 volt Stabilizer Interlock Relay (30 amp)


Figure 46

10

11

3

4

5

6

7

8

912

14

13

17

15

16

SPAREFUSES

25

23

24

21

22

19

2018

1

2

OH3740

10054 Rev 3/04

14. Boom Chains and Wear Pads

A. Tension Check of Intermediate Boom Chains (First50 Hours Only, Then 1000 Hour Intervals Thereafter)

Check the boom chain tension by measuring the chainsag of the intermediate boom chains.

1. Raise the boom to a horizontal (level) position.Lower both outriggers completely and fully extendthe boom, then retract it 2" (50,8 mm).

2. Measure the sag in the intermediate boom chainsbetween the bottom of the chains and the top ofthe primary intermediate boom at their closestpoint (Figure 47). Acceptable boom chain sag isbetween 1-1/2" (38,1 mm) and 2-1/2" (63,5 mm). Ifthe measurement is less than 1-1/2" (38,1 mm) ,the boom chains need to be adjusted. Followprocedures in paragraph 14B to adjust.

CHAIN SAGMEASUREMENT

CENTER SECTIONOF PRIMARY

INTERMEDIATE BOOMOR SECONDARY

INTERMEDIATE BOOMOA0492

Figure 47

B. Tension Adjustment of Intermediate Boom Chains(As Required)1. Retract the boom completely to check the position

of the secondary intermediate boom (Figure 48).The secondary intermediate boom section shouldextend [11-11/16"±1/4" (296,7 ± 6,4 mm)] beyondthe end of the primary intermediate boom section(Figure 48). To check the 8-1/2" (216 mm) alter-nate dimension as shown in Figure 48A the rearcover has to be removed. To adjust proceed asfollows;

Page 84 10054 Rev 3/04

14. Boom Chains and Wear Pads

A. Tension Check of Intermediate Boom Chains (First50 Hours Only, Then 1000 Hour Intervals Thereafter)

Check the boom chain tension by measuring the chainsag of the intermediate boom chains.


2. Measure the sag in the intermediate boom chainsbetween the bottom of the chains and the top ofthe primary intermediate boom at their closestpoint (Figure 47). Acceptable boom chain sag isbetween 1-1/2" (38,1 mm) and 2-1/2" (63,5 mm). Ifthe measurement is less than 1-1/2" (38,1 mm) ,the boom chains need to be adjusted. Followprocedures in paragraph 14B to adjust.

CHAIN SAGMEASUREMENT

CENTER SECTIONOF PRIMARY

INTERMEDIATE BOOMOR SECONDARY

INTERMEDIATE BOOMOA0492

Figure 47

B. Tension Adjustment of Intermediate Boom Chains(As Required)1. Retract the boom completely to check the position

of the secondary intermediate boom (Figure 48).The secondary intermediate boom section shouldextend [11-11/16"±1/4" (296,7 ± 6,4 mm)] beyondthe end of the primary intermediate boom section(Figure 48). To check the 8-1/2" (216 mm) alter-nate dimension as shown in Figure 48A the rearcover has to be removed. To adjust proceed asfollows;

Rev 3/04

INNER BOOM

Figure 48

PRIMARYINTERMEDIATE

BOOM

SECONDARYINTERMEDIATE

BOOM

2. If the distance measured is not correct remove therear cover from the outer boom.

a. Tighten the locknuts (Figure 50) located on theback of the secondary intermediate boom.

b. Tighten both locknuts equally until the11-11/16" ± 1/4" dimension is acheived. Besure the yoke remains parallel with the edge ofthe boom for equal tension of both chains(Figure 51).

c. Locate the intermediate boom retract chainlocknut on the bottom side of the outer boom(Figure 49) and torque the locknut to35-40 lbs-ft (47-54 Nm).

d. Extend the boom to full extension and thencompletely retract the boom. Recheck thedimension refer to step B1. Readjust ifnecessary.

e. Fully extend the boom and check the interme-diate boom chain sag. If the chain sag is lessthan 1-1/2" (38,1mm) fully retract the boomand retorque the intermediate boom retractchain locknut (Figure 49). Fully extend theboom and recheck the chain sag.

f. After adjustment is complete assemble therear cover to the outer boom.

10-1/4 ±1/4"

11-11/16 ±1/4"

OH0520

Figure 48AOH1130

8-1/2" (216 MM)(ALTERNATE MEASUREMENT)

PRIMARY INTERMEDIATE BOOMTO SECONDARY INTERMEDIATE

BOOM

13" (330 MM)(ALTERNATE MEASUREMENT)SECONDARY INTERMEDIATE

BOOM TO INNERBOOM

PRIMARYINTERMEDIATE

BOOMSECONDARYINTERMEDIATE

BOOM

INNERBOOM

Page 8510054 Rev 3/04

INNER BOOM

Figure 48

PRIMARYINTERMEDIATE

BOOM

SECONDARYINTERMEDIATE

BOOM


a. Tighten the locknuts (Figure 50) located on theback of the secondary intermediate boom.

b. Tighten both locknuts equally until the11-11/16" ± 1/4" dimension is acheived. Besure the yoke remains parallel with the edge ofthe boom for equal tension of both chains(Figure 51).

c. Locate the intermediate boom retract chainlocknut on the bottom side of the outer boom(Figure 49) and torque the locknut to35-40 lbs-ft (47-54 Nm).

d. Extend the boom to full extension and thencompletely retract the boom. Recheck thedimension refer to step B1. Readjust ifnecessary.

e. Fully extend the boom and check the interme-diate boom chain sag. If the chain sag is lessthan 1-1/2" (38,1mm) fully retract the boomand retorque the intermediate boom retractchain locknut (Figure 49). Fully extend theboom and recheck the chain sag.


10-1/4 ±1/4"

11-11/16 ±1/4"

OH0520

Figure 48AOH1130

8-1/2" (216 MM)(ALTERNATE MEASUREMENT)

PRIMARY INTERMEDIATE BOOMTO SECONDARY INTERMEDIATE

BOOM

13" (330 MM)(ALTERNATE MEASUREMENT)SECONDARY INTERMEDIATE

BOOM TO INNERBOOM

PRIMARYINTERMEDIATE

BOOMSECONDARYINTERMEDIATE

BOOM

INNERBOOM

10054 Rev 3/04

Figure 50 OH05311

YOKE

INTERMEDIATE BOOMEXTEND CHAINS

INNER BOOMEXTEND CHAIN

Figure 51OH0550

WEAR PADS

WEAR PADS RETRACT CHAIN


LOCKNUT


LOCKNUTS

Figure 49OA0512EXTEND CYLINDER

RETRACT CHAIN LOCKNUT

Page 86 10054 Rev 3/04

Figure 50 OH05311

YOKE



Figure 51OH0550

WEAR PADS

WEAR PADS RETRACT CHAIN


LOCKNUT


LOCKNUTS

Figure 49OA0512EXTEND CYLINDER


Rev 3/04


a. Tighten the locknut (Figure 50) located on theback of the inner boom.

b. Tighten the locknut until the 10-1/4 ± 1/4" orthe 13" alternate rear dimension is acheived.

c. Extend the boom far enough to expose theinner boom retract chain locknut on the bottomside of the primary intermediate boom (Figure52) and torque the locknut to 35-40 lbs-ft(47-54 Nm).

D. Tension Adjustment of Inner Boom Chain(As Required)

1. Retract the boom completely to check the positionof the inner boom (Figure 48). The inner boomsection should extend [10-1/4 ± 1/4" (260,4 ± 6,4mm)] beyond the end of the secondary intermedi-ate boom section (Figure 48). To check the 13"(330 mm) alternate dimension as shown in Figure48A the rear cover has to be removed. To adjustproceed as follows;

C. Tension Check of Inner Boom Chain (First 50 HoursOnly, Then 1000 Hour Intervals Thereafter)

Check the boom chain tension by measuring the chainsag of the inner boom chain.


2. Measure the sag in the inner boom chain betweenthe bottom of the chain and the top of thesecondary intermediate boom at their closest point(Figure 47). Acceptable boom chain sag isbetween 1-1/2" (38,1 mm) and 2-1/2" (63,5 mm). Ifthe measurement is less than 1-1/2" (38,1 mm),the boom chain needs to be adjusted. Followprocedures in paragraph 14D to adjust.

Page 8710054 Rev 3/04


a. Tighten the locknut (Figure 50) located on theback of the inner boom.

b. Tighten the locknut until the 10-1/4 ± 1/4" orthe 13" alternate rear dimension is acheived.

c. Extend the boom far enough to expose theinner boom retract chain locknut on the bottomside of the primary intermediate boom (Figure52) and torque the locknut to 35-40 lbs-ft(47-54 Nm).

D. Tension Adjustment of Inner Boom Chain(As Required)

1. Retract the boom completely to check the positionof the inner boom (Figure 48). The inner boomsection should extend [10-1/4 ± 1/4" (260,4 ± 6,4mm)] beyond the end of the secondary intermedi-ate boom section (Figure 48). To check the 13"(330 mm) alternate dimension as shown in Figure48A the rear cover has to be removed. To adjustproceed as follows;

C. Tension Check of Inner Boom Chain (First 50 HoursOnly, Then 1000 Hour Intervals Thereafter)

Check the boom chain tension by measuring the chainsag of the inner boom chain.


2. Measure the sag in the inner boom chain betweenthe bottom of the chain and the top of thesecondary intermediate boom at their closest point(Figure 47). Acceptable boom chain sag isbetween 1-1/2" (38,1 mm) and 2-1/2" (63,5 mm). Ifthe measurement is less than 1-1/2" (38,1 mm),the boom chain needs to be adjusted. Followprocedures in paragraph 14D to adjust.

10054 Rev 3/04

E. Chain Lubrication (1000 Hour Intervals)

With the boom extended fully, apply “LPS - 3” or“LUBRIPLATE” chain and cable fluid or equivalent toextend chains.

F. Wear Pad Check (50 Hour Intervals)

Visually inspect boom wear pads between the boomsections at the rear and front of the boom for excessivewear at every 50 hour interval.

The average expected life of boom pads can vary depend-ing upon vehicle use, weight of loads, operating conditions,and the location of boom pads inside the boom.

If the vehicle is used continuously or the weights of theloads are at or near maximum capacity, or if you areoperating in very dusty or dirty conditions, the boom padswill wear much faster. The pads that are under the moststress from the weight of the load will also wear faster thanother pads. For example the lower pads at the front of theboom are under far more stress than the pads attached tothe top, rear or sides of the boom. Consequently the lowerpads will require service more often.

Figure 52OH0660

EXTEND CYLINDER


d. Extend the boom to full extension and thencompletely retract the boom. Recheck thedimension refer to step D1. Readjust ifnecessary.

e. Fully extend the boom and check the innerboom chain sag. If the chain sag is less than1-1/2" (38,1mm) retract the boom part way andretorque the inner boom retract chain locknut(Figure 52). Fully extend the boom andrecheck the chain sag.


Page 88 10054 Rev 3/04

E. Chain Lubrication (1000 Hour Intervals)

With the boom extended fully, apply “LPS - 3” or“LUBRIPLATE” chain and cable fluid or equivalent toextend chains.

F. Wear Pad Check (50 Hour Intervals)

Visually inspect boom wear pads between the boomsections at the rear and front of the boom for excessivewear at every 50 hour interval.

The average expected life of boom pads can vary depend-ing upon vehicle use, weight of loads, operating conditions,and the location of boom pads inside the boom.

If the vehicle is used continuously or the weights of theloads are at or near maximum capacity, or if you areoperating in very dusty or dirty conditions, the boom padswill wear much faster. The pads that are under the moststress from the weight of the load will also wear faster thanother pads. For example the lower pads at the front of theboom are under far more stress than the pads attached tothe top, rear or sides of the boom. Consequently the lowerpads will require service more often.

Figure 52OH0660

EXTEND CYLINDER


d. Extend the boom to full extension and thencompletely retract the boom. Recheck thedimension refer to step D1. Readjust ifnecessary.

e. Fully extend the boom and check the innerboom chain sag. If the chain sag is less than1-1/2" (38,1mm) retract the boom part way andretorque the inner boom retract chain locknut(Figure 52). Fully extend the boom andrecheck the chain sag.


Rev 3/04

IMPORTANT: The boom has been factory lubricated forproper wear pad break-in and will normally not requirefurther lubrication. However, after replacing any wearpad(s) or after prolonged periods of inoperation, lightlubricating with “LPS-3” (or equivalent) of the boom wearsurfaces is recommended to keep the wear pads and boomwear surfaces lubricated properly. Light lubricating of theboom wear surfaces is also recommended in salt airclimates or when vehicle is to be put in storage to preventrusting.

G. Wear Pad Replacement(As Wear Pad Indicators Indicate)

Each boom pad is manufactured with a convenient wearpad indicator. This is the angled cut at each end of allwear pads (Figure 53). The total thickness of a new wearpad is .625" (15,9 mm). The angled cut will provide a totalwear thickness of .25" (6,4 mm). This will leave approxi-mately .375" (9,5 mm) of total unused material.

The pads must never be worn past the angled cut indicatorbecause the metal pad insert that holds the pads in placewill begin to wear into the boom pad sliding surfaces. Ifpads are worn past this point it will cause gouging on boomplate surfaces. This will result in premature wear of anynew wear pads installed if the surfaces are not groundsmooth again.

Replacement of boom wear pads must be performed by anauthorized Sky Trak distributor when the wear padsindicate.

.25"(6,4 MM)

.625"(15,9 MM)

METAL PADINSERT

WEAR PADSPACER BOOM

PLATE

ANGLED CUTWEAR PAD INDICATOR WEAR

PAD

Figure 53 SC00301

Page 8910054 Rev 3/04

IMPORTANT: The boom has been factory lubricated forproper wear pad break-in and will normally not requirefurther lubrication. However, after replacing any wearpad(s) or after prolonged periods of inoperation, lightlubricating with “LPS-3” (or equivalent) of the boom wearsurfaces is recommended to keep the wear pads and boomwear surfaces lubricated properly. Light lubricating of theboom wear surfaces is also recommended in salt airclimates or when vehicle is to be put in storage to preventrusting.

G. Wear Pad Replacement(As Wear Pad Indicators Indicate)

Each boom pad is manufactured with a convenient wearpad indicator. This is the angled cut at each end of allwear pads (Figure 53). The total thickness of a new wearpad is .625" (15,9 mm). The angled cut will provide a totalwear thickness of .25" (6,4 mm). This will leave approxi-mately .375" (9,5 mm) of total unused material.

The pads must never be worn past the angled cut indicatorbecause the metal pad insert that holds the pads in placewill begin to wear into the boom pad sliding surfaces. Ifpads are worn past this point it will cause gouging on boomplate surfaces. This will result in premature wear of anynew wear pads installed if the surfaces are not groundsmooth again.

Replacement of boom wear pads must be performed by anauthorized Sky Trak distributor when the wear padsindicate.

.25"(6,4 MM)

.625"(15,9 MM)

METAL PADINSERT

WEAR PADSPACER BOOM

PLATE

ANGLED CUTWEAR PAD INDICATOR WEAR

PAD

Figure 53 SC00301

10054 Rev 3/04

15. Emergency Boom Lowering

This section discusses emergency boom lowering proce-dures:

Section “A” In case of loss of engine power or hydraulicpump failure.

Section “B” In case of hydraulic line failure.

IMPORTANT: The following instructions are intended toserve as a guideline only. Many different factors mayplay an important role in this procedure. It is impossible tocover each and every combination that may be encoun-tered. Consult your local Sky Trak Distributor or the JLGService Departmentif you are unsure about any part of thisprocedure or for any specific instructions for your particularsituation.

A. In Case of Loss of Engine Power or HydraulicPump Failure:

In any event, the vehicle should be secured until thesituation has been properly evaluated. Secure the vehicleby following the procedures below.

1. Clear the area around the vehicle of all personnel.

2. Block all four wheels.

3. Section off a large area under the boom with string ortape to restrict any personnel from entering thispotentially dangerous area.

DO NOT get under a raised boom unless the boom isblocked up. Always block the boom before doing anyservicing which requires the boom to be up.

WARNING

Page 90 10054 Rev 3/04

15. Emergency Boom Lowering

This section discusses emergency boom lowering proce-dures:

Section “A” In case of loss of engine power or hydraulicpump failure.

Section “B” In case of hydraulic line failure.

IMPORTANT: The following instructions are intended toserve as a guideline only. Many different factors mayplay an important role in this procedure. It is impossible tocover each and every combination that may be encoun-tered. Consult your local Sky Trak Distributor or the JLGService Departmentif you are unsure about any part of thisprocedure or for any specific instructions for your particularsituation.

A. In Case of Loss of Engine Power or HydraulicPump Failure:

In any event, the vehicle should be secured until thesituation has been properly evaluated. Secure the vehicleby following the procedures below.

1. Clear the area around the vehicle of all personnel.

2. Block all four wheels.

3. Section off a large area under the boom with string ortape to restrict any personnel from entering thispotentially dangerous area.


WARNING

Rev 3/04

IMPORTANT: In the event of total loss of engine power orhydraulic pump failure with an elevated load, the situationmust be properly evaluated and dealt with on an individualbasis. Contact your local Sky Trak distributor or the JLGservice department at (877) 554-5438 or (717) 485-6657 forspecific instructions for your particular situation.

4. Temporarily block up or support the outer boom so itcannot be lowered.

5. If the load is in a position where it can be removedsafely, completely remove the load from the carriageand/or attachment, otherwise leave the load in place.

6. Place a tag on both the ignition switch and steeringwheel stating that the vehicle should not be operated.If you do not have a tag, tape over the ignitionswitch.

B. In Case of Hydraulic Line Failure:

In the event of a hydraulic line failure in any of the boomcontrol circuits, extreme CAUTION must be taken whenattempting to lower an elevated boom. Hydraulic oil underhigh pressure will escape through the fault in the line whichmay result in the boom lowering at a rapid rate. DO NOTperform this procedure unless you are absolutely sure ofwhat you are doing. Consult your local Sky Trak Distributoror the JLG Service Department before proceeding if youare uncertain about any of the following procedures.

WARNING

Page 9110054 Rev 3/04

IMPORTANT: In the event of total loss of engine power orhydraulic pump failure with an elevated load, the situationmust be properly evaluated and dealt with on an individualbasis. Contact your local Sky Trak distributor or the JLGservice department at (877) 554-5438 or (717) 485-6657 forspecific instructions for your particular situation.

4. Temporarily block up or support the outer boom so itcannot be lowered.

5. If the load is in a position where it can be removedsafely, completely remove the load from the carriageand/or attachment, otherwise leave the load in place.

6. Place a tag on both the ignition switch and steeringwheel stating that the vehicle should not be operated.If you do not have a tag, tape over the ignitionswitch.

B. In Case of Hydraulic Line Failure:

In the event of a hydraulic line failure in any of the boomcontrol circuits, extreme CAUTION must be taken whenattempting to lower an elevated boom. Hydraulic oil underhigh pressure will escape through the fault in the line whichmay result in the boom lowering at a rapid rate. DO NOTperform this procedure unless you are absolutely sure ofwhat you are doing. Consult your local Sky Trak Distributoror the JLG Service Department before proceeding if youare uncertain about any of the following procedures.

WARNING

10054 Rev 3/04

Wear protective clothing and proper eye protection whenworking with or around hydraulic oil. Wait for hydraulic oil tocool before attempting to repair the failure. Hot hydraulic oilcan cause severe burns and other serious injury.

1. Block or support the boom so it cannot be lowered.

IMPORTANT: Remove the load completely from the forksand/or attachment by using whatever additional equipmentmay be required for your particular situation.

2. If the boom has been extended, retract the boombefore proceeding. Boom retraction can beperformed by operating the boom retract controllever in the normal fashion.

3. If the vehicle is not in a potentially hazardouslocation, and the boom does not need to belowered immediately. Shut off the engine, find theline that failed and replace that line. After thefailure is fixed, remove the blocking, lower theboom, check the oil level and add as necessary.Start the engine and bleed the air from the system,then recheck the oil level. The vehicle can now beput back into service.

4. If the vehicle is in a potentially hazardous locationthat would require the boom to be lowered immedi-ately and if the line failure is in the boom raise line,(if in the lowering line, continue with step 5) theboom must be lowered by following this procedure:

a. Locate the fault in the line and use a containerto catch any oil that escapes. Transfer the oilto a container with a cover and label thecontainer as used oil. Dispose of the used oilat an approved recycling center.

b. (Using two people to perform this procedurewill make boom lowering much easier). Re-move the blocking from under the boom. Atthe base end of each hoist cylinder, locate thecounterbalance valve cartridges (Figure 54).Loosen the retainer nut and control the rate ofboom lowering by turning the adjusting screwon each cartridge simultaneously into thecartridge very slowly (clockwise). Hydraulicoil from inside the hoist cylinders will escapethrough the fault in the line.

WARNINGIf line failure is in the Raise or

Lower lines

Page 92 10054 Rev 3/04

Wear protective clothing and proper eye protection whenworking with or around hydraulic oil. Wait for hydraulic oil tocool before attempting to repair the failure. Hot hydraulic oilcan cause severe burns and other serious injury.

1. Block or support the boom so it cannot be lowered.


2. If the boom has been extended, retract the boombefore proceeding. Boom retraction can beperformed by operating the boom retract controllever in the normal fashion.

3. If the vehicle is not in a potentially hazardouslocation, and the boom does not need to belowered immediately. Shut off the engine, find theline that failed and replace that line. After thefailure is fixed, remove the blocking, lower theboom, check the oil level and add as necessary.Start the engine and bleed the air from the system,then recheck the oil level. The vehicle can now beput back into service.

4. If the vehicle is in a potentially hazardous locationthat would require the boom to be lowered immedi-ately and if the line failure is in the boom raise line,(if in the lowering line, continue with step 5) theboom must be lowered by following this procedure:

a. Locate the fault in the line and use a containerto catch any oil that escapes. Transfer the oilto a container with a cover and label thecontainer as used oil. Dispose of the used oilat an approved recycling center.

b. (Using two people to perform this procedurewill make boom lowering much easier). Re-move the blocking from under the boom. Atthe base end of each hoist cylinder, locate thecounterbalance valve cartridges (Figure 54).Loosen the retainer nut and control the rate ofboom lowering by turning the adjusting screwon each cartridge simultaneously into thecartridge very slowly (clockwise). Hydraulicoil from inside the hoist cylinders will escapethrough the fault in the line.

WARNINGIf line failure is in the Raise or

Lower lines

Rev 3/04

Figure 54

Wear protective clothing and proper eye protection whenworking with or around hydraulic oil. Wait for hydraulic oilto cool before attempting to repair the failure. Hot hydraulicoil can cause severe burns and other serious injury.

OH0210

COUNTERBALANCEVALVE

BOOM HOISTCYLINDERS

ADJUSTINGSCREW

RETAINERNUT

a. (Using two people to perform this procedurewill make boom lowering much easier.) At thebase end of each hoist cylinder, locate thecounterbalance valve cartridges (Figure 54).Loosen the retainer nut on each cartridge andturn the adjusting screws in (clockwise) untilthey bottom out. Doing this will render eachcounterbalance valve inoperative.

IMPORTANT: By turning the counterbalance cartridgeadjusting screws in to make the valve inoperative, thepressure settings of the cartridge have been altered and thevalve has lost its load holding ability. DO NOT attempt toreset these cartridges. By attempting to reset thesecartridges it will more than likely result in erratic (extremebouncing or racking at ends of cylinder stroke) loweringaction, which may cause damage to other components.Remove and discard both cartridges and replace with newparts.

5. If the vehicle is in a potentially hazardous locationthat would require the boom to be lowered immedi-ately and if the line failure is in the boom loweringline, the boom must be lowered by following thenext 4 steps.

WARNING

Page 9310054 Rev 3/04

Figure 54

Wear protective clothing and proper eye protection whenworking with or around hydraulic oil. Wait for hydraulic oilto cool before attempting to repair the failure. Hot hydraulicoil can cause severe burns and other serious injury.

OH0210

COUNTERBALANCEVALVE

BOOM HOISTCYLINDERS

ADJUSTINGSCREW

RETAINERNUT

a. (Using two people to perform this procedurewill make boom lowering much easier.) At thebase end of each hoist cylinder, locate thecounterbalance valve cartridges (Figure 54).Loosen the retainer nut on each cartridge andturn the adjusting screws in (clockwise) untilthey bottom out. Doing this will render eachcounterbalance valve inoperative.


5. If the vehicle is in a potentially hazardous locationthat would require the boom to be lowered immedi-ately and if the line failure is in the boom loweringline, the boom must be lowered by following thenext 4 steps.

WARNING

10054 Rev 3/04


1. Temporarily block or support the boom so it cannotbe lowered.


2. If the vehicle is not in a potentially hazardouslocation, and the boom does not need to beretracted immediately. Shut off the engine, find theline that failed and replace that line. After thefailure is fixed, remove the blocking, retract andlower the boom, recheck the oil level and add asnecessary. Start the engine and bleed the air fromthe system, then recheck the oil level. The vehiclecan now be put back into service.

IMPORTANT: If the boom has been extended, you mustfirst remove the load from the forks and/or attachmentbefore you attempt to lower the boom.

If line failure is in the Extend orRetract lines


b. Locate the fault in the line and use a containerto catch any oil that escapes. Transfer the oilto a container with a cover and label thecontainer as used oil. Dispose of the used oilat an approved recycling center.

c. Remove the blocking from under the boom.Clear the area around the vehicle of all person-nel and return to the operator's cab.

d. With the engine OFF, move the boom controllever forward to lower the boom. Oil willescape through the fault in the line.

6. Replace the failed hydraulic line. Check the oillevel and add as necessary. Bleed the air from thesystem and then recheck the oil level.

WARNING

Page 94 10054 Rev 3/04


1. Temporarily block or support the boom so it cannotbe lowered.


2. If the vehicle is not in a potentially hazardouslocation, and the boom does not need to beretracted immediately. Shut off the engine, find theline that failed and replace that line. After thefailure is fixed, remove the blocking, retract andlower the boom, recheck the oil level and add asnecessary. Start the engine and bleed the air fromthe system, then recheck the oil level. The vehiclecan now be put back into service.

IMPORTANT: If the boom has been extended, you mustfirst remove the load from the forks and/or attachmentbefore you attempt to lower the boom.

If line failure is in the Extend orRetract lines


b. Locate the fault in the line and use a containerto catch any oil that escapes. Transfer the oilto a container with a cover and label thecontainer as used oil. Dispose of the used oilat an approved recycling center.

c. Remove the blocking from under the boom.Clear the area around the vehicle of all person-nel and return to the operator's cab.

d. With the engine OFF, move the boom controllever forward to lower the boom. Oil willescape through the fault in the line.

6. Replace the failed hydraulic line. Check the oillevel and add as necessary. Bleed the air from thesystem and then recheck the oil level.

WARNING

Rev 3/04

Figure 55

3. If the vehicle is in a potentially hazardous locationthat would require the boom to be retracted imme-diately. Shut off the engine and refer to Figure 55to identify the failed hose. Use step “a” if thefailure is in the retract line or step “b” if the failureis in the extend line. If the failure is in either theextend or retract tubes (Figure 55) contact yourlocal Sky Trak distributor for repair parts or contactthe JLG service department for specific instruc-tions.

RETRACT LINE (Figure 55)

a. Locate the failed retract hose and remove thehose. In the same area locate the extendhose and remove it from the circuit. Replacethe failed retract hose with the extend hose.Place a container under the extend port on thecylinder to catch any oil that will escape duringboom retraction. Return to the operators cab,start the engine and slowly retract the boom.Stop the engine.

Transfer the oil to a container with a cover andlabel the container as used oil. Dispose of theused oil at an approved recycling center.

Reassemble a new extend line. After thefailure is fixed, remove the blocking, retractand lower the boom, check the oil level andadd as necessary. Start the engine and bleedthe air from the system, then recheck the oillevel. The vehicle can now be put back intoservice.

OH1120

EXTEND LINE

EXTEND TUBE

RETRACT LINE

RETRACT LINE

RETRACTTUBE

EXTEND LINE

CONTROL VALVE(ROTATED FOR CLARITY)

Page 9510054 Rev 3/04

Figure 55

3. If the vehicle is in a potentially hazardous locationthat would require the boom to be retracted imme-diately. Shut off the engine and refer to Figure 55to identify the failed hose. Use step “a” if thefailure is in the retract line or step “b” if the failureis in the extend line. If the failure is in either theextend or retract tubes (Figure 55) contact yourlocal Sky Trak distributor for repair parts or contactthe JLG service department for specific instruc-tions.

RETRACT LINE (Figure 55)

a. Locate the failed retract hose and remove thehose. In the same area locate the extendhose and remove it from the circuit. Replacethe failed retract hose with the extend hose.Place a container under the extend port on thecylinder to catch any oil that will escape duringboom retraction. Return to the operators cab,start the engine and slowly retract the boom.Stop the engine.


Reassemble a new extend line. After thefailure is fixed, remove the blocking, retractand lower the boom, check the oil level andadd as necessary. Start the engine and bleedthe air from the system, then recheck the oillevel. The vehicle can now be put back intoservice.

OH1120

EXTEND LINE

EXTEND TUBE

RETRACT LINE

RETRACT LINE

RETRACTTUBE

EXTEND LINE


10054 Rev 3/04

Figure 56

EXTEND LINE (Figure 56)

b. Place a container under the failure in theextend line to catch any oil that will escapeduring boom retraction. Return to the opera-tors cab, start the engine and slowly retractthe boom. Stop the engine.


Replace the failed extend line. After the failureis fixed, remove the blocking, retract and lowerthe boom, check the oil level and add asnecessary. Start the engine and bleed the airfrom the system, then recheck the oil level.The vehicle can now be put back into service.

OH1120

EXTEND LINE

EXTEND TUBE

RETRACT LINE

RETRACT LINE

RETRACTTUBE

EXTEND LINE


Page 96 10054 Rev 3/04

Figure 56

EXTEND LINE (Figure 56)

b. Place a container under the failure in theextend line to catch any oil that will escapeduring boom retraction. Return to the opera-tors cab, start the engine and slowly retractthe boom. Stop the engine.


Replace the failed extend line. After the failureis fixed, remove the blocking, retract and lowerthe boom, check the oil level and add asnecessary. Start the engine and bleed the airfrom the system, then recheck the oil level.The vehicle can now be put back into service.

OH1120

EXTEND LINE

EXTEND TUBE

RETRACT LINE

RETRACT LINE

RETRACTTUBE

EXTEND LINE


Rev 3/04

16. Emergency Brake Test

Test performance of the emergency brake as follows

• Ensure emergency brake is engaged and transmis-sion select lever is in “Neutral;”

• Fasten seat belt;

• Start engine and bring the machine to operatingtemperature;

• Apply the service brake;

• Place the travel select lever in (F) FORWARD andthe transmission in (1) first gear;

• Disengage the emergency brake, release servicebrake, and drive machine to an open area with afirm level surface, free of obstacles; and

• Move the unit slowly (approximately 1 mph[1,6 kph]) in a forward direction and engage theemergency brake. Ensure the emergency brakesystem stops the unit abruptly.

Page 9710054 Rev 3/04

16. Emergency Brake Test

Test performance of the emergency brake as follows

• Ensure emergency brake is engaged and transmis-sion select lever is in “Neutral;”

• Fasten seat belt;

• Start engine and bring the machine to operatingtemperature;

• Apply the service brake;

• Place the travel select lever in (F) FORWARD andthe transmission in (1) first gear;

• Disengage the emergency brake, release servicebrake, and drive machine to an open area with afirm level surface, free of obstacles; and

• Move the unit slowly (approximately 1 mph[1,6 kph]) in a forward direction and engage theemergency brake. Ensure the emergency brakesystem stops the unit abruptly.

10054 Rev 3/04

Specifications Fluid and Lubricant CapacitiesENGINE CRANKCASE OILCapacity with filter change ......................... 11.6 qts. (11 ltr)Filter .......................................................... 1.5 qts. (1,4 ltr)Type of Oil - Below 23° F (-5° C) .............................. 10W30 Above 23° F (-5° C) ........................... 15W40

equal to API, CD or CE specs.

FUEL TANKCapacity ............................................. 35.5 gals. (134,4 ltr)Usable ................................................ 33.5 gals. (126,8 ltr)Type of Fuel above 32° F (0° C) ............ Standard #2 DieselType of Fuel below 32° F (0° C) .......... Winterized #2 Diesel

COOLING SYSTEMCapacity - System (w/o heater) .................. 4 gals. (15,1 ltr)Capacity - Overflow Bottle ............................ 3 qts. (2,8 ltr)Type of Fluid ..................... 50/50 ethylene glycol and water

HYDRAULIC SYSTEMCapacity - System .............................. 59.5 gals. (225,2 ltr)Capacity - Reservoir ............................ 30.3 gals. (114,7 ltr)Type of Oil .................MIL-L-2104C, 10W or ISO Grade 46

(see table on page 71)

TRANSMISSIONCapacity with filter change ......................... 4.5 gals. (17 ltr)Type of Fluid ........................................... 10W-30 Motor Oil

(see table of approved lubricants on page 74)

AXLESDifferential Housing Capacity ....................... 18 qts. (17 ltr)Type of Lubricant - Above -15° F (-26° C) . 80W 90 Gear Oil Below -15° F (-26° C) ......... 75W GearWheel End Capacity - each (front) ...............54 ozs. (1,6 ltr)Wheel End Capacity - each (rear) ................ 54 ozs. (1,6 ltr)


Page 98 10054 Rev 3/04

Specifications Fluid and Lubricant CapacitiesENGINE CRANKCASE OILCapacity with filter change ......................... 11.6 qts. (11 ltr)Filter .......................................................... 1.5 qts. (1,4 ltr)Type of Oil - Below 23° F (-5° C) .............................. 10W30 Above 23° F (-5° C) ........................... 15W40

equal to API, CD or CE specs.

FUEL TANKCapacity ............................................. 35.5 gals. (134,4 ltr)Usable ................................................ 33.5 gals. (126,8 ltr)Type of Fuel above 32° F (0° C) ............ Standard #2 DieselType of Fuel below 32° F (0° C) .......... Winterized #2 Diesel

COOLING SYSTEMCapacity - System (w/o heater) .................. 4 gals. (15,1 ltr)Capacity - Overflow Bottle ............................ 3 qts. (2,8 ltr)Type of Fluid ..................... 50/50 ethylene glycol and water

HYDRAULIC SYSTEMCapacity - System .............................. 59.5 gals. (225,2 ltr)Capacity - Reservoir ............................ 30.3 gals. (114,7 ltr)Type of Oil .................MIL-L-2104C, 10W or ISO Grade 46


TRANSMISSIONCapacity with filter change ......................... 4.5 gals. (17 ltr)Type of Fluid ........................................... 10W-30 Motor Oil

(see table of approved lubricants on page 74)

AXLESDifferential Housing Capacity ....................... 18 qts. (17 ltr)Type of Lubricant - Above -15° F (-26° C) . 80W 90 Gear Oil Below -15° F (-26° C) ......... 75W GearWheel End Capacity - each (front) ...............54 ozs. (1,6 ltr)Wheel End Capacity - each (rear) ................ 54 ozs. (1,6 ltr)


Rev 3/04

TiresAIR PRESSURES17.50 x 25, 12 ply ..................................... 51 psi (352 kPa)17.50 R25, Radial (Two Star) .................... 73 psi (503 kPa)

HYDROFILL MIXTURE17.50 x 25, 12 ply ................ 243 lbs. (110,2 kg) Calcium

Chloride to 48 gals. (181,7 ltr) of Water (each tire)Total Hydrofill weight (each tire) ....... 643 lbs. (291,7 kg)

17.50 R25, Radial ................ 243 lbs. (110,2 kg) Calcium Chloride to 48 gals. (181,7 ltr) of Water (each tire)

Total Hydrofill weight (each tire) ....... 643 lbs. (291,7 kg)

NOTE: 17.50" tires (bias or radial) are not to be filled withwater only.

NOTE: For other types of ballast used with these tiresconsult the factory.

WHEEL NUT TORQUE ......... 450 - 500 lb-ft (610 - 680 Nm)

MAXIMUM GROUND PRESSURE (w/full load)

17.50 x 25 or R25 Size Tires .............. 75.5 psi (520 kPa)

Make and Model . Cummins 4BTA3.9 Turbo ChargedAftercooled Diesel

Horsepower . 116 hp (87,0 kW) @ 2500 rpm (U/Min)Low Engine Idle ........................ 1050± 50 rpm (U/Min)

Weights*Approximate Curb Weight .......... 28,085 lbs. (12740 kg) Shipping Weight .......................... 27,935 lbs. (12670 kg) *With open cab, 17.50 x 25 hydrofilled tires & full fuel tankOPERATING LOAD. ....................... 10,000 lbs (4536 kg)

Engine

MINIMUM WEIGHT OF EACH TIRE AND WHEELASSEMBLY WITH BALLAST17.5 - 25, 12 ply .....................................1003 lbs. (455 kg)17.5 R25, Radial (Two Star) ...................1159 lbs. (526 kg)

IMPORTANT: If any other type of ballast is added, thetotal weight of the tire and wheel assembly, includingballast Must Not Be Less Than the minimum assemblyweight listed above.

Page 9910054 Rev 3/04

TiresAIR PRESSURES17.50 x 25, 12 ply ..................................... 51 psi (352 kPa)17.50 R25, Radial (Two Star) .................... 73 psi (503 kPa)

HYDROFILL MIXTURE17.50 x 25, 12 ply ................ 243 lbs. (110,2 kg) Calcium

Chloride to 48 gals. (181,7 ltr) of Water (each tire)Total Hydrofill weight (each tire) ....... 643 lbs. (291,7 kg)

17.50 R25, Radial ................ 243 lbs. (110,2 kg) Calcium Chloride to 48 gals. (181,7 ltr) of Water (each tire)

Total Hydrofill weight (each tire) ....... 643 lbs. (291,7 kg)

NOTE: 17.50" tires (bias or radial) are not to be filled withwater only.

NOTE: For other types of ballast used with these tiresconsult the factory.

WHEEL NUT TORQUE ......... 450 - 500 lb-ft (610 - 680 Nm)

MAXIMUM GROUND PRESSURE (w/full load)

17.50 x 25 or R25 Size Tires .............. 75.5 psi (520 kPa)

Make and Model . Cummins 4BTA3.9 Turbo ChargedAftercooled Diesel

Horsepower . 116 hp (87,0 kW) @ 2500 rpm (U/Min)Low Engine Idle ........................ 1050± 50 rpm (U/Min)

Weights*Approximate Curb Weight .......... 28,085 lbs. (12740 kg) Shipping Weight .......................... 27,935 lbs. (12670 kg) *With open cab, 17.50 x 25 hydrofilled tires & full fuel tankOPERATING LOAD. ....................... 10,000 lbs (4536 kg)

Engine

MINIMUM WEIGHT OF EACH TIRE AND WHEELASSEMBLY WITH BALLAST17.5 - 25, 12 ply .....................................1003 lbs. (455 kg)17.5 R25, Radial (Two Star) ...................1159 lbs. (526 kg)

IMPORTANT: If any other type of ballast is added, thetotal weight of the tire and wheel assembly, includingballast Must Not Be Less Than the minimum assemblyweight listed above.

10054 Rev 3/04

Vehicle DimensionsLength (less forks) .............................. 246" (6248 mm)Width ................................................... 102.0" (2590 mm)Height ................................................. 101.5" (2578 mm)Wheelbase ......................................... 119.5" (3035 mm)Ground Clearance ................................ 16.8" (427 mm)Tread .................................................... 84.3" (2141 mm)Turning Clearance Radius ...................... 15' 0" (4,6 m)Max. Reach from Front Tiresto 24" (609 mm) load center ..................... 39' (11,9 m)

Electrical SystemRATING. ..................................... 12 VDC Negative GroundNUMBER & TYPE OF BATTERIES. ............................... 1

Maintenance Free

FUSE RATINGSOutrigger Switches ................................................ 7.5 ampRear Stabilizer Solenoids ...................................... 7.5 ampSteering Select Switch and Valve ......................... 7.5 ampHorn and Back-up Alarm (Optional - Heater Fan) .... 10 ampWarning lights, Emergency Brake Solenoid Switch,

Fuel Gauge and Hourmeter ................................. 10 ampIgnition Switch Feed for Entire Electrical System... 40 ampOutrigger and Extend Proximity Switch ................. 7.5 ampOutrigger Pressure Switches ................................. 7.5 amp

(Optional - Light Switch Relay) .............................. 7.5 amp(Optional - Enclosed Cab) ...................................... 10 amp(Optional - Lighting Package) ................................. 20 amp

RELAY RATINGSBoom Switch................................................... 12V 40 ampStabilizer Lock ................................................ 12V 40 ampBack-up Alarm ................................................ 12V 40 ampNeutral Start .................................................... 12V 40 ampEmergency Brake Disconnect ......................... 12V 40 amp(Optional - Light Switch) .................................. 12V 30 ampEmergency Brake Interlock ............................. 12V 30 ampBoom Extend Interlock.................................... 12V 30 ampBoom Extend Lockout ..................................... 12V 30 ampRight Outrigger Lockout .................................. 12V 30 ampOutrigger Lockout ............................................ 12V 30 ampLeft Outrigger Lockout ..................................... 12V 30 ampStabilizer Lock-Up ........................................... 12V 30 ampStabilizer Interlock .......................................... 12V 30 amp

REPLACEMENT BULBSHeadlights/Worklights

Replacement Bulbs - Hobbs.................................#73214Replacement Bulbs - Speaker .......................... #4830830

Warning Light Bulbs .................................. Qty. 4 (GE 161)Brake Light/Turn Signal - Rear ................................. #1157Turn Signal - Front ................................................... #1156

Page 100 10054 Rev 3/04

Vehicle DimensionsLength (less forks) .............................. 246" (6248 mm)Width ................................................... 102.0" (2590 mm)Height ................................................. 101.5" (2578 mm)Wheelbase ......................................... 119.5" (3035 mm)Ground Clearance ................................ 16.8" (427 mm)Tread .................................................... 84.3" (2141 mm)Turning Clearance Radius ...................... 15' 0" (4,6 m)Max. Reach from Front Tiresto 24" (609 mm) load center ..................... 39' (11,9 m)

Electrical SystemRATING. ..................................... 12 VDC Negative GroundNUMBER & TYPE OF BATTERIES. ............................... 1

Maintenance Free

FUSE RATINGSOutrigger Switches ................................................ 7.5 ampRear Stabilizer Solenoids ...................................... 7.5 ampSteering Select Switch and Valve ......................... 7.5 ampHorn and Back-up Alarm (Optional - Heater Fan) .... 10 ampWarning lights, Emergency Brake Solenoid Switch,

Fuel Gauge and Hourmeter ................................. 10 ampIgnition Switch Feed for Entire Electrical System... 40 ampOutrigger and Extend Proximity Switch ................. 7.5 ampOutrigger Pressure Switches ................................. 7.5 amp

(Optional - Light Switch Relay) .............................. 7.5 amp(Optional - Enclosed Cab) ...................................... 10 amp(Optional - Lighting Package) ................................. 20 amp

RELAY RATINGSBoom Switch................................................... 12V 40 ampStabilizer Lock ................................................ 12V 40 ampBack-up Alarm ................................................ 12V 40 ampNeutral Start .................................................... 12V 40 ampEmergency Brake Disconnect ......................... 12V 40 amp(Optional - Light Switch) .................................. 12V 30 ampEmergency Brake Interlock ............................. 12V 30 ampBoom Extend Interlock.................................... 12V 30 ampBoom Extend Lockout ..................................... 12V 30 ampRight Outrigger Lockout .................................. 12V 30 ampOutrigger Lockout ............................................ 12V 30 ampLeft Outrigger Lockout ..................................... 12V 30 ampStabilizer Lock-Up ........................................... 12V 30 ampStabilizer Interlock .......................................... 12V 30 amp

REPLACEMENT BULBSHeadlights/Worklights

Replacement Bulbs - Hobbs.................................#73214Replacement Bulbs - Speaker .......................... #4830830

Warning Light Bulbs .................................. Qty. 4 (GE 161)Brake Light/Turn Signal - Rear ................................. #1157Turn Signal - Front ................................................... #1156

Rev 3/04

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OH0690

Stability Tipping Limits Position 1Longitudinal stability “stacking”

(with rated load)

7% GRADE (4°)

This telescopic handler has been shown to meet or exceedASME and FEM stability limits in highly structured andcontrolled test situations. These stability tipping limits areextremes and are not intended to be achieved duringnormal worksite operation. The following is provided onlyas information to the operator of this vehicle and in no wayshould be used as a guideline for operating this vehicle.For safe operation, follow the instructions as provided onthe preceding pages of this manual.

Page 10110054 Rev 3/04

��

��

��

��

OH0690

Stability Tipping Limits Position 1Longitudinal stability “stacking”

(with rated load)

7% GRADE (4°)

This telescopic handler has been shown to meet or exceedASME and FEM stability limits in highly structured andcontrolled test situations. These stability tipping limits areextremes and are not intended to be achieved duringnormal worksite operation. The following is provided onlyas information to the operator of this vehicle and in no wayshould be used as a guideline for operating this vehicle.For safe operation, follow the instructions as provided onthe preceding pages of this manual.

10054 Rev 3/04

��

��

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Position 2Longitudinal stability “traveling”

(with no more than rated load)

Position 3Lateral stability “stacking” with rated load

(with frame tilted 4°)

12% GRADE (7°)22% GRADE (12°)

OH0140OH0570

Page 102 10054 Rev 3/04

��

��

��

��

��

��

Position 2Longitudinal stability “traveling”

(with no more than rated load)

Position 3Lateral stability “stacking” with rated load

(with frame tilted 4°)

12% GRADE (7°)22% GRADE (12°)

OH0140OH0570

Rev 3/04

��

��

Position 5Lateral stability “stacking”

(with no load)

OH0151

Position 4Lateral stability “traveling”

(with no load)

50% GRADE (27°) 10% GRADE (6°)

OH0121

Page 10310054 Rev 3/04

��

��

Position 5Lateral stability “stacking”

(with no load)

OH0151

Position 4Lateral stability “traveling”

(with no load)

50% GRADE (27°) 10% GRADE (6°)

OH0121

10054 Rev 3/04

Notes(OR, on this page, affix second copy of attachment

capacity chart if supplied with attachment)

Page 104 10054 Rev 3/04

Notes(OR, on this page, affix second copy of attachment

capacity chart if supplied with attachment)

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REPLACEMENT MANUALS

If the owner/operator or safety manuals that were originally shipped with yourvehicle are lost, stolen or need replacement, contact your local distributor forreplacement manuals.

If for any reason your distributor cannot supply the manuals you need; write,call or send a fax to the following address for ordering information.

JLG Industries, Inc.1 JLG DriveMcConnellsburg, PA 17233-9533 USA

Phone: (877) 554-5438 or (717) 485-6472Parts Fax: (800) 733-8939 or (717) 485-6441

Be sure to include the following information:1. Type of manual requested (owner/operator or safety)2. Vehicle Name3. Model and Serial Number

REPLACEMENT MANUALS

If the owner/operator or safety manuals that were originally shipped with yourvehicle are lost, stolen or need replacement, contact your local distributor forreplacement manuals.

If for any reason your distributor cannot supply the manuals you need; write,call or send a fax to the following address for ordering information.

JLG Industries, Inc.1 JLG DriveMcConnellsburg, PA 17233-9533 USA

Phone: (877) 554-5438 or (717) 485-6472Parts Fax: (800) 733-8939 or (717) 485-6441

Be sure to include the following information:1. Type of manual requested (owner/operator or safety)2. Vehicle Name3. Model and Serial Number

model 10054 - jlg industries...2004/04/29 · 10054 rev 3/04 page 3 ety practices the information...

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